MANUFACTURING

PROCESS-I
MODULE 5
LATHE WORKS
(Nomenclature of single point cutting tool,
tool signature and materials )

PREPARED BY-
SUMAN MAJUMDER
LECTURER IN MECHANICAL ENGINEERING
MBC INSTITUTE OF ENGINEERING AND TECHNOLOGY
BARDHAMAN
Definition of single point cutting tool:
It is that kind of a cutting tool which have only one cutting point or principal cutting edge.

1.Nomenclature of single point cutting tool, tool signature and

materials:
1.1Description of different part:
The single point cutting tool has only one cutting point or edge. These tools used for turning,
boring, shaping or planning operations. These tools used on lathe, boring and shaper
machines

FIG 1.1: SINGLE POINT CUTTING TOOL SHOWING DIFFERENT PARTS ON IT.

A single point cutting tool consists of a sharpened cutting part and the shank and main parts
or elements which are:
1: Shank
It is the main body of the tool on which tool is held on machine.
2: Flank:
The surface or surfaces below the adjacent to the cutting edge is called flank of the tool.
Flank situated in front of tool is called minor flank and Flank situated in side of tool is called
major flank.
3: Face
The surface on which the chip slides is called the face of the tool. This is also called Rake
plane.
4: Heel
It is the intersection of the flank and the base of the tool.
5: Cutting Edge
It is the edge created by intersection of face or rake plane and flank of the tool which actually
serves to remove the material from the work piece. The cutting edge consists of the side
cutting edge(major cutting edge) and end cutting edge(minor cutting edge) and the nose. Side
cutting edge is the intersecting line of major flank surface and face or rake, whereas end
cutting edge is the intersecting line of minor flank surface and face or rake.
6: Nose
It is the point where the side cutting edge and end cutting edge intersect.

1.2Tool geometry:
Tool geometry of a single point cutting tool can be described by different angles and radius of
particular edge. To define different angles in three dimension, it is essential to define three
axis and one origin.
To do that, the extreme outward point of nose can be taken as the origin of different axes.
Amongst two mutually perpendicular lines on the horizontal plane resting on nose, line
perpendicular to shank is taken as X-axis and line parallel to shank is taken as Y-axis, so as
usual the line passing through the said origin and perpendicular to both X and Y axis is taken
as Z-axis. In this way three mutually perpendicular planes XY, YZ and XZ will also be
considered to define angles.
A)End Cutting Edge Angle:

 The angle between the end cutting edge and Y-axis on XY plane is known as the end
cutting angle.
 This angle usually varies from 5 to 15 degree.
B)Side Cutting Edge Angle:
The angle between the side cutting edge and X-axis on XY plane is known as side cutting
edge angle.
C)Back Rake Angle:

 The back rack angle is the angle between the face or rake plane and X-axis in XZ
plane.
 The angle form to smooth flowing of chips from the face, known as rack angle. It
allows to smooth flow of chips.
 Softer the material, greater should be the positive rake angle.
 The back rake angle may be positive negative or zero.
D)Side Rack Angle:

 The angle between the face or rake and Y-axis in YZ plane is known as the side rack
angle. It allows chips to flow smoothly when material cut by side cutting edge.
 The amount by which a chip is bent depends upon this angle.  When the side rack
angle increases, the magnitude of chip bending decreases. Smoother surface furnish is
produced by a larger side rake angle.
E)End or Front Relief Angle:

 The intersecting line of major and minor flank is called front edge of tool. It is the
angle made by Z-axis and front edge of tool XZ plane.
 It is also known as a clearance angle. It is the angle that avoids tool
wear. It avoid the rubbing of flank with a workpiece.
 This angle may vary from 6 to 10 degrees.
F)Side Relief Angle:

 It is the angle made by the front edge of tool and Z-axis in YZ plane. It avoid rubbing
of side flank with a workpiece.
 This angle allows the tool to be fed sideways into the job in order to cut the work
material without rubbing.
 When the side relief angle is very small, the tool will rub against the job and therefore
it will get overheated and become blunt and the surface finish obtained will be poor.
G)Nose Radius:
The intersecting area of both cutting edges is known as the nose of the tool. The nose always
made in curve to avoid stress concentration which causes failure of tool. The maximum
radius of curvature is called nose radius.
FIG 1.2: DIFFERENT ANGLES SHOWN ON THREE VIEWS OF A SINGLE POINT
CUTTING TOOL

1.2.1 Positive and Negative rake angle:

1.2.1.1 Positive rake:
A positive rake occurs when rake plane goes downward with respect to horizontal plane

resting on tool tip or nose to meet shank.

FIG 1.2.1.1: SCHEMATIC DIAGRAM POSITIVE RAKE ANGLE.
As schematically shown here, a positive rake makes the tool tip comparatively sharper by
reducing wedge angle, and thus shearing action occurs smoothly during machining. However,
due to lower wedge angle, strength of tool tip reduces and consequently tool becomes
vulnerable under severe cutting temperature and impact loading.
Advantages of positive rake:
1) Reduced shear strain—Higher the value of positive rake angle lower will be the shear
strain.

2) Low power consumption—Due to lower wedge angle and reduced shear strain, cutting or
shearing occurs easily with minimum effort. This reduces power (or energy) consumption
while machining a particular work material under specific cutting condition.

3) Low cutting force—Due to less shear deformation of chip, Chip Reduction Coefficient
(CRC) also reduces. This results in lower cutting force, which consequently eliminates
detrimental effects of high force (such as vibration, inaccuracy, chatter marks, etc.).

4) Lower tendency of built-up edge formation—Built-up edge, forms on the rake surface of
the cutting tool, breaks down quickly and flow away with chip if tool with positive rake angle
is used.

5) Lower cutting temperature—Although heat generation in machining depends greatly on

other factors, positive rake angle contributes in reducing heat generation during machining.
This protects both the tool and job from detrimental effects of the severe cutting temperature.

5) Favourable for continuous chip formation—Since shear deformation is low, so positive

rake angle offers favourable condition for continuous chip formation, which indicates better
machinability.
Disadvantages of positive rake angle:

1) Weak tool tip—As positive rake angle indicates lower wedge angle, so strength of tool tip
reduces. Thus capability of the cutting tool to withstand higher cutting force and absorbing
larger heat during machining are also reduces. Thus higher speed, feed and depth of cut may
not be applied.

2) Lower tool life—Tools with positive rake angle reaches their life time quickly due to
gradual wear, especially flank wear.

3) Not suitable for old machines—Old machine tools usually induce vibration during cutting
due to various worn out parts and loose joints. In such case use of cutting tools with positive
rake angle should be avoided.
1.2.1.2 Negative rake:

FIG 1.2.1.2: SCHEMATIC DIAGRAM NEGATIVE RAKE ANGLE.

A negative rake occurs when rake plane goes upward with respect to horizontal plane resting
on tool tip or nose to meet shank. As schematically shown here, a positive rake makes the tool tip
comparatively thicker by increasing wedge angle. Due to higher wedge angle, strength of tool tip
increases and consequently tool becomes more sustainable under severe cutting temperature and
impact loading. Thus tool life increases. The following passages elaborate the advantages and
disadvantages of negative rage angle on a cutting tool.

Advantages of Negative Rake angle:

1) Stronger tool tip—Larger wedge angle makes the tool tip strong enough to sustain under
higher feed and depth of cut. Thus material removal rate (MRR) can be enhanced using such
tool without sacrificing tool life.

2) Longer tool life—It takes higher time to worn out a negative rake tool and thus life of
cutting tool enhances. Less chance of catastrophic failure also contributes in improving tool
life.

3) Suitable for old machine tools—Usually old machine tools create vibration because of
various worn out parts and loose joints. For such machines, cutting tool with negative rake is
preferred as it can absorb impact loading as well as can sustain longer under small vibration.

4) Larger feed and depth of cut—In order to increase material removal rate (MRR) for
enhancing productivity, higher value of feed rate and depth of cut can be utilized while
machining with a negative rake tool. However, it will increase cutting force and may
severely hamper the product quality.
Disadvantages of Negative Rake angle:
1) High shear deformation—Deformation of chip material during shearing action is very high
and this has many detrimental effects both on tool and workpiece.

2) High normal force on tool—Negative rake makes the normal force larger as compared to
frictional force (attributed to Merchant Circle Diagram). It can cause tool deflection and
vibration, which are undesirable during machining.

3) More power consumption—Higher the shear deformation larger will be the chip thickness
and thus Chip Reduction Coefficient (CRC) will also increase. Higher CRC indicates more
cutting force and thus higher cutting energy or power consumption. Thus lower depth of cut
and feed rate has to be utilized for a given rated power of the machine tool.

4) Built up edge retention—Lower frictional force (from Merchant Circle Diagram) may not
exceed bonding force of the built up edge and thus it will retain on the tool tip for a l0onger
time (until frictional force exceeds bonding force).

1.2.1.3 Zero Rake angle:

When rake plane lies on reference plane then it is called zero rake as rake plane makes zero
degree angle with the reference. As shown in the figure, zero rake angle is in between the
positive and negative rake angles. It can provide advantages of both of them; however, to
some extent. Cutting tool with zero rake angle is easy to design and manufacture. Such tools
also provide advantage while re-sharpening the tools. Thread cutting tools are usually
provided with zero rake angle.

FIG 1.2.1.3: SCHEMATIC DIAGRAM SHOWING ZERO RAKE ANGLE.

1.2.2 Factors influencing rake angle of the single point cutting

tool:
A) Type of material being cut: a harder material like cast iron may be machined with a
smaller rake angle than that required by a soft metal like mild steel or aluminium.

B) Type of tool material being used: tool material like cemented carbide permits turning at
a very high speed. It has been observed that in machining at a very high cutting speed rake
angle has a little influence of cutting pressure.

C) Depth of cut: in rough turning, a high depth of cut is given to withstand severe cutting
pressure. so the rake angle should be decreased to increase the lip angle that provides strength
to the cutting edge.
D) The rigidity of the tool holder and condition of the machine: an improperly supported
tool on an old and worn out machine can’t take up severe cutting pressure. so machining
under such conditions the tool used should have a larger rake angle than that at the normal
condition to reduce the cutting pressure.

1.3 Tool Signature

The tool signature or tool designation is used to denote a standardized system of specifying
the principal tool angles of a single-point cutting tool. Some common systems used for tool
designation or tool nomenclature are the following-
A) American or (ASA) System.
It defines the principle angles like side rake, back rack, nose, etc. without any reference to
their location concerning cutting edge. As such, this system of nomenclature does not give
any indication of the tool behavior with regard to the flow of chip during the cutting
operation the three reference planes adopted for designating different tool angles are similar
to those used in conventional machine drawing i.e, x-x,y-y, and z-z the last one containing
the base of the tool and the two plane being normal to this plane as well as mutually
perpendicular. Thus, this system is a coordinate system of tool nomenclature.
B) British system:
This system, according to B-S1886-1952, defines the maximum rake. The various tool
parameters in this system are indicated if the order of Back rake, Side rake, End relief angle,
Side relief angle, End cutting angle, Side cutting edge angle, and Nose radius.
C) Continental systems:
This category of tool nomenclature systems includes the German or DIN System (DIN-6581),
Russian Systems (OCT-BKC 6897and 6898), and Czechoslovakian System (CSN-1226). The
various tool parameters in these systems are specified with reference to the tool reference to
the tool reference planes.
D) International system:
It is an internationally adopted system, developed recently. It incorporates the salient features
of tool nomenclature of different systems in it.
Example: A tool with 8, 10, 6, 6, 6, 10, 0.2, signature in the A.S.A system is having the
following specification.
Back rake angle = 8º
Side rake angle = 100
End relief angle = 60
Side relief angle = 60
End cutting edge angle = 60
Side cutting edge angle = 100
Nose radius = 0.2 mm

1.4 Material Used For single Point Cutting tools :

Tool bits generally made of seven materials

 High-speed steel
 Cast alloys (such as stellite)
 Cemented carbides
 Ceramics
 Cermets
 Cubic Boron Nitride
 Polycrystalline Diamond
1.5 Preferable position of a cutting tool with respect to job axis:
To explain this topic, horizontal axis of circular cross section of cylindrical
lathe job has been considered, as because tool use to be held horizontally in tool
post.
Now in the figure, three different possible positions have been shown and
pointed as 1, 2 and 3 respectively.
In every position the effective horizontal axis and vertical axis are nothing but
normal and tangential lines at the point of contact by tool to circular cross
section respectively.
At position 1, as it can be seen, the effective rake and clearance angles are same
as true back rake and front clearance angle of the tool itself.
If the job moves to position 2, we can see in the figure that the effective rake
angle starts decreasing and ends up becoming negative and on the other hand
effective clearance angle increases. Increase in clearance angle is a good thing
as it may decrease power requirement and heat developed in tool and job by
decreasing tool and job friction. But decrease in rake angle, more preciously
negative rake angle, increase power requirement heavily and also cutting force
increases. Increase in cutting force in a tool which actually has positive rake
angle, meaning narrower wage angle, causes to increase induced stress in
cutting tool, which eventually make the tool to fail.
If the job moves to position 3, the effective rake angle increases, but effective
clearance angle starts to decrease. An increase in rake angle is very good as
because of decrease in shear strain power of cutting as well as cutting force
decrease. But decrease in clearance angle is very detrimental to quality of cut
surface and ultimately cutting becomes infeasible when it becomes very small
or negative as being shown in the figure.
So ultimately we can conclude that, the position 1 is safe and controllable if we
can use proper geometry of tool for proper material and cutting requirement.
FIG 1.5: SCHEMATIC DIAGRAM EXPLAING PROPER POSITION OF TOOL

WITH RESPECT TO JOB.

References
• Book: Principles of Mechanical Engineering by S. Singh (S. Shand).
• Book: Machining and Machine Tools by A. B. Chattopadhyay (Wiley).
• Book: Metal Cutting: Theory And Practice by A. Bhattacharya (New
Central Book Agency).
• Book: Manufacturing Processes by J. P. Kaushish (PHI).
• Book: Manufacturing Science by M. I. Haque and S. Khan (PHI).

FAQ:
1. Which cutting edge does cut metal predominantly?
Answer: Side cutting edge or main cutting edge.
2. What is role of side rake angle if back rake alone can facilitate chip flow?
Answer: Side rake angle make chip flow out of the cutting zone or position and makes it sure
that chip does not come back to cutting position again.
3. Can there be anything like negative end or front relief or clearance angle?
Answer: No. If it is then cutting will not be feasible by that cutting tool.
4. Why are lathe tools considered as single point cutting tool?
Answer: They are considered like that because they have only one cutting point or principal
cutting edge.
5. What is the utility of tool signature?
Answer: By using tool signature geometry of tool can be specified in a shorter way. Hence it
can also be used during purchase and sell of a cutting tool.

Descriptive questions:
1. Name different portion of a single point cutting tool with their definition. Show those
portions in figure. Name different types of cutting tool materials.
2. Draw front, top and side view of a single point cutting tool and show different important
cutting tool angles in those figures. Why is nose radius provided in a single point cutting
tool?
3. Define and show in a figure positive and negative back rake angle. What are the main
functions of back rake and side rake angle? State the functions of end relief or front
clearance angle and also state the importance of side relief or clearance angle. When should
negative rake be used?
4. Mention the meaning of a tool signature 6-9-7-6-6-11-0.2. Mention the proper position of
a job tool must be placed for safe and proper cutting and explain your answer.
MCQ:
1. On which plane do chips flow?
a) Major flank, b) Minor flank, c) Face or rake, d) shank.
2. why is back rake angle provided on a cutting tool?
a) To make chip flow easy, b) To increase tool strength, c) To decrease heat generation
during cutting, d) both a and c.
3. Why are relief or clearance angles provided on a cutting tool?
a) To avoid early tool failure, b) To decrease heat generation during metal cutting, c) To
avoid contact of tool with cut surface of job, d) All of a, b and c.
4. Fill in the blank.
During machining of a ductile material back rake angle should be _________.
a) Decreased, b) Increased, c) Zero, d) Have no influence.
5. Fill in the blank.
Value of side or main cutting edge angle varies between __________.
a) 00 to 50 , b) 50 to 150, c) 200 to 300 , d) 300 to 600 .
6. When is negative rake angle used?
a) When harder materials to be cut, b) To increase tool life, c) When softer materials to be
cut, d) Any time during metal cutting.
Answers: 1. c, 2. d, 3. d, 4. b, 5. b, 6. a.