Practical No 4

Title- Re-Sharpen Any One Single Point Cutting Tool As Per Given Specification

Course outcome-
Interpret geometries of various cutting tool.

Theoretical concept-

HSS Turning Tool Grinding

This first image shows a tool blank. There are 5

faces to consider at the cutting end, but only 3 of
them require grinding. The back (4) surface and
bottom (5) surface can be left untouched.
The remaining three faces require grinding along
two axis each, however they can still be created
within three grinding operations.
On most tools there is also a fourth grinding
operation which is a radius on the tool tip.
This radius increases tool life and improves
surface finish.
The numbered faces in this image also indicate the order in which the three faces are cut. Although there are
three faces to cut and each of them has two angles to set, the front and side faces both have two critical angles
and two non-critical. The top face has two angles, both of which are important.

Tool geometry.
The end and side faces both have a clearance/relief angle and another edge cutting angle. The relief angles are
needed to stop the tool rubbing. A tool with a greater relief angle usually has a lower rate of wear, but because
there is less material to support the cutting edge the tool can break more easily, it also cannot conduct heat
away so efficiently.
The top face has two rake angles because it can cut both 'into' and 'along' the work piece. These angles are
identified as a 'side rake' angle and a 'back rake' angle. The rake angle sets the angle of shear for the cut. A
greater rake angle reduces cutting forces and gives a better tool life, but too much rake can make the tool
fragile. The diagram below shows the terminology used to describe cutting tools

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A Tool Grinding Rest
Accurate grinding of the required faces can more easily be achieved with an adjustable grinding rest. The
photo on the right shows a simple grinding rest which is only angle adjustable (not height) and it has a sliding
fence which can be used to hold the cutter at a set angle as it travels across the edge of the grinding wheel.

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Tool Grinding Sequence
Throughout this sequence the tool temperature was kept reasonable by frequent dipping in a pot of water. Also
- always ensure that the safety guards are in place on the grinding wheel, and always wait for it to stop before
adjusting the rest. The first face to be cut was the side face. In this example of a normal right handed tool for
the lathe.

Grinding the side face of the tool

Then the grinding rest was tipped to give the required side clearance relief and the fence adjusted to give the
side cutting edge angle. The work was fed across the edge of the grinding wheel with a light inward pressure
to make the cut. The angle set by the table is the important angle here as is sets the side relief. The angle of
the fence is non-critical and is simply used so that the side relief doesn't have to be ground all the way along
the tool

Second to be cut was the end face shown in green below.

Grinding the end face of the tool

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The grinding rest was tipped to give the required end relief angle and the fence adjusted to give the front cutting
edge angle. Again the front cutting edge angle was not important, although it is usually set to make the tip and
less than 90 º. The relief angle is the critical one. If the tool tip is to be radiused, it is cut next.
This can be done as a freehand operation on the bench grinder, or by hand on a grinding slip, if only a very small
radius is needed.

Grinding tool tip radius by hand

Finally the top face was cut. This face had a side and back rake angle. To cut the top face, the grinding rest
was tipped to set the side rake angle and the fence angled to cut the back rake angle. Both these angles are
important to make an effective tool.

The completed tool

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