Lecture seventeenth - 1:

(( Manufacturing ))
Cutting Tool Shapes & Forms:
Looking to Figure [ 7 ( a, b ) ] to understand the cutting tool shapes & forms in which they are
defined by the Tool angles.
width

Height

Flank

Fig. ( 7 ): Conventional cutting tool angles.

Tool angles:
It is that parts of the cutting tool where cutting edges are found. It is on the end of shank or the tool
body (it is called Flank). The surfaces at that part have definite relationships to each other and defined
by angles.
Relief angle:
It depends upon the kind of cut., the larger the relief angle the lower the rate of wear on Flank. The
purpose of the relief angle as the name implies is to enable the side of the tool to clear the work and not
rub it.
Clearance angle ( Secondary relief angle ):
It is ground on the Shank below the insert of a Carbide or Ceramic Tool. It has no effect on the force,
power & the surface finish as long as it is large enough.
Rake angle:
It affects the angle of shear during the formation of chip, the larger the rake angle, the larger the shear
angle and the lower the cutting force and power, it is also an indication for a good surface finish.
 But increasing the rake angle to a certain point will leave less metal of the cutting tool to
support the cutting edge and to conduct away the heat.
 The rake angles shown above are positive. Rake angle measured counterclockwise from zero
are called negative rake angles [fig. (8)].

Assistant Professor Sahib M. Mahdi

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Lecture seventeenth - 1:

Fig. ( 8 ): The three possible types of Rake angles.

Cutting Edge angles:
 End Cutting Edge angle: It gives clearance to the trailing end of the cutting edge and reduce
drag that tends to cause Chatter. Too large an end – cutting edge angle takes away material
that supports the point and conduct away heat.
 Side Cutting edge angle: It affects tool life and surface finish; it enables a tool that is fed side
ways into a cut to contact the work first behind the tip.
Nose Radius:
It is favorable to long tool life and good surface finish. The amount of a nose radius that can be put on
a tool is limited because too large a nose radius is conductive to Chatter.
Tool Designation:
The shape of the tool may be described by a series of numbers specifying the values of the angles and
radius in the order just listed.

The main component of metal cutting:

1 – The Workpiece, the piece or object to be formed or shaped.
2 – The Tool, the device which is used to machine the Workpiece.
3 – The machine, to produce the power required to overcome the friction & the forces
that hold the metal together.

Assistant Professor Sahib M. Mahdi

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Lecture seventeenth - 1:

Mechanics of Chip Formation:

Consider an orthogonal cutting model as illustrated in fig. ( 9 ), where:

 In the case of orthogonal cutting, the cutting edge of the tool is at right angles to the
direction of relative motion between the tool and the workpiece.
 The cutting tool basically consists of two intersecting surfaces to form the cutting edge
[fig. (9 a)] above, which are the rake face and the shear plane.
 The surface along which the chip flows is known as the rake face. The cutting face or
the rake face makes an angle (  ) with the normal which is called the rake angle [fig.
(9 b)].
 The angle between the tool body and the new workpiece surface is defined as the
clearance or relief angle.
 The shear plane angle can be calculated from the change in size of the chip that is
deformed along the shear plane. The precut chip thickness ( to ) and the rake angle (  )
are known.
 The chip thickness ( tc ) is measured normal to the rake face of the tool along a line that
makes an angle of (  ) with the shear plane [fig. (10) below].

Assistant Professor Sahib M. Mahdi

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Lecture seventeenth - 1:

Fig. ( 10 ): The schematic drawing showing the relationship between ( to & tc ).

From the triangles:
∆ 𝑶𝑷𝑨, 𝒕𝒐 = 𝑶𝑨 . 𝒔𝒊𝒏 ∅

∆ 𝑶𝑨𝑸, 𝒕𝒄 = 𝑶𝑨 . 𝒄𝒐𝒔 ( ∅ − 𝜶 )
𝒕𝒐 𝑶𝑨 . 𝒔𝒊𝒏 ∅ 𝒔𝒊𝒏 ∅
𝒓 = = = ⟹ 𝒔𝒊𝒏 ∅ = 𝒓 . 𝒄𝒐𝒔 ( ∅ − 𝜶 ) 
𝒕𝒄 𝑶𝑨 . 𝒄𝒐𝒔 ( ∅ − 𝜶 ) 𝒄𝒐𝒔 ( ∅ − 𝜶 )

Or, we can say: 𝒔𝒊𝒏 ∅ = 𝒓 . ( 𝒄𝒐𝒔 ∅ . 𝒄𝒐𝒔 𝜶 + 𝒔𝒊𝒏 ∅ . 𝒔𝒊𝒏 𝜶 ), 𝒅𝒊𝒗𝒊𝒏𝒈 𝒃𝒚 𝒄𝒐𝒔 ∅
We will obtain that:

𝒕𝒂𝒏 ∅ = 𝒓 . 𝒄𝒐𝒔 𝜶 + 𝒓 . 𝒕𝒂𝒏 ∅ . 𝒔𝒊𝒏 𝜶

𝒓 . 𝒄𝒐𝒔 𝜶
𝒕𝒂𝒏 ∅ =
𝟏 − 𝒓 . 𝒔𝒊𝒏 𝜶

Assistant Professor Sahib M. Mahdi

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