Chapter -4 Design of Form Tool

CHAPTER 4

FORM TOOL DESIGN

4.1. INTRODUCTION

Form tool is one in which the cutting edge is of a shape that

produces the desired contour on the workpiece in the turning
operation. The form tool was designed to feed radially into the
workpiece. The use of form tool ensures a high output, uniform
contour of all the workpieces and accurate dimensions. It is
commonly applied in large-lot and mass production. In this chapter
the complicated profile of the form tools will be estimated
graphically and analytically. General program flow chart for
computer-aided-design (CAD) will be constructed for computing
and drawing the profile of the form tool.

Form tools can be classified as follows:

a) Flat form tool, Fig.4.1.
b) Dovetail form tool, Fig.4.2.
c) Circular form tool, Fig.4.3.

Fig.4.1. Flat form tool

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Chapter -4 Design of Form Tool

Workpiece

γ
Holder-clamping bolt

α Tool-clamping bolt

Tool

Height-adjustment

Clamping plate

Fig.4.2. Dovetail form tool in holder.

Tool point adjustment Circular form tool

Form tool holder

Serration
Tool-clamping bolt

Fig.4.3. Clamping the circular form tool in the holder by

radial serration on the holder that match those on the tool.

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Chapter -4 Design of Form Tool

4.2. FLAT FORM TOOL

The flat form tool is usually used in the horizontal position. Fig. 3.1
shows the end of a flat form tool. It is clear that the top of the tool
is reground when the tool is sharpened. Therefore the tool must has
adequate section to maintain an acceptable strength during its work-
ing life. Also, the tool holder must incorporate means of adjustment
so that the cutting edge of the tool can be set to the workpiece
centre-line after re-grinding.

4.2.1. Form Correction

For manufacturing purposes it is usual to dimension the tool in a
plane that is normal to the front clearance face, and so it is
necessary to make so-called “form correction” calculations. The
different between tool form and workpiece form was due to the
rake and clearance angles on the form tool. If the tool is set on
centre as shown in Fig.4.4, it must have the correct form in plane
OAB. Since, however, the tool must have clearance as shown,
lengths such as BC, taken perpendicular to the front clearance face
will be less than lengths such as AB taken on the horizontal, and
the form of the tool on a plane parallel to BC will be different from
its form on AB. When the tool is being made, the shaping and other
machining operations are carried out parallel to the clearance face,
so that for the purpose of making the tool it may be necessary to
determine its form when taken on a plane such as BC,

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Chapter -4 Design of Form Tool

perpendicular to the front clearance face. Form correction can be

made graphically or analytically.

The graphical method is simple and straightforward but has certain

inaccuracies inherent in all graphical constructions. The analytical
method, on the contrary, enables the dimensions to be determined
with any degree of accuracy. A drawback of the last method is the
complicated calculations required, especially for curvilinear profile.

O A B

α
α=clearance angle.

Fig.4.4. Form correction due to clearance angle.

4.2.2. Graphical Determination of Flat Form Tool Profile

In this method the points on the form are drawn on the tool face and
then projected in the direction of arrow “V”, Fig.4.5. The tool form
is not the same workpiece form but it takes an approximate
workpiece form. For example the half circle in the workpiece form
take elliptical form on the tool profile. As mentioned above, the
different between tool form and workpiece form due to the rake and
clearance angles on the form tool.

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Chapter -4 Design of Form Tool

Y
X
(x1,y1)
1
2
3
R 4
5
6 B
7
8
9
10
11

“V”

α (xt1,yt1) 1

2
3
4
5 B
Yt 6
7
8
9 11
10

Xt
Elliptical form

Fig.4.5. Graphical determination of tool profile.

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 Chapter -4 Design of Form Tool

4.2.3. Analytical Determination of Flat Form Tool Profile

Zi
a
o b
γ

α c
Rwi
d Yi

Yi

rw cos(γ)

a
rw sin(γ)
rw b
o γ
Rwi
Zi

α γ+α c

Yi
d

Fig.4.6. Analytical determination of tool profile.

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Chapter -4 Design of Form Tool

On the basis of the graphical construction given above, the

analytical relationships can be derived for calculating the
coordinates XtYt of the tool profile from the known coordinates XY
of the workpiece profile, Fig.4.6. Thus; From triangle cdb the radial
depth of the tool (Yi) is calculated form Eq.1;

Yi = Zi cos (γ+α) (4.1)

From triangle oac Rwi2 = [rw. sin(γ)]2 + [Zi + rw. cos(γ)]2

Zi + rw. cos(γ) = Rwi2 − [rw sin(γ )] 2

Then Zi = Rwi2 − [rw sin(γ )]2 - rw.cos(γ) (4.2)

Therefore at any point (XY) on the workpiece profile the radius Rwi
can be measured and the depth Yi can be calculated from the
following equation:

Yi = {R 2
wi }
− [rw sin(γ )]2 − rw . cos(γ ) cos(γ + α ) (4.3)

4.3. DOVETAIL FORM TOOL

Fig. 4.2 shows a dovetail form tool mounted in its holder. The
clearance angle is obtained by the inclination of the tool location
face of the holder. The dovetail form tool is reground on the top
face, and has a longer life than the flat form tool; much higher

79
Chapter -4 Design of Form Tool

cutting forces can be permitted than in the case of the flat form tool
because the tool is much stronger, and is held more rigidly. The
disadvantage associated with the dovetail form tool is that the front
clearance is obtained by the tool holder, and so a change of
clearance angle demands another tool holder. In practice it is
possible to select one clearance angle that is suitable for a wide
range of applications. A rake angle can be allowed for in a similar
way to the methods used in the case of the flat form tool.

4.4. CIRCULAR FORM TOOL

A circular form tool is a specially-shaped disc that is ground to

produce a cutting edge. Fig. 4.12 shows a circular form tool, and it
will be seen that the ground top face is below the tool centre-line so
that a front clearance is obtained when the cutting edge is set to the
workpiece centerline. The top face is re-ground to sharpen the tool,
which is then re-set by rotating it about its axis to bring the new
cutting edge into position.

do
di

Workpiece

Serration

Fig.4.12. Circular form tool.

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Chapter -4 Design of Form Tool

4.4.1. Design the Circular Form Tool

The design of circular form tools incorporates the determination of
the tool dimensions and the tool profile. The form tool dimensions
are based on the assigned tool geometry and the chip space. The
tool profile, on the other hand, is to be deduced from the required
workpiece profile.

Tool geometry: The tool profile and the tool performance depend
on the rake and the clearance angles. The rake angle (γ) is selected
according to the workpiece material. The clearance angle (α) is
almost independent on the workpiece material. A recommended
value of 12° is usually assigned.
Chip Space (K): The tool face should have a sufficient space to
allow for proper chip flow, Fig.4.13. The larger the assigned feed
(f) the larger is the chip space distance (K). For a practical cross
feed range of 0.02 to 0.2 mm/rev the minimum required chip space
distance (K) lies in the range 3 to 12 mm. An empirical relationship
has been established to calculate the distance (K) as follows:

K = 25 f 0.5 (4.4)

Wall thickness (Δ): Circular form tools should have a sufficient

wall thickness, Fig.4.13, to avoid cracking during heat treatment.
The minimum wall thickness (Δ) should not be less than 6-8 mm.

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Chapter -4 Design of Form Tool

4.4.2. Graphical Determination of Circular Form Tool Profile

The outside diameter of a circular form tool is determined in
accordance with the height of the profile to be turned. A graphical
construction, Fig.4.13, is recommended for this purpose in
designing positive rake form tools (γ>0), which is done as follows:

- About axis “o” of the workpiece concentric circles were drawn

with radii equal to the radii of the contour to be turned.

- Through point A, at the angle “γ”, a line representing the trace

of the plane ground to produce the tool face was drawn.

- From the same point A a second line at an angle equal to the

relief angle “α” was drawn.

- At the distance “K” from the tangent to the maximum circle a

line perpendicular to “oo1” was drawn. The distance “K” is the
minimum amount that will permit chip disposal from the tool
face. From the point of intersection “e” of the vertical line and
the line of the tool face, a line bisecting the angle (2θ) was
drawn. The point of intersection of this bisector and the line
drawn at the angle “α” is the centre of the circular tool (o2).

- Knowing the tool centre “o2”, it is possible to draw circles with

different radii (e.g. o2b, o2c….etc.) and determine all the other
dimensions graphically.

- Radial serrations with a 90-degree profile are made on one end

face of a circular form tool for setting up and clamping

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Chapter -4 Design of Form Tool

purposes, Figs.4.3 & 4.12. In most cases the tools have 34

serrations. With the aid of a very simple mechanism these
serrations are used to turn the tool for adjustment the tool point
after regrinding the tool face, Fig.4.3. The dimensions of radial
serrations depending on chip thickness and the amount of chip
to be cut; di = 10 to 27 mm while do = 20 to 50 mm.

4.4.3. Analytical Determination of Circular Form Tool Profile

The proper design of circular form tools should necessarily aim at
the minimization of their manufacturing costs. This can be
achieved by finding out the minimum size of the tool that gives the
required workpiece form. This can be expressed as follows:
RC Min

According to Fig.4.13, the following relationships can be deduced:

sin(α + γ )
L = Rc (4.5)
cos(θ − γ )

RC cos(α) = L sin(θ) + K + t (4.6)

From Eq.4.5 & 4.6 the tool radius Rc is given by

K +t
Rc = (4.7)
⎡ sin(α + γ ) ⎤
⎢cos(α ) − cos(γ − θ ) sin(θ )⎥
⎣ ⎦

dRc
For minimum tool size: = 0 , which gives:
dθ

83
Chapter -4 Design of Form Tool

θ = 45° + γ/2 (4.8)

The minimum tool radius is therefore given by:

K +t
Rc =
⎡ sin(α + γ ) ⎤
⎢cos(α ) − cos(45 − γ / 2) sin( 45 + γ / 2)⎥
⎣ ⎦
or
K +t
RC = (4.9)
cos(α ) − sin(α + γ )

D
t K Δ
d

o2 A A α
Rc
o b
L o1
c θ
θ
e
γ

Workpiece profile Section A-A

Fig.4.13.Graphical presentation of the circular form tool profile.

84
 Chapter -4 Design of Form Tool

Rc o2
α
a
b
o rci
c γ
Zi

Y
Rw rc
X Rwi Yi
rci
rw Rc

o2

Rc
a d
o rw b α
γ
Zi rci
Rwi
c

Fig.4.14.Analytical presentation of the circular form tool profile.

85
Chapter -4 Design of Form Tool

For this solution to be feasible, the minimum permissible wall

thickness and the central hole diameter are to be taken into
consideration that is:

Rc cos(α) - K - t ≥ Δ + d/2 (4.10)

With
1 t +d /2+ K +Δ
E= ; G=
1 − tan(α ) cos(γ ) − sin(γ ) K +t

From relationships (4.9) and (4.10) the feasibility condition is:

E≥G (4.11)

In case this condition is not satisfied the tool radius RC will be

given by:

K +Δ+t +d /2
Rc = (4.12)
cos(α )

The form depth of the tool in the radial direction is calculated at

different sections along the workpiece using equations 4.13 to 4.16,
which yields the corresponding tool form coordinates. From
Fig.4.14 the radial depth of the tool (Y) is given by;

Yi = Rc − rci ; Ymax . = Rc − rc (4.13)

From the triangle bco2;

rci2 = [Rc – Zi cos(α+γ)] + [Zi sin(α+γ)]

2 2
(4.14)

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Chapter -4 Design of Form Tool

∴ rci = Rc2 + Z i2 − 2 Rc Z i . cos(α + γ ) (4.15)

From the triangle oac;

Zi = Rwi2 − rw2 .sin 2 (γ ) − rw .cos(γ ) (4.16)

Where Rw, rw are the largest and the smallest radii of the workpiece
form respectively. Rc and rc are the largest and smallest tool radii; I
= 1,2,3,…n is the order of the ith radial sections taken at distance Xi
along the workpiece axis. The coordinates of the tool form points in
a radial section are therefore (Xi, Yi). The tool form width (B) is
taken equal to the workpiece form width.

4.5. ANALYTICAL DETERMINATION THE PROFILE OF

THE GRINDING WHEEL

The form-grinding wheel is used to grind the form on the tool after
its heat treatment, in a radial section. It will have therefore the
opposite form of that of the tool, Fig.4.15.

The form of the grinding wheel can be calculated from the

following equation:

ui = Ymax − Yi (4.17)

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Chapter -4 Design of Form Tool

Y xi
Tool Form

ymax y
i
X
X
ui
Umax

Grinding wheel form

Fig.4.15. Grinding wheel form.

4.6. OPTIMUM CUTTING VARIABLES

The optimum tool life of the form tool is determined as follows.

C2 ⎡ 1 − m ⎤
TL = (4.18)
C1 ⎢⎣ m ⎥⎦

Where C1 = labour and the machine hour cost rate, C2 = tooling

cost/regrind, m is the tool life exponent (m = 0.2 for HSS).
The optimum cutting speed is then given by;

Cv
VOpt = m P
(4.19)
T .f
L

Where CV = tool life relationship coefficient including all

correction factors for tool and workpiece materials, cutting fluids.
…etc., P = is the exponent of the feed. Fig.4.16 shows the general
program flow chart for CAD of circular form tool.

88
Chapter -4 Design of Form Tool

START

Input lathe M/C specifications, W.P. Yi = Rc - rci

and tool details, (m, Rwi, rw, n, B, Cv,
TL, t, d, Δ)
Ui = Yi – ymax.

Read γ, α, f
no
i=n
0.5
K = 25 f
yes

1 Display: Tool,
E=
1 − tan(α ) cos(γ ) − sin(γ ) (xi,yi), (xi,ui)

K +Δ+t +d /2
G=
K +t Cv
Vopt = m p
T .f
L

no
E≥G
Print Rc, (xi,yi), (xi,ui),
K +Δ+t +d /2 B, t, d, f, Vopt
yes Rc =
cos(α )

K +t Stop
Rc =
cos(α ) − sin(α + γ )

i=1

Z i = Rwi2 − [rw sin(γ )]2 − rw cos(γ )

rci = Rc2 + Z i2 − 2 Rc Z i cos(α + γ )

Fig.4.16. Program flow chart for CAD of circular form tools.

89
Chapter -4 Design of Form Tool

4.7. SOLVED EXAMPLES

Example 1
a) Calculate the profile of a flat form tool that used for producing
the workpiece shown in Fig.4.7 presenting your results in a tabular
form and draw these results by scale 1:1. The rake and clearance
angles of the tool are 10 & 8o respectively. The initial diameter of
the workpiece is 60 mm.

119

10

10
30

φ60 φ20 φ40 φ30

15 35
R60
10 9

Fig.4.7

b) Calculate the optimum cutting variables (V and f) given that:

• Torsional stress for workpiece material ≤ 100 Mpa.
• The maximum Torque transmitted by the machine spindle =500
N.m
• The maximum shear stress of the cutting tool material = 150
MPa, (tool thickness=20 mm, and overhang tool length=25 mm).

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Chapter -4 Design of Form Tool

• The maximum deflection of the tool point ≤ 0.01 mm

• The cutting power ≤ 5 kW
• The tangential cutting force was calculated from the following
equation;
Fc = 2850 x b x f2 N

Where b = length of cutting edge; Fc:Fr = 3:2 (W.P Fixed between

chuck and center).

Solution
a-I) Calculation of the tool Profile
The tool profile (Yi) was clculated from Equation 4.3 and the
results are illustrated in Table 4.1. Fig.4.8 shows the graphical
representation of the calculated tool profile.

Table 4.1. the calculated profile of the form tool

Xi Rwi Zi Yi

0 10 0 0
10 10 0 0
10 30 20.1 19.1
20 30 20.1 19.1
29 20 10.1 9.6
44 18.09 8.2 7.8
59 20 10.1 9.6
69 20 10.1 9.6
84 15 5.2 4.8
119 15 5.2 4.8

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Chapter -4 Design of Form Tool

0 20 40 60 80 100 120 Xt
0

10

20
Yt

Fig.4.8. The calculated profile of the form tool.

To determine cutting edge length, the circumference of the curved

part was calculated as following:
Sin(θ/2) = (15/60) ∴θ = 29o
b1
∴b1 = (29/360)*(120π) = 30.3
∴b = 10 +13.5 + 30.3 +10 + 15.8 + 35 = 114.6 mm
θ/2
∴Fc = 2850 * 114.6 * f = 3.27*10 f N 2 5 2 R60

1- The maximum torsional stress was occurred at the minimum

workpiece diameter (20 mm) using the following equation:

y
τ = Tc
Ip

n
Tc = ∑ T = ∑ Fci * Di =
i =1
Where n is the number of the machined surfaces.

⎡ 20 50 38.1 40 35 30 ⎤
Tc = 2850 f 2 ⎢10 * + 13.5 * + 30.3 * + 10 * + 15.8 * + 35 * ⎥
⎣ 2 2 2 2 2 2⎦
= 5746213 f 2

5746213 f 2 * 10
∴τ = ≤ 150 ∴ f = 0. 2 mm / rev.
π 4
( 20 )
32

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Chapter -4 Design of Form Tool

2- The feed value related to the maximum torque transmitted by the

spindle was calculated as following:
∑T = 5746213f 2≤500*1000 ∴f = 0.29 mm/rev

3- The maximum shear stress of tool material was calculated from

the following equation:

Fc 3.27 * 10 5 f 2
σs = = ≤ 120 ∴ f = 0.935 mm / rev.
B.H 119 x 20

4- The maximum deflection of the tool was calculated from the

following equation:

Fc L3t 3.27 * 10 5 f 2 * (25) 3

Yt = = ≤ 0.01 ∴ f = 313 mm / rev.
3EI t 5 1 3
3 * 2.1 * 10 * 119 * 20
12

Therefore the minimum value of feed was 0.2 mm/rev.

The cutting force related to this value of feed is:

Fc = 3.27*105 * (0.2)2 = 13080 N.

The cutting power was calculated from the following equation:

Fc *V 13080 *V
Pc = = ≤5
60 *1000 *η 60 *1000 * 0.72

∴V = 16.5 m / min .

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Chapter -4 Design of Form Tool

Example 2
Construct the profile of a flat form-tool that used in machining the

workpiece shown in Fig.4.9 graphically and verifying your graphical

presentation by analytical solution presenting the calculation in a tabular

form. The rake and clearance angles are 10 and 8° respectively.

45o 45o

φ100 φ40 φ60

20 10 50 10

Parting width
10

Fig.4.9

b) If the workpiece fixed between chuck and center; determine the

optimum values of cut (V & f ) given that:

-The tangential cutting force was calculated from the following equation;

Fc = 3800 b0.3 f(1-m) N

Where b = length of cutting edge.

- The optimum tool life is 60 min, and C2/C1 = 15.

- The max. torque transmitted by the machine spindle = 5x105 N.mm.

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Chapter -4 Design of Form Tool

- The Max. cutting power is 4 Kw (η=0.85).

Note: The maximum cutting torque must be calculated based on the

summation of the torques of each surface at the instance of contacting the

full form of the cutting tool with the workpiece. The torque of the

inclined surfaces was calculated based on its average radius.

c) Calculate the cutting speed for 50 min. tool life.

d) For the optimum cutting conditions calculate the thickness, and the

overhanging tool length of a parting off-tool that used in separating the

workpiece from the rod. Knowing that the permissible deflection of the

parting-off ≤ 0.2 mm, E=2.1x105 MPa, and its shear strength ≤ 120 MPa.

Solution
a-I) Calculation of the tool Profile
The tool profile (Yi) was clculated from Equation 4.3 and the results are
illustrated in Table 4.2. Fig.4.10 shows the graphical representation of
the tool profile.

Table 4.2. the calculated profile of the form tool

Xi Rwi Zi Yi

0 20 0 0
20 20 0 0
30 30 10.1 9.49
80 30 10.1 9.49
90 20 0 0

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Chapter -4 Design of Form Tool

a-II) The graphical presentation of tool profile was illustrated in Fig.4.9.

b) Solution for Form Tool

20
30

80 90

Yt 20 30

80 90

Xt

Fig.4.10

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Chapter -4 Design of Form Tool

C 2 ⎡1 − m ⎤ ⎡1 − m ⎤
TL = ⎢ ⎥ = 15⎢ = 60 ∴ m = 0.2
C1 ⎣ m ⎦ ⎣ m ⎥⎦
n
Tc = ∑ T = ∑ Fci * Di =
i =1

⎡ 0.3 80 90 100 ⎤
= 3800 f 0.8
⎢⎣20 * 2 + 14.14 * 2 * 2 + 50 * 2 ⎥⎦
0.3 0.3

= 1744885 f 0.8
≤ 50000 ∴ f = 0.21 mm / rev.

∴Fc = 3800 (20 + 14.14*2 + 50 )0.3 (0.21)0.8 = 4312.5 N

Fc * V 4312.5 * V
Pc = = =4
60 * 1000 * η 60 * 1000 * 0.85

∴V = 47.3 m / min .

c) From Equation 2.5

V .TLm = C 2 ; i.e. VT1m = VT2m = ......

∴ 47.3 * 60 0.2 = V2 * 50 0.2 ∴V2 = 49 m / min .

d) Solution for Parting-Off Tool

Fc = 3800 (10 )0.3 (0.21)0.8 = 2175.5 N

Fc 2175.5
σs = = ≤ 120 ∴ H =1.81 mm
B.H 10 * H

Fc .L3t 2175.5 * L3t

Yt = = = 0.2 ∴ Lt = 6.6 mm
3EI t 5 1 3
3 * 2.1 * 10 * * 10 * 1.81
12

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Chapter -4 Design of Form Tool

Actually the overhang tool length must exceed than 50 mm (>

radius of the initial rood diameter). Therefore take Lt = 55 mm and
recalculate the tool thickness as following:

Fc .L3t 2175.5 * 55 3
Yt = = = 0.2 ∴ H = 15.1 mm
3EI t 5 1 3
3 * 2.1 * 10 * * 10 * H
12

Example 3
a) Analytically construct the profile of a flat form tool with 10o rake
angle and 8o clearance angle that used in machining the workpiece
shown in Fig.4.11. Present your calculate in a tabular and graphic
forms.
b) Assign the proper cutting values (V and f) given that:
- Torsional stress for workpiece material ≤ 150 Mpa.
- The maximum Torque transmitted by the machine spindle = 300 N.m
- The cutting power ≤ 5 KW

Fc = 2500 x b x f 2 N

Where b = length of cutting edge; Fc : Fr = 3:2 (W.P Fixed between

chuck and centers).

c) If the overhang tool length =25 mm and the permissible deflection of

the tool point ≤ 0.01 mm calculate the cross-section dimensions of tool
shank.

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Chapter -4 Design of Form Tool

10 15 5 5 70

10 30 10

R5 R48

Fig.4.11
Solution
a) To determine the profile length, the length of the curved part was
calculated as following:
sin(θ/2) = (35/48) ∴θ = 93.63o b1

∴b1 = (93.63/360)*(96π) = 78.45 mm

θ/2
R48
b2 = (90/360)*(10π) = 7.85 mm
∴b = 10 + 15 + 7.85 + 5 +78.45 = 116.3 mm
∴Fc = 2500 * 116.3 * f2 = 2.91*105 f2 N
y
τ = Tc
Ip
n
Tc = ∑ T = ∑ Fci * Di =
i =1

⎡ 10 30 15 10 25.15 ⎤
= 2500 f 2 ⎢10 * + 15 * + 7.85 * + 5 * + 78.45 *
⎣ 2 2 2 2 2 ⎥⎦
= 3363459 f 2
10
3363459 f 2 *
∴τ = 2 ≤ 150 ∴ f = 0.09 mm / rev.
π 4
(10)
32

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Chapter -4 Design of Form Tool

b) Tc ≤ 300000 ∴3363459 f2≤ 300000 ∴f = 0.3 mm/rev.

∴Fc = 2.91*105 *0.092 = 2357 N

Fc *V 2357 *V
Pc = = =5
60 *1000 *η 60 *1000 * 0.72
∴V = 91.6 m / min .

c) Tool dimensions

B = 10 + 15 + 5 + 5 + 70 = 105 mm
Fc .L3t 2357 * 253
Yt = = = 0.01
3EI t 1
3 * 2.1 *10 5 * *105 * H 3
12
∴ H = 8.74 mm

4.8. PROBLEMS

1. Show with the aid of sketch the different types of form tools.
2. State the advantages and disadvantages of dovetail form tool?
3. Drive the equation for determining the profile of flat form tool.
4. Drive the equation that determining the profile of circular form
tool.
5. Writ the program flow chart for CAD of circular form tool.
6. Construct a flat form tool with 10o rake angle and 8o clearance
angle for producing the workpiece shown in Fig.4.17. Calculate
the tool profile presenting your results in a tabular form. The
tool should be represented by at least two views. The workpiece
material is steel rod with 80.2 mm diameter.

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Chapter -4 Design of Form Tool

a) Assign the proper cutting values (V and f) given that:

- Torsional stress for workpiece material ≤ 100 Mpa.
- The max. bending stress of the tool material ≤ 600 MPa,
(tool thickness= 50 mm and overhang length= 60 mm)
- The max. deflection of tool point ≤ 0.01 mm.
- The cutting power ≤ 5 KW
- The limiting width of cut is given by the following Eq.:

blim = (12 – 0.9 V + 0.06 V2).f-0.8 ≥ b mm

Fc = 2500 x b x f 0.6 N

Where b = length of cutting edge; (W.P Fixed between centers);

E= 2.1x105 MPa).

10

R20

100

50
80

Fig.4.17

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Chapter -4 Design of Form Tool

7. It is required to machine a steel workpiece with 50 mm length

and 32 mm diameter, to the dimensions illustrated in Fig.3.18
using a flat form tool. The workpiece was fixed between centers
of the lathe machine. Determine the optimum values of cut (n &
f ) given that:
-C2/C1 = 16
-The optimum tool life is 64 min.
-The maximum torque transmitted by the machine spindle =
3x105 N.mm
- The maximum deflection in the workpiece ≤ 0.15 mm.

Where b = length of cutting edge; E=2.1x105 MPa and Fc:Fr= 3:2

-The main cutting forces

Fc = 2500 b0.9 f (1-m) N

-The optimum cutting speed (V) equal

41 m/min
V =
T Lm . f 0 . 25

- Calculate the cutting power at the optimum cutting conditions

102
Chapter -4 Design of Form Tool

3 3 3

φ30 φ22

50

Fig.4.18

8. a) Draw the profile of a circular form tool (scale 1:2) that can be
used for producing the workpiece shown in Fig.1. Given that the
rake and clearance angles are 10 and 8o respectively and chip
space factor = 7 mm.

b) If a square flat form tool was used to produce the same

workpiece that shown in Fig.1, calculate the optimum cutting
conditions (V and S) given that:
- Maximum force offered by the feed mechanism ≤ 5000 N
- The maximum torque transmitted by machine spindle =300 N.m
- The maximum shear stress of the tool material =120 MPa.
- Maximum cutting power ≤ 8 Kw, η = 0.72

Fc = 3000 x b x f 2 N

Where b = length of cutting edge; Fc : Fr = 3:2 (W.P Fixed

between centers).

103
Chapter -4 Design of Form Tool

b) Calculate the maximum over hanging tool length that give

maximum tool deflection ≤ 0.02 mm at the optimum cutting
conditions, E = 2.1 x 105 MPa.

20

15 R 20

Fig.4.19

9. a) It is required to machine a steel workpiece to the dimensions

illustrated in Fig.4.20 (initial diameter of the workpiece = 30.5
mm) using flat form tool with 20 mm thickness. The workpiece
was fixed between centers of the lathe machine.
b) Determine the maximum value of feed (mm/rev) based on the
permissible torque transmitted by the machine spindle = 3x105
N.mm; given that:
- C2/C1 = 16
- The tool life is 64 min. and cutting speed = 20 m/min.
- The main cutting forces

Fc = 2100 b0.75 f(1-m) N

104
Chapter -4 Design of Form Tool

Where b = length of cutting edge; E=2.1x105 MPa and Fc:Fr= 3:2

c) Determine the maximum tool overhang length based on the

maximum tool deflection ≤ 0.1 mm.
c) Calculate the tool life if this cutting tool working at cutting
speed equal 30 m/min.

8 5 8

φ30 φ18

145

Fig.4.20

10. Construct a flat form tool with 10° rake angle and 10° clearance
angle for producing the shown workpiece profile. Calculate the
tool profile presenting your results in a tabular form. The tool
should be represented by at least two views.
Assign the proper cutting values (V and f) and tool dimensions
(length and thickness) such that the permissible values of
stresses of the tool and workpiece not exceeded the following
values:

- Bending stress for workpiece and tool materials ≤ 250 Mpa.

- Torsional stress for workpiece material and shear stress for

105
Chapter -4 Design of Form Tool

cutting tool material ≤ 100 Mpa.

- The cutting power ≤ 20 kW.

Fc = 9500 x b x f 0.095

Where b= length of cutting edge; Fc:Fr=3:2 (W.P Fixed between

centers).

R10

φ50 φ45

25 25 20

100

Fig.4.21

106