DESIGN OF CUTTING TOOLS

ADTDM -4TH SEM

A4-07

MSME Technology Centre Bhiwadi 2

COURSE OBJECTIVES/INSTRUCTIONAL OBJECTIVES
Students will be able
• Classify cutting tools.
• Understand the process of cutting tools & tools used.
• Understand the Properties of cutting fluid.

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COURSE OUTCOMES :
Students will be able
• Understand the concept of & applications of cutting tool.
• Understand the Properties of cutting fluid.
• Understand practical use of cutting tools

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UNITS
1. INTRODUCTION CUTTING TOOL
2. TOOL GEOMETRY
3. METAL CUTTING THEORY
4. CUTTING TOOL LIFE
5. DESIGN OF CUTTING TOOL
6. MAINTENANCE OF CUTTING TOOL

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INTRODUCTION CUTTING TOOL
UNIT-1

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OUTCOMES
Student should be able to
• Define the cutting tool.
• List the different types of cutting tool.
• Understand the cutting tool.

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CONTENTS
• Introduction
• Definition of cutting tool
• Different types of cutting tool

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Introduction
• One of most important components in machining process
• Performance will determine efficiency of operation
• Two basic types (excluding abrasives)
• Single point
• Multi point
• Must have rake and clearance angles ground or formed on them

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 Cutting-Tool Materials
The tools are classified into an extensive line of material used, such as:

• Lathe tool bits generally made of five materials

• High-speed steel
• Cast alloys (such as stellite)
• Cemented carbides
• Ceramics
• Cermets
• More exotic finding wide use
• Borazon and polycrystalline diamond

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 High-Speed Steel Toolbits
• May contain combinations of tungsten, chromium, vanadium,
molybdenum, cobalt
• Can take heavy cuts, withstand shock and maintain sharp cutting edge
under red heat
• Generally two types (general purpose)
• Molybdenum-base (Group M)
• Tungsten-base (Group T)
• Cobalt added if more red hardness desired

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 Cemented-Carbide Toolbits
• Capable of cutting speeds 3 to 4 times high-speed steel toolbits
• Low toughness but high hardness and excellent red-hardness
• Consist of tungsten carbide sintered in cobalt matrix
• Straight tungsten used to machine cast iron and nonferrous materials
(crater easily)
• Different grades for different work

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 Coated Carbide Toolbits
• Made by depositing thin layer of wear-resistant titanium nitride,
titanium carbide or aluminum oxide on cutting edge of tool
• Fused layer increases lubricity, improves cutting edge wear resistance by 200%-
500%
• Lowers breakage resistance up to 20%
• Provides longer life and increased cutting speeds
• Titanium-coated offer wear resistance at low speeds, ceramic coated for
higher speeds

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Ceramic Toolbits
• Permit higher cutting speeds, increased tool life and better surface finish
than carbide
• Weaker than carbide used in shock-free or low-shock situation
• Ceramic
• Heat-resistant material produced without metallic bonding agent such as cobalt
• Aluminum oxide most popular additive
• Titanium oxide or Titanium carbide can be added

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Diamond Toolbits
• Used mainly to machine nonferrous metals and abrasive nonmetallics
• Single-crystal natural diamonds
• High-wear but low shock-resistant factors
• Polycrystalline diamonds
• Tiny manufactured diamonds fused together and bonded to suitable carbide
substrate

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 Types of Cutting Tools
• The types of cutting tools we’ll focus here is on milling and lathe cutting tools, including end mills, drills, and taps.
• End Mills are the most common cutting tools for CNC and manual mills and are generally used for machining the sides
and faces of a workpiece.
1. High-Speed Steel End Mill materials are designed for a variety of milling process on most materials. These tools are
available in a variety of sizes and can be single or double ended.
2. Standard Carbide End Mills are designed for general milling operations on all materials.
3. Performance Carbide End Mills are designed for specific applications, such as machining plastic, steel, and
aluminum.
• Drills are useful for mill and lathe work to drill holes into a workpiece. Drill bits are available in a variety of sizes and
styles. Center drills, Spot drills, Screw machine drills, and jobber length drills are just to name a few.
1. Center Drills are double ended high-speed steel and are ideal for setting up a live center (similar to a dead center).
It can cut at a 60-degree divot at the end of a workpiece.
2. Carbide steel spot/chamfer drill-mills are ideal for countersinking or spot drilling, drilling and edge chamfering.
3. Screw Machine Drills can be utilized for general-purpose drilling for most materials including steel, and are
available in a variety of sizes, including fractional, wire, and letter systems.
4. Jobber Length Drills could also be utilized for general-purpose drilling for most materials, including steel.

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• Taps, such as Spiral point taps or spiral flute taps, are ideal for cutting
threads into previously drilled holes. Taps are available for both general-
purpose and high-performance operations.
• General Purpose Spiral Flute Taps are ideal for creating threads in part on a
CNC mill.
• General Purpose Spiral Point Taps can be utilized on most metals and are
ideal for creating threads and through holes in a part of CNC mill.
• High-Performance Spiral Flute Taps are ideal for threading aluminum and
stainless-steel parts.
• High-Performance Spiral Flute Taps can be used for threading aluminum and
stainless-steel parts.

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 CUTTING TOOL
NEED OF CUTTING TOOL IN
INDUSTRY:

DIFFERENT TYPES OF CUTTING

TOOL

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IMPORTANT ELEMENTS FOR METAL CUTTING:

1. MATERIAL OF CUTTING TOOL HARDER THAN THE JOB

MATERIAL
2. SHARP EDGE
3. RELATIVE MOTION BETWEEN CUTTING TOOL & WORK

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HISTORY OF CUTTING TOOL

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Question
• 1. what are the Cutting-Tool Materials used for manufacturing?
• 2. what are the Types of Cutting Tools?
• 3. Definition of cutting tool?

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TOOL GEOMETRY
UNIT-2

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 OUTCOMES
Student should be able to
• Differentiate between single & multi point cutting tool.
• Explain the single point cutting tool with nomenclature.
• Explain the multipoint cutting tool with nomenclature.
• Understand the nomenclature of drill, tap, die, reamer, milling cutter, hob,
broach

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CONTENTS
• Single point cutting tool
• Nomenclature of single point cutting tool
• Tool signature, Multi point cutting tool
• Nomenclature of multi point cutting tool - Drill, Tap, Die , Reamer,
Milling cutter, Hob, Broach.

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BASIC GEOMETRY OF CUTTING TOOL

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POINT ANGLES
BASIC GEOMETRY OF CUTTING TOOL
• BASIC GEOMETRY OF CHISEL
• GEOMETRY OF HACK-SAW
cutting tool
1. Single Point cutting tool:
• One cutting point or tip is available
• Example: Lathe Machine, Planning Machine tool
2. Multi-Point cutting tool:
• More than One cutting point or tip is available
• Example: Milling cutter, Grinding wheel, drill tool, extra.

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Single Point Cutting Tool Geometry /
Nomenclature:
• Shank Angle:
• Flank Side Cutting edge angle
• Face End cutting edge angle
Side relief angle
• Heel End relief angle
• Nose Back Rack angle
Side rack angle
• Nose radius
• Cutting Edges

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Nomenclature of single point cutting tool:
• 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.
• 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.
2: Flank:
• The surface or surfaces below the adjacent to the cutting edge is called flank of the tool.
3: Face
• The surface on which the chip slides is called the face of the tool.
4: Heel
• It is the intersection of the flank and the base of the tool.
5: Nose
• It is the point where the side cutting edge and end cutting edge intersect.
6: Cutting Edge
• It is the edge on the face of the tool which removes the material from the work piece. The cutting edge consists of the
side cutting edge(major cutting edge) and cutting edge(minor cutting edge) and the nose.

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Single Point Cutting Tool Advantages:
• The main advantages are:
• Design and fabrication are easy.
• This tool is a little cheaper in price.
Single Point Cutting Tool Disadvantages:
• The main disadvantages are:
• There is having little high tool wear rate.
• Shorter tool life. Single Point Cutting Tool Application:
This tool is used in several machines for producing a flat surface like:
• Low metal removal rate. Lathe machine
Shaper Machine and more
• Low productive.

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 FAQ:
1.What is Single Point Cutting Tool?
2.Is Drill bit Single Point a tool?
• No. It is a different one. Drill bit tool used in the drilling machine.
3.What is the Nomenclature of the Single Point tool?
4.Is this tool Perform in Milling Machine?
• No. Here Multiple cutting tools perform.
5.On Which Machine Single Point cutting tool used? and What
Operation it performs?
• The machines like: Lathe, Shaper, Planer, Slotter, these tools used.
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 Tool Geometry
• Both material and geometry of the cutting tools play very important roles
on their performances in achieving effectiveness, efficiency and overall
economy of machining

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Why SIGNATURE ???
• The numerical code that describes all the key angles of a given cutting
tool . A tool signature may be used for HSS or carbide inserts
• Convenient way to specify tool angles by use of a standardized
abbreviated system is known as tool signature or tool nomenclature.
• It indicates the angle that a tool utilizes during the cut.
• It specifies the active angles of the tool normal to the cutting edge.
• This will always be true as long as the tool shank is mounted at right
angles to the W/P axis.

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Tool Designation
• 1. ASA System (American Standard Association)
• 2. ORS System (Orthogonal Rake System)
• 3. NRS System (Normal Rake System)

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ASA (American Standard Association)
• It is pure geometrical in nature i.e no calculation as of mechanics.
• The ASA specify the tool geometry with three intersecting orthogonal
plane i.e one plane parallel to and other plane perpendicular to the cutting
tool n both of the them orthogonal to base of tool
1. P(b)-Base plane ; plane perpendicular to velocity vector or parallel to the base of
tool.
2. P(l)- Machine longitudinal plane ; plane orthogonal to the base plane n taken in
direction of assumed longitudinal feed.
3. P(t)- machine transverse plane; plane perpendicular to both Base plane and
Longitudinal plane
• It uses rectangular coordinate system but actual cutting plane of cutting
tool.

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Various tool angle specified in ASA system
• Back rake angle
• Side rake angle
• End relief angle
• Side relief angle
• End cutting edge
• Side cutting edge

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Schematic diagram of
ASA system

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TOOL DESIGNATION (ASA)
ORS (Orthogonal Rake System )
• ORS also called as old ISO system.
• The actual cutting plane is utilized and all the angles are measured in a
plane corresponding to cutting tool.
• The cutting plane is defined as the plane where the base of cutting tool is
present
• The cutting plane is defined as the plane normal to base plane and passing
through the principal cutting edge
• Base plane P(b):-Plane perpendicular to the cutting velocity vector
• Cutting plane P(c):-Plane perpendicular to P(b).and taken along principle
cutting edge.
• Orthogonal plane P(o):-Plane perpendicular to bot P(b) & P(c) and the axes.
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Various tool angle specifies in ORS system
• Inclination angle (i)
• Orthogonal rake angle ()
• Orthogonal clearance of principal flank angle
• Auxiliary orthogonal clearance angle
• Principal cutting edge angle
• Auxiliary cutting angle
• Nose radius

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Schematic diagram
of ORS system

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TOOL DESIGNATION (ORS)
ISO System or NORMAL RAKE system (NRS)
• The major problem with ORS system are these:
1.The true geometry of the cutting tool is not revealed when the cutting edges
are inclined from the base plane.
2.Also, tool grinding in ORS required additional calculation for setting of angles in
the cutter grinder .
• To overcome this problem NRS was introduced
• In this system the rake angle is visualized in the normal plane in place of
orthogonal plane in ORS
• In this system the base and cutting plane are same as ORS , but the third plane is
perpendicular to cutting edge of tool it is called the normal plane .
• In this system, the side rake angle is defined as the angle between the base plane
of tool and the rake face of the tool measured in a plane normal to side cutting
edge

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Typical problem of Tool Signature

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NOMENCLATURE OF FILE
NOMENCLATURE OF FILE
NOMENCLATURE OF FILE
METAL FORMING
NOMENCLATURE OF SINGLE POINT CUTTING TOOL
POSITIVE & NEGATIVE RAKE ANGLE
RIGHT- HAND & LEFT- HAND TOOL
RH ,LH & SYMMETRICAL TOOL
EFFECT OF CENTRE HIGHT
LATHE TOOL &
OPERATIONS(EXTERNAL)
LATHE OPERATIONS (EXTERNAL)
LATHE TOOL & OPERATIONS (INTERNAL)
LATHE TOOL & OPERATIONS (INTERNAL)
LATHE TOOL& OPERATIONS (INTERNAL)
LATHE TOOL& OPERATIONS (INTERNAL)
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Classification of cutting tools

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What is multi point cutting tool?
• A multi-point cutting tool contains more than two main cutting edges
that simultaneously engage in cutting action in a pass. Sometime,
cutters with two cutting edges (more than one) are also considered
multi-point cutting tools (instead of considering it as a double point
cutter). The number of cutting edges present in a multi-point cutter
may vary from three to few hundreds. Since cutting edge appears at
the intersection of rake surface and flank surface, so a set of rake
surface and flank surface also exists for each cutting edge.

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 Examples of multi-point cutting tool
• Milling cutters are the common example for this category. Except fly
milling cutter (a single point cutter), others are usually multi-point
cutter. It can contain three cutting edges (say small end mills) to as high
as 40 cutting edges for heavy duty large cutters. Apart from milling
cutters, few other examples of multi-point cutter are enlisted below.
• Reamer (tool for reaming operation)
• Broach (tool for broaching operation)
• Hob (tool for hobbing operation)
• Grinding wheel (abrasive cutter)
• Hone (tool for honing operation)

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Advantages of multi-point cutting tool
• Since total feed rate or depth of cut is equally distributed among all cutting
edges, so chip load on each cutting edge reduces greatly. Thus higher feed rate or
depth of cut can be utilized to improve material removal rate for enhancing
productivity.
• Because of the distribution of chip load, force acting on each cutting edge
reduces significantly. Sometime, one component of cutting force as a whole gets
eliminated/reduced automatically (resultant of one cutting force component in a
particular direction may become zero).
• During machining, none of the cutting edge remains in continuous contact with
the work piece; instead, engagement and disengagement occur repeatedly. This
provides sufficient time to disperse heat from the tool body, which protects the
cutter from excessive heating and plastic deformation. Thus lower rate of
increase in tool temperature is observed due to intermittent cutting action.
• Due to lesser period of engagement and lesser heat accumulation within the tool
body, tool wear rate also reduces. Consequently, life of the cutter increases
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Disadvantages of multi-point cutting tool
• Due to intermittent cutting, cutting edges or teeth are subjected to
fluctuating load. This creates noise, vibration and endurance failure of
the cutter.
• Design and fabrication of the cutter is comparatively difficult. This
makes such cutter costlier.

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NOMENCLATURE OF TWIST DRILL
POINT GEOMETRY OF TWIST DRILL
HELICAL ANGLE OF THE DRILL
EFFECTS OF IMPROPER DRILL BREAKAGE
GEOMETRY
DRILL BREAKAGE
Reamers - Nomenclature and Definitions
AXIS
- The longitudinal centre-line of the reamer.
BODY
- That portion of the reamer extending from the entering end of the reamer to the commencement of the shank.
SHANK
- That portion of the reamer by which it is held and driven.
(i) Straight or parallel shank for machine use. A cylindrically ground shank without square.
(ii) Parallel hand shank. A cylindrical ground shank provided with a square at its extreme for driving the reamer.
(iii) Taper shank. A shank of recognized standard taper for machine use.
RECESS
- That portion of the body which is reduced in diameter below the cutting edges, pilot or guide diameters.
FLUTES
- The grooves in the body of the reamer to provide cutting edges, to permit the removal of chips, and to allow cutting fluid to reach the cutting edges.
CUTTING EDGE
- The edge formed by the intersection of the face and the circular land or the surface left by the provision of primary clearance.

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FACE
- That portion of the flute surface adjacent to the cutting edge on which the chip impinges as it is cut from the work.
LAND
-That portion of the fluted body not cut away by the flutes; the surface or the surfaces included between the cutting edge and the heel.
CIRCULAR LAND
-The cylindrically ground surface adjacent to the cutting edge, on the leading edge of the land .

HEEL

- The edge formed by the intersection of the surface left by the provision of secondary clearance and the flute.

PRIMARY CLEARANCE

- That portion of the land removed to provide clearance immediately behind the cutting edge.

SECONDARY CLEARANCE

- That portion of the land removed to provide clearance behind the primary clearance or circular land.

TAPER LEAD

- The tapered cutting portion at the entering end to facilitate the entry of the reamer into the hole. (It is not provided with a circular land).

BEVEL LEAD

- The angular cutting portion at the entering end to facilitate the entry of the reamer into the hole. (It is not provided with a circular land).

BACK TAPER

- The reduction in diameter per inch length of reamer from the entering end towards the shank

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NOMENCLATURE OF REAMER
TYPES OF REAMER
TAP NOMENCLATURE
• Bottoming Tap: A tap having a chamfer length of 1-2 threads.
• Chamfer: The tapering of the threads at the front end of each land of a chaser, tap or die by cutting away and
relieving the crest of the first few teeth to distribute the cutting action over several teeth.
• Chamfer Angle: The angle formed between the chamfer and the axis of the tap or die by cutting away the relieving
the crest of the first few teeth to distribute the cutting action over several teeth
• Crest : The surface of the thread which joins the flanks of the thread and it’s farthest from the cylinder or cone from
whi8ch the thread projects
• Flank: The part of a helical thread surface which connects the crest and the root and which is theoretically a straight
line in an axial plane section.
• Flute: The longitudinal channel formed in a tap to create cutting edges on the thread profile and to provide chip
spaces and cutting fluid passage.
• Hand of Threads: A thread when viewed axially, winds in a clockwise and receding direction for LEFT-HAND
THREADS and counter clockwise and receding direction for RIGHT-HAND THREADS
• Hook, Chordal : A concave face having an angle of inclination specified between a chord passing through the root
and crest of a thread form at the cutting face, and a radical line through the crest at the cutting edge.
• Hook, Tangential: A concave face having an angle of inclination specified between a line tangent to the hook surface
at the cutting edge and a radial line to the same point. Hook Angle The angle of inclination of a concave face usually
specifies either as CHORDAL HOOK or TANFENTIAL HOOK
• Interrupted Thread Tap: A tap having an odd number of lands with alternative teeth in the thread helix removed. In
some cases alternative teeth are removed only for a portion of the thread length.
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• Land : One of the threaded sections between the flutes of a tap
• Lead of Thread : The distance a screw thread advances axially in one complete turn. On a single start
tap the lead and pitch are identical. In a multiple start tap the lead is the multiple of the pitch
• Major Diameter : The diameter of the major cylinder or cone, at a given position on the axis that
bounds the roots an external thread of the crests of an internal thread
• Minor Diameter: The diameter of the minor cylinder or cone, at a given position on the axis that
bounds the roots an external thread of the crests of an internal thread
• Pitch Diameter : The diameter of an imaginary cylinder or cone, at a given point on the axis, of such a
diameter and location of its axis that its surface would pass through the thread in such a manner as
to make the thread ridge and the thread groove equal and, therefore, is located equidistant between
the sharp major and minor cylinders or cones of a given thread form. On a theoretically perfect
thread, these widths are equal to one half of the basic pitch (measured parallel to the axis.) See
illustration below.
• Plug Tap : A tap with 3 to 5 chamfered threads.
• Spiral Point : The angular fluting in the cutting face of the land at the chamfered end. It is formed at
an angle with respect to the tap axis of opposite hand to that of rotation. Its length is usually greater
than the chamfer length and its angle with respect to the tap axis is usually great enough to direct
the chips ahead of the tap. The tap may or may not have longitudinal lines.
• Square : Four driving flats parallel to the axis on a tap shank forming a square or square with round
corners.
• Taper Tap: A tap having a chamfer length of 7 to 10 threads

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NOMENCLATURE OF TAP
NOMENCLATURE OF THREAD
TAPPING OPERATION
Die/ Die nuts for external threads
• A die cuts an external thread on cylindrical material,
such as a rod, which creates a male threaded piece
that functions like a bolt. Dies are generally made in
two styles: solid and adjustable. An adjustable die
may be adjusted either by an integrated screw or by
a set of screws set in to the die holder (termed a
"die stock").
• A tap is used to cut the female portion of a mating
pair, like a nut, while a die is used to cut the male
portion, like a screw or bolt

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 Milling Cutter - Nomenclature and Angles
• A milling cutter can be considered as the cluster of single point cutting
tool. Above figure shows a plain milling cutter. The various parts of milling
cutter teeth are cutting edge, face, filling, and body. The teeth of milling
cutter either straight (the cutting edge is parallel to the axis of rotation) or
helical shaped.

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 Elements of plain milling cutter
• Body of cutter: It is the main frame of milling cutter, on which the teeth rest.
Periphery: It is defined as the locus of cutting edges of tooth of cutter.
Cutting edge: It is the portion that touches the workpiece during cutting action. It is the intersection of teeth
face and tooth flank.
Fillet: portion where one teeth joins the face of another tooth. It is a reinforcement to cutting tooth.
Face of teeth: it is the surface upon the chip is formed while cutting. It may be curved or flat.
• Back of tooth: it is the created by fillet and the secondary clearance angle.
Land: it is the narrow surface on the back of cutting edge. Land is the result of providing the clearance angle.
Bottom Land: the blank space between the consecutive teeth.
Root diameter: diameter passing through centre of cutter and joining two ends of the periphery.
Root diameter: passing through centre of cutter and joining two bottom fillet.

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 • Angles of milling cutter
• Lip angle: It is the angle between the face of the teeth and the land of the teeth. Land is
a narrow surface on the back of teeth.
Relief angle: it is the angle between the tangent to the outside diameter of the cutter
at cutting edge and the land of the tooth. The function relief angle is to avoid the
interference between the land of the tooth and the work surface. The relief angle
varies with the type of material to be machined.
Radial rake angle: it is the angle between the face of teeth and the radial line passing
through the cutting edge of the tooth. The radial rake angle may be positive, negative
or zero. It is provided free cutting by allowing chips to flow smoothly on the face of the
cutter.
Zero rake angle: tooth face and radial line
coincide.
Positive rake angle: tooth body and tooth face is
the same side of the radial line.
Negative rake angle: tooth surface and radial
angle are on opposite side of the radial line.
Axial rake angle: angle between the line of peripheral cutting
edge and axis of the cutter. It is an angle in a plane
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NOMENCLATURE OF PLAIN MILLING CUTTER
HOLDING OF MILLING CUTTER
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The hob
• he hob is a cutting tool used to cut the teeth into the workpiece. It is
cylindrical in shape with helical cutting teeth. These teeth have
grooves that run the length of the hob, which aid in cutting
and chip removal. There are also special hobs designed for special
gears such as the spline and sprocket gears.

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Common types of hobs include:
• Roller chain sprocket hobs
• Worm wheel hobs
• Spline hobs
• Chamfer hobs
• Spur and helical gear hobs
• Straight side spline hobs
• Involute spline hobs
• Serration hobs
• Semitopping gear hobs

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NOMENCLATURE OF HOB
 Uses
Hobbing is used to make the following types of finished gears:
• Cycloid gears (see below)
• Helical gears
• Involute gears
• Ratchets
• Splines
• Sprockets
• Spur gears
• Worm gears
• Hobbing is used to produce most throated worm wheels, but certain tooth profiles
cannot be hobbed. If any portion of the hob profile is perpendicular to the axis, the
hob will not have the cutting clearance generated by the usual backing off process
and will not cut well.

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SPECIAL CUTTERS
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Introduction to Broaching
• Broaching is where a tool, with successively increasing tooth size, is
moved through the workpeice, creating the desired shape with a
single pass.
• Broaching is similar to sawing, with the exception that a saw requires
multiple passes, and the teeth are not increased in size along the
length of the tool.
• Broaching can be used for holes of various geometry, grooves, and
flat surface features.

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Basic Geometry of a Broach

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Cutting Geometry of a Broach

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Fundamentals of Broaching
• In broaching, the tool (or work) is translated past the work (or tool)
with a single stroke of velocity V.
• The feed is provided by a gradual increase in height of successive
teeth.
• The rise per tooth varies depending on whether the tooth is for
roughing (tr), semifinishing (ts), or final sizing or finishing (tf).

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Advantages and Disadvantages
• Broaching is a rapid method of producing a finished feature.
• Complex geometries are possible using broaching
• Custom tools must be produced for each feature at $15K to $30K per tool
• Standard keyways can used off the shelf tooling
• Broaching requires that the geometry be two dimensional with a straight
profile.
• Broaching requires that the tool be able to pass fully through the part.
• Broach designs require that the tool be stiff enough for the work required,
small geometries are a challenge.

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Broach Design

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Principle Components of a Broach

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Broach Examples

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BROACH & BROACHING
OPERATIONS
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NOMENCLATURE OF BROACH
Question
1. Differentiate between single & multi point cutting tool?
2. Explain the single point cutting tool with nomenclature.
3. Explain the multipoint cutting tool with nomenclature.
4. Explain the nomenclature of drill?
5. Explain the nomenclature of tap?
6. Explain the nomenclature of die?
7. Explain the nomenclature of reamer?
8. Explain the nomenclature of milling cutter?
9. Explain the nomenclature of hob?
10. Explain the nomenclature of broach?

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METAL CUTTING THEORY
UNIT-3 MSME Technology Centre Bhiwadi 150
OUTCOMES
Student will be able to -
• List the methods of metal cutting.
• Elaborate the orthogonal and oblique cutting.
• Differentiate between the orthogonal and oblique cutting.
• Understand the mechanics of metal cutting.
• Understand the chip formation process.
• Explain chip breakers.

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CONTENTS
• Methods of metal cutting,
• Orthogonal cutting
• Oblique cutting
• Mechanics of metal cutting
• Chip formation
• Chip breakers

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 Learning About Various Metal Cutting
Methods
• Within steel and the rest of the metal working world, cutting and separating metals is a vital process. There are numerous metal cutting methods out there, starting with basic hand-held items like hacksaws, chisels or shears.
We have these products available at Wasatch Steel, and we also have the necessary items for many larger cutting projects. Let’s look at several machine-cutting processes, and how they work with various metals.
• Turning
Turning involves applying the sharp point of a cutting tool to a metal surface as it’s rapidly spun. This removes the top layer of metal to a pre-determined size.
• Grinding
Grinding involves a smooth metal surface and very high-quality metal. A grinding machine has an abrasive wheel that turns while making contact with the metal, wearing the surface down and helping separate it.
• Drilling
Drilling requires a drill bit applied directly to metal, then the typical combination of force and rotation that you’d see when a screw was being drilled into a wall. Drilling allows for very precise holes in metal where needed.
• Welding
Welding or burning techniques involve application of high heat to the surface metal, which brings it up to a temperature at which it will soften and then break along a precise line.
• Flame
A gas flame that reaches a temperature of above 3,500 degrees Celsius can also be used. This heats the metal to melting point, then directs a stream of oxygen onto the spot, causing the metal to burn and melt along a line.
• Laser
Laser cutting is relatively similar – using a concentrated beam of light that can be reduced to a single point at a very high temperature. This allows exact, precise shapes to be cut out of metal, and lasers are often controlled by a computer to
get maximum accuracy here.
• Plasma
A more recent technique is plasma cutting, which uses a plasma torch to pump either oxygen or inert gas out of the nozzle while simultaneously sending an electrical arc through the gas. This creates plasma hot enough to melt metal while
moving quickly enough to blow metal molten away.
• Water Jet
Water jets, or erosion technology, mimic the effect of water on metal in the natural environment – just at a much higher rate. This method doesn’t rely on any heat, and can therefore be used on metals that are sensitive to high heat.

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 METHODS OF METAL CUTTING
(ORTHOGONAL & OBLIQUE CUTTING)
 Orthogonal Cutting :-
• Orthogonal cutting is a type of cutting in which the cutting tool is
perpendicular to the direction of tool motion. In this cutting, the flow of
chip is perpendicular to cutting edge. The tool has lesser cutting life in
this type of cutting.

In Orthogonal cutting, the direction of flow of chip is perpendicular to the direction of movement of cutting edge.
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 Oblique Cutting :-
• Oblique cutting is a type of cutting in which cutting tool is at an
oblique angle to the direction of tool motion. In this cutting, the flow
of chip is not perpendicular to cutting edge. The tool has greater
cutting life as compared to orthogonal cutting.

In Oblique cutting, the direction of flow of chip is not perpendicular to the direction of movement of cutting edge.
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• The main difference between orthogonal and oblique cutting is that
in orthogonal cutting, cutting edge of tool is perpendicular to the
direction of motion but in oblique cutting the cutting edge make an
angle with direction of motion.
Link for deferance
• https://www.youtube.com/watch?v=ZZg2IGKxxCY

• Apart from this , there are other difference which are stated below :-

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MECHANICS OF METAL CUTTING

chip

cutting tool

workpiece
MECHANICS OF METAL CUTTING
MECHANICS OF METAL CUTTING
MECHANICS OF METAL CUTTING
HEAT GENERATION IN METAL CUTTING
METAL DEFORMATION
METAL DEFORMATION
METAL DEFORMATION
METAL DEFORMATION
GEOMETRY OF CHIP FORMATION
CHIP FORMATION
TYPES OF CHIP
Three Types of Chips
Resulting Finishes of Chip Formation
CHIP BREAKER
Definition of chip breaker
• the function of a chip breaker is to improve chip control and to
reduce cutting resistance. A better balance between the two will
increase the machining performance.
• If chips can be broken into suitable lengths by the chip breaker, they
will not wrap around the workpiece, vibration will decrease and tools
will not be so easily damaged. Chip breakers also affect cutting
resistance. Reduced cutting resistance can avoid chipping and
fracturing of the cutting edge caused by vibration. Additionally, lower
cutting resistance can decrease the load and heat, and can delay the
development of tool wear.

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• How are chips actually broken? Grooved type chip breakers near the
cutting edge make the chips curl and discharge quickly. In this case,
the chips are curled and discharged when broken as they hit the
workpiece or cutting edge flank, in other words, when the flow of
material is hindered. Chips with a large radius curvature are broken
when a bending moment* opposite to the direction of the curl
occurs. Additionally, chips can curl in on themselves and are broken
by their own weight. As seen in the bottom picture to the right, chips
can be broken by a bending moment when the curvature radius of
the chip formed by the chip breaker is too small.

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Question
1. what are the List of methods for metal cutting?
2. What is Orthogonal Cutting?
3. What is Oblique Cutting ?
4. Right down the difference between orthogonal and oblique cutting?
5. Explain chip breakers?

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CUTTING TOOL LIFE
UNIT NO:4
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 Student will be able to -
• Understand the tool life and tool wear.
• List of different types of tool wear.
• Understand the materials of cutting tool.
• List the different types of cutting tool materials.
• Explain the importance of cutting fluid machining.
• Explain the properties and purposes of cutting fluid.
• Elaborate the selection procedure of cutting fluid.
• Understand the characteristics of cutting tool materials.

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CONTENTS
• Tool life & Tool wear, Face wear, Flank wear, Nose wear, Machinability,
Heat generation in metal cutting, Cutting tool materials,
Characteristics of cutting tool material, Types of cutting tool material,
Cutting fluids, Purpose of cutting fluid, Properties of cutting fluid,
Selection of cutting fluid

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Tool Life
• Useful cutting life of tool expressed in time
• Time period measured from start of cut to failure of the tool
• Time period between two consecutive resharpenings or replacements

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Ways of measuring tool life
• No. of pieces of work machined
• Total volume of material removed
• Total length of cut.
• Limiting value of surface finish
• Increase in cutting forces
• Dimensional accuracy
• Overheating and fuming
• Presence of chatter

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 Modes of tool failure
1. Temperature failure
a. Plastic deformation of Cutting Edge (CE) due to high temp
b. Cracking at the CE due to thermal stresses.
2. Rupture of the tool point
a. Chipping of tool edge due to mechanical impact
b. Crumbling of CE due to Built up Edge (BUE)
3. Gradual wear at tool point
a. Flank wear
b. Crater wear

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Tool wear
• Tool wear causes the tool to lose its original shape- ineffective cutting
• Tool needs to be resharpened

Causes of Tool Wear

1. Attrition wear 2. Diffusion wear
3. Abrasive wear 4. Electrochemical wear
5. Chemical wear 6. Plastic deformation
7. Thermal cracking

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Attrition wear
• At low cutting speeds
• Flow of material past cutting edge is irregular and less stream lined
• BUE formed and discontinuous contact with the tool
• Fragments of tool are torn from the tool surface intermittently
• High
• Slow and interrupted cutting
• Presence of vibrations
• Found in carbide tools at low cutting speeds

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Diffusion wear
• Diffusion of metal & carbon atoms from the tool surface into the w/p
& chip.
• Due to
• High temp
• High pressure
• Rapid flow of chip & w/p past the tool
• Diffusion rate depends on the metallurgical relationship
• Significant in carbide tools

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Abrasive wear
• Due to
• Presence of hard materials in w/p material.
• strain hardening induced in the chip & w/p due to plastic deformation.
• Contributes to flank wear
• Effect can be reduced by fine grain size of the tool & lower percentage
of cobalt

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Electrochemical wear
• When ions are passed b/w tool & w/p
• Oxidation of the tool surface
• Break down of tool material @ chip tool interface

Chemical wear
• Interaction b/w tool and work material
• Plastics with carbide tools
• Cutting fluid

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Plastic Deformation
• When high compressive stresses acts on tool rake face- tool deformed
downways – reduces relief angle
• Modifies tool geometry and accelerates other wear processes

Thermal cracking
• Due to cyclic thermal stresses at cutting edge
• Comb cracks
• Transverse cracks
• Chipping of tool
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Flank Wear
• Tool slides over the surface of the work piece and friction is
developed
• Due to Friction and abrasion.
• Adhesion between work piece & tool- BUE
• Starts at CE and starts widening along the clearance face
• Independent of cutting conditions and tool / work piece materials
• Brittle and discontinuous chip
• Increases as speed is increased.

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• Primary stage rapid wear due
to very high stress at tool
point
• Wear rate is more or less
linear in the secondary stage
• Tertiary stage wear rate
increases rapidly resulting in
catastrophic failure.

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Crater wear
• Direct contact of tool and w/p
• Forms cavity
• Ductile materials – continuous chips
• Initiates rapid rupture near to nose
• Leads to
• weakening of the tool
• Increase in cutting temp
• Cutting forces & friction

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Measurement of tool life
• Time for Total destruction in case of HSS or time to produce 0.75 mm wear
for carbide tools
• Tool life expressed by Taylor’s eqn
• VTb = C
• V = cutting speed in cm/min
• T= tool life in min
• b= const= 0.1 for HSS
• C= 50 for HSS
• Cemented carbide : b=0.125, C=100
• Tool life expressed in volume of metal removed
• L = TVfd

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 Factors Affecting the Life of a Cutting Tool

• Type of material being cut

• Microstructure of material
• Hardness of material
• Type of surface on metal (smooth or scaly)
• Material of cutting tool
• Profile of cutting tool
• Type of machining operation being performed
• Speed, feed, and depth of cut
Tool Failure
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Measurement of tool life
• Diamond Indentor technique
• Radioactive techniques
• Test at elevated cutting speeds
• Facing tests
• Test with low wear criterion

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Factors affecting tool life
1. Cutting speed
2. Physical properties of w/p
3. Area of cut
4. Ratio of feed to depth of cut
5. Shape and angles of tool
6. Tool material and its heat treatment
7. Nature and quantity of coolants
8. Rigidity of tool and w\p

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CUTTING TOOL MATERIAL
CHARACTERISTIC:
• HOT HARDNESS

• WEARRESISTANCE

• TOUGHNESS

• COST AND EASINESS IN FABRICATION

TYPES OF CUTTING TOOL MATERIAL

PRINCIPAL CUTTING TOOL MATERIALS:

• CARBON STEELS
• MADIUM ALLOY STEELS
• HIGH – SPEED STEELS
• STELLITES
• CEMENTED CARBIDES
• CERAMICS
• DIAMONDS
• ABRASIVES
Cutting tool materials – HSS alloying
• Element Properties

• Tungsten Increases hot hardness

• Hard carbides formed, improving abrasion resistance

• Molybdenum Increases hot hardness

• Hard carbides formed, improving abrasion resistance

• Chromium Depth hardenability during heat treat

• Hard carbides formed, improving abrasion resistance
• Some corrosion resistance

• Vanadium Combines with carbon for wear resistance

• Retards grain growth for better toughness

• Cobalt Increases hot hardness, toughness

• Carbon Hardening element

• Forms carbides
Cutting-Tool Materials
• Lathe tool bits generally made of five materials
• High-speed steel
• Cast alloys (such as stellite)
• Cemented carbides
• Ceramics
• Cermets
Lathe Tool bit Properties
• Hard
• Wear-resistant
• Capable of maintaining a red hardness during machining operation
• Red hardness: ability of cutting tool to maintain sharp cutting edge even
when turns red because of high heat during cutting
• Able to withstand shock during cutting
• Shaped so edge can penetrate work
High-Speed Steel Tool bits
• May contain combinations of tungsten, chromium, vanadium,
molybdenum, cobalt
• Can take heavy cuts, withstand shock and maintain sharp cutting edge
under red heat
• Generally two types (general purpose)
• Molybdenum-base (Group M)
• Tungsten-base (Group T)
• Cobalt added if more red hardness desired
Cemented-Carbide Toolbits
• Capable of cutting speeds 3 to 4 times high-speed steel toolbits
• Low toughness but high hardness and excellent red-hardness
• Consist of tungsten carbide sintered in cobalt matrix
• Straight tungsten used to machine cast iron and nonferrous materials
(crater easily)
• Different grades for different work
Ceramic Toolbits
• Permit higher cutting speeds, increased tool life and better surface
finish than carbide
• Weaker than carbide used in shock-free or low-shock situation
• Ceramic
• Heat-resistant material produced without metallic bonding agent such as
cobalt
• Aluminum oxide most popular additive
• Titanium oxide or Titanium carbide can be added
Diamond Tool bits
• Used mainly to machine nonferrous metals and abrasive non metallics
• Single-crystal natural diamonds
• High-wear but low shock-resistant factors
• Polycrystalline diamonds
• Tiny manufactured diamonds fused together and bonded to suitable carbide
substrate
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Question
1. What to mean by the tool life and tool wear?
2. Explain List of different types of tool wear?
3. Explain the materials of cutting tool?
4. Explain the importance of cutting fluid machining?
5. Explain the properties and purposes of cutting fluid?
6. Elaborate the selection procedure of cutting fluid?
7. What are the characteristics of cutting tool materials?

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DESIGN OF CUTTING TOOL
UNIT NO. 5

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Student will be able to -
• Calculate the metal cutting parameters & cutting forces.
• Calculate the shear plane angle.
• Understand the concept of merchant circle diagram.
• Design the single point cutting tool.
• Design the multipoint cutting tool

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CONTENTS
• Metal cutting parameters, Cutting forces, Determination of shear
plane angle, Design of single point cutting tool, Design of multi point
cutting tool

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Metal cutting parameters
• Material machinability
• Cutting Tool Material
• Cutting speed and spindle speed
• Depth of cut
• Feed rate
• Tool geometry
• Coolant
• Machine/ Spindle Power
• Rigidity of machine

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• Material machinability
• The machinability of a material decides how easy or difficult it is to cut. The
material’s hardness is one factor that has a strong influence on the machinabilty.
Though a general statement like “a soft material is easier to cut than a harder
material” is true to a large extent, it is not as simple as that. The ductility of a
material also plays a huge role.
• Cutting Tool Material:
• In metal-cutting, High Speed steel and Carbide are two major tool materials widely
used. Ceramic tools and CBN (Cubic Boron Nitride) are the other tool materials used
for machining very tough and hard materials. A tool’s hardness, strength, wear
resistance, and thermal stability are the characteristics that decide how fast the tool
can cut efficiently on a job.

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• Cutting speed and spindle speed:
• Cutting speed is the relative speed at which the tool passes through the work
material and removes metal. It is normally expressed in meters per minute (or
feet per inch in British units). It has to do with the speed of rotation of the
workpiece or the tool, as the case may be. The higher the cutting speed, the
better the productivity. For every work material and tool material combo,
there is always an ideal cutting speed available, and the tool manufacturers
generally give the guidelines for it.
• Spindle speed: Spindle speed is expressed in RPM (revolutions per minute). It
is derived based on the cutting speed and the work diameter cut (in case of
turning/ boring) or tool diameter (in case of drilling/ milling etc). If V is the
cutting speed and D is the diameter of cutting, then Spindle speed N = V /(Pi x
D)

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• Depth of cut:
• It indicates how much the tool digs into the component (in mm) to remove
material in the current pass.
• Feed rate:
• The relative speed at which the tool is linearly traversed over the workpiece to
remove the material. In case of rotating tools with multiple cutting teeth (like a
milling cutter), the feed rate is first reckoned in terms of “feed per tooth,”
expressed in millimeters (mm/tooth). At the next stage, it is “feed per revolution”
(mm/rev).
• In case of lathe operations, it is feed per revolution that states how much a tool
advances in one revolution of workpiece. In case of milling, feed per revolution is
nothing but feed per tooth multiplied by the number of teeth in the cutter.
• To actually calculate the time taken for cutting a job, it is “feed per minute” (in
mm/min) that is useful. Feed per minute is nothing but feed per revolution
multiplied by RPM of the spindle.

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• Tool geometry:
• For the tool to effectively dig into the component to remove material most
efficiently without rubbing, the cutting tool tip is normally ground to different
angles (known as rake angle, clearance angles, relief angle, approach angle, etc).
The role played by these angles in a tool geometry is a vast subject in itself.
• Coolant:
• To take away the heat produced in cutting and also to act as a lubricant in cutting
to reduce tool wear, coolants are used in metal-cutting. Coolants can range from
cutting oils, water-soluble oils, oil-water spray, and so on.
• Machine/ Spindle Power:
• In the metal-cutting machine, adequate power should be available to provide the
drives to the spindles and also to provide feed movement to the tool to remove
the material. The power required for cutting is based on the metal removal rate –
the rate of metal removed in a given time, generally expressed in cubic
centimeters per minute, which depends on work material, tool material, the
cutting speed, depth of cut, and feed rate.

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• Rigidity of machine:
• The rigidity of the machine is based on the design and construction of the
machine, the age and extent of usage of the machine, the types of bearings
used, the type of construction of slide ways, and the type of drive provided to
the slides. All play a role in the machining of components and getting the
desired accuracy, finish, and speed of production.
• Thus, in getting a component finished out of a metal-cutting machine at the
best possible time within the desired levels of accuracy, tolerances, and
surface finish, some or all the above parameters play their roles. As already
mentioned in the beginning, each of the parameters can create a positive or
negative impact on other parameters, and adjustments and compromises are
to be made to arrive at the best metal-cutting solution for a given job.

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What is cutting force?
• Cutting force is the resistance of the material against the intrusion of
the cutting tool. The force directions and amplitudes differ
in different cutting processes such as turning, milling, drilling, etc.
performed in manufacturing machines –often CNC .These highly
dynamic cutting forces can be measured and analyzed to enable
optimization of these cutting processes.

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How to measure cutting forces
• Cutting forces in machining processes can be measured with different
technologies, among which dynamometers are the most effective and
reliable ones. Some dynamometers are based on the piezoelectric
effect. However, integrated monitoring solutions can also be
customized by using suitable force sensors or strain sensors. There
are three main kinds of piezoelectric dynamometers for measuring
cutting forces: stationary 3-component dynamometers, stationary 6-
component dynamometers, and rotating 4-component
dynamometers

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 Why do we measure cutting forces? What are
cutting forces measured for?
• Metal-cutting is still the most important machining process. It provides the basis for technical products of
all kinds. Manufactured products are expected to offer convincing quality and they must be cost-effective.
Thus, there has been a constant increase in the requirements to be met by cutting processes. Detailed
knowledge of cutting processes is essential in order to meet these requirements. Key indicators include
the acting forces and moments.
• During cutting processes, the tools undergo high mechanical, thermal, and chemical stress making an
impact on cutting performance and tool wear (see Fig. 2 below). Particularly when developing new tools,
it is crucial to know how they behave – typical questions being: What cutting forces occur? How does the
tool behave in different situations (process stability)? How can the tool be designed so that force peaks
are avoided (service life) and the machining process still takes place quickly and efficiently?
• Only accurate measurements during the development ensure the achievement of process reliability and
prevention of rejects. For example, when milling a case, a watchmaker needs to ensure that the process
runs smoothly and is stable, even in constantly changing engagement conditions, and that the tool is not
overstressed.
• One increasing possibility is to utilize force/moment measurements in advanced programming in CNC
machines to build up intelligent machining strategies. The force signals can be connected to the machines
via different options and are being used to improve processes, to increase traceability, and to ensure
sustainable machining operations.

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Therefore, the analysis of tool wear, i.e. measuring and analyzing the
mechanical load of the tool, is the foundation for:
• Improving cutting processes,
• Improving cutting tools (geometry, coating)
• Improving auxiliary equipment (such as coolants)
• Dimension machine structures and components
• Comparing and optimizing machining strategies
• Verifying process models and simulations
• Performing intelligent programming by means of integrating the measurand
force into the machine control system

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This is done through:
• Measuring and analyzing forces applied in plastomechanic processes
• Detecting characteristic constants, i.e. specific forces relevant for
machinability
• Providing information about the energy induced into a process
• Utilizing advanced programming commandos such as synchronous
actions in NC (numeric control)

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The graphic displays the orthogonal force components occurring during
turning operations: Fc, Ff and Fp. The vectoral sum force components Fa and
also the resultant force R are shown.
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Determining Shear Plane Angle
• Based on the geometric parameters of the orthogonal model, the
shear plane angle φ can be determined as:
• where r = chip ratio, and α = rake angle

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MEASUREMENT OF FORCES
FORCE RELATIONSHIP
FORCE RELATIONSHIP IN METAL CUTTING
Cutting Force and Thrust Force
Forces in metal cutting: (b)
forces acting on the tool that can
be measured

F, N, Fs, and Fn cannot be directly

measured
Forces acting on the tool that can be
measured:

Cutting force Fc and

Thrust force Ft
 Design of single point cutting tool
• Design of single point cutting tool is an important aspect of tool
engineering. This unit deals with the design of tool shank, design of
single point cutting tool, and various forces involved during machining of
the workpiece. Strength and rigidity of tool is also taken into account
while designing single point cutting tool.

Objectives
After studying this unit, you should be able to
design tool shank,
design single point cutting tool,
select appropriate tool material, and
calculate and analyze the forces acting on tool.

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DESIGN OF TOOL SHANK
• The shank of a cutting tool is generally analyzed for strength and
rigidity. Tool is assumed to be loaded as a cantilever by tool forces at
the cutting edge as shown in Figure 2.1.

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 Design of Cutting Tools and Holding Devices
• The notations used in design of shank is given below :
• F = Permissible tangential force during machining, N
• f = Chatter frequency, cycle per second (c.p.s)
• H = Depth of shank, mm
• B = Width of shank, mm
• L0 = Length of overhung, mm
• d = Deflection of shank, mm
• E = Young’s modulus of material, N/mm2
• I = Moment of inertia, mm4
• hc = Height of centres, mm
• σut = Ultimate tensile strength, N/mm2
• σper = Permissible stress of shank material, N/mm2
• Lc = Length of centres, mm

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• The main design criterion for shank size is rigidity. The deflection at the
cutting edge is limited to a certain value depending on the size of machine,
cutting conditions and tool overhung. The tool overhung (L0) is related also
to the shank size as well as to the end support conditions. Figure 2.2 shows
graph of the amplitude and frequency of chatter for several overhung
values. It is seen from Figure 2.2 that only below L0/H = 2, the amplitude is
practically zero. The recommended value of (L0/H) lies between 1.2 and 2.
For the given value of chatter frequency f, the shank deflection can be
calculated from the (Eq. 2.1) given as follows.

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• Symbol used in figure are : αb – Back rake angle αs – Side rake angle
θe – End relief angle θs – Side relief angle Ce – End cutting edge angle
Cs – Side cutting edge angle
• Size It is determined by the width of shank, height of shank and
overall length.
• Shank Shank is main body of a tool. It is held in a holder.

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MARCHANT’S FORCE CIRCLE
MARCHANT’S FORCE CIRCLE
Forces in Metal Cutting
• Equations can be derived to relate the forces that cannot be
measured to the forces that can be measured:
F = Fc sin + Ft cos
N = Fc cos - Ft sin
Fs = Fc cos - Ft sin
Fn = Fc sin + Ft cos
• Based on these calculated force, shear stress and coefficient of
friction can be determined
QUESTIONS
• How to calculate the metal cutting parameters & cutting forces?
• How to calculate the shear plane angle?
• What do you Understand the concept of merchant circle diagram?
• How to Design the single point cutting tool?
• How to Design the multipoint cutting tool?

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MAINTENANCE OF CUTTING
TOOL
UNIT-6

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Student will be able to
• Understand the process of re-sharpening of cutting tool.
• Understand the storage of cutting tool.
• Understand the precautions of cutting tool while using..

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Content
• Re-sharpening of cutting tool, Storage of cutting tool, Precautions of
cutting tool

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 Re-sharpening of cutting tool
MAXIMIZING TOOL LIFE
ABOUT RESHARPENING By properly resharpening carbide tipped tools, the end user can greatly enhance the value of the tooling
investment
• It is important that certain techniques for resharpening be used to maximize the tool's life and productivity
• A resharpening schedule should be implemented based on proven tool life to avoid excessive downtime or catastrophic tool failure
• DRILLS-
Resharpen the lips and check lip relief angle, lip heights and chisel edge angle (refer to original factory specifications). If the drill point was
originally cam relieved then it should be resharpened as cam relieved. If there are primary and secondary reliefs on the drill, then this
should be repeated using standards from the factory for each drill diameter.
• REAMERS
Resharpen the chamfers using the factory primary and secondary relief angles specifications. If necessary, grind the secondary reliefs on
the steel body for proper clearance. Do not grind the flute faces.
• END MILLS-
For center & end cutting tools: Resharpen the end cutting edges and reestablish the primary lands per original factory specifications.
For slotting and peripheral cutting tools: Relieve diameter to remove wear lands and reestablish factory primary and secondary lands. For
radial edged tools, hone a .003" to .005" land on cutting edges. Clearing the steel body may be necessary after several regrinds to prevent
dragging.

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• COUNTERBORES
Resharpen cutting edges to remove wear lands, then reestablish the primary and secondary lands as
needed.
• COUNTERSINKS
Face grind to remove wear land(s) or cam relieve to factory specifications.
• MILLING CUTTERS
Re-relieve to factory specifications. Regrind side teeth where cutter thickness is not critical.
• COATED TOOLS
Resharpening methods for preserving the flute face coating:
• Drills - Grind lips only
• Reamers - Grind relief on chamfers only
• Counterbores - Grind relief on cutting edges only
• End Mills - Grind relief on OD and/or end teeth only
• Milling Cutters - Grind relief on OD and/or side teeth only

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 Cutting Tool Storage
• You invest a lot in your cutting tools and you count on them to be there when you need them. It only makes sense to invest in a reliable tool bit storage solution to organize them, keep them safe and readily available for when you really
need them.
• We now carry CNC Tool Storage systems, Tool Carts and Cutting Tool Dispensers from Huot. Huot manufactures all of their Tool Storage Systems and Tool Dispensers right here in the USA. They have been manufacturing durable,
dependable Tool Storage units for over 80 years.
• Each Huot cutting tool storage system is designed and built to meet the most exacting standards and specifications, earning the highest international certifications for quality according to ISO 9001.
• CNC Tool Storage Carts
• CNC Tool storage carts provide the most flexibility when moving cutting tools from tool room to machine or sharing with multiiple machines. Many optional configurations are available.
• CNC Tool Storage Racks - Floor Mount
• Floor mount CNC tool storage racks are available in different sizes and may be stacked for even more storage. Optional shelves, doors and more are available.
• CNC Tool Storage Racks - Wall Mount
• Wall mount CNC tool storage racks are available with or without an enclosure. Shelves can be set flat or at a 20 degree angle for easier access.
• CNC Tool Storage Racks - Bench Top
• Compact bench top CNC tool storage racks organize your toolholders, collets, or both.
• Cutting Tool Dispensers - Lockable
• These cutting tool storage cabinets provide the utmost in security as well as convenience. Use anywhere theft or industrial espionage may be an issue.
• Cutting Tool Dispensers - Non-Lockable
• These dispensers for drills, reamers, router bits and more can be used anywhere security is not an issue. Many can also be stacked together and locked inside a single cabinet or tool room for one key access.
• Drill - Tap - Reamer Indexes
• Pre-marked tool storage for all your drills, taps and reamers.
• Cutting Tool Protection
• Protective covers for your cutting tools keep operators safe and prevent tool damage caused by bumping into other tools.

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