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Cutting tools
-NAM
Cutting Tool Technology
Two principal aspects:
1. Tool geometry
2. Tool material
CLASSIFICATION
According to the number of major cutting edges
(points) involved as follows:
Three ways of holding and presenting the cutting edge for a single-point
tool:
(a) solid tool, typical of HSS;
(b) brazed insert, one way of holding a cemented carbide insert; and
(c) mechanically clamped insert, used for cemented carbides, ceramics,
Common insert shapes: (a) round, (b) square, (c) rhombus with two 80point angles,
(d) hexagon with three 80point angles, (e) triangle (equilateral), (f) rhombus with
two 55 point angles, (g) rhombus with two 35point angles. Also shown are typical
features of the geometry.
What is tool signature ? And what are
the different systems of specifying tool
geometry?
In simple words The numerical code that
describes all the key angles of a given cutting
tool is called tool signature
1. Tool-in-Hand System
2. Machine Reference System - ASA system
3. Tool Reference Systems
◦ Orthogonal Rake System - ORS
◦ Normal Rake System - NRS
4. Work Reference System - WRS
1. Tool-in-Hand System
There is no quantitative information, i.e., value of
the angles.
IMPORTANT TERMS OF SINGLE POINT
CUTTING TOOL
seven element defining the tool signature
2. Machine Reference System - ASA
system
ASA ( American Standards Association) system
πR = Reference plane; plane perpendicular to the
velocity vector
πX = Machine longitudinal plane; plane perpendicular
• Clearance angles:
αx = side relief angle: angle of inclination of the principal flank from the
• Cutting angles:
φs = side cutting edge angle: angle between the principal cutting edge (its
Xo and Yo axes.
3.Orthogonal Rake System – ORS
Xo and Yo axes.
The main geometrical angles used to express
tool geometry in Orthogonal Rake System (ORS)
• Rake angles
from auxiliary cutting plane, πC’ and measured on auxiliary orthogonal plane,
πo’ as indicated in Fig. 3.8.
• Cutting angles
φ = principal cutting edge angle: angle between π C and the direction of
Shock Resistance
◦ Able to take the cutting loads and forces
molybdenum, cobalt
Can take heavy cuts, withstand shock and maintain sharp cutting
Typical composition:
Grade T1: 18% W, 4% Cr, 1% V, and 0.9% C
Cast Alloy
Usually contain 25% to 35% chromium, 4% to
25% tungsten and 1% to 3% carbon
◦ Remainder cobalt
Qualities
◦ High hardness
◦ High resistance to wear
◦ Excellent red-hardness
Operate 2 ½ times speed of high-speed steel
Weaker and more brittle than high-speed steel
Cemented Carbides
For these grades, TiC and/or TaC are substituted for some of
the WC
Titanium carbide
◦ Addition provides resistance to tool cratering
◦ Content increased
Toughness of tool decreased
Abrasive wear resistance at cutting edge lowered
Tantalum carbide
◦ Addition provides resistance to tool cratering
Without affecting abrasive wear resistance
◦ Addition increases tool's resistance to deformation
Cermets
Combinations of TiC, TiN, and titanium carbonitride
(TiCN), with nickel and/or molybdenum as binders.
•Some chemistries are more complex
•Applications: high speed finishing and semi finishing of steels,
stainless steels, and cast irons
Higher speeds and lower feeds than steel-cutting
carbide grades
Better finish achieved, often eliminating need for
grinding
Coated Carbides
Cemented carbide insert coated with one or more
thin layers of wear resistant materials, such as TiC,
TiN, and/or Al2O3
•Coating applied by chemical vapor deposition or
physical vapor deposition
•Coating thickness (0.0001 to 0.0005 in)
Applications:
◦ cast irons and steels in turning and milling operations
◦ Best applied at high speeds where dynamic force and
thermal shock are minimal
Primarily fine-grained Al 2O 3, pressed and
sintered at high pressures and temperatures into
insert form with no binder
Orthogonal cutting
In orthogonal cutting the tool approaches the work piece
with its cutting edge parallel to the uncut surface and at
right angle to the direction of cutting. Thus tool approach
angle and cutting edge inclination are zero.
Here only two component forces are acting cutting force
Fc and thrust force Ft. So the metal cutting may be
considered as 2 Dimensional cutting.
wor
k
tool
feed
Oblique cutting
The cutting edge is inclined at an angle i (known as
inclination angle ) with the normal to the direction of tool
travel . The cutting edge may are may not clear the width
of the work piece.
The chip flow on tool face making an angle with the
normal on the cutting edge. The chip flows side ways in a
long curl.
Three components of the forces (mutually perpendicular
act at the cutting edge).
Oblique cutting occur when the major edge of the
cutting tool is presented to the work piece at an angle
which is not perpendicular to the direction of feed.
Assumptions in calculating the cutting forces: -
Establish a relation between three velocities in
orthogonal cutting ?
Vc=Chip velocity
Vs =Shear velocity
V= cutting velocity
Φ=Shear angle
α =Rake angle
The cutting velocity V: it is the velocity of the tool relative
to the work and directed parallel to Fh.
The chip velocity Vc: it is the velocity of the chip relative
to the tool and directed along the tool face.
The shear velocity Vs: it is the velocity of the chip relative
to the work piece and directed along the shear plane.
The out ward flow of the metal causes the chip to be thicker
after separation from the parent metal. Metal prior to being cut
Is much longer than the chip which is removed.
t1 = L2 = r
t2 L1
From the triangle ABC BC = Sin f But BC =t1
AB
AB = t1 ------ (1)
Sin f
From the triangle ABD BD = Sin 90-(f-a)
AB
But Sin 90-(f-a) =cos (f-a) And BD= t2
r Cos a = 1 – r Sin a
Tan f
Tan f = r Cos a
1- r Sin a
There fore shear angle can be shown from the above equation