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LECTURE-07 THEORY OF METAL CUTTING - Tool Geometry

NIKHIL R. DHAR, Ph

D E P A R T ME N TO FI N D U S T R I A L& P R O D U C T E N G I

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Introduction
P r o d u c t i o n o r m a n u f a c t u r i n g o f a n y o b j e c t i s a v a l u e a d d i t i o n p r o c e s s b y w h i c hr a wm a t e r i a l o fl o wu t i l i t ya n dv a l u ed u et oi t si r r e g u l a rs i z e , s h a p e a n d f i n i s h i s c o n v e r t e d i n t o a h i g h u t i l i t y a n d v a l u e d p r o d u c t w i t h d e f i n i t e s i z e , s h a p e a n d f i n i s h i m p a r t i n g s o m e d e s i r e d f u n c t i o n a b i l i t y . Ma c h i n i n gi sa ne s s e n t i a l p r o c e s so fs e m i f i n i s h i n ga n do f t e nf i n i s h i n g b yw h i c hj o b so fd e s i r e ds h a p ea n dd i m e n s i o n sa r ep r o d u c e db y r e m o v i n g e x t r a m a t e r i a l f r o mt h e p r e f o r m e d b l a n k s i n t h e f o r mo f c h i p s w i t h t h e h e l p o f c u t t i n g t o o l s m o v e d p a s t t h e w o r k s u r f a c e s i n m a c h i n e t o o l s . T h e c h i p s a r e s e p a r a t e d f r o mt h e w o r k p i e c e b y m e a n s o f a c u t t i n g t o o l t h a t p o s s e s s e sav e r yh i g hh a r d n e s sc o m p a r e dw i t ht h a t o ft h e w o r k p i e c e ,a sw e l l a sc e r t a i ng e o m e t r i c a l c h a r a c t e r i s t i c st h a td e p e n d u p o nt h ec o n d i t i o n so ft h ec u t t i n go p e r a t i o n . A m o n ga l l o ft h e m a n u f a c t u r i n gm e t h o d s , m e t a l c u t t i n g ,c o m m o n l yc a l l e dm a c h i n i n g ; i s p e r h a p st h em o s t i m p o r t a n t . F o r g i n g sa n dc a s t i n g sa r es u b j e c t e dt o s u b s e q u e n t m a c h i n i n g o p e r a t i o n s t o a c q u i r e t h e p r e c i s e d i m e n s i o n s a n d s u r f a c e f i n i s h r e q u i r e d . A l s o , p r o d u c t s c a n s o m e t i m e s b e m a n u f a c t u r e d b y m a c h i n i n g s t o c k m a t e r i a l s l i k e b a r s , p l a t e s , o r s t r u c t u r a l s e c t i o n s .
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Methods of Machining
I nt h em e t a l c u t t i n go p e r a t i o n , t h et o o l i sw e d g e s h a p e da n dh a sa s t r a i g h t c u t t i n ge d g e . B a s i c a l l y , t h e r ea r et w om e t h o d so fm e t a l c u t t i n g , d e p e n d i n gu p o nt h ea r r a n g e m e n to ft h ec u t t i n ge d g ew i t h r e s p e c t t o t h e d i r e c t i o n o f r e l a t i v e w o r k t o o l m o t i o n :
Orthogonal cutting or two dimensional cutting Oblique cutting or three dimensioning cutting.

Orthogonal Machining

Oblique Machining

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Orthogonal Cutting
T h e c u t t i n g e d g e o f t h e t o o l r e m a i n s a t 9 0 t ot h ed i r e c t i o no ff e e d( o ft h et o o l o rt h e w o r k ) T h ec h i pf l o w si n ad i r e c t i o nn o r m a l t ot h e c u t t i n g e d g e o f t h e t o o l T h ec u t t i n ge d g eo ft h et o o l h a sz e r o i n c l i n a t i o n w i t h t h e n o r m a l t o t h e f e e d T h e c h i p f l o w s i n t h e p l a n e o f t h e t o o l f a c e . T h e r e f o r e ,i tm a k e sn oa n g l ew i t ht h e n o r m a l ( i n t h e p l a n e o f t h e t o o l f a c e ) t o t h e c u t t i n g . T h es h e a rf o r c ea c t so n as m a l l e ra r e a ,s o s h e a r f o r c e p e r u n i t a r e a i s m o r e . T h et o o l l i f ei ss m a l l e rt h a no b t a i n e di no b l i q u ec u t t i n g( f o rs a m ec o n d i t i o n so f c u t t i n g ) T h e r e a r e o n l y t w o m u t u a l l yp e r p e n d i c u l a r c o m p o n e n t s o f c u t t i n g f o r c e s o n t h e t o o l T h e c u t t i n g e d g e i s b i g g e r t h a n t h e w i d t h o f c u t .
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Oblique Cutting
T h e c u t t i n g e d g e o f t h e t o o l r e m a i n s i n c l i n e d a t a n a c u t e a n g l e t o t h e d i r e c t i o n o f f e e d ( o f t h e w o r k o r t o o l ) T h ed i r e c t i o no ft h ec h i pf l o wi sn o tn o r m a l t o t h e c u t t i n g e d g e . R a t h e r i t i s a t a n a n g l e t o t h e n o r m a l t o t h e c u t t i n g e d g e . T h e c u t t i n g e d g e i s i n c l i n e d a t a n a n g l e t o t h en o r m a l t ot h ef e e d .T h i sa n g l ei sc a l l e d . inclination angle T h e c h i p f l o w s a t a n a n g l e t o t h e n o r m a l t o t h ec u t t i n ge d g e .T h i sa n g l ei sc a l l e d flow angle. c a l l e d c h i p f l o wa n g l e . T h e s h e a r f o r c e a c t s o n a l a r g e r a r e a , h e n c e t h e s h e a r f o r c e p e r a r e a i s s m a l l e r T h e t o o l l i f e i s h i g h e r t h a n o b t a i n e d i n o r t h o g o n a l c u t t i n g T h e r e a r e o n l y t h r e e m u t u a l l y p e r p e n d i c u l a r c o m p o n e n t s o f c u t t i n g f o r c e s o n t h e t o o l T h e c u t t i n g e d g e i s s m a l l e r t h a n t h e w i d t h o f c u t .
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T h ec h i pf l o w sa ta na n g l e t ot h en o r m a l t ot h ec u t t i n ge d g e .T h i sa n g l ei s

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Cutting Tool Geometry

C u t t i n gt o o l i sd e v i c ew i t hw h i c h am a t e r i a l c o u l db ec u tt ot h ed e s i r e ds i z e , s h a p e o r f i n i s h . S o a c u t t i n g t o o l m u s t h a v e a t l e a s t a s h a r p e d g e . T h e r e a r e t w o t y p e s o f c u t t i n g t o o l . T h e t o o l h a v i n g o n l y o n e c u t t i n g e d g e i s c a l l e d .F o re x a m p l e cutting tools shaper tools, lathe tools, planer tools t o o l h a v i n g m o r e t h a n o n e c u t t i n g e d g e i s c a l l e d multipoint cutting tools e x a m p l e drills, milling cutters, broaches, grinding wheel honing tool As i n g l e p o i n t c u t t i n g t o o l m a y b e e i t h e r right or left hand cut tool o n t h e d i r e c t i o n o f f e e d . Primary Cutting Edge

L e f t h a n d c u t t i n g t o o l

R i g h t h a n d c u t t i n g t o o l

Department of Industrial & Production Engineering

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Tool-in-hand Nomenclature

T h e g e o m e t r y o f a c u t t i n g t o o l c o n s i s t s o f t h e f o l l o w i n g e l e m e n t s : . F a c e o r r a k e i s t h e s u r f a c e o surface, flank, cutting edges and the corner t h ec u t t i n gt o o l a l o n gw h i c ht h ec h i p sf l o wo u t .F l a n ks u r f a c e sa r et h o s ef a c i n g t h ew o r kp i e c e .T h e r ea r et w of l a n ks u r f a c e s ,p r i n c i p a l a n da u x i l i a r yf l a n k s u r f a c e s .P r i n c i p a l c u t t i n ge d g ep e r f o r m st h em a j o rp o r t i o no fc u t t i n ga n di s f o r m e db yt h ei n t e r s e c t i n gl i n eo ft h ef a c ew i t ht h ep r i n c i p a l f l a n ks u r f a c e . A u x i l i a r yc u t t i n ge d g e( o f t e nc a l l e de n dc u t t i n ge d g e )i sf o r m e db yt h e i n t e r s e c t i o n o f t h e r a k e s u r f a c e w i t h t h e a u x i l i a r y f l a n k s u r f a c e . C o r n e r o r c u t t i n g p o i n t i s t h e m e e t i n g p o i n t o f t h e p r i n c i p a l c u t t i n g e d g e w i t h t h e a u x i l i a r y c u t t i n g e d g e .

T o o l a x i s

S h a n k o f t o o l A u x i l i a r y c u t t i n g e d g e R a k e o r F a c e P r i n c i p a l c u t t i n g e d g e P r i n c i p a l f l a n k s u r f a c e C o r n e r A u x i l i a r y f l a n k s u r f a c e Department of Industrial & Production Engineering

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Single Point Cutting Tool

S i d e r a k e a n g l e (

E n d c u t t i n g e d g e a n g l e ( e)

S i d e c l e a r a n c e a n g l e ( x) S i d e c u t t i n g e d g e a n g l e ( s ) B a c k r a k e a n g l e (

N o s e r a d i u s ( r )

E n d c l e a r a n c e a n g l e ( y)

Note: A l l t h e r a k e a n d c l e a r a n c e a n g l e s a r e m e a s u r e i n n o r m a l d i r e c t i o n

Department of Industrial & Production Engineering

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Side Cutting Edge Angle ( ): T h e s i d e c u t t i n g e d g e a n g l e ( S C E A ) i s u s u a l l y r e f e r r e d t o s a st h el e a da n g l e . I t i st h ea n g l ee n c l o s e db e t w e e nt h es i d ec u t t i n ge d g ea n dt h e l o n g i t u d i n a l d i r e c t i o no ft h et o o l . T h ev a l u eo ft h i sa n g l ev a r i e sb e t w e e n d e p e n d i n g u p o n t h e m a c h i n a b i l i t y , r i g i d i t y , a n d , s o m e t i m e s , t h e s h a p e o f t h e w o r k p i e c e . A s t h i sa n g l ei n c r e a s e sf r o m0 t o1 5 , t h ep o w e rc o n s u m p t i o nd u r i n gc u t t i n gd e c r e a s e s . H o w e v e r , t h e r e i sa l i m i t f o ri n c r e a s i n g t h e S C E A , b e y o n dw h i c he x c e s s i v e v i b r a t i o n s t a k e p l a c eb e c a u s eo ft h el a r g et o o l w o r k p i e c ei n t e r f a c e . O nt h eo t h e rh a n d , i ft h ea n g l ew e r e t a k e n a s 0 , t h e f u l l c u t t i n g e d g e w o u l d s t a r t t o c u t t h e w o r k p i e c e a t o n c e , c a u s i n g a n i n i t i a l s h o c k . U s u a l l y , t h e r e c o m m e n d e d v a l u e f o r t h e l e a d a n g l e s h o u l d r a n g e b e t w e e n 30.

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h e e n d c u t t i n g e d g e a n g l e ( E C E A Auxiliary or End Cutting Edge Angle ( ): T e s e r v e st oe l i m i n a t er u b b i n gb e t w e e nt h ee n dc u t t i n ge d g ea n dt h em a c h i n e d s u r f a c e o f t h e w o r k p i e c e . A l t h o u g h t h i s a n g l e t a k e s v a l u e s i n t h e r a n g e o f 5 t o 3 0 , c o m m o n l y r e c o m m e n d e d v a l u e s a r e 8 to 15. Side Clearance Angle ( ) and End Clearance Angle ( x c l e a r a n c e( r e l i e f )a n g l e ss e r v et oe l i m i n a t er u b b i n gb e t w e e nt h ew o r k p i e c ea n d t h es i d ea n de n df l a n k , r e s p e c t i v e l y . U s u a l l y ,t h ev a l u eo fe a c ho ft h e s ea n g l e s r a n g e s b e t w e e n 5 and 15.
y

):

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