Rake angle on cutting

tools





Presented by
Mr. Mahesh Todkar
M. Tech. (Manufacturing Engineering)
National Institute of Technology, Warangal.

Contents
Introduction to Tool Geometry
Significance of Rake angle
Definitions of Rake angle
Rake angles on Various Cutting Tools
Conversion of Rake angles
Rake angle in oblique cutting
Types of Rake angle
Selection of Rake angles
Effects of Rake angle on Chip flow
Effects of Rake angle on cutting forces
Conclusions
References
Introduction to Tool Geometry
Role of material and
geometry
Tool Geometry affect:
Chip control
Productivity of
machining
Tool life
Direction and magnitude
of the cutting forces
Quality of machining
What is Tool
Geometry?
Significance of Rake angle
Shearing of work material and formation of chip

Ease of controlling chip flow direction

Cutting angle, angle of shear and Power

Cutting force direction and magnitude

Strength to tools

Cutting speeds & feeds
Definitions of Rake angle
Definition: Angle of inclination of rake face from
reference plane.
Reference plane:








Systems of description of tool geometry:
ASA
ORS
NRS
Rake angle on Single point cutting tools
Rake angle on Single point
cutting tool:

ASA System:
Back rake angle (
y
)
Side rake angle (
x
)

Designation of tool
geometry


y
,
x
,
y
,
x
,
e
,
s
, r (inch)


Rake angle on Single point cutting tools
ORS System:
Orthogonal rake angle (o)
Designation of tool geometry
,
o
,
o
,
o
,
1
, , r (mm)


Rake angle on Single point cutting tools
NRS System:
Normal rake angle (n)

Designation of tool
geometry
,
n
,
n
,
n
,
1
, , r (mm)



Conversion of Rake angles
Purposes:
Understand
actual tool
geometry
Benefits of
various systems
Communication
Methods:
Analytical
Graphical
Transformation
matrix method
Vector method
Rake angle in Oblique cutting
Oblique cutting Vs Orthogonal cutting
Chip flow deviation angle (
c

)
Effective Rake angle (
e
)
Rake angle on Double point cutting tools
Twist Drill:
Rake angle on Multi-point cutting tools
Plain Milling Cutter:
Rake angle on Multi-point cutting tools
Face Milling Cutter:
Types of Rake angle
Rake angle may be
Positive Rake angle
Negative Rake angle
Zero Rake angle
Selection of Rake angle
Factors to consider:

Hardness of work material

Type of cutting operation

Material and shape of the cutting tool

Strength of cutting edge

Recommended Rake angles
Work Material Tool Material
HSS & Cast
Alloys
Cemented carbides
Brazed Throw away
Back Side Back Side Back Side
Mild Steel 8 10 0 6 -5 -5
Medium Carbon Steels 0 10 0 6 -5 -5
Alloy Tool Steels 0 10 -5 -5 -5 -5
Stainless Steel 0 10 0 6 -5 -5
Cast Iron 5 5-10 0 8 -5 -5
Aluminium Alloy 20 15 0 15 0 5
Copper Alloy 5 10 0 8 0 5
Magnesium Alloy 20 15 0 15 0 5
Titanium Alloy 0 5 0 6 -5 -5
All angles are in Degrees
Effects of Rake angle on Chip Flow
Chip reduction coefficient () depends on
Tool rake angle,
Chip-tool interaction, mainly friction,

For Orthogonal cutting

=
(

2
)


Chip thickness ratio, r =

2


=
1

Effects of Rake angle on Cutting Forces
Cutting forces affected by
Cutting speed,
Cutting tool material,
Tool geometry,
Depth of cut, etc.
Main Cutting force (F
c
)
F
c
= A
c
* k
s

k
s
= k
s11
h
-z
k
v
k

k
t
k
a


Where,
k

=
1.5
100


Cutting Power, P
c
= F
c
* V
Conclusion
Rake angle is most significant in tool geometry.

Choice to use any system to describe Rake angle.

Proper selection of Rake angle enhances the overall machining
process and its economy.

Carbide inserts with negative Rake angle facilitate high cutting
speeds & feeds.

Rake angle is important geometric parameter to be considered
in cutting tools and carbide insert manufacturing industries.
References
[1] M. C. Shaw, Metal Cutting Principles, Oxford University Press, London.
[2] A. Bhattacharyya, Metal Cutting: Theory and Practice, Central press, Calcutta, 1984.
[3] P. C. Sharma, Production Engineering, S. Chand & Company Ltd., New Delhi, 2006.
[4] E. Abele, M. Fujara, Simulation-based twist drill design and geometry optimization,
Manufacturing Technology 59 (2010) 145150.
[5] H. Saglam, S. Yaldiz, F. Unsacar, The effect of tool geometry and cutting speed on
main cutting force and tool tip temperature, Materials and Design 28 (2007) 101111.
[6] H. Saglam, F. Unsacar, S. Yaldiz, Investigation of the effect of rake angle and
approaching angle on main cutting force and tool tip temperature, International Journal
of Machine Tools & Manufacture 46 (2006) 132141.
[7] M. Gunay, E. Aslan, Experimental investigation of the effect of cutting tool rake angle
on main cutting force, Journal of Materials Processing Technology 166 (2005) 4449.
[8] M. Gunay , E. Aslan, Investigation of the effect of rake angle on main cutting force,
International Journal of Machine Tools & Manufacture 44 (2004) 953959.
[9] R. Komanduri, M. Lee, L.M. Raff, The significance of normal rake in oblique
machining, International Journal of Machine Tools & Manufacture 44 (2004) 11151124.
[10] I. A. Kattan, K. R. Currie, Developing New Trends of Cutting Tool Geometry,
Journal of Materials Processing Technology 61 (1996) 231-237.
Thank You