PowerPoint to accompany

Technology of Machine Tools

6th Edition

Krar • Gill • Smid

Cutting Tools
Unit 29

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 29-2

Objectives
• Use the nomenclature of a cutting-tool point
• Explain the purpose of each type of rake and
clearance angle
• Identify the applications of various types of
cutting-tool materials
• Describe the cutting action of different types
of machines
 29-3

Cutting Tools
• One of most important components in
machining process
• Performance will determine efficiency of
operation
• Two basic types (excluding abrasives)
– Single point and multi point
• Must have rake and clearance angles ground
or formed on them
 29-4

Cutting-Tool Materials
• Lathe toolbits 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
 29-5

Lathe Toolbit 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
 29-6

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
 29-7

Cast Alloy Toolbits

• 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
 29-8

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
 29-9

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
 29-10

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
 29-11

Cermet Toolbits
• Cutting-tool insert made of ceramics and
metal
• Most made from aluminum oxide, titanium
carbide and zirconium oxide compacted and
compressed under intense heat
• Advantages
– Exceed equivalent tool life of carbides
– Can be used for machining at high temperatures
– Produce improved surface finish
– Used to machine steels up to 45 Rc hardness
 29-12

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
 29-13

Polycrystalline Cutting Tools

• Offer greater wear
• Greater shock resistance
• Greatly increased cutting speeds
• Improved surface finish
• Better part-size control
• Up to 100 times greater tool life than
carbide tools
• Increased productivity
 29-14

Cubic Boron Nitride Toolbits

• Borazon next to diamond on hardness scale
• Cutting tools made by bonding layer of
polycrystalline cubic boron nitride to
cemented-carbide substrate
• Exceptionally high wear resistance and
edge life
• Used to machine high-temperature alloys
and hardened ferrous alloys
 29-15

Cutting-Tool Nomenclature

• Cutting edge: leading edge of that does cutting

• Face: surface against which chip bears as it is
separated from work
• Nose: Tip of cutting tool formed by junction of
cutting edge and front face

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 29-16

Cutting-Tool Nomenclature

• Nose radius: radius to which nose is ground

– Size of radius will affect finish
• Rough turning: small nose radius (.015in)
• Finish cuts: larger radius (.060 to .125 in.)
• Point: end of tool that has been ground for cutting
purposes
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 29-17

Cutting-Tool Nomenclature

• Base: Bottom surface of tool shank

• Flank: surface of tool adjacent to and below
cutting edge
• Shank: body of toolbit or part held in toolholder

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 29-18

Lathe Toolbit Angles and Clearances

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 29-19

Lathe Cutting-tool Angles

Negative
Positive rake:
rake:point
face of
cutting tool contacts
and cutting
metal
edge
first
contact
andmetal
chip moves
first and chip
up
moves
the face
downofthe
theface
toolbit
of
the toolbit

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 29-20

Positive Rake Angle

• Considered best for efficient
removal of metal
– Creates large shear angle at shear zone
– Reduces friction and heat
– Allows chip to flow freely along chip-tool
interface
• Generally used for continuous cuts on
ductile materials not too hard or abrasive
 29-21

Factors When Choosing Type and

Rake Angle for Cutting Tool
• Hardness of metal to be cut
• Type of cutting operation
– Continuous or interrupted
• Material and shape of cutting tool
• Strength of cutting edge
 29-22

Negative Rake Angle

• Used for interrupted cuts
and when metal is tough
or abrasive
• Creates small shear angle and long shear
zone
– More friction and heat created
• Heat desirable when tough metals
machined with carbide cutting tools
 29-23

Advantages of Negative Rake

• Shock from work meeting cutting tool is on
tool's face
– Prolongs life of tool
• Hard outer scale on metal does not come
into contact with cutting edge
• Surfaces with interrupted cuts can be
readily machined
• Higher cutting speeds can be used
 29-24

Shape of Chip
• Altered in number of ways to improve
cutting action and reduce amount of power
required
• Continuous straight ribbon chip can be
changed to continuous curled ribbon
– Changing angle of the keeness
• Included angle produced by grinding side rake
– Grinding chip breaker behind cutting edge of
toolbit
 29-25

Cutting-Tool Life: Reported As

• Number of minutes tool has been cutting
• Length of material cut
• Number of cubic inches or cubic centimeters
(cm3) of material removed
• Number of inches or millimeters of hole
depth drilled (case of drills)
 29-26

To Prolong Cutting-Tool Life

• Reduce friction between chip and tool as
much as possible
– Provide cutting tool with suitable rake angle
• Allows chips to flow away freely
• Large rake angle creates large shear angle
• Small rake angle creates small shear angle
– Highly polishing cutting-tool face with honing
stone
• Reduces friction on chip-tool interface
• Reduces size of built-up edge
 29-27

Results of a Large Shear Angle

• Thin chip is produced
• Shear zone relatively short
• Less heat created in shear zone
• Good surface finish produced
• Less power required for machining
operation
 29-28

Results of a Small Shear Angle

• Thick chip produced
• Shear zone is long
• Heat is produced
• Surface finish not quite as good as with
large-rake-angle cutting tools
• More horsepower required for machining
operation
 29-29

Tool Life
• Number of parts produced by cutting-tool
edge before regrinding is required
• Cutting tools must be reground at first sign
of dullness
• Three types of wear
– Flank wear (1)
– Nose wear (2)
– Crater wear (3)
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 29-30

Tool Life
Crater wear occurs as result
of chips sliding along When flank wear
chip-tool interface, is .015 to .030 in.
result of built-up need to be reground
edge on cutting
tool
Occurs on side of cutting
edge as result of friction
Nose wear occurs between side of cutting-tool
as result of friction between edge and metal being
nose and metal being machined machined

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 29-31

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
 29-32

Turning
• High proportion of work machined in shop
turned on lathe
– Workpiece held securely in chuck or between
lathe centers
– Turning tool set to given depth of cut, fed
parallel to axis of work (reduces diameter of
work)
• Chip forms and slides along cutting tool's upper
surface created by side rake
 29-33

Turning

Assume cutting machine steel: If rake and relief clearance

angles correct and proper speed and feed used, a continuous
chip should be formed.
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 29-34

Planing
• Workpiece moved back and forth under
cutting tool
– Fed sideways a set amount at end of each table
reversal
• Should have
proper rake
and clearance
angles on cutting
tool
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 29-35

Plain Milling
• Multi-tooth tool having several equally spaced
cutting edges around periphery
• Each tooth considered single-point cutting tool
(must have proper rake and clearance angles)
• Workpiece held in vise or fastened to table
– Fed into horizontal revolving cutter
– Each tooth makes successive cuts
– Produces smooth, flat, or profiled surface depending on
shape of cutter
 29-36

Nomenclature of a Plain Milling Cutter

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 29-37

End and Face Milling

• Multi-tooth cutters held vertically in
vertical milling machine spindle or
attachment
• Used primarily for cutting slots or grooves
• Workpiece held in vise and fed into
revolving cutter
• End milling
– Cutting done by periphery of teeth
 29-38

Nomenclature of an
End Mill

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 29-39

Nomenclature of an
End Mill

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 29-40

Inserted Blade Face Mill

• Consists of body that holds several equally
spaced inserts
– Required rake angle
– Lower edge of each insert has relief or
clearance angle ground on it
• Cutting action occurs at lower corner of
insert
– Corners chamfered to give strength
 29-41

Drilling
• Multi-edge cutting tool that cuts on the point
• Drill's cutting edges (lips) provided with lip
clearance to permit point to penetrate
workpiece as drill revolves
• Rake angle provided by helical-shaped flutes
– Slope away from cutting edge
• Angle of keeness
– Angle between rake angle and clearance angle
 29-42

Characteristics of a Chip formation

Drill Point of a drill

Cutting-point angles for

standard drill
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