TOPIC – I Geometry of Single Point Cutting Tool

Angles and their

MANUFACTURING
TECHNOLOGY II
Significance

Compiled by Dr. R. PANNEER Ph.D.

F

Importance of clearance angle in cutting process

P
Tool
Cutting

Leading Edge
(a) Heel fouls work and prevents leading

Workpiece
edge from cutting
Cutting Tool Angles – Page 2
P

Clearance Angle
F
 (a) Flat Surface (6° to 8°)
Clearance angle
(b) Heel cleared away allowing leading edge to
Cutting Tool Angles – Page 3

enter the workpiece, cutting action.

Clearance angle is
defined as: the angle Clearance Angle
between the
flank face of the tool and the tangent to the work surface
originating at the cutting edge.
All cutting tools must have clearance angle. However, an
excessive angle will not increase the efficiency of cutting
and may weaken the tool.
It is affected by the shape of the work.
(a) Flat surfaces (shaping)
(b) External cylinders (turning)
(c) Internal cylinders (boring)
Cutting Tool Angles – Page 4
P

Clearance Angle
(a) External Cylinder ( 5o to 7o )
F
Clearance Reduced
Cutting Tool Angles – Page 5

Shape of work helps

to create Clearance
P
Clearance Angle
(b) Internal Cylinder ( 8o upwards)
X
F

Primary
Clearance
Cutting Tool Angles – Page 6

Secondary Clearance prevents fouling

at point X through shape of work
(a) Schematic illustration of a right-hand cutting tool for turning.
Single Point Cutting Tool
Right-Hand Cutting Tool
Although these tools have traditionally been produced from solid tool-
steel bars, they are now replaced by inserts of carbide or other tool
materials of various shapes and sizes, as shown in (b).
Cutting Tool Angles – Page 7
Cutting Tool Angles – Page 8

Single Point Cutting Tool

Right-Hand Cutting Tool
 Designations for a Right-Hand Cutting Tool
Single Point Cutting Tool
Right-hand means the tool travels form right to left.
Cutting Tool Angles – Page 9
Cutting Tool Angles – Page 10

Single Point Cutting Tool

General recommendations for tool angles in turning
Two-Dimensional
Cutting Process
Schematic illustration of a two-
dimensional cutting process,
also called orthogonal cutting:
(a) Orthogonal cutting with a
well-defined shear plane, also
known as the Merchant Model.
Note that the tool shape, depth
of cut, to, and the cutting
speed, V, are all independent
variables,
(b) Orthogonal cutting without
a well-defined shear plane.
Cutting Tool Angles – Page 11
End cutting edge angle (ECEA)
Top View

Single Point Cutting Tool

Geometry of positive rake single point cutting tool
Nose Radius (NR)
Side cutting edge angle (SCEA)
Back rake angle (αb)
Side rake angle
(αs)
Lip angle
Front View
Side View
Side relief angle (SRA)
End relief angle (ERA)
Cutting Tool Angles – Page 12
Top View
Nose Radius (NR)
Side cutting edge angle (SCEA)
Side rake angle (αs)

Single Point Cutting Tool

Geometry of negative rake single point cutting tool
End cutting edge angle (ECEA)
Back rake angle (αb)
Lip angle
Side View
Front View
Side relief angle (SRA)
End relief angle (ERA)
Cutting Tool Angles – Page 13

Single Point Cutting Tool

 The most important geometry’s to consider on a
cutting tool are:

Back Rake Angles
End Relief Angles
Side Relief Angles
Cutting Tool Angles – Page 14

 The geometry of a cutting tool is determined by:

 Properties of the tool material

 Properties of the workpiece
 Type of cut
Back Rake Angle:
Rake Angles
It is defined as the angle between the face of the tool and
a line parallel to the base of the shank in a plane parallel to
the side cutting edge.
It affects the ability of the tool to shear the work material
and form chip.
It can be positive or negative
Positive: reduced cutting forces, limited deflection of
work, tool holder, and machine
Negative: typically used to machine harder metals-
heavy cuts
Cutting Tool Angles – Page 15
The Rake angle may also be defined as: is the angle that the
Rake Angles, cont.
Cutting Tool Angles – Page 16

tool makes with the workpiece normal, see Fig.

The side rake
angle and the back Rake Angles, cont.
rake angle combine to
Side Rake Angles: It is the angle by which the face of the
tool is inclined side ways.
form the effective rake angle. This is also called true rake
angle or resultant rake angle of the tool.
Cutting Tool Angles – Page 17
The rake angle is always at the topside of the tool.
Cutting Tool Angles – Page 18

Rake Angles, cont.

The Rake Angle has two major effects during the
metal cutting process.

One major effect is its influence on tool strength.

A tool with negative rake will withstand far more loading
than a tool with positive rake.
The other major effect is its influence on cutting pressure
A tool with a positive rake angle reduces cutting forces
The Rake Angle:
by allowing the chips to flow more freely across the rake
surface.
The basic tool geometry is determined by the rake
angle of the tool.
It allows the chip to flow in convenient direction.
Rake Angles, cont.
The rake angle has the following functions:
It reduces the cutting force required to shear the metal
and consequently helps to increase the tool life and
reduce the power consumption. It provides keenness to
the cutting edge.
It improves the surface finish.
Cutting Tool Angles – Page 19
Cutting Tool Angles – Page 20

Positive Rake Angle

Positive rake or increased rake angle:
Reduce the strength of the tool section.
Positive Rake Angle, cont.
But, we have Problems….as we increase the angle:
Reduce the capacity of the tool to conduct heat away
from the cutting edge.
to conduct heat better, in some tools, zero to negative
Cutting Tool Angles – Page 21

However, to increase the strength of the tool and allow it

rake angles are used.

when cutting tough, alloyed materials that tend to work-
Positive Rake Angle, cont.
Some areas of cutting where positive rake may prove
more effective are:-
harden, such as certain stainless steels,
when cutting soft or gummy metals,
or when low rigidity of workpiece, tooling, machine tool,
or fixture allows chatter to occur.
The shearing action and free cutting of positive rake tools will
often eliminate problems in these areas.
Cutting Tool Angles – Page 22
heat
Negative Rake Angle
To provide greater strength at
the cutting edge and better
conductivity,
rake
zero
or
are
negative
angles
employed on carbide, ceramic,
polycrystalline diamond, and
polycrystalline
cubic
boron
nitride cutting tools.
Cutting Tool Angles – Page 23
their superior hardness at high temperature results in their
Negative Rake Angle, cont.
These materials tend to be brittle, but their ability to hold
selection
operation.
for
high
speed
and
continuous
Negative rakes increases tool forces but this is necessary to
machining
provide added support to the cutting edge. This is particularly
important in making intermittent cuts and in absorbing the
impact during the initial engagement of the tool and work.
Cutting Tool Angles – Page 24
possess good toughness (low transverse rupture strength).
Negative Rake Angle, cont.
Negative rakes are recommended on tool which does not
Thus negative rake (or small rake) causes high compression,
Cutting Tool Angles – Page 25

tool force, and friction, resulting in highly deformed, hot chip.

R
educe Summary Positive vs. Negative Rake Angles
 Positive rake angles: d cutting forces
Smaller deflection of work, tool holder, and machine
Considered by some to be the most efficient way to
cut metal
Creates large shear angle, reduced friction and heat
Allows chip to move freely up the chip-tool zone
Generally used for continuous cuts on ductile
materials which are not to hard or brittle
Cutting Tool Angles – Page 26
N Summary Positive vs. Negative Rake Angles
egati
ve rake angles:
Initial shock of work to tool is on the face of the tool
and not on the point or edge. This prolongs the life
of the tool.
Higher cutting speeds / feeds can be employed.
Cutting Tool Angles – Page 27
permits turning at very high speed. At high speeds rake angle
has little influence on cutting pressure. Under such condition
Rake Angle Selection depends on:
minimum rake angle or even negative rake angle is provided

Type of material being cut: A harder material like cast

iron may be machined by smaller rake angle than that
required by soft material like mild steel or aluminum.
to increase the tool strength.
Type of tool material: Tool material like cemented carbide
Cutting Tool Angles – Page 28
 Rigidity of the tool holder and machine: An improperly
supported tool on old or worn out machine cannot take up
Rake Angle Selection depends on:, cont.
high cutting pressure. So while machining under the above
Depth of cut: In rough turning, high depth of cut is given to
remove maximum amount of material. This means that the
tool has to withstand severe cutting pressure. So the rake
angle should be decreased to increase the lip angle that
provides the strength to the cutting edge.
condition, the tool used should have larger rake angle.
Cutting Tool Angles – Page 29
 Relief angles are
Relief Angles provided to minimize
physical interference
or rubbing contact with machined surface and the workpiece.
Relief angles are for the purpose of helping to eliminate tool
breakage and to increase tool life.
If the relief angle is too large, the cutting tool may chip or
break. If the angle is too small, the tool will rub against the
workpiece and generate excessive heat and this will in turn,
cause premature dulling of the cutting tool.
Small relief angles are essential when machining hard and
strong materials and they should be increased for the weaker
and softer materials.
Cutting Tool Angles – Page 30
A smaller angle
should be used for Relief Angles, cont.
interrupted cuts or heavy
feeds, and a larger angle for semi-finish and finish cuts.
Side Relief Angle: The Side relief angle prevents the side
flank of the tool from rubbing against the work when
longitudinal feed is given. Larger feed will require greater side
relief angle.
End Relief Angle: The End relief angle prevents the side
flank of the tool from rubbing against the work. A minimum
relief angle is given to provide maximum support to the tool
cutting edge by increasing the lip angle. The front clearance
angle should be increased for large diameter works.
Cutting Tool Angles – Page 31
The following are the advantages of increasing this angle:
Cutting Edge Angles
Side Cutting Edge Angle:
It increases tool life as, for the same depth of cut; the
cutting force is distributed on a wider surface.
It diminishes the chip thickness for the same amount of
feed and permits greater cutting speed.
It dissipates heat quickly for having wider cutting edge.
Cutting Tool Angles – Page 32
 Cutting Edge Angles, cont.
Side Cutting Edge Angle: The side cutting edge angle of
the tool has practically no effect on the value of the cutting
force or power consumed for a given depth of cut and feed.
Large side cutting edge angles are lightly to cause the tool to
chatter.

End Cutting Edge Angle: The function of end cutting edge

angle is to prevent the trailing front cutting edge of the tool
from rubbing against the work. A large end cutting edge angle
unnecessarily weakens the tool. It varies from 8 to 15
degrees.

Cutting Tool Angles – Page 33

The nose of a tool is
slightly rounded in all Nose Radius
turning tools.
The function of nose radius is as follows:
Greater nose radius clears up the feed marks caused by the
previous shearing action and provides better surface finish.
All finish turning tool have greater nose radius than rough
turning tools.
It increases the strength of the cutting edge, tends to
minimize the wear taking place in a sharp pointed tool with
consequent increase in tool life.
Accumulation heat is less than that in a pointed tool which
permits higher cutting speeds.
Cutting Tool Angles – Page 34
It is the system of
designating the principal Tool Signature
angles of a single
point cutting tool.
The signature is the sequence of numbers listing the various
angles, in degrees, and the size of the nose radius.
There are several systems available like:
American standard system (ASA),
Orthogonal rake system (ORS),
Normal rake system (NRS), and
Maximum rake system (MRS).
Cutting Tool Angles – Page 35
The system most
commonly used is Tool Signature, cont.
American Standard
Association (ASA), which is:
relief angle, End cutting edge angle, Side cutting edge
angle and Nose radius.
Back rake angle, Side rake angle, End relief angle, Side
For example a tool may designated in the following sequence:
8-14-6-6-6-15-1
1. Back rake angle is 8
2. Side rake angle is 14
3. End relief angle is 6
7. Nose radius is 1 mm
4. Side relief angle is 6
5. End cutting edge angle is 6 6. Side cutting edge angle is 15
Cutting Tool Angles – Page 36
Designations for a Right-Handed Cutting Tool
(a) Designations and symbols
for a right-hand cutting
tool; solid high-speed-steel
tools have a similar
designation.
(b) Square insert in a right-
hand tool holder for a
turning operation. A wide
variety of tool holder is
available for holding
inserts at various angles.
Thus, the angles shown in
(a) can be achieved easily
by selecting an appropriate
insert and tool holder.
Cutting Tool Angles – Page 37