14MEPS0 - Metal cutting Engineering

14MEPSO - Metal Cutting Engineering

Prepared by: T. Prakash, [email protected], https://prakaasht.wordpress.com

Acknowledgement: Adopted from NPTEL Course Material

Systems of description of tool geometry

• Tool in Hand System

• Machine Reference Systems
• Tool Reference Systems
o Orthogonal Rake System – ORS
o Normal Rake System – NRS

• Tool-in-Hand System – where only the salient features of the cutting tool point are identified or visualized as
shown in Fig. 1. There is no quantitative information, i.e., value of the angles.

Fig. 1 Basic features of single point tool (turning) in Tool-in-hand system

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(iii) Demonstration (expression) of tool geometry in :

Machine Reference System:

This system is also called ASA system; ASA stands for American Standards Association. Geometry of a
cutting tool refers mainly to its several angles or slope of its salient working surfaces and cutting edges.
Those angles are expressed w.r.t. some planes of reference.

In Machine Reference System (ASA), the three planes of reference and the coordinates are chosen based on
the configuration and axes of the machine tool concerned.

The planes and axes used for expressing tool geometry in ASA system for turning operation are shown in
Fig. 2.

Fig. 2 Planes and axes of reference in ASA system feed

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The planes of reference and the coordinates used in ASA system for tool geometry are :
π - π - π and X – Y - Z
R X Y m m m

Where,

π = Reference plane; plane perpendicular to the velocity vector (shown in Fig. 1.4)
R

π = Machine longitudinal plane; plane perpendicular to π and taken in the direction of assumed
X R
longitudinal feed
π = Machine Transverse plane; plane perpendicular to both π and π [This plane is taken in the direction
Y R X
of assumed cross feed]
The axes X , Y and Z are in the direction of longitudinal feed, cross feed and cutting velocity (vector)
m m m

respectively. The main geometrical features and angles of single point tools in ASA systems and
their definitions will be clear from Fig. 3.

Fig. 3 Tool angles in ASA system

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 14MEPS0 - Metal cutting Engineering

Definition of:
Rake angles: [Fig. 3] in ASA system:

γ = side (axial rake: angle of inclination of the rake surface from the reference plane (π ) and easured on
x R

Machine Ref. Plane, π .

X

γ = back rake: angle of inclination of the rake surface from the reference plane and measured on Machine
y
Transverse plane, π .
Y

Clearance angles: [Fig. 3]:

α = side clearance: angle of inclination of the principal flank from the machined surface (or CV) and measured
x
on π plane.
X

α = back clearance: same as α but measured on π plane.

y x Y

Cutting angles: [Fig. 3]:

φ = approach angle: angle between the principal cutting edge (its projection on π ) and π and measured on
s R Y
π
R

φ = end cutting edge angle: angle between the end cutting edge (its projection on π ) from π and measured
e R X
on π
R

Nose radius, r (in inch):

r = nose radius : curvature of the tool tip. It provides strengthening of the tool nose and better surface finish.

Tool Reference Systems

Orthogonal Rake System – ORS:

This system is also known as ISO – old.

The planes of reference and the co-ordinate axes used for expressing the tool angles in ORS are:

π - π - π and X - Y - Z
R C O o o o

which are taken in respect of the tool configuration as indicated in Fig. 4

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 14MEPS0 - Metal cutting Engineering

Fig. 4 Planes and axes of reference in OR

Where,

π = Reference plane perpendicular to the cutting velocity vector, CV

R

π = cutting plane; plane perpendicular to π and taken along the principal cutting edge
C R

π = Orthogonal plane; plane perpendicular to both π and π

O R C

and the axes;

X = along the line of intersection of π and π
o R O

Y = along the line of intersection of π and π

o R C

Z = along the velocity vector, i.e., normal to both X and Y axes.

o o o

The main geometrical angles used to express tool geometry in Orthogonal Rake System (ORS) and
their definitions will be clear from Fig. 4.

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 14MEPS0 - Metal cutting Engineering

Fig. 5 Tool angles in ORS system

Definition of –
Rake angles [Fig. 5] in ORS:

γ = orthogonal rake: angle of inclination of the rake surface from Reference plane, π and measured on the
o R
orthogonal plane, π
o

λ = inclination angle; angle between π from the direction of assumed longitudinal feed [π ] and measured
C X
on π
C

Clearance angles [Fig. 5]:

α = orthogonal clearance of the principal flank: angle of inclination of the principal flank from π and
o C
measured on π
o

α ’ = auxiliary orthogonal clearance: angle of inclination of the auxiliary flank from auxiliary cutting plane,
o
π ’ and measured on auxiliary orthogonal plane, π ’ as indicated in Fig. 6.
C o

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 14MEPS0 - Metal cutting Engineering

Cutting angles [Fig. 5]:

φ = principal cutting edge angle: angle between π and the direction of assumed longitudinal feed or π
C X
and measured on π
R

φ = auxiliary cutting angle: angle between π ’ and π and measured on π

1 C X R

Nose radius, r (mm):

r = radius of curvature of tool tip

Fig. 6 Auxiliary orthogonal clearance angle

Normal Rake System – NRS: This system is also known as ISO – new.

ASA system has limited advantage and use like convenience of inspection. But ORS is advantageously used
for analysis and research in machining and tool performance. But ORS does not reveal the true picture of the
tool geometry when the cutting edges are inclined from the reference plane, i.e., λ≠0. Besides, sharpening or
resharpening, if necessary, of the tool by grinding in ORS requires some additional calculations for correction
of angles.

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These two limitations of ORS are overcome by using NRS for description and use of tool geometry.

The basic difference between ORS and NRS is the fact that in ORS, rake and clearance angles are visualized
in the orthogonal plane, π , whereas in NRS those angles are visualized in another plane called Normal plane,
o

π . The orthogonal plane, π is simply normal to π and π irrespective of the inclination of the cutting edges,
N o R C

i.e., λ, but π (and π ’ for auxiliary cutting edge) is always normal to the cutting edge. The differences between
N N

ORS and NRS have been depicted in Fig. 7.

The planes of reference and the coordinates used in NRS are:

π - π - π and X – Y – Z
RN C N n n n

where,
π = normal reference plane
RN

π = Normal plane: plane normal to the cutting edge

N

and
X =X
n o

Y = cutting edge
n

Z = normal to X and Y
n n n

It is to be noted that when λ = 0, NRS and ORS become same, i.e. π ≅ π , Y ≅ Y and Z ≅ Z .
o N N o n o

Definition (in NRS) of

Rake angles:
γ = normal rake: angle of inclination angle of the rake surface from π and measured on normal plane,
n R
π
N

α = normal clearance: angle of inclination of the principal flank from π and measured on π
n C N

α ’= auxiliary clearance angle: normal clearance of the auxiliary flank (measured on π ’ – plane normal to
n N
the auxiliary cutting edge.

The cutting angles, φ and φ and nose radius, r (mm) are same in ORS and NRS.
1

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 14MEPS0 - Metal cutting Engineering

Fig. 7 Differences of NRS from ORS w.r.t. cutting tool geometry.

(b) Designation of tool geometry

The geometry of a single point tool is designated or specified by a series of values of the salient angles and
nose radius arranged in a definite sequence as follows:

Designation (signature) of tool geometry in

• ASA System – γ , γ , α , α , φ , φ , r (inch)

y x y x e s

• ORS System – λ, γ , α , α ’, φ , φ, r (mm)

o o o 1

• NRS System – λ, γ , α , α ’, φ , φ, r (mm)

n n n 1

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 14MEPS0 - Metal cutting Engineering

Difference Between ORS System and NRS System of Tool

Designation

Geometry of the cutting tool is one crucial factor that in uences overall performance
(machinability) as well as productivity of machining. Thus cutting tool must be selected
judiciously prior to machining based on the work material and cutting conditions. Tool signature
displays various features of a cutting tool, and thus it enables quick selection of a cutting tool for
speci c application. There are several standard systems for designation of a single point turning
tool; each displays certain features (like angles and radius) of the cutting tool. Few commonly
used systems are— American Standards Association (ASA) system, Orthogonal Rake System
(ORS), Normal Rake System (NRS) and Master Rake System (MRS). A same tool may have
different tool signatures based on the system of designation followed to specify.

ORS System and NRS System of turning tool designation are sometime confusing as several
similarities exist between them even though they are not exactly same. The ORS system
employed the orthogonal plane (πO), which is a plane perpendicular to the xed reference plane.
Thus it displays orthogonal rake angle and orthogonal clearance angle in relevant tool signature.
ORS system is the most popular one as majority of analysis is carried out considering orthogonal
machining (i.e. chip owing in orthogonal direction). On the other hand, NRS system employs a
normal plane (πN), which is plane perpendicular to the cutting edge of the tool. The angle
between normal plane and orthogonal plane is nothing but the inclination angle (λ). Thus these
two planes coincide when inclination angle becomes zero. Accordingly, ORS and NRS becomes
same for a cutting tool having zero inclination angle (λ). Tool signatures along with the name of
various features used in these two systems are depicted below. Similarities and differences
between these two systems of tool designation are also elaborated in the following sections.

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 14MEPS0 - Metal cutting Engineering

Similarities between ORS and NRS systems

Both systems are conventionally used for designating turning tools; however, ORS system
is more frequently used.
Both systems specify few common features in the corresponding tool signatures. Such
common features include inclination angle, principal cutting edge angle, auxiliary cutting
edge angle and nose radius of the cutting tool.
Both systems specify nose radius value in millimeter (mm). This is unlike ASA system
where nose radius is expressed in inch.
Two planes namely Reference plane and Cutting plane are also common in both systems.
Angle between Orthogonal plane (used in ORS) and Normal plane (used in NRS) is equal to
the inclination angle (λ). So when λ becomes 0º then two planes coincide. Accordingly,
ORS system and NRS system becomes exactly same if the cutting tool has zero inclination
angle (λ = 0º).

Differences between ORS and NRS systems

ORS system NRS system

ORS stands for Orthogonal Rake System. NRS stands for Normal Rake System.

It is the ISO old system of turning tool It is the ISO new system of turning tool
designation. So this system is no more used designation, and thus is currently used as
as an ISO standard. international standard.

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 14MEPS0 - Metal cutting Engineering

Three planes used as reference in ORS system Three planes used as reference in NRS system
are: are:
Reference plane (πR) Reference plane (πR)
Cutting plane (πC) Cutting plane (πC)
Orthogonal plane (πO) Normal plane (πN)

These three planes are always mutually Three planes are not necessarily mutually
perpendicular. perpendicular. It will be perpendicular only
when inclination angle (λ) is zero.

Tool signature in ORS does not reveal true Tool signature in NRS reveals true picture
picture if inclination angle λ ≠ 0º. irrespective of λ value.

If ORS system is used while mounting the tool No such corrections are required if NRS
in 3-D vice for re-sharpening it by grinding then system is used for re-sharpening purpose.
additional calculations for angle correction are Values as per tool signature in NRS are
required. su cient for accurate mounting in a 3-D vice.

Wh en ORS System and NRS System Will Be Same?

References
Normal Rake System (NRS) differs from the Orthogonal Rake System (ORS) due to the
presence of inclination angle in cutting tool. Inclination angle (λ) is de ned as the angle of
inclination of principal cutting edge from the reference plane (πR ) and measured on
cutting plane (πC). Therefore if inclination angle (λ) of the cutting tool becomes zero then
ORS and NRS will be exactly same.

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 14MEPS0 - Metal cutting Engineering

Comparison Among ASA, ORS and NRS Systems of Tool

Designation

A tool signature displays various features of a cutting tool in an abridged but standardized
form. Because of the availability of different tool designation systems for writing a tool
signature, one needs to know that particular system for interpreting it. Since different tool
designation systems utilize different features of the tool for expressing tool signature, so a
particular cutting tool may have different versions of tool signature based on the system
followed for writing it.

Single point cutting tools (like turning tool, shaping tool, boring tool, planing tool, etc.) can
be designated in three different ways—American Standards Association (ASA) system,
Orthogonal rake System (ORS) and Normal Rake System (NRS). Each of them has certain
advantages over other two. A comparison among these three systems of tool designation
is discussed below.

Planes used for reference purpose

ASA system—It utilizes three mutually perpendicular planes namely Machine
longitudinal plane, Machine transverse plane and Reference plane. Reference plane
is a plane perpendicular to cutting velocity vector in turning. Machine longitudinal
plane is perpendicular to reference plane and is along longitudinal axis of lathe. As
the name suggests, machine transverse plane is along the transverse axis of the
lathe and is perpendicular to other two planes.
ORS system—It also utilizes three mutually perpendicular planes namely Reference
plane, Cutting plane, and Orthogonal plane. As usual, reference plane is a plane
perpendicular to cutting velocity vector in turning. Cutting plane contains principal
cutting edge of the tool and is perpendicular to reference plane. Orthogonal plane is
perpendicular to other two planes.
NRS system—It also utilizes three planes for reference purpose (Reference plane,
Cutting Plane and Normal Plane) but they may not be mutually
Perpendicular. Hence normal plane is a plane perpendicular to the principal cutting
edge and is inclined>with the orthogonal plane by an angle equals to inclination angle
(λ) of the tool. So if>λ = 0º, then both normal plane and orthogonal plane will coincide.

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Tool designation in three systems

All three systems of turning tool designation express tool signature in different ways.
Various angles expressed by these three tool designation systems are depicted below. All
the images are self-explained.

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 14MEPS0 - Metal cutting Engineering

Unit of nose radius in tool signature

As shown in above diagrams, ASA system expresses nose radius of the cutting tool in inch
unit; whereas ORS and NRS express the same feature in mm unit.

Tool signature interpretation

As displayed below, tool signature can be interpreted by comparing it with the standard
designation style. While comparison, note that you are utilizing same system and the
sequence is properly maintained. The following images show how to interpret tool
signature for obtaining various angles. Tool angles in one system can also be further
converted into angles of other systems.

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 14MEPS0 - Metal cutting Engineering

Features of auxiliary ank surface displayed in tool

signature
ASA system displays the angle between auxiliary cutting edge and machine longitudinal
plane using end cutting edge angle but it does not reveal any information about the
inclination of auxiliary ank surface. On the other hand, ORS and NRS provide some
information about it using auxiliary clearance angles (orthogonal/normal).

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ASA system is advantageous particularly in measuring the tool angles for inspection. ORS
is commonly used in various analyses (especially when orthogonal machining is
assumed) including estimation of cutting force, judging machinability and performance
on machining. However, while setting the angles in a 3-D vice for re-sharpening the
cutting tool by grinding, if ORS system is followed then further angle corrections are
required (if the tool has non-zero inclination angle). These limitations can be eliminated
by employing NRS system.

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