Multi Point Cutting tool Design

Dr.V. Umasankar
SMEC
Mitsubhishi Chip breakers
During cutting the layer adjacent to the tool get
deformed causing the curling the chip into spiral form.
The force applied during cutting deforms the layer in
contact with the tool, this layers becomes thick and
finally results in curling.
This also changes the direction of flow when it slides
over the tool flank face. Another reason for curl is non
uniform temperature of the chip throughout its
thickness.
The curled chip may break due to
Stress and strain reaching its ultimate point
By striking on tool flank
By striking against the surface of the workpiece.
Need for chip control

During machining chips are produced. The chips themselves

produce valuable research and diagnostic data for metal cutting
engineers, while for production engineers, chips tend to be
troublesome and hinder productivity.

Machine tools are constantly improving, highly capable robots

have been developed and recently, automation of production
systems such as FA (factory automation) has greatly increased. To
achieve automation of production systems, machining process
problems must be eliminated. To achieve this, effective chip
control and highly reliable tooling has to be implemented.
If continuous or scattered chips are produced resulting from poor
chip control, or vibration occurs, tool damage and deterioration of
the product will result. Additionally, vibration leads to a decrease
in the accuracy of the component.
As stated above, the quality of chip control greatly affects the
whole production process, including safety, efficiency, accuracy
and product quality control.
 Controlling chips with breakers is the easiest and the most effective method, so
manufacturers are constantly engaged in research and development for different chip
breaker geometries that will be effective in ever widening application areas.

Ground Chip Moulded Chip

Breaker Breaker

High Sharpness Main stream recent

Good Surface development
finish Wide chip control
range
Basics of designing chip breakers
For rough machining such as heavy and semi-heavy machining
with a large depth of cut and at high feed rates, chip control and
the tool’s fracture resistance needs to be considered.
This means that chip breakers have to be designed to have a large
breaker width where the chip pocket is widened and so improves
chip control. When prioritizing cutting edge strength, a flat,
negative land is usually designed for the cutting edge.
For finishing, due to the low feed and small depth of cut, it is
necessary to decrease the chip curl radius so that they are easily
broken. These types of chip breakers are designed to have a
smaller breaker width.

The load on the cutting edge during finishing is low and

sharpness is prioritized rather than cutting edge strength,
therefore allowing a design with a small edge honing and a
positive land.
 Breaker for semi
Breaker for finishing
to heavy
machining

Breaker for Breaker for

Finishing roughing
What is ISO 13399?
International standard with Cutting tool data representation and
exchange.
Cutting tools are required to have parameters up to the world
standards like in the regulation of the database and CAD data.
Another purpose of ISO 13399 is to establish smooth data
communication between systems.
2. Purpose
Troublesome conversion with the manufacturers is unnecessary
when you have cutting tool data that complies with ISO 13399.
This can then be imported to PLM, CAM, CAM, CNC, or even
as a tool management system.
3. Dimension symbols conforming to ISO 13399
As shown below, new dimension symbols complying
with ISO 13399.
DRILL TYPES
A variety of drills are manufactured to suit different operations,
workpiece materials, hole dimensions and special applications,
such as surgery. The design of drills may vary in the number and
width of the flutes, the amount of helix or rake angle of the flutes,
or the shape of the land and margins. In addition, the flutes may
be straight or helical, and the helix may be a right-hand or left-
hand. Within the general classification of drills flat drills, twist
drills and number of the special drills.
A Twist drill
The most commonly used drill is the general-purpose twist drill,
which has two helical flutes. This drill is designed to perform
well on a wide variety of materials, equipment, and job
conditions. The general-purpose drill can be made to suit
different conditions and materials by varying the point angle.
B Low-helix twist drill
The low-helix twist drill was developed primarily to drill brass
and thin materials.
This modification of a twist drill is used to make shallow holes in
some aluminum and magnesium alloys. Because of its design, the
low helix drill can remove the large volume of chips formed by
high rates of penetration when it is used on machines such as
lathes.
C High-helix twist drills
High-helix twist drills are designed for drilling deep holes in
aluminum, copper, die-cast material, and other metals where the
chips have a tendency to jam in a hole.
The high helix angle (35 to 45°) and the wider flutes of these
drills assist in clearing chips from the hole, but weaken the drill
body. It is used for cutting softer metals and other low strength
materials.
D Core drill A coredrill, designed with three or four
flutes, is used primarily to enlarge cored, drilled, or
punched holes.
Due to greater number of teeth the core drill has
advantages over the twist drills in productivity and
finish. A core drill is named because its first use was in
drilling out the hole left by a casting core, a cylinder
placed in a mould for a casting that leaves an irregular
hole in the product.
E Spade drills
Spade drills or flat drills are similar to gun drills in that the
cutting end is a flat blade with two cutting lips. Spade drills are
usually clamped in a holder and are easily replaced or
resharpened. They are available in a wide range of sizes from
very small micro drills to drills up to 300mm in diameter. Some
of the smaller spade drills have replaceable carbide inserts.
F Gun drill
Gun drills belong to the pressurized coolant family of hole
making tools. They are outstanding for fast, precision machining
regardless of hole depth. As a rule, a gun drill can hold hole
straightness within 0.8mm per 1m of penetration, even when the
tool is reasonably dull. For most jobs a gun drill can cut from 12
to 25 meters in alloy steel before re-sharpening is necessary.
G Center drill
Center drills are used in metalworking to provide a starting hole
for a larger-sized drill or to make a conical indentation in the end
of a workpiece in which to mount a lathe center. In either use, the
name seems apt, as the drill is either establishing the center of a
hole or making a conical hole for a lathe center.
H Trepanning drill
A trepaning drill is a hollow drill that cuts a ring and leaves a
center core. Trepanning drills usually have multiple carbide
inserts and rely on cutting fluid to cool the cutting tips and to
flush chips out of the hole. Because trepanning drills don’t
remove all the metal from a hole less horsepower is needed to
make the hole
I Ejector drill
An ejector drill is used for deep hole drilling of medium to large
diameter holes (about 20mm up to about 100mm diameter). As a
rule, the drill head is screwed to the body by means of a four-start
square thread. The drill body is essentially a tube within a tube
with cutting fluid traveling down between the tubes. Chip
removal is back through the center of the drill.
The basic construction of a conventional twist drill is depicted in
Fig.. From this illustration two distinct cutting regions can be
established: firstly, the main cutting edge, or lips; secondly at the
intersection of the clearance and main cutting edge – termed the
chisel edge.
In fact for a twist drill, the cutting process can be equated to that
of a left-hand oblique turning tool, where the rake and clearance
face geometries are identical and the correlation between these
two machining processes have been validated in the experimental
work.
Both of these region remove material, with the cutting lips
producing efficient material removal, while the chisel edge’s
contribution is both inefficient and is mainly responsible for
geometric errors in drilling, coupled to high thrust loads.
The main cutting edges are accountable for a relatively
conventional chip formation. An oblique cutting action occurs to
the direction of motion, being the result of an offset of the lips
that are parallel to a radial line – ahead of centre – which is
approximately equal to half the drill point’s web thickness and
increases toward the centre of the drill.
An oblique cutting action occurs to the direction of motion, being
the result of an offset of the lips that are parallel to a radial line –
ahead of centre – which is approximately equal to half the drill
point’s web thickness and increases toward the centre of the drill.
This obliquity is responsible for inducing chip flow in a direction
normal to the lips in accordance with Stabler’s Law.
The increasing chip flow obliquity can be seen in Fig. a, by
observing the flow lines emanating from the chip’s interface
along the lips and up the flute face. Such an oblique cutting
action serves to increase the twist drill’s effective rake angle
geometry.
Stabler’s Law – for oblique cutting, can be formulated,
as below:
Chip flow (cos η) = cos I (bc/b)
Where: I = inclination of cutting edge,
bc = chip flow vector,
b = direction of cutting vector.
Under the chisel point, or web, the material removal mechanism
is quite complex. Near the bottom of the flutes where the radii
intersect with the chisel edge, the drill’s clearance surfaces form a
cutting rake surface that is highly negative in nature.
As the centre of the drill is approached, the drill’s action
resembles that of a ‘blunt wedge-shaped indentor’. An indication
of the inefficient materia removal process is evident by the severe
workpiece deformation occurring under the chisel point, where
such deformed products must be ejected by the drill to produce
the hole. These ‘products’ are extruded, then wiped into the drill
flute whereupon they intermingle with the main cutting edge
chips.
Under the chisel point, or web, the material removal
mechanism is quite complex. Near the bottom of the
flutes where the radii intersect with the chisel edge, the
drill’s clearance surfaces form a cutting rake surface
that is highly negative in nature.
As the centre of the drill is approached, the drill’s action
resembles that of a ‘blunt wedge-shaped indentor’
An indication of the inefficient material removal process is
evident by the severe workpiece deformation occurring under the
chisel point, where such deformed products must be ejected by
the drill to produce the hole
These ‘products’ are extruded, then wiped into the drill flute
whereupon they intermingle with the main cutting edge chips.
This fact has been substantiated by force and energy analysis,
based on a combination of cutting and extruding behaviour under
the chisel point, where agreement has been confirmed with
experimental torque and thrust measurements.
Multiple-point cutting tools are a series of
single-point tools mounted in or integral with a
holder or body and operated in such a manner
that all the teeth (tools) follow essentially the
same path across the workpiece.
The cutting edges may be straight or in the form of various
contours to be reproduced on the workpiece.
Multiple-point tools may be either linear-travel or rotary.
Twist Drill Geometry
‘Frittering’ refers to the break-out at the hole’s edge as the drill
exit’s the part, on some brittle materials, such as on several
Powder Metallurgy compacts.
‘Web’ refers to the internal core of the drill – which imparts
mechanical strength to the drill. The web increases in thickness
the further one gets from the chisel edge (i.e. shown in Fig. 47 –
in lower diagrams and with cross-sections).
Hence, if the drill is reground many times, the chisel point width
will obviously increase, this necessitates that the chisel point
must be ‘thinned’, otherwise too high a thrust force occurs and an
inefficient drilling action will result.
‘Split-point’ ground drills are sometimes referred to as
‘Multifacet drills’.
Surface Integrity’ has been coined to describe the ‘altered
material zone’ (AMZ), for localised sub-surface layers that differ
from those of the bulk material
‘Short-hole drilling’ operations cover depth-to-hole-diameter-
ratios of up to 6D (i.e. for diameters up to 30 mm), whilst larger
drilled holes are limited to depths of 2.5D.
Where: D = nominal drill diameter.
‘Deep-hole drilling’ and ‘Gun-drilling’ operations are virtually
the same, with the term Deep-hole drilling being the preferred
term in this text.
Four of the most commonly-ground drill point
geometries being:
Conventional – the ‘original’ Morse geometry, having a
straight chisel edge, with poor self-centring drilling
action (Fig. a),
Split-point – there are a range of point-splitting
techniques available to alter the point profile, which has
the effect of modifying the chisel point to allow a
reasonable self-centring action (Fig.b)
Web-thinning – as its name implies, the chisel point is web-
thinned/notched, by regrinding to reduce the width of the chisel
point, while slightly modifying the profile, giving a partial self-
centring action (Fig. c),
Helical – the chisel point is ground to an ‘S-shape’, which
modifies both the chisel point and its profiled shape, improving
the drilling performance and self-centring action (Fig.d).
The conventional twist drill chisel point geometry can be seen in
Fig., together with associated nomenclature for critical features
and tolerance boundaries.
From the relatively complex geometry and dimensional
characteristics shown in Fig., the obtainable accuracy of holes
generated whilst drilling is dependent upon grinding the drill to
certain limits.
The conventional twist drill chisel point geometry can be seen in
Fig. 46, together with associated nomenclature for critical
features and tolerance boundaries. From the relatively complex
geometry and dimensional characteristics shown in Fig. 46, the
obtainable accuracy of holes generated whilst drilling is
dependent upon grinding the drill to certain limits.
Any variations in geometry and dimensions, such as:
dissimilar lips and angles, chisel point not centralised, and so on,
have a profound effect on both the hole dimensional accuracy and
roundness, with some ‘helical wandering’ as the drill passes
through the workpiece.
Hole accuracy and in particular the ‘bell-mouthing effect’ , is
minimised by previously centre-drilling prior to drilling to ‘size’.
The main cause of such this ‘bellmouthing’ is probably the
inconsistency in the drill geometry.
Such effects are exacerbated using Jobber drills, or even worse,
by utilising longer-series drills, which tend to either slightly
‘unwind’, or bend as a result of lessening rigidity promoting
some drill bending/deflection
the rigidity of a tool such as a drill will decrease by the ‘square of
the distance”.
Therefore it follows that the greater the drill penetration into the
workpiece, the progressively larger the deflection and, the further
from the ‘true axis of rotation’ will be the subsequent drill’s path.
This deflected drilled hole slope angle ‘ϕ’ , can be defined in the
following manner:
A twist drill produces both torque and thrust as it rotates and is
fed into the workpiece. The main contribution to torque is
through the lips, with a small amount of torque being generated
by the chisel point as the drill rotates against the resistance of the
workpiece (see Fig. 49). The thrust force (Fig. 49) is the result of
the selected penetration rate (i.e. feed), in combination with the
bulk hardness of the workpiece and its work-hardening ability
and the efficiency of the coolant supply – if any – to the cutting
edges (i.e lips).
The resolution of the cutting resistance into their various
components when twist drilling, is shown in Fig. 49 at a mid-
point along the lips.
The thrust force is just one of the cutting resistances in a
drilling operation, contributions to drill resistance are
from the:
Lips – equal lip lengths and angles are important for a
‘balanced cutting action’, this being considered an
efficient cutting process,
Chisel edge – is highly negatively skewed and as it acts
like a ‘blunt wedge-shaped indentor’, extruding the
workpiece material from this vicinityLand, or margin –
via a rubbing, or frictional action.
The general purpose drill points found on most jobber drills are
118° angled drills. They are typically used for cutting into soft
metals such as aluminum, whereas the 135° variant is best suited
for hardened materials, such as stainless steel.
A 135° drill is flatter than 118°, which means that more of its
cutting lips engage with the material surface sooner to begin the
full metal cutting action.
Figures 1 & 2 illustrate two types of milling
cutters and indicate the difference in
nomenclature between their angles and single
Point tools.
Figure 2 shows the peripheral cutting edge angle
as 0°, with positive and negative directions
indicated.
With linear-travel tools, the relative
motion between the tool and workpiece is along
a straight-line path. The teeth of rotary cutting
tools revolve about the tool axis.

The relative motion between the workpiece and a rotary

cutting tool may be either axial or in a plane normal to the
tool axis. In some cases, a combination of the two motions is
used. Certain form-generating tools involve a combination
of linear travel and rotary motions.
Solid Plain Milling Cutter
Figure 1
 Figure 2

Face Milling
Cutter with
inserted Teeth
Whether a cutting tool is single-point or one
component of a milling cutter, various angles
must provide the most efficient cutting action.

Theoretical considerations may dictate larger

angles, but actual cutting experience may dictate
smaller angles for greater tool strength without
chatter. Advantages from increasing any angle
always must be considered together with the effect on tool
strength.