MFG Tooling - 04 Cutting Tool Design

Tool Design
Cutting Tool Design
Nageswara Rao
Posinasetti
Guidelines for Cutting tool Design
Rigidity
Strength
Weak links
Force limitations
Speed, feed and size
Related force components
Chip disposal
Uneven motions
Chatter
January 31, 2008 Nageswara Rao Posinasetti 2
Basic tool angles (Tool

Signature)
Back rake angle
Side rake angle
End relief angle
Side relief angle
End cutting edge angle
Side cutting edge angle
Nose radius
1
2
3
Selecting carbide Tools
Establish the operating conditions
Select the
– Cemented carbide grade
– Nose radius
– Insert shape
– Insert size
– Insert thickness
– Tool style
– Rake angle
– Shank size
– Chip breaker
Establish the operating

conditions
Feed, speed and depth of cut greatly

influence the machining performance.
Also lead angle affects the
performance
FIGURE F-27 The difference in style A and style D holders for

depth of cut and cutting edge engagement length (copyright ©
General Electric Company).
Richard R. Kibbe, John E. Neely,31,

January 2008 Nageswara Rao Posinasetti 12
Roland O. Meyer, and Warren T. Copyright ©2002 by Pearson Education, Inc.
White Upper Saddle River, New Jersey 07458
Machine Tool Practices, 7e All rights reserved.
4
FIGURE F-28 Large, well-formed chips were produced by this
tool with built-in chip breaker (Kennametal, Inc., Latrobe, PA).
Large depth
of cut

To reduce cutting edge chipping
Increase the speed

Decrease the feed and/or depth of cut
Change to a tougher grade carbide
insert
Use a negative rake
Hone the cutting edge before use
Check the rigidity and tool overhang
Select the cemented carbide grade
Straight carbides - Cast iron, Resistance to

Tungsten carbide nonferrous and edge wear
(WC) and cobalt nonmetallic
binder materials
5
Select the cemented carbide grade
Straight carbides - Cast iron, Resistance to

Tungsten carbide nonferrous and edge wear
(WC) and cobalt nonmetallic
binder materials
WC + Titanium Steels Resistance to
carbide + Tantalum cratering
carbide with cobalt
binder
Coated carbides
6
Select the nose radius
Based on surface finish
FIGURE F-34 Surface finish versus nose radius

(copyright © General Electric Company).

7
Select the insert shape
Round – strong and large radius, good

for higher feed rates
Square – medium stronger
Traingular – least stronger, less
number of cutting edges, but more
versatile in use
FIGURE F-35 Insert shapes for various

applications (Kennametal, Inc., Latrobe, PA)

8
FIGURE F-36 A 38-degree triangular insert used

for a tracing operation (copyright © General Electric
Company).

Select the insert size
Smallest size based on the depth of cut

used
Cutting edge should be 1.5 times that
of the length of cutting edge
engagement.
9
Select the insert thickness
Gives the strength of the tool
FIGURE F-37 Insert thickness as determined by length of

cutting edge engagement and feed rate (copyright © General
Electric Company).

Select the tool style
Based on the geometry of the

operation to be performed.
10
FIGURE F-38 Several of the many tool styles available
(Kennametal, Inc., Latrobe, PA).

11
12
Select the rake angle
FIGURE F-39 Side view of back rake angles.

13
Select the shank size
FIGURE F-40 Determining shank size according to depth of

cut, feed rate, and tool overhang (copyright © General Electric
Company).

FIGURE F-41 A boring bar with various

interchangeable adjustable heads (Kennametal, Inc.,
Latrobe, PA).

14
Select the chip breaker
FIGURE F-42 Chip breakers used are the adjustable chip deflator
(center) with a straight insert and the type with the built-in chip control
groove.

FIGURE F-43(b, c) (a) Negative rake two-sided Kenloc inserts; *Maximum

D.O.C. and feed rates (ipr) are limited by the insert thickness and cutting edge
length. Application ranges are for AISI 1045 steel at 180 to 220 BHN
(Kennametal, Inc., Latrobe, PA.)

15
Tool Holder Identification
FIGURE F-44 ASA tool identification system (Tool Application

Handbook; data courtesy of Kennametal, Inc., Latrobe, PA,
1973.)

Carbide Insert Identification
16
FIGURE F-45 ASA carbide insert identification (Tool Application
Handbook; data courtesy of Kennametal, Inc., Latrobe, PA, 1973.)

17
Multiple-Point Cutting Tools

Drilling
Reaming
Milling
Gear cutting
18
Power requirement for Drilling
Torque, M = 25,200 f 0.8 d 1.8

Thrust , T = 57,500 f 0.8 d 0.8 + 625 d 2
d = drill diameter, in
f = feed in/rev
19
Power requirement for Reaming

⎡ ⎛d ⎞ ⎤
2
⎢1− ⎜ 1⎟ ⎥
M = 23,300 k f 0.8 d 1.8 ⎢ ⎝d⎠ ⎥
⎢ ⎛ d1 ⎞ ⎥
0.2
⎢1 + ⎜ ⎟ ⎥
⎣ ⎝d⎠ ⎦
⎡ ⎛d ⎞ ⎤
⎢ 1−⎜ 1⎟ ⎥
T = 42,600 k f 0.8 d 0.8 ⎢ ⎝d⎠ ⎥
⎢⎛ d ⎞ ⎥
0.2
⎢ ⎜1 + 1 ⎟ ⎥
⎣⎝ d⎠ ⎦
d1 = reamer diameter, in.
f = feed in/rev
Power
M N
Power in HP Pc =
63,025
M = tool torque, in-lb
N = speed, rpm
Power in Watts = Hp * 746
20
21
Milling Cutters
22
23
24
25
26
Machining Power
Depends on the material removal rate
Uses empirical equations developed
based on experiments
See Machinery’s Handbook
– pp 1046 – 1055 (26th Edition)
27
28
29
Pc = power at the cutting tool
Pm = power at the motor
Kp = power constant (see tab 24, 25 and 30)
Q = metal removal rate (tab 29)
fm = feed rate, in/min or mm/min

f = feed rate for turning, in/rev or mm/rev
Drilling
30
T = Thrust; lb or N
M = Torque; in-lb or N.m
NJanuary
= Spindle
31, 2008
rpm Nageswara Rao Posinasetti 93
31
32

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Tool Design

Cutting Tool Design

Guidelines for Cutting tool Design

Basic tool angles (Tool

January 31, 2008 Nageswara Rao Posinasetti 5

January 31, 2008 Nageswara Rao Posinasetti 6

January 31, 2008 Nageswara Rao Posinasetti 8

January 31, 2008 Nageswara Rao Posinasetti 9

Establish the operating

 Feed, speed and depth of cut greatly

January 31, 2008 Nageswara Rao Posinasetti 11

FIGURE F-27 The difference in style A and style D holders for

Richard R. Kibbe, John E. Neely,31,

Richard R. Kibbe, John E. Neely,31,

To reduce cutting edge chipping

 Increase the speed

Select the cemented carbide grade

Straight carbides - Cast iron, Resistance to

January 31, 2008 Nageswara Rao Posinasetti 15

Straight carbides - Cast iron, Resistance to

January 31, 2008 Nageswara Rao Posinasetti 16

January 31, 2008 Nageswara Rao Posinasetti 17

January 31, 2008 Nageswara Rao Posinasetti 18

Select the nose radius

 Based on surface finish

January 31, 2008 Nageswara Rao Posinasetti 20

FIGURE F-34 Surface finish versus nose radius

Richard R. Kibbe, John E. Neely,31,

 Round – strong and large radius, good

January 31, 2008 Nageswara Rao Posinasetti 22

FIGURE F-35 Insert shapes for various

Richard R. Kibbe, John E. Neely,31,

January 31, 2008 Nageswara Rao Posinasetti 24

FIGURE F-36 A 38-degree triangular insert used

Richard R. Kibbe, John E. Neely,31,

Select the insert size

 Smallest size based on the depth of cut

January 31, 2008 Nageswara Rao Posinasetti 27

 Gives the strength of the tool

January 31, 2008 Nageswara Rao Posinasetti 28

FIGURE F-37 Insert thickness as determined by length of

Richard R. Kibbe, John E. Neely,31,

Select the tool style

 Based on the geometry of the

January 31, 2008 Nageswara Rao Posinasetti 30

Richard R. Kibbe, John E. Neely,31,

January 31, 2008 Nageswara Rao Posinasetti 32

January 31, 2008 Nageswara Rao Posinasetti 33

January 31, 2008 Nageswara Rao Posinasetti 35

January 31, 2008 Nageswara Rao Posinasetti 36

Select the rake angle

January 31, 2008 Nageswara Rao Posinasetti 38

FIGURE F-39 Side view of back rake angles.

Richard R. Kibbe, John E. Neely,31,

January 31, 2008 Nageswara Rao Posinasetti 40

FIGURE F-40 Determining shank size according to depth of

Richard R. Kibbe, John E. Neely,31,

FIGURE F-41 A boring bar with various

Richard R. Kibbe, John E. Neely,31,

January 31, 2008 Nageswara Rao Posinasetti 43

Richard R. Kibbe, John E. Neely,31,

FIGURE F-43(b, c) (a) Negative rake two-sided Kenloc inserts; *Maximum

Feed, speed and depth of cut greatly

Increase the speed

Based on surface finish

Round – strong and large radius, good

Smallest size based on the depth of cut

Gives the strength of the tool

Based on the geometry of the