Manufacturing

Tooling
Cutting Tool Design

Nageswara Rao
Posinasetti

Elements of Machining
Š Cutting tool
Š Tool holding
Š Guiding device
Š Work piece
Š Machine tool

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Chip Formation
Š Cutting tool harder and wear resistant
than the workpiece material
Š Interference between the tool and
workpiece designated as feed and
depth of cut
Š Relative motion between the tool and
workpiece termed as cutting speed or
velocity to overcome the resistance

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 Cutting process parameters
Š The cutting speed, V, is the speed with which the
cutting tool moves through the work material. This is
generally expressed in feet per minute (fpm) or
metres per second (ms-1).
Š Feed rate, f, may be defined as the small relative
movement per cycle (per revolution or per stroke) of
the cutting tool in a direction usually normal to the
cutting speed direction.
Š Depth of cut, d, is the normal distance between the
unmachined surface and the machined surface.

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 Type of Chips
Š The chip formation in metal cutting
could be broadly categorised into three
types:
– Continuous chip,
– Continuous chip with BUE, and
– Discontinuous chip

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FIGURE F-14 The three types of chip formation: (a)

continuous; (b) continuous with built-up edge; (c) discontinuous
(segmented). (J.E. Neely, Practical Metallurgy and Materials of
Industry, 2nd ed., Wiley, New York, copyright © 1984.)

Richard R. Kibbe, John E. Neely,29,

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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.

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Continuous chip
ŠContinuous chips are normally produced
when machining steel or ductile metals at
high cutting speeds.
ŠThe continuous chip which is like a ribbon
flows along the rake face.
ŠContinuous chip is possible because of the
ductility of metal (steel at high temperature
generated due to cutting) flows along the
shear plane instead of rupture.
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Continuous chip

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CHIP

TOOL

WORKPIECE
Fig. From P N Rao – Metal
Cutting and Machine Tools,
Tata McGraw Hill, 2000
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Continuous chip
Š It can be assumed that each layer of
metal flows along the slip plane till it is
stopped by work hardening.
Š Each of these layers get welded to the
previous ones because of the high
temperature, thus forming a continuous
chip.

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CHIP
1
2
TOOL
3
4
5

9 8 7 6 4 3 2 1
5

WORKPIECE

Fig. From P N Rao – Metal

Cutting and Machine Tools,
Tata McGraw Hill, 2000
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Continuous chip
ŠSome ideal conditions that promote
continuous chips in metal cutting are:
– sharp cutting edge,
– small chip thickness (fine feed),
– large rake angle,
– high cutting speed,
– ductile work materials and
– less friction between chip tool interface through
efficient lubrication.

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Continuous chip
Š This is the most desirable form of chip
since the surface finish obtained is
good and cutting is smooth.
Š It also helps in having higher tool life
and lower power consumption.
Š However, because of the large coils of
chips, the chip disposal is a problem.

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Continuous chip
ŠHowever, because of the large coils of chips,
the chip disposal is a problem.
ŠTo help in this direction various forms of chip
breakers have been developed which are in
the form of a step or groove in the tool rake
face.
ŠThe chip breakers allow the chips to be
broken into small pieces so that they can be
easily disposed off.
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Discontinuous chip
Š When brittle materials like cast iron are
cut, the deformed material gets
fractured very easily and thus the chip
produced is in the form of
discontinuous segments.
Š In this type the deformed material
instead of flowing continuously gets
ruptured periodically.
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 Discontinuous chip

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Discontinuous chip
Š Discontinuous chips are easier from
the chip disposal view point.
Š However, the cutting force becomes
unstable with the variation coinciding
with the fracturing cycle.

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12,500
Cutting force, Lb

10,000

7,500

5,000
1.0 2.0 3.0
Distance cut, inches

Fig. From P N Rao – Metal

Cutting and Machine Tools,
Tata McGraw Hill, 2000
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Discontinuous chip
ŠAlso they generally provide better surface
finish.
ŠHowever, in case of ductile materials they
cause poor surface finish and low tool life.
ŠHigher depths of cut (large chip thickness),
low cutting speeds and small rake angles are
likely to produce discontinuous chips.

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Continuous chip with BUE

ŠWhen the friction between tool and chip
is high while machining ductile
materials, some particles of chip adhere
to the tool rake face near the tool tip.
ŠWhen such sizeable material piles up
on the rake face, it acts as a cutting
edge in place of the actual cutting edge.
ŠThis is termed as built up edge (BUE).

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Continuous chip with BUE

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 Continuous chip with BUE
ŠBy virtue of work hardening, BUE is
harder than the parent work material.
ŠAs the size of BUE grows larger, it
becomes unstable and parts of it gets
removed while cutting.
Š The removed portions of BUE partly
adheres to the chip underside and
partly to the machined surface.

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Continuous chip with BUE

Fig. From P N Rao – Metal

Cutting and Machine Tools,
Tata McGraw Hill, 2000
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Continuous chip with BUE

ŠThis causes finished surface to be
rough.
ŠHowever, since the cutting is being
carried by the BUE and not the actual
tool tip, the life of the cutting tool
increases while cutting with BUE.
ŠThat way BUE is not harmful while
rough machining.

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 Continuous chip with BUE
ŠThe conditions that normally induce the
formation of BUE are
– low cutting speed,
– high feed, and
– low rake angle.
ŠOne of the prerequisites for the formation of
BUE is the work hardenability of the
workpiece material.
ŠHigher the work hardenability, rougher is the
machined surface produced.
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 Manipulating Factors
Š Cutting speed
Š Size of cut
Š Effect of tool geometry
Š Tool material
Š Cutting fluid
Š Work piece material

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Cutting Forces
Š Cutting force
Š Radial force
Š Axial force

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Power requirements in
Turning

C V f n3 d n 4
HP =
33,000

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Table 3.1 (p 47)

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 Tool Wear
Š Crater wear
Š Flank wear

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 Mechanism of tool wear
Š Abrasive action of hard particles of work
material
Š Plastic deformation of the cutting edge
Š Chemical decomposition of the cutting tool
contact surfaces
Š Diffusion between work and tool surfaces
Š Welding of asperities between work and tool

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Tool Life
Š Criteria for tool life
– Change of quality of the machined surface
– Change in the magnitude of the cutting
force
– Change in the cutting temperature
– Costs

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Tool Life Equation

V Tn = C
Š V = cutting speed, fpm
Š T = tool life, minutes
Š C = a constant
Š n is a constant
– HSS = 0.10 to 0.15
– Carbides = 0.20 to 0.25
– Ceramics = 0.6 to 1.0

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Tool Life Equation

V T n f n1 d n 2 = K
Š V = cutting speed, feet per minute
Š T = tool life, minutes
Š d = depth of cut, in
Š f = feed rate, inches per revolution
Š K = a constant
Š n1 = exponent for feed (0.5 to 0.8)
Š n2 = exponent for depth of cut (0.2 to 0.4)
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The following equation was obtained when
machining AISI 2340 steel with HSS tool. A
100 minute tool life was obtained using V =
75 fpm, f = 0.0125 ipr, d = 0.10 in.Calculate
the effect upon the tool life for a 20%
increase in the cutting speed, feed and depth
of cut, taking each separately. Calculate the
effect of a 20% increase in each of the above
parameters taken together.

V T 0.13 f 0.77 d 0.37 = 2.035

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Other tool life equations

K = V T n f n1 d n 2 Bhn1.25

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