Mechanics of Metal Cutting

(Practical Applications of Tool Design)

1
The Mechanics of Metal Cutting is controlled by
three main elements.
•Rake Angles
•Lead Angles
•Clearance Angles

2
Rake Angles

3
 Side rake
Single point tool geometry

γ
f
Primary motion
of the job

Side Clearance
Feed motion
α Section F-F
f
P
F F
End α k k !r
p r
clearance

ψ
γp Back rake Lead
angle

Section P-P
4
Basic Cutting Tool Geometry-Turning

SCEA

Side Cutting Edge Angle

Back Rake
Side Rake

5
 Rake Angles Control Edge
Strength
FORCE

POSITIVE
•TRS measures the bending
fracture strength of carbides

6
Rake Angles Control Edge Strength
R C E
FO

NEGATIVE

SUPPORTED:
•Measure of deformation More Compressive
Loading
resistance
7
Rake Angles - Basic Milling Geometry

8
POSITIVE AXIAL RAKE POSITIVE RADIAL RAKE

9
NEGATIVE AXIAL RAKE NEGATIVE RADIAL RAKE

10
POSITIVE AXIAL RAKE NEGATIVE RADIAL RAKE

11
 Rake Angles Control
Edge Strength

Radial Rake has a Radial Rake

major impact on (+) (-)
cutting edge strength
Radial Rake absorbs
the interrupted cut

Axial Rake

12
 Cutting Forces
Ft = Tangential Force

Ff = Feed Force

Ft Fr = Radial Force

Ff
Fr

13
 Rake Angles control
Cutting Forces

-5
NEGATIVE
Cutting Forces
change
approximately
+6 1% per degree
of Rake change
(mild steel)
POSITIVE

14
Rake Angles control
Cutting Forces

Radial Rake
(+) (-)

Axial Rake has a

major impact on
cutting forces.

15
 Rake Angles control
Cutting Forces

Both axial and radial Radial Rake

(+) (-)
rake have comparable
effects on cutting
forces.

16
 Rake Angles Control
Cutting Forces
Negative Positive
Radial Rake Radial Rake

Designed for a specified clearance under the

heel of the insert.
17
Top Topography is used to
Enhance Axial Rake

18
 Chip Flow Characteristics

Rake angles control the direction of chip flow

(-) (-) (+)

(+) (+) (-)

Positive / Positive Negative / Negative Negative / Positive

(Shear-Clear)

19
 Rake Angles:Drills

Radial Rake Axial Rake Angle (Helix)

20
 Negative Positive
Axial Axial
Rake Rake

Spiral Point Spiral Flute

21
 Rake Angles:Reamers
Axial Rake Angle

Neutral Axial Rake

Radial
rake Primary
Positive Axial Rake angle Clearance

Secondary
Clearance

Negative Axial Rake

22
Lead Angles

23
 Lead Angle controls the
Direction of Cutting Forces

45 Lead
Angle

Axial
load
Table Feed
Radial
load

24
 Direction of Cutting Forces

Direction of Cutting
Forces

25
 Direction of Cutting Forces

Increasing the Lead

Angle places the forces
more into the Radial
Plane.

26
 Lead Angles control
direction Cutting Forces

Forces
directed into
the spindle

Forces directed
across the
spindle

27
 Lead Angles control
direction Cutting Forces

90° 118° 140°

The greater the angle, the greater the rigidity.

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Clearance
Angles

29
 Clearance Angles
90 Degree included
79 Degree included
Angle
Angle
5 degree Neg. Rake

5 degree
Positive. NEGATIVE
Rake
POSITIVE

6° Degrees 5° Degrees
Clearance Clearance

30
Back Clearance

31
 Clearance Angles

Radial Rake
Arc of the cut
(+) (-)

Radial Rake is designed to

provide a specified amount
of clearance under the heel of
the insert

32
 Clearance Angles

Lip Relief
Angle

Flank
Margins
Body Point
Angle
Clearance
Drill
(Radial) Diameter

33
Tap Margins

Concentric
Grind
(No Clearance)

34
 Tap Margins

CONCENTRIC CON-ECCENTRIC ECCENTRIC

No Clearance Partial Clearance Clearance

35
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