Unit 3: CNC Tooling: Prepared By: MR.B.K Patil, DTC

Unit 3 : CNC Tooling
Prepared by : Mr.B.K Patil,DTC

Diploma in Mechatronics Semester 5 CNC Technology
Syllabus:
3.0 CNC Tooling
Cutting Tool Materials, Turning Tool Geometry & Milling

3.1
Tooling Systems
Tool Presetting, Automatic Tool Changers, Work Holding

3.2
& Cutting Process Parameter Selection

3.1 Tooling for CNC Machines
In conventional machines, the cutting tool cuts metal for about 25% of
the total machining time whereas the CNC machine tools are
expected to cut metal for 70 to 80% of the time.
The tooling used CNC machines should be,
(a) Rigid to withstand high metal removal rates.
(b) Capable of being pre-set and re-set in the shortest possible time to keep
the down time to minimum.
(c) Accurate enough to produce repetitive accuracy on the job.

Cutting Tool Materials, Turning Tool
3.1
Geometry & Milling Tooling Systems
CUTTING TOOL MATERIALS AND PROPERTIES

1. The most Important properties of the cutting tools materials are:
1. The material must withstand excessive wear even though the
relative hardness of the tool materials changes.
2. Ability to retain hardness under severe working condition.
3. Ability to withstand cutting forces.
4. Cost and easiness of fabrication should have within

reasonable limits.
5. The frictional coefficient must remain low for minimum wear

and reasonable surface finish

TYPES OF TOOL MATERIAL
CARBON STEELS
It contains the percentage of carbon in the range of 0.8 to 1.5.
It may only be used in manufacture of tools operating at low
cutting speed(12 mt / min).
They are comparatively cheap, easy to forge and simple to
harden.
Disadvantages of carbon tool steel are their comparatively low
heat and wear resistance

HIGH – SPEED STEEL
It is general purpose metal for low and medium cutting speed
owing to its superior hot hardness and resistance to wear.
HSS operate at cutting speeds 2 to 3 times higher than for
carbon steels and retain their hardness up to 900c
Three general types of HSS are high tungsten, high
molybdenum and high cobalt
Tungsten in HSS provides hot hardness and form stability.
Molybdenum maintains keenness of the cutting edges. Cobalt
makes the cutting tool more wear resistance.

STELLITE
Stellite is the trade name of a non-ferrous cast alloy composed
of cobalt, chromium and tungsten
The range of elements in these alloys in 40% cobalt, 30% to
35% chromium, 10% to 12% tungsten.
Stellite can be operated on steel at cutting speeds 2 times
higher than for HSS.
They are used for non - metal cutting application such as rubber
plastics etc.

CARBIDES
They are composed principally of carbon mixed with other
elements.
The basic ingredients of most carbide is tungsten carbide that is
extremely hard. Pure tungsten powder is mixed under high heat
1500c with pure carbon in the ratio of 94% and 6% weight
The two types of carbides are the tungsten and titanium and
both are more wear resistant.
Carbides are designed for machining tougher materials chiefly
for various materials.

COATED CARBIDES
The Coated carbide has substrate and coating layer.
Substrate for toughness having hard materials and soft
materials (cobalt + carbide)
Coating layer of carbide (Very hard)
A good substrate
Perform well on all work material
Better impact strength to resist fracture.
Allow good coating adhesion.

COATED CEMENTED CARBIDES
The cemented carbide with a very thin coat of carbides. The

layer of titanium carbides was only a few microns thick but
change the performance of carbide tools. By changing to a GC
Inserts from a uncoated insert, cutting speed and /or tool life
was dramatically increased. The effect of the coating continues
long after it partly worn off resulting in the reduction of crater
wear when machining steel. Higher temperature could be
tolerated and thus higher speeds and feeds.

COATED CARBIDES(GC)
More than 75% turning operations and more than 40% of milling
operations are today performed with coated carbides.
The main coated materials are
Titanium carbide (Tic)
Titanium Nitride (Tin)
Aluminium Oxide – ceramic (Al2 O3)
Titanium carbon nitride (TiCN)

CERMETS
Cermets – Ceramics and metal.
Characteristics of Cermets
High Hardness
High hot hardness
Resist Oxidation
Low friction
Advantages of Cermets
High Efficiency
Long life
Large Batch
Avoid build up edges
Surface finish control
Cermets has properties to use it for higher cutting speed and wear
resistance.

DIAMONDS
The diamond is the hardest known material and can be run at
cutting speed about 50 times greater than that of HSS tool and
5 to 6 times of life than carbide.
Diamond is incompressible, readily conducts heat and has low
coefficient of friction.
Diamond are suitable for cutting very hard material such as
glass etc..
By polycrystalline diamond the tool life is 30 times of carbide.

PRACTICAL APPLICATION
SOLID TOOLS
Dia 1.5 mm End mills, Dia 0.4 mm Drills, Dia 2.5 mm
Reamers.
SUITABILITY
Minimum Overhang
Vibration free machine
No play and Misalignment

Summary of Applications for Various
Cutting Tool Materials
Tool material Work materials Remarks

Carbon steel Low strength, softer materials, non Low cutting speeds, low strength
ferrous alloys, plastics materials
Low/medium alloy steels Low cutting speeds, low strength

Low strength, softer materials, non materials
ferrous alloys, plastics
HSS Low to medium cutting speeds, low to
medium strength materials
All materials of low and medium, strength
Cemented carbides and hardness Not suitable for low speed application
Not for titanium alloys, not for non-ferrous

Coated carbides All materials up to medium strength and alloys as the coated grades do not offer
hardness additional benefits over uncoated
Ceramics Cast iron, alloy steels, stainless steels, Not for low speed operation or
super alloys interrupted cutting. Not for machining Al,
Ti alloys.
Cast iron, Ni-base super alloys, non
ferrous alloys, plastics

INDEXABLE INSERTS
Correct cutting geometry

Precise Dimensions
No Re sharpening
Rapid replacement
Chip breaker, Built in feature
ISO Standard Tooling available world wide.

Indexable Inserts
• At the high cutting speeds and feeds used on CNC machines, the brazed
tools are normally not used. Indexable carbide inserts are used to take up
higher cutting speed and to minimize the tool change time.
• The tool change time with the brazed tool is many times more compared
to tool change time with indexable inserts, where the inserts is taken out
and indexed.
• Harder and special grade carbides should be used to achieve faster rate
of metal removal. The indexable inserts of tungsten carbide are further
coated with a wear resistant layer of titanium carbide or titanium nitride for
better results.

Indexable Inserts
• Indexable inserts are available in various shapes and with varying

geometry.
• The Chip breakers can be formed on the inserts either by shaped

grooves in the insert itself or by way of clamping arrangements.

ISO Standard Tooling
available for inserts and
holders

ISO Standard Tooling
available for inserts and
holders

Work Holding Devices
• The work piece must be securely fastened, and the set-up must be rigid
enough to withstand the forces which will be developed during machining
operation.
• The work piece or holding device becomes loose during machining,

damage can result to the tooling and/or machine.
• The machine operator should be sure that all work holding devices are
free from burr and chips before using.
• The work holding devices, generally specified by the part programmer,

should be located in the proper position on the machine table.
• To reduce the clamping /unclamping time, hydraulic and pneumatic

actuation is widely used in work holding devices.

Types of Work holding Devices
• Swivel-base vise - Bolted the table or sub plate. Swivel base enables
the vise to be swiveled 360° in a horizontal plane.
• Angle plates - Are L - shaped pieces of cast iron or steel accurately

machined to a 90° angle. They are made in a variety of sizes and have
holes or slots which provide a means for fastening the work piece.
• V-blocks - Are generally used in pairs to support round work, a U -

shaped clamp may be used to fasten the work in a V - block.
• Step blocks - Are used to support for strap clamps when work being
fastened to the table or work holding device.
• Parallels - Are flat, square, or rectangular pieces of metal used to

support the work piece for set-up.

Types of Work holding Devices
• Clamps or straps - Are used to fasten work to the table, angle plate, or
fixture.
They are made in a variety of sizes and are usually supported at the end
by the step block and bolted to the table by a T bolt.
It is good practice to place the T bolt in the clamp or strap as close to the
work as possible.
• Support jacks - Are used to support the work piece to prevent distortion
of the work piece during clamping.
• Sub plates - Are generally flat plates that may be fitted to the machine
table to provide quick and accurate location of work pieces, work holding
devices or fixtures.

3.2 TOOL PRESETTING AND
HOLDING SYSTEMS
DEFINITION
A toolholder is a device that acts as an

interchangeable interface between the machine
tool spindle and the cutting tool such that the
efficiency of either is optimized.

ADAPTERS
• A link between the cutting edge and the spindle nose to obtain
successful and flexible manufacturing in machining centres.
MACHINE TOOLS WITH 100% PERFORMANCE. CUTTING TOOLS WITH 100% PERFORMANCE.
TOOLHOLDERS WITH 100% PERFORMANCE.

Elements
Retention Knob
Machine-tool spindle
Taper (back end)

Gage-line
Particular plane defining a
cone. Used as reference for the
dimension A.
Dimension A + L1
Distance between tool origin
Flange and gage line, allowing to
locate the tool origin with
A
regard to the programming
origin.
Driving slots or Tenons L1
Cutting tool
Chuck, arbor or holder (front end)
The most effective adapter seating into
spindle
No Yes
SK µ
40 1,2
50 2

The Taper Norms
ISO = International Standard Organization : Worldwide
DIN = Deutsche Industrie Norm : Germany
ANSI = American National Standard Institute : USA
JIS = Japanese Institution for Standardization : Japan
CAT = Suited to this company : Caterpillar
NF = Norme française : France

MILLING TOOLING SYSTEMS
NECK
Retention
Knob FLANGE
Adop
ter SQUARE
PILOT
THREAD
CAT BT DIN
Fig. 2. Retention Knob as used in

the Top of Tool Assembly for
Fig.1. Complete Tool Assembly Clamping and Releasing Purpose as
(for Parallel Shank Tooling) as used in a CNC Machining Centre.
used in a CNC Machining
Centre.

• A milling tool to be used in CNC machine tool is an assembly of a

number of parts besides the actual cutting tool as shown in Fig.1.
• The assembly consists of the adopter to suit the spindle taper such as
ISO 40 or 50.
• Collets for holding the straight shank of the end mill.
• Retention knob which is used by the hydraulic draw bar in the spindle
housing for retaining or releasing the tool from the spindle, besides the
actual cutting tool, the end mill.
• Typical retention knob design as used in spindle tooling is shown in

Fig.2.

Fig.3.
Fig.4.

Fig. 5 Typical Digital Tool Setting System, which is Essentially a Digital

Height Gauge useful for Machining Centre Tooling.

• CNC machine tools are versatile, they need to use a large variety of tools
to accomplish the range of machining tasks they are capable of.
• There are a number of shapes of the adopter depending on the machine

tool standard followed by the machine tool builder.
• The typical BT style and the ANSI CAT-V style are shown in Fig.3.The
actual shape of the adopter will have to suit the tool change gripper.
• The generation of actual geometry is taken care of by the CNC part

programme, which is essentially the coordinates through which the cutting
tool tip moves.
• It is important to know the actual dimensions of the tool when it is placed in

the spindle.

• The actual point to be programmed in a CNC part program is the tip of

the tool where the axes will be moving with respect to a known point in
the spindle, e.g. the centre of the spindle in case of machining centres.
• It therefore becomes necessary to know precisely the deviation of the

tool tip from the gauge point on the spindle. Hence the tool setting
equipment is generally used.
Tool Pre-setting
• The tools are set to known dimensions away from the machine tool.
• The pre-setting of tools can be planned and carried out in advance, so

that tools are available to ensure continuity of production and minimize
down time due to tool set-up on job changes.

Tool Pre-setting
• A simple mechanical type tool-setting device is shown in Fig.4.
• In this system the base is provided with the exact taper as used in the
actual machine tool. The assembled tool is therefore placed in the spindle
taper.
• The measurement is done with the help of a micrometer head, which is

attached to a U-clamp as shown in Fig. 4.
•The U-clamp can be moved manually on a post, which has precise

location slots that are separated by an exact distance (e.g. 25 mm).
• The length of the tool can therefore be measured by the measurement of

the micrometer plus the slots along the post.

Tool Pre-setting
• A similar tool setting device, which can measure the length as well as
the diameter of a spindle tooling, is shown in Fig. 5.
• The tool-measuring probe moves on two precise axes to measure both

the length and the diameter of a spindle-tooling unit.
• The display is shown digitally so that there is no error in measurement.
• Further they are provided with a serial port for outputting the measured
values directly into any tool management system or a personal computer
for the purpose of generating the tool offset values.

Tool Pre-setting
• Some presetting systems are also provided with an optical projector

such that the point of contact between the probe end and the tool can be
more accurately identified.
•Tool presetting fixture is shown in Fig.

PRACTICAL APPLICATION
INDEXABLE INSERTS
Correct cutting geometry
Precise Dimensions
No Re sharpening
Rapid replacement
Chip breaker, Built in feature
ISO Standard Tooling available world wide.

Types of Tool Magazines
1. Tool Turret 2. Drum or Disc type

3. Chain type

1. Tool Turret
Turning centres are available with the tool turret containing 8-12 tools.
As the tool change command is received by the control system, the
tool turret moves to a fixed tool change position and the required tool
comes to the cutting position.
2. Drum or Disc type tool magazine
The drum rotates for the purpose of tool change to bring the required
tool to the tool change arm. As the number of tools in the magazine
increases its diameter becomes too large.

3. Chain type tool magazine
• For storing large number of tools a chain type tool magazine

provides The necessary flexibility. The capacity may be as small
as 30 to and as high as 100

Automatic Tool Changers
Double Gripper
Tools
Magazine Spindle
• The CNC machines are designed to perform a number of operations in

a single setting of the work piece.
• The tool is automatically selected and changed based on the tool
control function (T-word) in the part programme.
• On the machining centres, automatic tool changers (ATC) are provided
to reduce the idle time between change over from one operation to
another.

3.2 Automatic Tool Changers
• The ATC consists of a tool magazine for storing the tools and a tool
change unit for transferring the tool from tool magazine to spindle.
• The tool already fitted on the spindle is removed and replaced in the tool
magazine. The initial position of various tools is fed to the control system,
which then keeps updating the data regarding tool number fitted in the
particular pocket in the tool magazine.
Tool magazines with up to 60 tools are quite common.

The tool change cycle consists of two parts
(i) Tool Selection Cycle
The tool for successive operation is selected during the previous

machining operation. The selected tool comes to the tool change
position, whenever the tool selection command is received by the
system.

The tool change cycle consists of two parts
(ii) Tool Transfer Cycle

• In this part of the tool change cycle, the tool which is lying
selected in the magazine, is transferred to the spindle and the tool
which is in the spindle is transferred to the magazine.
• Before the tool transfer takes place, the spindle is turned off and
moves to the tool change position, so that the tools will not hit the work
piece.

Automatic Pallet Change / Multi Pallet Machines
• To further reduce the non-productive time, the CNC machines are
provided with automatic pallet change systems. Twin-pallet CNC
machines are very common but machines with up to 5 pallets are also
being used.
• The muIti pallet system enables the operator to load the work piece on
one pallet while machining of work piece on second pallet is going on.
This helps in rapid change of work piece, thereby reducing the idle time
of the machine.

Swarf removal
• CNC machines are designed to work at optimum cutting conditions with

the improved cutting tools on a continuous operation basis. Since the
cutting time is much more in CNC machines, the volume of swarf generated
is also more.
• Unless the swarf is quickly and efficiently removed from the cutting zone,
it can affect the cutting process and the quality of the finished product. Also
the swarf cannot be allowed to accumulate at the machine tool because it
may hamper the access to the machine tool.

Swarf removal
• In addition some auxiliary functions like automatic component loading or

automatic tool change may also be affected by accumulation of swarf.
• To avoid these problems an efficient swarf control system should be

provided with the CNC machine tools with some mechanism to remove
the swarf from the cutter and cutting zone and for the disposal of swarf
from the machine tool area itself.

Swarf Removal from Cutting Zone
• The swarf removal from the cutting zone is generally taken care of by the
design configuration of the machine.
• Slant bed and vertical bed turning centres have the advantages over flat
bed or horizontal bed configuration in that the swarf does not accumulate on
the guide ways. Similarly horizontal machining centres are advantageous to
vertical machining centres.
• But swarf removal by gravity is not adequate in CNC machines.
• To supplement the gravity system, multiple coolant jets are arranged

around the cutting tool and the coolant, under pressure, takes away the
accumulated swarf from the cutting area.
• Compressed air jets are also used for swarf clearance from the cutting
zone.
Swarf Disposal From Machine Tool
• Continuously operating linear or rotary conveyors are used for

removing the swarf from the machine tool. The system is such that the
swarf from the cutting zone falls directly on the conveyor and is
immediately taken away.
• The swarf from the conveyor is taken to disposal bins, which can then
be collected and removed from the machine area.

Shrinkfit
• A shrinkfit toolholder works in conjunction with a specialized heater.
• The holder takes advantage of thermal expansion and contraction to

clamp the tool.
• At normal shop temperature, the bore in which the tool locates is
slightly undersize compared to the tool shank.
• Heating the holder opens up this bore, allowing the tool to be inserted.
• As the holder cools, the bore shrinks around the tool to create a
concentric and rigid clamp.

Shrinkfit
Ø d0 of the bore
<
Infrared picture
Ø tool shank

Unit 3: CNC Tooling: Prepared By: MR.B.K Patil, DTC

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Unit 3 : CNC Tooling

Prepared by : Mr.B.K Patil,DTC

3.0 CNC Tooling

Cutting Tool Materials, Turning Tool Geometry & Milling

Tool Presetting, Automatic Tool Changers, Work Holding

Diploma in Mechatronics Semester 5 CNC Technology

(c) Accurate enough to produce repetitive accuracy on the job.

Diploma in Mechatronics Semester 5 CNC Technology

CUTTING TOOL MATERIALS AND PROPERTIES

2. Ability to retain hardness under severe working condition.

3. Ability to withstand cutting forces.

4. Cost and easiness of fabrication should have within

5. The frictional coefficient must remain low for minimum wear

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

The cemented carbide with a very thin coat of carbides. The

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Tool material Work materials Remarks

Low/medium alloy steels Low cutting speeds, low strength

Not for titanium alloys, not for non-ferrous

Diploma in Mechatronics Semester 5 CNC Technology

Correct cutting geometry

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

• Indexable inserts are available in various shapes and with varying

• The Chip breakers can be formed on the inserts either by shaped

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

• The work piece or holding device becomes loose during machining,

• The work holding devices, generally specified by the part programmer,

• To reduce the clamping /unclamping time, hydraulic and pneumatic

Diploma in Mechatronics Semester 5 CNC Technology

• Angle plates - Are L - shaped pieces of cast iron or steel accurately

• V-blocks - Are generally used in pairs to support round work, a U -

• Parallels - Are flat, square, or rectangular pieces of metal used to

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

A toolholder is a device that acts as an

Diploma in Mechatronics Semester 5 CNC Technology

TOOLHOLDERS WITH 100% PERFORMANCE.

Diploma in Mechatronics Semester 5 CNC Technology

Taper (back end)

Driving slots or Tenons L1

Diploma in Mechatronics Semester 5 CNC Technology

ISO = International Standard Organization : Worldwide

DIN = Deutsche Industrie Norm : Germany

ANSI = American National Standard Institute : USA

JIS = Japanese Institution for Standardization : Japan

CAT = Suited to this company : Caterpillar

NF = Norme française : France

Diploma in Mechatronics Semester 5 CNC Technology

Fig. 2. Retention Knob as used in

Diploma in Mechatronics Semester 5 CNC Technology