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In design of a single point cutting tool the following factors are to be considered.
i) Type of work piece material and tool material;
ii) Type of operation and surface finish required;
iii) Optimum tool angles;
iv) Permissible cutting speed, feed and depth of cut;
v) Cutting forces;
vi) Condition of work holding:
a) Work held as a cantilever;
b) Work held in between two centres, both of which can be live or one live and
the other dead.
c) Work held in chuck and tailstock centre.
vii) Overhung of the tool from the tool post;
viii) Accuracy of the work in terms of permissible deflection (maximum) of job with
respect to the tool.
Table-I: Recommended tool geometry for single point cutting turning tools [2]
Carbide Tools
Material BHN Brazed Throwaway End Side
Back Side Back Side ECEA
Relief Relief
Rake rake Rake rake
Gray or flake graphite cast iron 140 0 6 5 neg 5 neg 5 5 5
Nodular or ductile cast iron 180 0 6 5 neg 5 neg 5 5 5
Malleable cast iron 220 5 neg 5 neg 5 neg 5 neg 5 5 5
Free machining plain carbon 180
0 6 5 neg 5 neg 5 5 5
steel, plain carbon steel
Free machining alloy steel 250 0 6 5 neg 5 neg 5 5 5
Alloy steels, cast steels 350 0 6 5 neg 5 neg 5 5 5
Hot work die steel, tool steel 500 5 neg 5 neg 5 neg 5 neg 5 5 5
Ferritic stainless steel 180 0 6 0 5 5 5 5
Austenitic stainless steel 200 0 6 0 5 5 5 5
Martensitic stainless steel 180 0 6 0 5 5 5 5
440 0 6 5 neg 5 neg 5 5 5
Precipitation hardening 220-320
0 6 0 5 5 5 5
stainless steel
Aluminium alloys 40*-110 3 15 0 5 8 8 5
Magnesium alloys 30*-80 3 15 0 5 8 8 5
Copper alloys 120-185 5 8 0 5 5 5 5
Titanium alloys 280-360 0 6 0 5 5 5 5
High temperature alloys 260-320 0 6 0 5 5 5 5
Table-II: Recommended tool geometry for single point cutting turning tools [2]
Depth of cut has the greatest influence upon the cutting force, followed by feed,
with cutting speed having the least influence. Feed has the greatest effect on surface
finish when it is set according to nose radius. The cutting speed has maximum influence
on temperature generated at cutting zone during machining. Considering all above
factors, the tool designer has to make correct compromise so as to get best machining
operation under the given condition.
A general rule used by many production people to achieve the greatest machining
efficiency is to use the heaviest feed that will allow the required surface finish, use the
maximum depth of cut consistent with available power and rigidity of workpiece and
machine, and then establish the cutting speed to give the desired tool life. Too fast a
cutting speed will increase tool costs and down time for tool changing. Too slow a speed
simply cannot produce enough pieces to make a profit. Somewhere between too fast and
too slow is a cutting speed that will give the best tool life for overall efficiency.
Usually the best cutting speed is the one that will reduce the total cost of
machining to a minimum cost per piece. However, cost may be secondary, the objective
may be to set the maximum production rate. Many variables like the cost of labour on the
machines, over head costs, set up time, tool costs, tool changing time, time to machine
the workpiece, tool grinding time, grinding room labour costs etc. determine the
minimum cost and maximum production rate. The majority of these variables may be
changed to known quantities for a particular job. When these quantities are determined, it
is possible to plot costs and production rates vs. cutting speeds. The resulting graph
will show speeds for minimum cost and maximum production rate. The theoretical best
cutting speed will lie between the points of minimum cost and maximum production.
Table-IV: Cutting speeds and feeds for turning non-ferrous materials [3]
Radial Force, Py
This acts in a radial direction from the centre of the work piece. It is the force that
holds the tool to the correct depth of cut. It is the smallest of the three tool forces-only 20
percent as large as the tangential force. It requires no power in that there is no velocity in
the radial direction. It should be kept to a minimum to reduce deflection, vibration and
chatter.
It is difficult to measure chip thickness and evaluate the values of ζ while machining
brittle materials and the value of τs is roughly estimated from
τs = 0.175 BHN [4.6]
Where, BHN= Brinnel Hardness Number
But most of the engineering materials are ductile in nature and even some semi-
brittle materials behave ductile under the cutting condition.
The angle relationship reasonably accurately applicable for ductile metals is
β0 + η - γ0 = 450 [4.7]
And the value of τs is obtained from,
τs = 0.186 BHN ( approximate) [4.8]
0.6 ∆
Or, τs = 0.74 σu ε ( more suitable and accurate) [4.9]
Where, σu = ultimate tensile strength of the work material
ε = cutting strain ≈ ζ – tan γ0
∆ = % elongation
Substituting Equation 4.7 in Equation 4.1, we get
Pz = t so τs (cot β0 + 1) [4.10]
Again, cot β0 = ζ – tan γ0
So, Pz = t so τs(ζ – tan γ0 + 1) [4.11]
Problem 1: Design a HSS cutting tool to machine mild steel work piece in a lathe.
Assume suitable data.
Solution:
Since not much data available to solve above problem, we have to make following
assumptions.
1. BHN of material = 200 Kg/ mm2
2. Back Rake Angle, Side Rake Angle and Side Cutting Edge Angle for HSS tool for
machining mild steel are 100, 120 , 450 respectively.
3. Dynamic Shear Stress of mild steel can be calculated using τs = 0.186 BHN Kg/ mm2
4. Ultimate Tensile Strength of HSS is 1000 N / mm2 .
5. Factor of Safety for rough machining is 10.
6. Shank of Tool Section is square.
7. Tool Over Hung is 30 mm.
8. Chip Reduction Co-efficient is 2.5 for rough machining.
Calculation:
Conversion of tool angles from ASA system to ORS
Px = t so τs (ζ – tan γ0 – 1) sinΦ
= 2 x 0.3 x 372 ( 2.5 – tan15.26– 1)sin 45 = 193.6 ≈ 194 N
The nearest standard cross section value is 12 mm. Therefore cross section of tool shank
selected is 12 mm x 12mm.
Cutting Tool Material can be M2 (T83 W6 Mo5 Cr4 V2) or T1 ( T72 W18 Cr4 V1)
Generally M type HSS materials are cheaper compared to T type material.
The various M type HSS materials are M1, M2, M3, M4, M7, M10, M33, M36, M41,
M42, M43, M44, M45, and M46.
The various T type HSS materials are T1, T2, T4 and T6.
The design of chip breaker is optional.
Reference:
1. Manufacturing Science-II by A.B. Chattopadhyay, NPTEL website at
www.nptel.iitm.ac.in
2. Tool Design by Cyril Donaldson, page 304
3. ASTME, “Manufacturing, Planning and Estimating Hand Book”, F.W.Wilson(ed),
McGraw-Hill, New York, 1963
4. Metal Cutting- Theory and Practice by A. Bhattacharyya, page 577
5. Metal Cutting- Theory and Practice by A. Bhattacharyya, page 580