——————— DESIGN OF CUTTING TOOLS 213 [5 Cutting Tool | force Cutting force material @ 4) Cuming Cutting. force force ) teh FIGURE 4-1 Progressive formation of a metal chip. Rake angle Relief angle are oe FIGURE 4-2 Rake and relief ans tool. gles of a cutting214 TOOL DESIGN + rake | {a ) lit (ch FIGURE 4-3 Variation of vake angles from positive to negative: (a) positive rake, (b) zero rake, (c) negative rake, requirements and cutting forces. The smaller point angle resulting from positive rake angles penetrates the metal more readily and reduces cutting pressure. It should be noted, however, that high positive rake angles result in a fragile cutting edge. They are limited to machining softer materials and are well suited to this type of application because of the keenness of the cutting edge. On the other hand, negative rake angles provide a stronger cutting edge and are suitable for cutting high-strength alloys. Relief angles, sometimesWorkpiece Zero or negative relict allows heel of too! re to drag on workpicce materi! and prevent tool from entering ' anh sees \ Workpiece i ) —~ Greater relief angles fe _— Provide a keener cutting _——~ edge that will penetrate the workpiece more readily bar abi pte a ragie 5a cutting \ Workpiece ae DESIGN OF CUTTING TOOLS 215 ‘Small relief angles — provide stronger / iar Pines cone FIGURE 4-4 Effect of variation in relief angles. incorrectly referred to as clearance angles, ere to allow the cutting edge to penetrate the work piece (see Fig. 4-4). They prevent rubbing or physical interference between the heel of the tool and the workpiece. Relief angles are always positive. An edged cutting tool must always have positive relief to cut successfully. Small relief angles give more support to the cutting edge and are generally used when maehining high-strength alloys. Larger relief angles provide a keener cutting edge and allow the tool point to penetrate the work material more easily. However, as in the case of high positive rake angles, a large relief angle results in a fragile cutting edge that is suitable only for softer low-strength alloys. Relief and rake angles are common to all edged cutting tools, although there may be small differences in terminology when referring to different tools, For example, in the common twist drill (Fig. 4-5) the helix angle is equivalent to the rake angle of a single-point tool. The lip relief angle is equivalent to the relief angle of a single-point tool. Another example is shown in Fig. 4-6. The relief shown on the mill cutter is referred to as