DIGITAL ASSIGNMENT-1

REG NO: 19BME0439

NAME: N. SREEVATHSA
SLOT CODE: G-2
COURSE NAME: MACHINING PROCESSES AND
METROLOGY
COURSE CODE: MEE2006
FACULTY NAME: PROF.VENKATESHWARLU B
DATE: 3rd SEPTEMBER 2020
Question No: 1
Explain various angles of tool geometry with a neat
sketch and give an example of representing tool
nomenclature as per ASME standards?

Answer:

Tool Geometry

1. Both geometry and material of the cutting tools play

very important roles on their performances in achieving
effectiveness, efficiency and overall economy of
machining
2. Cutting tools may be classified according to the number
of major cutting edges (points) involved as follows:
• Single Point cutting tools
Examples: Turning Tools, Shaping, Planning and
slotting tools
• Boring Tools
• Double Point Tools
• Multipoint Tools
• Gear Shaping Cutters
Single point Cutting Tool
 Rake Angles of Cutting Tools

1. Angle of inclination of rake surface from reference

plane
2. Rake angle is provided for ease of chip flow and
overall machining
3. Rake angle may be positive or negative or even zero

Positive Rake Angle:

1. Make the tool sharper and more pointed and reduces

strength of the tool, as the small included angle in the
tip may cause it to chip away.

2. Used in the cutting of soft materials

3. Reduce cutting forces and power requirements.

4. HSS tools are typically given a positive rake angle

5. Helps in the formation of continuous chips in ductile

materials.

6. Can help avoid the formation of a built-up edge.

7. They are used in machining of low-strength ferrous and

non-ferrous metal. Positive rake angle is not preferred
to high-speed operation
Negative Rake Angle:

1. Make the tool blunter, increasing the strength of the

cutting edge.

2. Used to cut high strength materials

3. Cemented carbide tools are normally given negative rake

angle.

4. Increase the cutting forces.

5. It can be used in the high-speed cutting operation.

6. Higher cutting force during machining, this also

increases the power consumption.

7. Increase vibration, friction and temperature at cutting

edge.

Neutral Rake Angle:

1. Simplest and easiest to manufacture

2. It causes a massive crater wear when compared to other

types

3. Neutral rake angle obstructs the movement of chip flow

and causes build-up edge chip formation
Chip Disposal and Rake Angle

All 3-types of Rake Angles

 Clearance Angles of Cutting Tools

1. Clearance angle is essential provided to avoid rubbing

of tool (Flank) with machined surface which causes
loss of energy and damages for both tool and job
surface
2. Clearance angle must be positive
3. 3 to 15 degrees depending upon tool work materials
and type of machining operations like turning, drilling
and boring etc
 Back Rake Angle

1. If viewed from the side facing the end of the

workpiece, it’s the angle formed by face of the tool
and a line parallel to the floor
2. A positive rake angle tilts the tool face back and a
negative rake angle tilt it forward and up
3. The angle between the face of the tool and line
perpendicular to the base of the tool measures on
perpendicular plane through the side cutting edge
4. It is the angle which measures the slope of the face
of the tool from the nose, towards the rack.
 Side Rake Angle

1. If viewed behind the tool down the length of the tool

holder, it is the angle formed by the face of the tool
and the central line of the workpiece
2. A positive side rake angle tilts the tool face down
toward the floor and a negative rake angel tilts the
face up and toward the workpiece
3. The angle between the face of the tool and a line
parallel with the base of the tool, measured in a plane
perpendicular to the base and side cutting edge is
called side rake angle
4. It is the angle that measures the slope of the tool
face from cutting edge.
 Side Relief Angle

1. If viewed behind the tool down the length of the

toolholder, it’s the angle formed by the side flank of the
tool and a vertical line down to the floor
2. Increasing the side relief angle tilts the side flank away
from the workpiece
3. The angle between the portion of the side flank
immediately below the side cutting edge and line
perpendicular to the base of tool measured at
right angles to the side flank is known as side relief
angle.
 End Relief Angle

1. If viewed from the side facing the end of the

workpiece it’s the angle formed by the end flank of
the tool and a vertical line down to the floor
2. Increasing the end relief angle tilts the end flank
away from the workpiece
3. The angle between the portion of the side flank
immediately below the side cutting edge and a line
perpendicular to the base of the tool
4. Relief angles are for the purpose of helping to
eliminate tool breakage and to increase tool life. The
included angle under the cutting edge must be made
as large as practical. If the relief angle is too large,
the cutting tool may chip or break.
 End Cutting Edge Angle

1. If viewed from above looking down on the cutting tool,

it’s the angle formed by the end flank of the tool and
a line parallel to the workpiece centre line
2. Increasing the end cutting edge angle tilts the far
end of the cutting edge away from the workpiece
3. The end cutting edge angle avoids interference
between the machined surface and the tool (end
cutting edge). Usually 5°–15°.
4. Decreasing the end cutting edge angle increases
cutting edge strength, but it also increases cutting
edge temperature.
5. Decreasing the end cutting edge angle increases the
back force and can result in chattering and vibration
while machining.
 Side Cutting Edge Angle

1. If viewed from above looking down on the cutting tool,

it is the angle formed by the side flank of the tool
and a line perpendicular to the workpiece centreline
2. A positive side cutting edge angle moves the side
flank into the cut and a negative angle moves the side
flank out of the cut
3. At the same feed rate, increasing the side cutting
edge angle increases the chip contact length and
decreases chip thickness. As a result, the cutting
force is dispersed on a longer cutting edge and tool
life is prolonged.
4. Increasing the side cutting edge angle decreases chip
control.
5. Increasing the side cutting edge angle decreases the
chip thickness and increases chip width. Thus,
breaking chips is difficult.
 Nose Radius

1. Nose radius is the rounded tip on the cutting edge of

a single point tool
2. The greater the nose radius, the greater the degree
of roundness at the tip
3. A zero-degree nose radius creates a sharp point
4. Nose radius is the radius value at the tip of the
cutting tool, measured on reference plane
5. The larger tool nose radius causes the increase of
cutting force, lower surface residual compressive
stress, and deeper residual stress penetration layer

Advantages of providing nose radius in cutting tool

1. Prevents tool tip from sudden unplanned breakage.

2. Absorbs and distributes shock during impact loading in
machining.
3. Offers a small amount of rubbing between flank surface
and machined surface, which leads to better finish of
the machined surface.
4. Easier to manufacture, very sharp edge cannot be
manufactured efficiently.
5. Easy manufacturing also results in cheaper tool.
Disadvantages of providing nose radius in cutting tool

1. Increase in cutting force and power consumption.

2. Larger heat generation.
3. Changes chip flow direction.
4. Prevents obtaining high surface finish.
5. No cutting action or chip formation (usually in micro-
machining) if depth of cut is substantially lower than
nose radius.

Different Cases of Tool Nose Radius

 Lip Angle

1. Lip angle is the angle between the rake surface and

flank surface when viewed on orthogonal plane
2. Point angle is the angle between the principal cutting
edge and auxiliary cutting edge when viewed on
reference plane. Lip angle and point angle are
independent.
3. Lip clearance is the relief given to the cutting edges
that allow drill to enter into the workpiece without any
hindrance.
4. In general purpose drills, the clearance angle behind
the cutting edge is 12°. Too much clearance angle causes
the breaking of the lip of drill due to insufficient
support.
 Nomenclature of the Tool

Tool Signature:

1. The numerical code that describes all the key angles

of a given cutting tool. A tool signature may be used
for HSS tools or Carbide Inserts
2. Convenient way to specify the tool angles by use of a
standardized abbreviated system is known as Tool
Signature or Tool Nomenclature
3. It indicates the angles that a tool utilizes during the
cut
4. It specifies the active angles of the tool normal to
the cutting edge
5. This will always be true as long as the tool shank is
mounted at right angles to the workpiece axis

Representation of Tool Signature

Nomenclature of Single Point Cutting Tool
 Example of Tool Signature

Tool Signature – 0-7-6-8-15-16-0.8

1. Back Rake Angle (Alpha-b) = 0 degrees

2. Side Rake Angle (Alpha-s) = 7 degrees
3. End Relief Angle (Theta-c) = 6 degrees
4. Side Relief Angle (Theta-s) = 8 degrees
5. End Cutting Edge Angle (Ce) = 15 degrees
6. Side Cutting Edge Angle (Cs) = 16 degrees
7. Nose Radius (R) = 0.8 mm
Question No: 2
Explain various lathe operations with a neat
sketch?
Answer:

Lathe Machine Operations

To perform different lathe machine operations on a lathe,

the workpiece may be supported and driven by any one of the
following methods:

1. Workpiece held between centres and tool driven by

carriers and catch plates.
2. Workpiece held on a mandrel which is supported between
centres and driven by carriers and catch plates.
3. Held and driven by chuck with the other end supported on
the tailstock centre.
4. Held and driven by a chuck or a faceplate or an angle plate.
Lathe Machine
Lathe Machine Operations
 Turning Operation

1. It is the most common type of operation in all

lathe machine operations. Turning is the
operation of removing the excess material from
the workpiece to produce a cylindrical surface to
the desired length.
2. The job held between the centre or a chuck and
rotating at a required speed. The tool moves in a
longitudinal direction to give the feed towards
the headstock with proper depth of cut. The
surface finish is very good.
Shoulder Turning:
When a workpiece has different diameters and is to be
turned, the surface forming steps from one diameter to the
other is called the shoulder, and machining this part of the
workpiece is called shoulder turning.
Taper Turning:

1. A” taper” is the uniform increase or decrease in the

diameter of the workpiece and measured along with its
length.
2. Taper turning means to produce a conical shape by a
gradual reduction in diameter from a cylindrical workpiece.
3. The amount of taper in the workpiece is usually specified
on the basis of the difference in diameter of the taper to
its length. It is known as a cone and it is indicated by the
letter K.
It has the formula K = D-d / 1 to produce the taper on
the workpiece.

D = Larger diameter of taper.

d = Small diameter of taper.

 Facing Operation

1. It is an operation of reducing the length of the

workpiece by feeding the perpendicular to the lathe
axis.
2. This operation of reducing a flat surface on the end of
the workpiece.
3. For this operation, regular turning tool or facing
tool may use.
4. The cutting edge of the tool should set to the same
height as the centre of the workpiece.
5. Facing on the lathe uses a facing tool to cut a flat
surface perpendicular to the work piece's rotational axis
Facing consist of 2 operations

Roughing: Here the depth of cut is 1.3mm

Finishing: Here the depth of cut is 0.2-0.1mm.

Facing Operation

Turning Operation
 Grooving Operation

1. It is the process of reducing the diameter of a

workpiece over a very narrow surface.
2. It is done by a groove tool. A grooving tool is similar
to the parting-off tool.
3. It is often done at the end of a thread or adjacent to
a shoulder to leave a small margin.
4. Grooving is a type of specific turning operation that
cut grooves or forms a narrow cavity of a certain
depth on external, internal surfaces, cylinder, cone,
or a face of the part
5. The groove shape, or at least a significant part of it,
will be in the shape of the cutting tool.
 Forming Operation

It is the process of turning a convex, concave or of any

irregular shape. Form-turning may be accomplished by the
following method:

1. Using a forming tool.

2. Combining cross and longitudinal feed.
3. Tracing or copying a template.

1. Forming tools are not supposed to remove much of the

material and is used mainly for finishing formed
surfaces.
2. Generally, two types of forming tools are used straight
and circular.
3. Straight type is used for wider surface and the circular
type for narrow surfaces.
Grooving Operation

Forming Operation
 Drilling Operation

1. Drilling is the operation of producing a cylindrical hole

in a workpiece.
2. It is done by a rotating tool, the rotating side of the
cutter, known as drilling drill.
3. In this operation, the workpiece is revolving in a chuck
or a faceplate and the drill is held in the tailstock drill
holder or drill chuck.
4. The feeding is adopted is affected by the movement
of the tailstock spindle.
5. This method is adopted for the drilling regular-
shaped workpiece.
 Reaming Operation

1. Reaming is the operation of finishing and sizing a hole

which has been already drilled or bored.
2. The tool is used is called the reamer, which has multi-
plate cutting edges.
3. The reamer is held on the tailstock spindle, either
directly or through a drill chuck and is held stationary
while the work is revolved at a very slow speed.
Reaming Operation

Drilling Operation
 Boring Operation

1. Boring is the operation of enlarging the hole which is

already drilled, punched or forged.
2. It cannot produce a hole. Boring is similar to the
external turning operation and can be performed in a
lathe.
3. In this operation, the workpiece is revolved in a chuck
or a faceplate and the tools which are fitted to the
tool post is fed into the work.
4. Counterboring is the operation of enlarging the end of
the hole through a certain distance. It is similar to a
shoulder work in external turning.
5. The operation is similar to boring and plain boring
tools or a counterbore may be used. The tool is used
called a counterbore. The speed is slightly less than
drilling.
 Tapping Operation

1. Tapping is the operation of cutting internal threads

of small diameter using a multipoint cutting tool called
the tap.
2. In a lathe, the work is mounted on a chuck or on a
faceplate and revolved at a very slow speed.
3. A tap of required size held on a special fixture is
mounted on the tailstock spindle.
4. Tapping is the process of cutting a thread inside a
hole so that a cap screw or bolt can be threaded into
the hole. Also, it is used to make threads on nuts
5. Turning is a lathe operation in which the cutting tool
removes metal from the outside diameter of a
workpiece.
Tapping Operation

Boring Operation
 Threading Operation

1. It is the important operation in the lathe to obtain

the continuous ”helical grooves” or ” threads’‘.
2. When the threads or helical grooves are formed on
the out surface of the workpiece is called external
thread cutting.
3. When the threads or helical grooves are formed on
the inner surface of the workpiece is called internal
thread cutting.
4. The workpiece is rotating between the two centres
i.e., live centre and dead centre is the lathe.
5. Here the tool is moved longitudinally to obtain the
required type of the thread. When the tool is moved
from right to the left, we get the left-hand thread.
6. Here the motion of the carriage is provided by the
lead screw.
7. A pair of change gears drives the lead screw and by
rotating the handle the depth of cut can be
controlled.
 Knurling Operation

1. It is an operation of obtaining a diamond shape on

the workpiece for the gripping purpose.
2. This is done to provide a better gripping surface
when operated by hands. It is done using a knurling
tool.
3. The tool consists of a set of hardened steel roller,
and it is held rigidly on the tool post.
4. Knurling is done at the lowest speed available on a
lathe. It is done on the handles and also in case of
ends of gauges.
5. The feed varies from 1 to 2 mm per revolution. Two
or three cuts may be necessary to give the full
impression
 Knurling Operation

Threading Operation
 Chamfering Operation

1. It is the operation of getting a bevelled surface at

the edge of a cylindrical workpiece.
2. This operation is done in case of bolt ends and shaft
ends. Chamfering helps to avoid damage to the sharp
edges and protect the operation getting hurt during
other operations.
3. Chamfering on bolt helps to screw the nut easily.