Design and Analysis of single point cutting tool

ABSTRACT
This study presents tool wear characterization of single
point cutting tool inserts coated with titanium nitride (Tin) and
Al2O3.The single point cutting tool of material SAE-AIsI 1037
carbon steel is selected. The coated tools exhibited superior wear
resistance over the uncoated tool. The Al2O3/Tin coated tool had the
lowest flank wear due to the high abrasive resistance. The coating is
done according to the boundary conditions of the existing cutting tool
as we selected, More than one layer are coated. The analysis of coated
cutting tool is reported. Modeling of a cutting tool is designed by
existing dimension. Normal cutting tool is selected and subjected to
various load condition and the reports are plotted. Feed force and
cutting force are Analysis induced in the coated tool material. A
proper Finite Element Model is developed using Cad software
Solidworks 2013. Then the Finite element analysis is done to
determine the total deformation in the existing Single point cutting
tool for the given loading conditions using Finite Element Analysis
software ANSYS WORKBENCH. In the first part of the study, the
static loads acting on the cutting tool. The material of maximum
Efficiency of single point cutting tool. The material is coated with
TIN and AL2O3.Static and thermal analysis of coated material is
carried out and comparison of Efficiency is plotted.

Literature review
S. PalDey
The wear resistant properties of (Ti,Al)N for various
machining applications as compared with coatings such as TiN,
Ti(C,N) and (Ti,Zr)N. They have found that the high hardness (28_32
GPa), relatively low residual stress (/5GPa), high oxidation resistance,
high hot hardness, and low thermal conductivity make (Ti,Al)N
coatings most desirable in dry machining and machining of abrasive
alloys at high speeds. Multicomponent coatings based on different
metallic and nonmetallic elements such as, Cr and Y drastically
improve the oxidation resistance, Zr and V improve the wear
resistance, whereas, Si increases the hardness, boron improves the
abrasive wear behavior and resistance to chemical reactivity of the
film. The presence of a large number of interfaces between individual
layers of a multilayered structure results in a drastic increase in
hardness and strength. So it is possible to design new wear resistant or
functional coatings based on a multilayer or a multi component
system to meet the demanding applications of advanced materials.
J.A. Ghani
The wear mechanism of TiN-coated carbide and uncoated
cermets tools at various combinations of cutting speed, feed rate, and
depth of cut for hardened AISI H13 tool steel is investigated. They
have observed that the time taken for the cutting edge of TiN-coated
carbide tools to initiate cracking and fracturing is longer than that of
uncoated cermets tools, especially at the combinations of high cutting
speed, feed rate, and depth of cut and at the combinations of low
cutting speed, feed rate, and depth of cut, the uncoated cermets tools
show more uniform and gradual wear on the flank face than that of
the TiN-coated carbide tools.

J.G. Lima
The machinability of hardened steels at different levels of
hardness and using a range of cutting tool materials is evaluated. They
have proved in their result that turning of AISI 4340 steel using low
feed rates and depths of cut, the forces were higher when machining
the softer steel and that surface roughness of the machined part was
improved as cutting speed was elevated and deteriorated with feed
rate
J. Rech
Found out that coatings exhibit to the best tribological
improvements compared to uncoated tools. Four complementary
methods were used to qualify the performance of the tribological
system with the purpose of reaching a better global understanding of
the capability of coatings, chip formation mechanisms, cutting forces,
interface temperature. TiN and (Ti,Al) N+MoS2 coatings have shown
the best tribological improvements compared to uncoated tools

M.Y. Noordin
Presented hard turning of martensitic stainless steel using wiper
coated carbide tool at various cutting speeds and feeds. It was found
that low cutting speed and low feed produces the longest tool life. The
combination of high cutting speed and high feed was found to be
unfavorable for hard turning of stainless steel. Wiper coated carbide
tool achieved very fine surface finish, much better than the theoretical
values and within the strict range of finish machining criteria.

CHAPTER I.
INTRODUCTION
GEOMENTRY OF CUTTING TOOL
A cutting tool (or cutter) is any tool that is used to remove
material from the work piece by means of shear deformation. Cutting
may be accomplished by single-point or multipoint tools. Single-point
tools are used in turning, shaping, plaining and similar operations, and
remove material by means of one cutting edge. Milling and drilling
tools are often multipoint tools. Grinding tools are also multipoint
tools. Each grain of abrasive functions as a microscopic single-point
cutting a tiny chip. Edge (although of high negative rake angle), and
shears.
1.1 Types of cutting tool:
Single point cutting tool
Multipoint cutting tool
1.1.1 Single point cutting tool:
It is simplest form of cutting tool & it has only one cutting edge.
Examples shear tools, lathe tools, planer tools, boring tolls etc.

1.1.2 Multipoint cutting tool:

In this two or more single point cutting tools arranged together as
a unit. The rate of machining is more & surface finish is also better in
this case.
Example- milling cutter, drills, brooches, grinding wheels,
abrasive sticks etc.

1.2 TERMINOLOGY
1.2.1 Single point cutting tool:
The single point cutting tool mainly consist of tool shank & cutting
part called point. The point of cutting tool is bounded by cutting face,
end flank, side/ main flank, & base. The chip slide along the face. The
side main cutting edge ab is formed by intersecting of face & side
main flank. The end cutting edge ac is formed by the intersection of.

The point a which the intersection of end cutting edge &

side cutting edge is called nose. Mainly the chip cuts by side .cutting
edge.

Shank It is main body of tool. The shank used to grippesd in tool

holder.
Flank The surface or surface below the adjacent of the cutting edge
is called flank of the tool.
Face It is top surface of the tool along which the chips slides.
Base It is actually a bearing surface of the tool when it is held in
tool holder or clamped directly in a tool post.
Heel It is the intersection of the flank & base of the tool. It is curved
portion at the bottom of the tool.
Nose It is the point where side cutting edge & base cutting edge
intersect.
Cutting edge It is the edge on face of the tool which removes the
material from workpiece. The cutting edges are side cutting edge
(major cutting edge) & end cutting edge (minor cutting edge)
Tool angles-Tool angles have great importance. The tool with proper
angle, reduce breaking of tool, cut metal more efficiently, generate
less heat.

1.2.1Nomenclature:

-Region of the interface

Cp

-Solid specific heat capacity, J/kg K

-Coating thickness, mm

-Feed rate, mm/rot

-Geometry height, m

-Heat transfer coefficient, W/m2 K

-Solid thermal conductivity, W/m K

- Geometry length, m

- Depth of cut, m

q(t)

-Heat rate, W

q(t)

- Heat flux, W/m2

- Radius of the geometry, m

S1, S2

- Surfaces of the geometry

- Temperature, C

-Time, s

- Ambient temperature, C

x, y, z

- Cartesian coordinates, m

vc

- Cutting speed, m/min

- Solid density, kg/m3

- Computational domain

1.2.2 Properties of existing tool:

Material

SAE-AIsI 1037 carbon steel

Density

7.79 g/cm3

Elastic modulus

210 Gpa

Poissons Ratio

0.29

Specific heat

450j/kg-k

Thermal expansion

11.9m/m-k

Ultimate strength

550 mpa

Yield strength

520 mpa

CHAPTER II.
COATING
Machining efficiency is improved by reducing the
machining time with high speed machining. But the softening
temperature and the chemical stability of the tool material limits the
cutting speed. When cutting ferrous and hard to machine materials
such as steels, cast iron and super alloys, softening temperature and
the chemical stability of the tool material limits the cutting speed.
Therefore, it is necessary for tool materials to possess good hightemperature mechanical properties and sufficient inertness. While
many ceramic materials such as Al2O3 and TiN possess high
temperature strength, they have lower fracture toughness than that of
conventional tool materials such as high-speed steels and cemented
tungsten carbides. The machining of hard and chemically reactive
materials at higher speeds is improved by depositing single and multi
layer coatings on conventional tool materials to combine the
beneficial properties of ceramics and traditional tool materials.
Coatings are diffusion barriers; they prevent the interaction
between chip formed during the machining and the cutting material
itself. The compounds which make up the coatings used are extremely
hard and so they are very abrasion resistant. Typical constituents of
coating are Titanium Nitride (TiN), and alumina (Al2O3). All these
compounds have low solubility in iron and they enable inserts to cut
at much higher rate. Carbide substrates are used because of their
Higher Productivity by high speed machining. Improved
toughness and crack resistance by optimal dispersion of hard
particles.- Improved plastic deformation resistance and welding
resistance for high cutting speed operations.

2.1 Types of coating

2.1.1 Single layer coating

During the deposition process some carbon was taken up from the
surface of the hard metal as part of coating and this changed the
carbon balance at the junction of the coating and the hard metal
substrate. This lowering of the carbon balance caused the formation of
a brittle compound at the interface between the coating and the
substrate and made early coated indexable inserts sensitive to
chipping of cutting edge. The next development was to put down a
coating of TiN which prevented any decarburising of the hard metal
substrate but the coating which is gold in colour, did not adhere well
to the hard metal base. TiN is an even better diffusion barrier than TiC
but TiC has better abrasion resistance.
2.1.2 Multi layer coatings

Although single-layer coatings are finding a range of

applications in many sectors of engineering, there are an increasing
number of applications where the properties of a single material are
not sufficient. One way to surmount this problem is to use a
multilayer coating that combines the attractive properties of several
materials, each chosen to solve a problem in the application. Multi
layer coatings can consist of 19 as many as eight layers within a total
thickness of 10 micrometers or less. Simple examples of this include
the use of interfacial bonding layers to promote adhesion, or thin inert
coatings on top of wear resistant layers to reduce the corrosion of
cutting tools.

Normal Rake System NRS

This system is also known as oblique tool reference
system or ISO new. ASA system has limited advantage and use like
convenience of inspection. But ORS is advantageously used for
analysis and research in machining and tool performance. But ORS
does not reveal the true picture of the tool geometry when the cutting
edges are inclined from the reference plane 0. Besides, sharpening
or resharpening, if necessary, of the tool by grinding in ORS requires
some additional calculations for correction of angles.
These two limitations of ORS are overcome by using NRS for
description and use of tool geometry. The basic difference between
ORS and NRS is the fact that in ORS, rake and clearance angles are
visualized in the orthogonal plane, o, whereas in NRS those angles
are visualized in another plane called Normal plane, N. The
orthogonal plane, o is simply normal to R and C irrespective of
the inclination of the cutting edges, i.e., , but N (and N for
auxiliary cutting edge) is always normal to the cutting edge. The
differences between ORS and NRS have been depicted

TOOLSHANK:
The shank of a cutting tool is generally analyzed for strength and
rigidity. Tool is assumed to be loaded as a cantilever by tool forces at
the cutting edge

Figure 1Deflections and Frequency of Chatter for Several

Overhung Values
The notations used in design of shank is given below :
F = Permissible tangential force during machining, N
f = Chatter frequency, cycle per second (c.p.s)

H = Depth of shank, mm
B = Width of shank, mm
L0 = Length of overhung, mm
d = Deflection of shank, mm
E = Youngs modulus of material, N/mm2
I = Moment of inertia, mm4
hc= Height of centers, mm
ut= Ultimate tensile strength, N/mm2
per= Permissible stress of shank material, N/mm2
Lc = Length of centers, mm

TOOL MATERIAL SELECTION:

The tool engineer is required to select material for variety of products
such as cutting tools, jigs, punches, dies, special machine etc. A tool
engineer must possess the knowledge of these materials and
understand their properties. In addition, the various aspects of tooling,
material cost, fabrication, manufacturing methods and the proper
functioning of product should be considered

Ceramics
These are also called as cemented oxide. Its major constituent is
aluminum oxide and hot hardness temperature is about 1200C. It also
has higher cutting speed of about 300 to 400 m/min. It has better
resistance to abrasion than cemented carbide. It also exhibits low
coefficient of friction with most of work materials. These are used for
higher production rate and for continuous operation only. The
disadvantages of ceramic are very low toughness and highly brittle in
nature. Fabrication for ceramic is done through powder metallurgical
techniques.
Cermets
This is combination of ceramic and metal. It is substitute for ceramics.
It contains 90% ceramics and 10% nickel. The method employed for
fabrication of cermet is also powder metallurgical technique. Its hot
hardness temperature is about 1000C and cutting speed is about 250
m/min. Cermet gives better toughness than ceramic. It gives very
good wear resistance.
Diamond
Diamond possesses all the desirable characteristics but has
very high cost. Diamond is made by graphitization technique. Its hot
hardness temperature is about 2000C. Its hardness is higher than any
other material. It is chemically inert and has high thermal
conductivity. Its cutting speed is about 500 m/min. Diamond is
extensively used for machining of non-ferrous alloys such as
aluminum, magnesium, copper, brass etc. Diamond is not used for
machining of ferrous material because diamond is basically pure
carbon and diffusion of carbon into iron takes place due to affinity of
iron atoms toward carbon.
Cubic Boron Nitride
Cubic Boron Nitride consists of atoms of boron and nitrogen. It is
hardest material next to diamond. It is substitute for diamond during
machining of ferrous alloys. It has high hardness and thermal
conductivity.

UCON
It is combination of columbium, titanium and tungsten. It
contains 50% columbium, 30% titanium and 20% tungsten. Method
of fabrication is rolling. Its hardness is 2500 to 3000 Vickers. The
speed range for UCON is 250 to 500 m/min of steel of 200 BHN.
Cost of UCON is higher than diamond and is used only for very hard
material. It has excellent shock resistance, resistance to diffusion and
adhesion wear.

Sialon
It contains silicon, aluminum, oxygen and nitrogen. It is even costlier
than ucon. Sialon is used during machining of interrupted cuts. Sialon
tips are used for machining of aerospace alloys.

FORCE CALCULATION:
The forces acting on the tool are an important aspect of machining.
The knowledge of force is required for determination of power and
also to design the various elements of machine tool, tool holders and
fixtures.
The cutting forces vary with the tool angle and accurate
measurement of forces is useful in optimizing tool design.
Dynamometers are capable of measuring tool forces with increasing

accuracy. The component of forces acting on the rake face of tool,

normal to the cutting edge is called cutting force, i.e. in the direction
of line YO

Figure 2force acting on work piece

Cutting force Fc, is largest of three forces acting on workpiece and its
direction is in the direction of cutting velocity.
The force component acting on tool in direction of OX, parallel to the
direction of feed, is feed force, Ft. It acts tangential to main cutting
force, Fc.
The forces involved in machining are relatively low as compared to
those in other metal working operations such as forging. This is
because the layer of metal being removed (i.e. the chip) is thin, so
forces to be measured are less in case of machining.
Here Fc is cutting force, Fs is shear force, is shear angle, is
frictional angle and is rake angle, t1 is uncut chip thickness, and t2
is chip thickness.

Figure 3 Merchants Force Circle

If shear stress is greater than ultimate shear stress then only cutting
takes place.

WEAR PROPERTIES:

Table1 shows that the crater wear in stage I occurs if the

cumulative mean average value, mean RMS value and mean area of
AE signal are in the range of 0413 mV, 0623 mV and0995 mV.s,
respectively. The same in stage II, varies in the range of 413 to 708
mV, 623 to1030 mV and 995 to 1661 mVs and in Stage III, the
respective cumulative mean AE parameters are above 708 mV, above
1030 mV and above 1661 mVs, respectively

Variation of flank angle with time

INTERNATIONAL TOLERENCE
IT grades shows a tolerance allowable for difference of the diameters
of a hole and a shaft. As the number added after IT increases, the
tolerance becomes rough. Depending on the basic size, the tolerance
value in each grade varies.
In the catalog, IT grades are shown as a guide of dimensional
dispersion in the diameters of holes machined with the drill. For
information, H8 tolerance for a 8.0 hole is 0 to + 0.022 mm, the
width of the value is the same as that of IT 8.
In the Table shown below, tolerance areas attainable with typical
drilling tools are distinguished by using different colours.Solid drills
are generally used for machining holes of IT 9 to 12. For machining a
hole of better than IT 8, finishing process such as reaming is required.

For a hole better than IT 5, high-precision finishing is required. Above

description is based on machining of
General steel. In practice, the IT grade attained with the tool varies
widely depending on the hardness and the composition of the work
material.

MODELLING:
3d models
Uncoated existing tool

ALUMINUN OXIDE
COATED:

TIN coated

2D diagram:

THERMAL ANALYSIS OF SINGLE POINT CUTTING TOOL

CONCLUSION:
Thus, the single point cutting tools is modeled and the change
of material in TIN and ALUMINUM OXIDE is coated in modeling
software. The nomenclature of the single point cutting tool is
discussed and the part model is ready for the analysis, The design of
single point cutting tool is derived and reported.

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