Cutting Tools

LSS IMPROVE PHASE Operator Training

PROJECT NAME- COST SAVING TOOLING
PROJECT LEADER- GIRISH TORVI

www.o-i.com
O-I TIANJIN MOULD PLANT

Cutting Tools
1.

Engineering Principals Identifies the tool design features and application factors used to effect change in tool performance. This section establishes common terminology used for all metal cutting tools for all processes. The material covered in the five courses within the engineering principals section is applicable for all tools and for metal cutting processes. The topics covered in the engineering principals section include:
1. 2. 3. 4.

Mechanics of Metal cutting Cutting edge materials Operating conditions, tool life and productivity

Tool Failure Analysis 5. Surface Finish -

Cutting Tools
1.

Turning Processes The six courses offered in this section apply the selection criteria introduced in the engineering principals section to processes traditionally performed on the lathe or turning center. Each process uses static tooling with a rotating workpiece. Processes covered in this section include: 1. Toolholder Selection
2. 3. 4. 5. 6.

Boring Bar Selection Insert Selection Grooving Tool Selection Cutoff Tool Selection Single Point Threading

Cutting Tools
1.

Machining Center Processes The four courses offered in this section apply the selection criteria introduced in the engineering principals section to processes traditionally performed on machining centers. Each process uses dynamic tooling with the tool rotating and the workpiece is stationary. Rotating tool processes include:
1. 2. 3. 4.

Face Mill Selection End Mill Selection Drill Selection Tap Selection

Cutting Tools
  

One of most important components in machining process Performance will determine efficiency of operation Two basic types (excluding abrasives)  Single point and multiple point Must have rake and clearance angles ground or formed on them

Cutting Tools
  

One of most important components in machining process Performance will determine efficiency of operation Two basic types (excluding abrasives)  Single point and multiple point Must have rake and clearance angles ground or formed on them

Cutting-Tool Materials


Toolbits generally made of seven materials  High-speed steel  Cast alloys (such as stellite)  Cemented carbides  Ceramics  Cermets  Cubic Boron Nitride  Polycrystalline Diamond


Toolbits

Cutting Tool Properties



Hardness  Cutting tool material must be 1 1/2 times harder than the material it is being used to machine. Capable of maintaining a red hardness during machining operation  Red hardness: ability of cutting tool to maintain sharp cutting edge  Also referred to as hot hardness or hot strength

11 / 2

Cutting Tool Properties



Wear Resistance  Able to maintain sharpened edge throughout the cutting operation  Same as abrasive resistance Shock Resistance  Able to take the cutting loads and forces

High-Speed Steel


May contain combinations of tungsten, chromium, vanadium, molybdenum, cobalt Can take heavy cuts, withstand shock and maintain sharp cutting edge under red heat Generally two types (general purpose)
Molybdenum-base (Group M)  Tungsten-base (Group T)


Cobalt added if more red hardness desired

10

Carbide Cutting Tools



First used in Germany during WW II as substitute for diamonds Various types of cemented (sintered) carbides developed to suit different materials and machining operations
Good wear resistance  Operate at speeds ranging 150 to 1200 sf/min


Can machine metals at speeds that cause cutting edge to become red hot without loosing harness

11

Cemented-Carbide Applications


Used extensively in manufacture of metal-cutting tools  Extreme hardness and good wear-resistance First used in machining operations as lathe cutting tools Majority are single-point cutting tools used on lathes and milling machines

 

12

Types of Carbide Lathe Cutting Tools



Blazed-tip type  Cemented-carbide tips brazed to steel shanks  Wide variety of styles and sizes Indexable insert type  Throwaway inserts  Wide variety of shapes: triangular, square, diamond, and round  Triangular: has three cutting edges  Inserts held mechanically in special holder


U


13

Reasons Indexable Inserts More Popular than Brazed-Tip Tools

1. 2. 3. 4. 5. 6.
 

Less time required to change cutting edge Amount of machine downtime reduced considerable thus production increased Time normally spent in regrinding eliminated Faster speeds and feeds can be used Cost of diamond wheels eliminated Indexable inserts cheaper than brazed-tip

14

Coated Carbide Inserts

 

Give longer tool life, greater productivity and freer-flowing chips Coating acts as permanent lubricant  Permits higher speed, reduced heat and stress Two or three materials in coating give tool special qualities  Innermost layer of titanium carbide  Thick layer of aluminum oxide  Third, very thin layer titanium nitride

15

Coatings


Titanium carbide  High wear and abrasion resistance (moderate speed)  Used for roughing and finishing Titanium nitride  Extremely hard, good crater resistance  Excellent lubricating properties Aluminum oxide  Provides chemical stability  Maintains hardness at high temperatures

16

Tool Geometry

Terms adopted by ASME

SIDE RELIEF SIDE CLEARANCE

17

Cutting-Tool Terms


Front, End, Relief (Clearance)



Allows end of cutting tool to enter work

Side Relief (Side)



Permits side of tool to advance into work

Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 18

Cutting-Tool Terms


Side Cutting Edge Angle



Angle cutting edge meets work

 

Positive Negative - protects point at start and end of cut

Nose Radius
Strengthens finishing point of tool  Improves surface finish on work  Should be twice amount of feed per revolution



Too large

chatter; too small

weakens point

19

Side Rake


Large as possible to allow chips to escape Amount determined

Type and grade of cutting tool  Type of material being cut  Feed per revolution


Angle of keenness


Formed by side rake and side clearance

Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

20

Back Rake


Angle formed between top face of tool and top of tool shank


Positive


Top face slopes downward away from point Top face slopes upward away from point

Negative


Neutral

Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

21

Cemented-Carbide Cutting-Tool Angles and Clearances

 

Vary greatly Depend on three factors

Hardness of cutting tool  Workpiece material
 

Type of cutting operation

May have to be altered slightly to suit various conditions encountered

22

Cutting Speeds and Feeds



Important factors that influence speeds, feeds, and depth of cut

Type and hardness of work material  Grade and shape of cutting tool


Rigidity of cutting tool  Rigidity of work and machine

 

Power rating of machine

23

Machining with Carbide Tools



To obtain maximum efficiency



Precautions in machine setup

  

Rigid and free from vibrations Equipped with heat-treated gears Sufficient power to maintain constant cutting speed Cutting tool held as rigidly as possible to avoid chatter

Cutting operation


24

Suggestions for Using Cemented-Carbide Cutting Tools



Work Setup
Mount work in chuck or holding device to prevent slipping and chattering  Revolving center used in tailstock for turning work between centers
 

Tailstock spindle extended minimum distance and locked securely Tailstock should be clamped firmly to lathe bed

25

Suggestions for Using Cemented-Carbide Cutting Tools



Tool Selection  Use cutting tool with proper rake and clearances  Hone cutting edge  Use side cutting edge angle large enough tool can be eased into work  Use largest nose radius operating conditions permit

26

Tool Setup
1.

Hold carbide tool in turret-type holder Amount of tool overhang enough for chip clearance Cutting tool set exactly on center Designed to operate while bottom of tool shank is in horizontal position If rocker-type tool post: remove rocker, invert rocker base, shim tool to correct height, Use special carbide tool holder (having no rake) Always keep it from touching work and machine parts to avoid damaging tool point

2. 3. 4.

5.

27

Machine Setup


Always make sure machine has adequate power rating for machining operation and no slippage in clutch and belts Set correct speed for material cut and operation performed  Too high cause rapid tool failure  Too low result in inefficient cutting action Set machine feed for good metal-removal rate and good surface finish  Too light causes rubbing  Too coarse slows down machine creates heat

28

Cutting Operation
1. 2. 3.

Never bring tool point against work that is stationary Always use heaviest depth of cut possible for machine and size of cutting tool Never stop machine while feed engaged  Will break cutting edge  Stop feed and allow tool to clear before stopping machine 1 2

29

Metal-Cutting

30

Turning

Assume cutting machine steel: If rake and relief clearance angles correct and proper speed and feed used, a continuous chip should be formed.
31

Planing or Shaping


Workpiece moved back and forth under cutting tool



Fed sideways a set amount at end of each table reversal

Should have proper rake and clearance angles on cutting tool

32

Plain Milling
 Multi-tooth

tool having several equally spaced cutting edges around periphery tooth considered single-point cutting tool (must have proper rake and clearance angles) held in vise or fastened to table

 Each

 Workpiece
 

Fed into horizontal revolving cutter

Each tooth makes successive cuts  Produces smooth, flat, or profiled surface depending on shape of cutter
33

Plain Milling

Copyright The McGraw-Hill Companies, Inc. Permission required for 34 reproduction or display.

Inserted Blade Face Mill



Consists of body that holds several equally spaced inserts

Required rake angle  Lower edge of each insert has relief or clearance angle ground on it


Cutting action occurs at lower corner of insert



Corners chamfered to give strength

35

Face Milling

36

End Milling


Multi-fluted cutters held vertically in vertical milling machine spindle or attachment Used primarily for cutting slots or grooves Workpiece held in vise and fed into revolving cutter End milling


 

Cutting done by periphery of teeth

37

Nomenclature of an End Mill

Copyright The McGraw-Hill Companies, Inc. Permission required for 38 reproduction or display.

Nomenclature of an End Mill

Copyright The McGraw-Hill Companies, Inc. Permission required for 39 reproduction or display.

Drilling
 

Multi-edge cutting tool that cuts on the point Drill's cutting edges (lips) provided with lip clearance to permit point to penetrate workpiece as drill revolves Rake angle provided by helical-shaped flutes


Slope away from cutting edge

Angle of keeness


Angle between rake angle and clearance angle

40

Characteristics of a Drill Point

Chip formation of a drill

Cutting-point angles for standard drill

41

42

Collects in to tool holders

43