MANUFACTURING PROCESSES

Introduction to
Machining Process
&
Cutting Tool Geometry
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 MATERIAL REMOVAL PROCESSES
• The MATERIAL REMOVAL PROCESSES are a
family of SHAPING OPERATIONS in which excess
material is removed from a starting workpart so
that what remains is the desired final geometry.
• The most important branch of the family is
conventional machining , in which a sharp
cutting tool is used to mechanically cut the
material to achieve the desired geometry.

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 MATERIAL REMOVAL PROCESSES
• The three principal machining processes are
turning, drilling, and milling.

TURNING DRILLING MILLING

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 MATERIAL REMOVAL PROCESSES
• Machining is important commercially and
technologically for several reasons:
– Variety of work materials .
– Variety of part shapes and geometric features .
– Dimensional accuracy.
– Good surface finishes .

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 MATERIAL REMOVAL PROCESSES
• On the other hand, certain disadvantages are
associated with machining and other material
removal processes:
– Wasteful of material
– Time consuming

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 MATERIAL REMOVAL PROCESSES
• Machining is generally performed after other
manufacturing processes such as casting or bulk
deformation (e.g., forging, bar drawing).
• The other processes create the general shape of
the starting workpart, and machining provides
the final geometry, dimensions, and finish.

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 CUTTING TOOL
• A CUTTING TOOL has one or more sharp cutting
edges and is made of a material that is harder
than the work material.
• The cutting edge serves to separate a chip from
the parent work material.

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 CUTTING TOOL

Necessities of cutting operation

• Tool should be harder than workpiece (in
conventional approach)
• Adequate sharpness of the cutting tool
• Relative motion between tool and workpiece
• Orientation of cutting tool w.r.t. workpiece

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 CUTTING TOOL
Basic cutting tool geometry
α
Rake angle

α + γ + β = 90°

Workpiece
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 SINGLE POINT CUTTING TOOL
• A SINGLE-POINT tool has one cutting edge and is
used for operations such as turning.
• In addition to the tool features shown in Figure,
there is one tool point from which the name of
this cutting tool is derived .
• During machining, the point of the tool
penetrates below the original work surface of the
part.
• The point is usually rounded to a certain radius,
called the nose radius. [Link]
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SINGLE POINT CUTTING TOOL 3-D VIEW

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 SINGLE POINT CUTTING TOOL 3-D VIEW

Shank is the part of

the tool by which it
is held.

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SINGLE POINT CUTTING TOOL 3-D VIEW

End Cutting
Edge

Side Cutting
Edge

Side Flank
End Flank
Nose / Corner / Tip 13
SINGLE POINT CUTTING TOOL 3-D VIEW

RAKE FACE

End Cutting
Edge

End Flank Side Cutting

Side Flank Edge14
 CUTTING WEDGE ANGLES
• Wedge angles are defined as the angles between
flank and rake face.

Top Wedge
Angle

End Wedge
Side Wedge
Angle
Angle 15
 CUTTING TOOL ANGLES

End Cutting Edge Angle (µe)

RAKE FACE
SHANK

Side Cutting Edge Angle (µs)

EF

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 CUTTING EDGE ANGLE
• Side cutting edge angle (μs) may vary from 10°
to 20°, depending on the material cut.
• If this angle is too large (over 30°), the tool will
tend to chatter.

• End cutting edge angle (μe) may vary from 5° to

30°, depending on the type of cut and finish
desired.

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 NOSE RADIUS
Nose Radius

SHANK

EF

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 NOSE RADIUS
• The nose is the part of the tool bit which is
shaped to a point and forms the corner between
the side cutting edge and the end cutting edge.
• The nose is the rounded end of the tool bit.

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 CUTTING TOOL ANGLES

Back Rake Angle (αb)

SF

End Relief /Clearance

Angle EF
(βe) 20
END RELIEF (CLEARANCE) ANGLE(βe)
• The end relief (clearance) angle is the angle ground
below the nose of the tool, which permits the cutting tool
to be fed into the work. Generally kept 10° to 15°.

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 BACK (TOP) RAKE ANGLE (αb)
• The back (top) rake angle is the backward slope
of the tool face away from the nose.
• The back rake angle is generally about 20° and is
provided for in the tool holder .
• Back rake permits the chips to flow away from
the point of the cutting tool.
• Two types of back or top rake angles are provided
on cutting tools and are always found on the top
of the toolbit.
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 POSITIVE RAKE
• Positive rake, where the point of the cutting tool
and the cutting edge contact metal first and the
chip moves down the face of the toolbit.
[Link]

Positive Rake Angle

FLANK

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 POSITIVE RAKE
• Generally, positive rake angles:
– Make the tool more sharp and pointed. This reduces
the strength of the tool, as the small angle in the tip
may cause it to chip away.
– Reduce cutting forces and power requirements.
– Helps in the formation of continuous chips in ductile
materials.
– Can help avoid the formation of a built-up edge.
– Are suitable for lower cutting speeds.
– Are suitable for ductile materials.
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 POSITIVE RAKE
• High-speed steel-cutting tools are almost always
ground with positive rake angles.
• HSS has good strength and toughness, so that
the thinner cross section of the tool created by
high positive rake angles does not usually cause a
problem with tool breakage.

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 POSITIVE RAKE
NOTE
Because there is less strength at the point of
positive rake angle tools than with negative-rake
tools, tool failure is more likely with large
positive rake angles at high cutting speeds or
with intermittent cuts.

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 NEGATIVE RAKE
• Negative rake, where the face of the cutting tool
contacts the metal first and the chip is forced up
the face of the toolbit.

Negative Rake Angle

FLANK

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 NEGATIVE RAKE
• Negative rake angles are generally preferred for
ceramic, diamond, and cubic boron nitride
tools (Brittle in nature).
• As a group, these materials have higher
hardness and lower toughness.
• In other sense these materials are strong in
compression but are relatively weak in
tension because of their brittle nature.
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 NEGATIVE RAKE
• Negative rake angles also provide greater
strength at the cutting edge and better heat
conductivity.
• The surface finish is usually poorer with
negative rakes, although they can have
good finish at higher speeds.

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 NEGATIVE RAKE
• Generally, negative rake angles :
– Make the tool more blunt,
– increasing the strength of the cutting edge
– Causes high compression
– Increase the cutting forces.
– Can increase friction, resulting in higher
temperatures.
– Are suitable for higher cutting speeds.
– Are suitable for hard brittle materials.
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 NEGATIVE RAKE
NOTE
• Negative-rake tools are most likely to produce a
built-up edge with a rough continuous chip and a
rough finish on the work, especially at lower
cutting speeds and with soft ductile materials.
• Better finishes with negative rake can be
obtained at high speeds with hard brittle
materials.

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 CUTTING TOOL ANGLES

End Wedge Angle (γe)

Side Rake Angle

(αs)

EF

Side Relief /Clearance EF

Angle (β )
s 32
SIDE RELIEF (CLEARANCE) ANGLE (βs)
• The side relief (clearance) angle is the angle
ground on the flank of the tool below the cutting
edge .
• This angle is generally 6° to 10°.

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 SIDE RAKE ANGLE (αs)
• The side rake angle is the angle at which the face
is ground away from the cutting edge.
• For general-purpose toolbits, the side rake is
generally 14°.
Positive Side Rake Angle Negative Side Rake Angle

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 TOOL SIGNATURE
• Convenient way to specify tool angles by use of
a standardized abbreviated system is known as
tool signature or tool nomenclature.
• It indicates the angles that a tool utilizes during
the cut.
• The seven elements that comprise the signature
of a single point cutting tool can be stated in the
following order:

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 TOOL SIGNATURE

Tool signature 0-7-6-8-15-16-0.8

1. Back rake angle (0°)
2. Side rake angle (7°)
3. End relief angle (6°)
4. Side relief angle (8°)
5. End cutting edge angle (15°)
6. Side cutting edge angle (16°)
7. Nose radius (0.8 mm)
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 MULTI-POINT CUTTING TOOL
• MULTIPLE-CUTTING-EDGE TOOLS have more
than one cutting edge and usually achieve their
motion relative to the workpart by rotating.
• Drilling and milling use rotating multiple-cutting-
edge tools.
• Figure shows a helical milling cutter used in
peripheral milling.
• Although the shape is quite different from a
single point tool, many elements of tool
geometry are similar.
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 MULTI-POINT CUTTING TOOL

Direction of
Rotation

Cutting Edges
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MULTI-POINT CUTTING TOOL

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MULTI-POINT CUTTING TOOL

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MULTI-POINT CUTTING TOOL

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MULTI-POINT CUTTING TOOL

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MULTI-POINT CUTTING TOOL

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 THEORY OF METAL MACHINING
• Machining is a manufacturing process in which a
sharp cutting tool is used to cut away material to
leave the desired part shape.
• The predominant cutting action in machining
involves shear deformation of the work material
to form a chip; as the chip is removed, a new
surface is exposed.
• Machining is most frequently applied to shape
metals.
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A Cross-sectional View Of The Machining Process

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 THEORY OF METAL MACHINING
• Machining is not just one process; it is a group of
processes.
• The common feature is the use of a cutting tool
to form a chip that is removed from the
workpart.
• To perform the operation, relative motion is
required between the tool and work, provided by
a machine tool.

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 THEORY OF METAL MACHINING
• This relative motion is achieved in most
machining operations by means of a PRIMARY
MOTION, called the CUTTING SPEED, and a
secondary motion, called the feed and depth of
cut.
• The shape of the tool and its penetration into the
work surface, combined with these motions,
produces the desired geometry of the resulting
work surface.
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 Conventional Turning
Machining Drilling
Milling
Others

Material Grinding
Abrasive
Removal
Processes Others
Process

Mechanical
Electrochemical
Non- Thermal
Conventional 48
Chemical
THANK YOU

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