Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
PowerPoint to accompany
Krar Gill Smid
Technology of Machine Tools
6
th
Edition
Cutting Tools
Unit 29
29-2
Objectives
Use the nomenclature of a cutting-tool
point
Explain the purpose of each type of rake
and clearance angle
Identify the applications of various types
of cutting-tool materials
Describe the cutting action of different
types of machines
29-3
Cutting Tools
One of most important components in
machining process
Performance will determine efficiency of
operation
Two basic types (excluding abrasives)
Single point and multi point
Must have rake and clearance angles ground
or formed on them
29-4
Cutting-Tool Materials
Lathe toolbits generally made of five
materials
High-speed steel
Cast alloys (such as stellite)
Cemented carbides
Ceramics
Cermets
More exotic finding wide use
Borazon and polycrystalline diamond
29-5
Lathe Toolbit Properties
Hard
Wear-resistant
Capable of maintaining a red hardness
during machining operation
Red hardness: ability of cutting tool to
maintain sharp cutting edge even when turns
red because of high heat during cutting
Able to withstand shock during cutting
Shaped so edge can penetrate work
29-6
High-Speed Steel Toolbits
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
29-7
Cemented-Carbide Toolbits
Capable of cutting speeds 3 to 4 times high-
speed steel toolbits
Low toughness but high hardness and
excellent red-hardness
Consist of tungsten carbide sintered in
cobalt matrix
Straight tungsten used to machine cast iron
and nonferrous materials (crater easily)
Different grades for different work
29-8
Coated Carbide Toolbits
Made by depositing thin layer of wear-resistant
titanium nitride, titanium carbide or aluminum
oxide on cutting edge of tool
Fused layer increases lubricity, improves cutting
edge wear resistance by 200%-500%
Lowers breakage resistance up to 20%
Provides longer life and increased cutting speeds
Titanium-coated offer wear resistance at low
speeds, ceramic coated for higher speeds
29-9
Ceramic Toolbits
Permit higher cutting speeds, increased tool
life and better surface finish than carbide
Weaker than carbide used in shock-free or low-
shock situation
Ceramic
Heat-resistant material produced without metallic
bonding agent such as cobalt
Aluminum oxide most popular additive
Titanium oxide or Titanium carbide can be added
29-10
Diamond Toolbits
Used mainly to machine nonferrous metals
and abrasive nonmetallics
Single-crystal natural diamonds
High-wear but low shock-resistant factors
Polycrystalline diamonds
Tiny manufactured diamonds fused together and
bonded to suitable carbide substrate
29-11
Cutting-Tool Nomenclature
Cutting edge: leading edge of that does cutting
Face: surface against which chip bears as it is
separated from work
Nose: Tip of cutting tool formed by junction of
cutting edge and front face
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
29-12
Cutting-Tool Nomenclature
Nose radius: radius to which nose is ground
Size of radius will affect finish
Rough turning: small nose radius (.015in)
Finish cuts: larger radius (.060 to .125 in.)
Point: end of tool that has been ground for cutting
purposes
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
29-13
Cutting-Tool Nomenclature
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
Base: Bottom surface of tool shank
Flank: surface of tool adjacent to and below cutting
edge
Shank: body of toolbit or part held in toolholder
29-14
Lathe Toolbit Angles
and Clearances
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
29-15
Lathe Cutting-tool Angles
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
Positive rake: point of
cutting tool and cutting edge
contact metal first and chip
moves down the face of
the toolbit
Negative rake: face of
cutting tool contacts metal
first and chip moves
up the face of the toolbit
29-16
Positive Rake Angle
Considered best for efficient
removal of metal
Creates large shear angle at shear zone
Reduces friction and heat
Allows chip to flow freely along chip-tool
interface
Generally used for continuous cuts on
ductile materials not too hard or abrasive
29-17
Factors When Choosing Type and
Rake Angle for Cutting Tool
Hardness of metal to be cut
Type of cutting operation
Continuous or interrupted
Material and shape of cutting tool
Strength of cutting edge
29-18
Shape of Chip
Altered in number of ways to improve
cutting action and reduce amount of power
required
Continuous straight ribbon chip can be
changed to continuous curled ribbon
Changing angle of the keeness
Included angle produced by grinding side rake
Grinding chip breaker behind cutting edge of
toolbit
29-19
Tool Life
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
Occurs on side of cutting
edge as result of friction
between side of cutting-tool
edge and metal being
machined
When flank wear
is .015 to .030 in.
need to be reground
Nose wear occurs
as result of friction between
nose and metal being machined
Crater wear occurs as result
of chips sliding along
chip-tool interface,
result of built-up
edge on cutting
tool
29-20
Factors Affecting the Life of a
Cutting Tool
Type of material being cut
Microstructure of material
Hardness of material
Type of surface on metal (smooth or scaly)
Material of cutting tool
Profile of cutting tool
Type of machining operation being performed
Speed, feed, and depth of cut
29-21
Turning
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
Assume cutting machine steel: If rake and relief clearance
angles correct and proper speed and feed used, a continuous
chip should be formed.
29-22
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
Nomenclature of a Plain Milling Cutter
29-23
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
Nomenclature of an
End Mill
29-24
Nomenclature of an
End Mill
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
29-25
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
Characteristics of a
Drill Point
Cutting-point angles for
standard drill
Chip formation
of a drill
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
PowerPoint to accompany
Krar Gill Smid
Technology of Machine Tools
6
th
Edition
Operating Conditions
and Tool Life
Unit 30
30-27
Objectives
Describe the effect of cutting conditions
on cutting-tool life
Explain the effect of cutting conditions
on metal-removal rates
State the advantages of new cutting-tool
materials
Calculate the economic performance
and cost analysis for a machining
operation
30-28
Operating Conditions
Three operating variables influence metal-
removal rate and tool life
Cutting speed
Feed rate
Depth of cut
30-29
Reduction in Tool Life
Operating Conditions
CUTTING
SPEED + 50%
FEED
RATE + 50%
DEPTH OF
CUT + 50%
90% 60% 15%
30-30
General Operating Condition
Rules
Proper cutting speed most critical factor to
consider establishing optimum conditions
Too slow: Fewer parts produced, built-up edge
Too fast: Tool breaks down quickly
Optimum cutting speed should balance
metal-removal rate and cutting-tool life
Choose heaviest depth of cut and feed rate
possible
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
PowerPoint to accompany
Krar Gill Smid
Technology of Machine Tools
6
th
Edition
Carbide Cutting
Tools
Unit 31
31-32
Objectives
Identify and state the purpose of the
two main types of carbide grades
Select the proper grade of carbide for
various workpiece materials
Select the proper speeds and feeds for
carbide tools
31-33
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
31-34
Blending
Five types of powders
Tungsten carbide, titanium carbide, cobalt,
tantalum carbide, niobium carbide
One or combination blended in different
proportions depending on grade desired
Powder mixed in alcohol (24 to 190 h)
Alcohol drained off
Paraffin added to simplify pressing
operation
31-35
Compaction
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
Must be molded to shape and size
Five different methods to
compact powder
Extrusion process
Hot press
Isostatic press
Ingot press
Pill press
Green (pressed) compacts soft, must be
presintered to dissolve paraffin
31-36
Presintering
Green compacts heated to about 1500 F in
furnace under protective atmosphere of
hydrogen
Carbide blanks have consistency of chalk
May be machined to required shape
40% oversize to allow for shrinkage that occurs
during final sintering
31-37
Sintering
Last step in process
Converts presintered machine blanks into
cemented carbide
Carried out in either hydrogen atmosphere
or vacuum
Temperatures between 2550 and 2730 F
Binder (cobalt) unites and cements carbide
powders into dense structure of extremely
hard carbide crystals
31-38
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
31-39
Types of Carbide Lathe
Cutting Tools
Brazed-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
31-40
Grades of Cemented Carbides
Two main groups of carbides
Straight tungsten carbide
Contains only tungsten carbide and cobalt
Strongest and most wear-resistant
Used for machining cast iron and nonmetals
Crater-resistant
Contain titanium carbide and tantalum carbide in
addition to tungsten carbide and cobalt
Used for machining most steels
31-41
Tool
Geometry
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
SIDE RELIEF
SIDE CLEARANCE
Terms adopted
by ASME
31-42
Cutting-Tool Terms
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
Front, End, Relief
(Clearance)
Allows end of cutting tool to
enter work
Side Relief (Side)
Permits side of tool to
advance into work
31-43
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
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
PowerPoint to accompany
Krar Gill Smid
Technology of Machine Tools
6
th
Edition
Cutting Fluids
Types
and Applications
Unit 34
34-45
Objectives
State the importance and function of
cutting fluids
Identify three types of cutting fluids and
state the purpose of each
Apply cutting fluids efficiently for a
variety of machining operations
34-46
Cutting Fluids
Essential in metal-cutting operations to
reduce heat and friction
Centuries ago, water used on grindstones
100 years ago, tallow used (did not cool)
Lard oils came later but turned rancid
Early 20
th
century saw soap added to water
Soluble oils came in 1936
Chemical cutting fluids introduced in 1944
34-47
Economic Advantages to Using
Cutting Fluids
Reduction of tool costs
Reduce tool wear, tools last longer
Increased speed of production
Reduce heat and friction so higher cutting speeds
Reduction of labor costs
Tools last longer and require less regrinding, less
downtime, reducing cost per part
Reduction of power costs
Friction reduced so less power required by
machining
34-48
Heat Generated During
Machining
Heat find its way into one of three places
Workpiece, tool, chips
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
Too much, work
will expand
Too much, cutting edge
will break down rapidly,
reducing tool life
Act as disposable
heat sink
34-49
Heat Dissipation
Ideally most heat taken off in chips
Indicated by change in chip color as heat
causes chips to oxidize
Cutting fluids assist taking away heat
Can dissipate at least 50% of heat created during
machining
34-50
Characteristics of a Good
Cutting Fluid
1. Good cooling capacity
2. Good lubricating
qualities
3. Resistance to
rancidity
4. Relatively low
viscosity
5. Stability (long life)
6. Rust resistance
7. Nontoxic
8. Transparent
9. Nonflammable
34-51
Types of Cutting Fluids
Most commonly used cutting fluids
Either aqueous based solutions or cutting oils
Fall into three categories
Cutting oils
Emulsifiable oils
Chemical (synthetic) cutting fluids
34-52
Oil Categories
Sulfurized mineral oils
Contain .5% to .8% sulfur
Light-colored and transparent
Stains copper and alloys
Sulfochlorinated mineral oils
3% sulfur and 1% chlorine
Prevent excessive built-up edges from forming
Sulfochlorinated fatty oil blends
Contain more sulfur than other types
34-53
Inactive Cutting Oils
Oils will not darken copper strip immersed
in them for 3 hours at 212F
Contained sulfur is natural
Termed inactive because sulfur so firmly
attached to oil very little released
Four general categories
Straight mineral oils, fatty oils, fatty and
mineral oil blends, sulfurized fatty-mineral oil
blend
34-54
Emulsifiable (Soluble) Oils
Mineral oils containing soaplike material
that makes them soluble in water and causes
them to adhere to workpiece
Emulsifiers break oil into minute particles
and keep them separated in water
Supplied in concentrated form (1-5 /100 water)
Good cooling and lubricating qualities
Used at high cutting speeds, low cutting
pressures
34-55
Functions of a Cutting Fluid
Prime functions
Provide cooling
Provide lubrication
Other functions
Prolong cutting-tool life
Provide rust control
Resist rancidity
34-56
Functions of a Cutting Fluid:
Cooling
Heat has definite bearing on cutting-tool wear
Small reduction will greatly extend tool life
Two sources of heat during cutting action
Plastic deformation of metal
Occurs immediately ahead of cutting tool
Accounts for 2/3 to 3/4 of heat
Friction from chip sliding along cutting-tool face
Water most effective for reducing heat (rust)
34-57
Functions of a Cutting Fluid:
Lubrication
Reduces friction between chip and tool face
Shear plane becomes shorter
Area where plastic deformation occurs
correspondingly smaller
Extreme-pressure lubricants reduce amount
of heat-producing friction
EP chemicals of synthetic fluids combine
chemically with sheared metal of chip to
form solid compounds (allow chip to slide)
34-58
Cutting-Tool Life
Heat and friction prime causes of cutting-
tool breakdown
Reduce temperature by as little as 50F, life
of cutting tool increases fivefold
Built-up edge
Pieces of metal weld themselves to tool face
Becomes large and flat along tool face,
effective rake angle of cutting tool decreased
34-59
Application of Cutting Fluids
Cutting-tool life and machining operations
influenced by way cutting fluid applied
Copious stream under low pressure so work
and tool well covered
Inside diameter of supply nozzle width of
cutting tool
Applied to where chip being formed
34-60
Milling
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
Face milling
Ring-type distributor recommended to flood
cutter completely
Keeps each tooth of cutter immersed in cutting
fluid at all times
Slab milling
Fluid directing to both
sides of cutter by fan-shaped
nozzles width of cutter
