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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 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.
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SINGLE POINT CUTTING TOOL 3-D VIEW

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SINGLE POINT CUTTING TOOL 3-D VIEW

Side Flank

End Flank
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SINGLE POINT CUTTING TOOL 3-D VIEW

Side Cutting
Side Flank Edge
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 SINGLE POINT CUTTING TOOL 3-D VIEW

End Cutting
Edge

End Flank 12
SINGLE POINT CUTTING TOOL 3-D VIEW

SF SIDE FLANK

EF END FLANK

EF

Nose / Corner / Tip

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SINGLE POINT CUTTING TOOL 3-D VIEW

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 SINGLE POINT CUTTING TOOL
PHOTOGRAPH
RAKE FACE

End Cutting
Edge

End Flank Side Cutting

Side Flank Edge 15
 RAKE FACE
• Rake face is the surface over which the chip ,
formed in the cutting process, slides.

EF

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 FLANK FACE
• Flank face is the surface(s) over which the
surface, produced on the workpiece, passes.

EF

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 CUTTING EDGE
• Cutting edge is a theoretical line of intersection
of the rake and the flank surfaces.

EF

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 CUTTING WEDGE
• Cutting wedge is the tool body enclosed
between the rake and the flank faces.

EF

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 WEDGE ANGLE
• Wedge angle is defined as the angle between
flank and rake face.

EF
End Wedge
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Angle
 WEDGE ANGLE
• Wedge angle is defined as the angle between
flank and rake face.

Side Wedge
Angle

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 SHANK
• Shank is the part of the tool by which it is held.

EF

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 CUTTING TOOL ANGLES
2
1

3 4

7 5

6
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 CUTTING TOOL ANGLES

End Cutting Edge Angle (µe)

RAKE FACE
SHANK

Side Cutting Edge Angle (µs)

EF

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 SIDE CUTTING EDGE ANGLE(µs)
• Side cutting angles 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.

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 END CUTTING EDGE ANGLE (µe)
• This angle may vary from 5° to 30°, depending
on the type of cut and finish desired.

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CUTTING TOOL ANGLES

Nose
Angle SHANK

EF

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CUTTING TOOL ANGLES
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 radius 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) 30
END RELIEF (CLEARANCE) ANGLE(βe)
• The end relief (clearance) angle is the angle ground
below the nose of the toolbit, which permits the cutting
tool to be fed into the work.
• It is generally 10° to 15° for general-purpose tools .

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 END WEDGE ANGLE (γe)
• End wedge angle is defined as the angle between
end flank and rake face.
End Wedge
Angle

EF
End Wedge
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Angle
 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.

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
• Cemented carbides, for example, are used with
rake angles in the range from -5° to +10°.
• Ceramics have rake angles between -5° to -15 °.

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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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44
 CUTTING TOOL ANGLES

Side Wedge Angle (γ )

s
Side Rake Angle

(αs)

EF

Side Relief /Clearance EF

Angle (β )
s 45
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 WEDGE ANGLE (γS)
• Side wedge angle is defined as the angle between
side flank and rake face.

Side Wedge Angle

Side Wedge
Angle
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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°.

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 SIDE RAKE ANGLE (αs)

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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 2
1

3 4

7 5

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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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