International Technology and Innovation Conference 2006
INVESTIGATION OF TURNING TOOL SYSTEM WITH
ON-LINE TOOL GEOMETRY ADJUSTMENT
WU Wenge*,t , LIU Zhanqiangt , CHENG Yunping*
* College of Mechanical Engineering and Automatization, North University of China, Taiyuan 030051, China
t School of Mechanical Engineering, Shandong University, Jinan 250061, China
Key words: Tool geometry, turning tool, cutting tool
system, Simulation.
Abstract
Metal cutting is one of the most important methods of
removing unwanted material in the production
mechanical components. The tool geometry such as rake
angles and cutting edge inclination angles play significant
roles in determining machining performance. Varying these
angles directly affects effects of machining parameters such
as cutting forces, cutting temperatures, tool wear, tool life,
surface integrity, dimensional stability. The necessity and
possibility of the on-line geometry adjustment of turning
tools are investigated in this paper. A brief design of a
device facilitating this on-line geometry variation is
described. Based on the 'classical' oblique cutting
operation, analytically simulated prediction of the
tangential cutting forces were presented with MATLAB
software. A new turning tool mechanism having the
function of intelligent in-process controllability in changing
the tool inclination angle and tool approach angle.
1 Introduction
The various angles in a single-point cutting tool have
important functions in machining operations. Cutting-edge
angles affect chip formation, tool strength and cutting
forces to various degrees. Rake angles are important in
controlling both the direction of chip flow and the strength
of the tool tip. Positive rake angles improve the cutting
operation by reducing forces and temperatures. However
positive angles result in a small included angle of the tool
tip.
The side rake angle is more important than the back rake
angle, although the latter usually controls the direction of
chip flow. Relief angles control interference and rubbing at
the tool-workpiece interface. If the relief angle is too large,
the tool tip may chip off. If it is too small, flank wear may
be excessive.
of One of the functions of inclination angle is to alter the chip
flow direction, and the manner in which side flow
increases with the inclination of the cutting edge. When
inclination angle is increased, the effective rake angle is
increased.
From the foregoing discussion, it is evident that there are a
number of geometrical quantities that may be varied as
well as several operating variables. The task of selecting
cutting tool inserts and cutting conditions is traditionally
carried out on the basis of the experience of process
planners with the help of data from machining handbooks
and tool catalogues. This situation urges the need for
development of some intelligent tooling system to reduce
these inefficiencies for optimum economic and
technological machining performance. Since the
introduction of the first controlled cutting tools in the
latel980s [I], the technology has moved on dramatically.
The current generation of tools is capable of carrying out
multiple operations and can be adjusted without human
intervention. A complete understanding of the production
process is essential to increasing productivity, but the use
of intelligent tooling often proves to be the key factor for
success.
2 Principle of adjustability of tool geometry
It need to understand the interdependence of the four basic
geometric angles of a lathe tool which rake angle Yo,
clearance angle am inclination angle As and approach angle
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 Section 1 Advanced Manufacturing Technology

"y. Here the primary cutting edge is basic vector, tool rake
angle can be considered that after rotation of face with Yo =
0 0
around primary cutting edge are measured with tool
reference plane to obtain the variables value. So, tool
clearance angle can be considered that after rotation of (2)
major flank with ao= 0

r
0
around primary cutting edge are
measured relative to tool cutting plane to obtain the 1

variables value. It is considered that after rotation of face OR = II -IP, = 11 -[(f)' +// cos[130-'(:')+ A,]
with As 0 around the normal vector perpendicular to
0
=

cutting edge plane which through a base point of primary (3)

cutting edge are measured relative to tool reference plane
to obtain the desired inclination angle. According to the
geometry relationship, inclination angle As, approach angle
"y, side rake angle y! and back rake angle YP can be
-p--
n
expressed as follows

tgAs =tgYj 'COSK, -tgYj . sinK, (1)

Under the conditions of tool rake angle with yo*90° and

ao "* 90° , variables of tool approach angle "y can be
varied inclination angle. As inclination angle increases, the
effective rake angle increases and the chip becomes thinner a) Illustrating change in tool approach angle
and longer.

2.1 Modeling tooling mechanism with adjustable tool

geometry

The mechanism model facilitating inclination angle change

is modeled in this paper. This model is derived directly
from a study [2], which deals solely with the mechanism
L
used to implement a variation of the tool inclination angle
and the approach angle.
b) Illustrating change in tool inclination angle
As show in Fig.l, tool rotation necessitates movement
Fig. 1: analytical diagram for the model of mechanism with
around one specific point. Since a mechanical element with
adjustable tool geometry.
point P as its center of rotation is impossible to achieve, an
assumed point "I" is chosen as center of rotation with a
distance 11 to the tool tip. Point "2"is chosen at a distance
12 from "I" in order to analyze the rotation of the tool
holder around "1".It is apparent from Fig.! that after
rotation of the tool holder around" 1" to obtain the desired
inclination angle +As or -As. According to the tool geometry
indicated the height deviation r5H and the radial deviation
r5R can be expressed as follows:

Fig.2: analytical diagram for compensate the tool tip deviation

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 International Technology and Innovation Conference 2006

It is essential that the new variable tool mechanism should tool holder 2 tool holder 1

be designed with rigidity being one of the major

considerations to ensure a high level of dimensional
accuracy as well as reducing vibrations caused by load
while machining. Current tooling systems prevent this by Slope SJ pin 1 Slope ~ pin 2 Slope Sl

completely clamping the tool holder in the tool holder Fig. 3: three specific slopes which work simultaneously to
housing. With the proposed tooling mechanism, the compensate the tool tip deviation.
movement of the tool holder is necessary to facilitate the The tool holder 1 and tool holder 2 can now in this way,
change in tool's inclination and approach angle. This are with all three slopes working together to change its
further important design considerations. Movement of the inclination and approach angle. A design of a device
tool holder in two planes, one parallel to the approach facilitating this on-line geometry variation as seen in Fig.4.
angle and perpendicular to the base, and visa versa both
changing their angles. Secondly, keeping the tool tip 4 3 2
stationary in space (on the workpiece axis) as the geometry
variations take place. And lastly, development of an on-line
automated control system to facilitate the necessary
geometry variations. It must at all times be kept in mind
that available space for the operation is among the most
limiting factors in the mechanism's design. A slider
mechanism would thus be most suitable due to this space
limitation, especially this mechanism is to be as rigid as 9 8 7 6 5
possible.
A slider input link driven by a motor-lead screw system,
with the output link being the tool holder itself, would be
best for this mechanism [3]. As in Fig 2 and Fig 3, a
specific slope 8 1 is required to move "2" up and down by
this slope as a result of horizontal back and forth
movement of the input link (x-direction) as the tool holder I-motorised lead screw 2-bolt 3-bolt 4-pin 1
rotates about "1" to form any desired inclination angle. It 5-flange 6- flange 7-bolt 8-tool holder 1
can be seen that a second slope 8 2 on the input link is 9-cutter 10- tool holder 1 11- pin 2
required to compensate for the height deviation by moving Fig.4: tooling mechanism.
"1" vertically (y-direction) while the tool holder is rotating,
simultaneously changing the inclination angle by slope 8 1 3 Simulated results of the cutting forces
and thus compensating for the height deviation. In order to In order to gain analytically simulated prediction of the
compensate for the radial deviation bH , a third slope 8 3 is cutting forces, the MATLAB software is used. For the
introduced. Slope 8 3 must be designed on the tool holder 2. 'classical' oblique cutting operation, the three forces
The angle of slope 8 3 can be expressed as follow. components for the modified mechanics of cutting

8. I,-[Uf)'
+I,,]i cos [a +pI
analysis were expressed by equations which incorporate
the 'edge' force components [4]. The practical force
= 8 = [(H)2 2]. H
l
IgB H
2" +/1 sm[a+ Pl -2" components Fe, Ffand F p can be expressed as follows

Fc =~( cos(Pn-Yn)+tanAstan1]csinPn ) C 1b
~ + I COS/L,
sm<bnCOS2«(Pn + Pn - Yn) + tan 21]c sin 2Pn
•
(4)

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 Section 1 Advanced Manufacturing Technology

F =. fA ( sin(Pn-Yn) )+C b
2
f
sm~n cos As ~COS2 (~n + Pn - Yn) + tan 2 1]c sin 2 Pn
F =~( COS(Pn -Yn)tanAs -tan1]c sin Pn )+C1SinAsb
p
sln~n ~COS2(~n + Pn - Yn)+tan 2 1]c sin 2 Pn 65,2
(5)
where A =area of cut =h X b
where C] and C2 are the edge forces per unit width of cut
and As, Ym lle,cPmfJmt are the conventional inclination angle,
normal rake angle, chip flow angle, normal shear angle, 10
5
normal frication angle and work material shear stress in
·10 ·10
the thin shear zone with respect to the cutting edge and
normal plane. ap =lmm,j=0.2mmlrev
Based on the 'classical' oblique cutting deformation Fig.5: analytical trends of tangential cutting force vs. tool
geometry and the 'collinearity conditions' between the geometry.
shear force and shear velocity in the shear zone as well as C]=5N/mm , Yn=Oo, r]=0.5, fJ=300;r =100Mpa
the friction force and chip velocity in the rake face the
following relationships apply
r 1 ( cOSllc )cos Yn
cos As 1004
tan¢n = -~-~--
1- rl ( cosllc )sin Yn 100,35
cos As
~ 10(13 tc~
tanPn = tanpcOsllc t.:L
tanys cosYn 100-25
tan ('Yn +}In
~ a )_
- - - - - .- - - (6)
tanllc -slnYn tanys 100.2
10
5
where r] is the chip length ratio and fJ is the friction angle. 10
Kr(°) 0 5
Thus combining the above equations the force -5 o
-5 AsC')
components and chip flow angle can be expressed by the
following functional relationships:
ap =lmm,j=0.3mmlrev
Fig.6: analytical trends of tangential cutting force vs. tool

llc = !unctions(Yn' As,lj,P) (8) geometry.

As an example of the predictive capability of Eqs. 5 C]=5N/mm , Yn=Oo, r]=0.5, /3=30°,t =lOOMpa

through 8, the resulting simulation of the analytical trend of
tool geometry As, and K r, vs. tangential cutting force Fe are
shown in Fig.5 and Fig.6.
As can be seen from the computer generated surface plots in
Fig.5 and Fig.6, a definite absolute minimum tangential
cutting force is observed in both instances around As=O° and
kr=O°, resulting purely from the very general constant
selection mentioned above. The same can be said for the
scale of the figure-the very general selection of the
above mentioned constants, results in the seemingly
insignificant variation in force for large variation in kr and As .
Since the trend of the generated surface is significant, the
scale is negligible.

4 Conclusion

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 International Technology and Innovation Conference 2006

This mechanism model is a pilot study for the possibility

of on-line varying tool inclination angle and tool approach
angle during machining process,
The model is realized through the use of three specific
slopes which work simultaneously to compensate the tool
tip deviation due to the change of tool geometry so that the
tool tip always stays at working point in space.
It need to be research further, which has a promising
future in intelligent machining.

Acknowledgements
Financial support from the China Postdoctoral Science
Foundation, under grant no.2005037766 is
acknowledged with gratitude.

References

[I] Nigel Jones, "'intelligent' tooling make its presence felt",

Machinery and Production Engineering, 157, 3980:
28-30, 1999.
[2] Andree Fritsch, "Reducing process lines through
intelligent tooling concepts", Automotive
Manufacturing International, 53,1999.
[3] X. D. Fang, S. M. R. Najmossadat, "Mechanical design
of a new tooling mechanism with on-line
controllability of inclination angle", Int. J. Mach. Tools
Manuj, 36(1): 103-113, 1996.
[4] Z. Katz, J. W. Sheppard, "Analysis of on-line tool
geometry variation for machining with optimal power",
Machining Science and Technology, 6(2): 171-186,
2002.
[5] E . J .A. Armarego, "The unified-generalized mechanics
of cutting approach-a step towards a house of predictive
performance models for machining operations",
Machining Science and Technology, 4(3): 319-362, 2000.

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