ADDITIVE MANUFACTURING PROCESS

ASSIGNMENT
1)Explain various types of cutters and their
applications
Classification based on number of cutting edges
A) Single point Cutting tool B) Multipoint Cutting tool
SINGLE POINT CUTTING TOOL
1) It contains one main cutting edge in the cutter body
2) While machining with single point cutting tool only one
main cutting edge continuously remains in contact with
workpiece
3) heat generation in the tool is very high
4) Since only one point to cut the material remove rate and
productivity are low
Applications: Turning, shaping, boring, slotting etc.

Source: https://www.indiamart.com/proddetail/single-point-cutting-tool-3718843655.html
 MULTI-POINT CUTTING TOOLS
1) It contains more than one cutting edges in the cutter body
2) While machining more than one cutting edge
simultaneously engage in material removing process
3) due to more cutting edges rate of heat generation is less
compared to single point
4)It offers higher material removal rate and more productivity
Applications: Milling cutter, grinding wheel, reaming etc.

Source:
https://www.accessengineeringlibrary.com/content/book/9781
260122312/toc-chapter/chapter13/section/section11

Information source: www.difference.minaprem.com

 SOLID CUTTERS AND INSERT CUTTERS
SOLID CUTTERS
1) These are permanent cutters once the cutter is broken
or due to wear and tear it becomes (blunt)we have to
change the complete cutter
2) These are expensive compared to insert cutters
3) These have less varieties of cutters compared to
insert cutters
4) heat dissipation is less in this type of cutters
Primarily solid cutters can be classified into three types
A) Flat end mill B) Bull nose C) Ball Mill
FLAT END MILL CUTTER
They produce sharp edge at the bottom of pockets and
slots
1) Corner Radius =0 degrees
2) Further they can be classified into centre cutting and
non- centre cutting flat end mill cutter
Applications:
Side Milling: machining edge surface of the part
Face Milling: machining top surface of the part
Plunge milling, Ramping etc…
Coating Material: Titanium nitrate, ALTIN etc…
Materials used: HSS, Cobalt, Solid carbide etc.

Flat end mill cutter

Source: https://www.industrybuying.com/carbide-end-mills-anubis-
MA.EN.SO.1386064/

BALL NOSE CUTTER

Used to decrease the stress concentration
Mostly used for cutting 3D Shapes
1) Corner Radius= D/2 OR R1
Applications: Milling contoured surfaces, slotting and
pocketing etc…
General coating material: aluminium chromium nitrate
Materials used: High temp titanium alloy, carbide etc.

Source: http://www.puritoolsandsteel.com/product/carbide-
ball-nose-end-mill-cutter/
BULL NOSE CUTTER
They have radius at bottom which makes for a nicer surface
finish for work piece
Corner radius: CR>0
Based on our requirements we can define corner radius as per
ISO standards.
Applications: Contour milling, shallow slotting, pocketing etc.

Source: https://www.ingersoll-imc.com/product-family/4051
 INSERT CUTTERS
1)These are used for specific operations
2) They are less price and more economical
3) In this type of tool pressure will apply on insert, so the
insert box is safe
4) Once the insert tool is broken unlike solid cutter, we can
simply change insert tool
Materials used: HSS, carbide, solid carbide etc.
Some Applications and examples of insert cutters
Turning inserts: chip control, external and internal turning
Source: https://www.sandvik.coromant.com/en-gb/products/turning-inserts-
grades-steel/pages/default.aspx

Parting and grooving

Source: https://www.sandvik.coromant.com/en-
gb/products/corocut-qd/Pages/default.aspx
Threading Insert cutters
Source:
https://www.sandvik.coromant.com/SiteCollectionImages/tools/threading/corot
hread-266/inserts.jpg

Boring and reaming

Source: https://www.sandvik.coromant.com/en-
gb/products/corobore_br20/pages/default.aspx
2) Different types of origin coordinate systems and
its function with diagram.
Primarily in CNC origins can be divided into three types
1) PART ORIGIN 2) MACHINE ORIGIN 3) Program origin
PART ORIGIN (set by operator)
The part origin can be set at any point inside the machine's
electronic grid system
Part origin and program origin should be same.
PROGRAM ORIGIN (set by operator or engineer)
It is also called home position of the tool. Program origin is
point from where the tool starts for its motion while executing
a program and returns back at the end of the cycle
MACHINE ORIGIN (Defined by machine manufacturer)
The machine origin is a fixed point set by the machine tool
builder, usually it cannot be changed. Any tool movement is
measured from this point

Source:
http://ecoursesonline.iasri.res.in/pluginfile.php/3156/mod_page/conte
nt/6/Module%2010%20Lesson%201%20Fig.10.1.1.jpg
MATERIAL ORIGIN POINTS
Centre Origin (Computer Programming)
In this we take centre of the raw material as the origin

CORNER ORIGIN (manual programming)

In this the corner of the raw material with respect to machine
table is taken as corner origin
3) Describe the different types of CNC machines with
specifications and describe the function of machine table,
ATC, and spindle.
In primary level CNC Machines can be classified into two
types:
A) CNC Turning (LATHE MACHINE)
B) CNC Milling Machine
CNC TURNING
1) Job rotating tool fix
2) Used in cylindrical or conical works
3) when processing the outer circle surface finish is better
4) Produce fragmented, discontinuous or continuous chips
5) Used for machining outer and inner cylindrical or conical
surfaces like shafts, bushes etc.
Applications: Drilling, reaming, tapering, knurling etc.
Source: https://www.lvcnc.com/sck-46b-turret-slant-bed-cnc-lathe-machine.html
CNC MILLING:
1) Tool rotating job fix
2) Generally Milling machines are used for most of the works
as they are more flexible and versatile
3)Holds Tools in ATC
4) When processing large flat surface is better
5) Always produce discontinuous chips
6) We can do lakhs of lines of programming in this machine
as per the requirements.
Used for Concave, Convex, contour shapes.
Applications: Grooving, threading, curved surfaces etc.

Source: https://www.stylecnc.com/uploads/160704/1-
160F41UF2D5.jpg
Milling machines can be further classified into VMC & HMC
VMC (Vertical milling machine)
In this the spindle is placed vertically to the machine
Chips fall on table since its vertical
Source: https://associatedmanufacturing.in/wp-content/uploads/2016/03/VMC-Machine.jpg

HMC (Horizontal milling machine)

Used for Flat type of works
Spindle is horizontally placed or oriented WRT Machine
Chips fall away from table
One HMC can perform the work of multiple VMC’s

Source:
https://www.okuma.com/stuff/contentmgr/files/2/1776d1a540a7517fbd42827a31a2fe1b/imag
e/vmcvshmc_nb.jpg
Based on number of axis also we can differentiate CNC -
machines like
2-axis, 3-axis, 4-axis, 5-axis etc.
MODERN CNC MACHINE WITH SPECIFICATIONS

DOOSAN DVF 8000

Maximum X Axis travel distance 1000MM
Maximum Y Axis travel distance 900MM
Maximum X Axis travel distance 685MM
Feed Rate Rapid traverse
X= 45m/mm, Y=45m/mm, Z=45m/mm
Maximum Spindle speed 18000 r/min
Maximum Work space weight 700KG
Dimensions of machine: L=4097MM, H=3670MM, B=2950MM
Weight of machine =14500KG
Control system used: Fanuc
MACHINE TABLE:
The table is placed on the top of saddle, it holds the jobs and
also the job holding devices. A number of T slots are there for
holding the work piece and jigs and fixtures. In milling -
operation the table is moved by the motor which gets signals
from the program codes
ATC: Automatic Tool Changer
It is used to improve the speed of production and tool carrying
capacity of the machine, tools are changed very quickly as it
is computer controlled
Types: 1) Drum type- Holds lower than 30 tools
2) Chain type: when the tools are higher than 30 then chain
type of ATC is used.

Source: https://www.u-techindia.com/wp-
content/uploads/2017/09/50ChainTypePocket_H5BBF.jpg
SPINDLE:
The spindle is the rotating tool holder
The tools are installed in the tapered part of the spindle
The spindle has different speeds based on the motor it is used.
The spindle speed is set up according to the properties of the
material. Mostly three types of spindles are used
1) Cartridge spindle, self-contained spindles and fabricated
spindles.

Source: https://5.imimg.com/data5/OT/PD/MY-6298596/cnc-router-spindle-
500x500.png

Submitted to: C.R.Tripathy Sir

Submitted by Golla Vara Prasad (GU-2018-3221)
THANK YOU