BTM 3334

CNC MACHINING

TOPIC 5: CNC TOOLING

LECTURER:
DR. MUSFIRAH ABDUL HADI
 Lecture Objectives

 At the end of the lecture, you will be able to:

 Identify the types and applications of cutting tools used with
CNC equipment.
 Explain the meaning of tool speeds and feed for milling
operations.
 Calculate tool speed and feed rate for milling operations.
 Understand the difference between climb milling and
conventional milling.
 Explain the need for using cutting fluid for CNC operations.
 Explain tooling systems use with automatic tool changers.
 Design Features of CNC Tooling

 In general the following points are to be considered

while designing of CNC tooling :
(a) To give high accuracy.
(b) For variety of operations.
(c) Quick changing of tools to keep the down time
minimum.
(d) Flexibility.
(e) Rigidity of tooling to withstand cutting forces.
(f) Rigidity to transmit the power at higher speeds.
 Cutting Tools for CNC Machines

 Cutting tools are available in three basic material

types: high-speed steel, cemented carbide, and
ceramic.
 High-speed steel is generally used on aluminium and
other nonferrous alloys.
 Tungsten carbide is used on high-silicon aluminium,
steels, stainless steels, and exotic metals.
 Ceramic inserts are used on hard steels.
 Inserted carbide tooling is becoming the preferred
tooling for many CNC applications.
 High-Speed Steel Cutting Tool

 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
 Cemented Carbide Cutting Tool

 Capable of cutting speeds 3 to 4 times high-speed

steel cutting tool
 Low toughness but high hardness and excellent
red-hardness
 Consist of tungsten carbide sintered in cobalt
matrix (work as a binder)
 Different grades for different work
Type of cutting tool
Cemented Carbide Cutting Tool
 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

 Tooling for Drilling

Twist Drill
 Most important tool used is the twist drill.
 Comprise of 2 helical grooves/flutes that cut around a
center (web), shank (straight/tapered)
 The web gives strength to the drill in resisting deflection.
 Accuracy tends to decrease when either the drill length or
drill size is increased – less stiffness and more torsional
deflection.
 Metal cutting twist drills are made from a wide range of
material ranging from carbon tool steel to solid carbide.
Tooling for Drilling
 Tooling for Drilling

Center Drill
 To better locate a hole center, center drills are used due
to its short and stubby character as compare to twist drill.
 The initial work is used to guide the twist drill into the
material
 Good practice: the countersunk portion is approx. 0.003
to 0.006 in. larger than the twist drill diameter
Tooling for Drilling
 Tooling for Drilling

Spade Drill
 Consists of a blade holder to which one of several
different size drill point blades can be bolted in.
 The larger web of the spade drill ensures that during
drilling penetration less flexturing occurs and thus more
accurate hole results.
 Spade drills are designed to machine a hole from the solid
in one pass - no need for center drilling or multiple pass
drilling. However the hole depth is limited because flutes
does not exist to carry out the cut chips.
 To fully utilize the cutting tool, a 50% or greater torque
machine is required with increased machine rigidity.
Tooling for Drilling
 Tooling for Drilling

Indexable Insert Drill

 Made of carbide that helps penetration into the hardest of
material.
 It offers a penetration rates of 5 to 10 times that of a twist
drill or spade drill.
 However it requires a machine to have higher spindle
horsepower, pressurized coolant system and rigidity
Tooling for Drilling
 Tooling for Hole Operation

 Boring: enlargement of existing hole & accurate

readjustment of the center location of the enlarged hole
 Reaming: increase the accuracy of a hole dimension size
 Tapping: cutting threads on the inside of a hole
 Counterboring : enlargement of a hole to a depth
slightly larger than the head of a specific bolt/pin to allow
the head to burried below the machined surface.
 Countersinking: enlargement of the top end of a hole
in the form of coneshaped depression to allow a flat or
oval head machine screw to be flush or slightly below the
surface when inserted.
Tooling for Hole Operation
 Cutting Parameters

 Cutting speed selected for a particular tool will depend on

several factors, some of which are:
 Type of hole operation, material hardness, hole depth
 Type of tool used and type of lubricant or coolant used
 Type of hold-down fixture and CNC machine used
 Cutting Parameters

Machining Calculation: Drilling

Cutting Parameters
 Tooling for Milling

End Mill:
2 flutes vs 4 flutes :
 Different hardness of material
 Plunging directly into center of solid material
 Suitable for rough drilling hole, counterboring and
boring, as well as slotting and cavity cutting
 Tooling for Milling

End Mill:
 Tooling for Milling

Shell End Mills:

 Several cutter sizes can
be fitted to one mounting
arbor
 Facing uses this cutter
 Tooling for Milling

Carbide Indexable Insert End Mills:

 Speed and Feed

 Speed is the relative movement between tool and w/p,

which produces a cut

 Feed is the relative movement between tool and w/p,

which spreads the cut
Speeds
Exercise of Speeds

39.27 m/min

509 rpm
Feed
Exercise of Feed
Climb and Conventional Milling
 Feed Direction for Milling Operations

Climb Milling (Down)

 The tool to make a chip of maximum thickness at
the start of the cut at and near the part surface
 Less clamping and horsepower is required
 Recommended in order to get a more accurate
roughing cuts with minimum machining marks
and machining thin parts or parts that are hard to
hold down
 Cutter are less prone to be dull as the chips are
pushed behind and away

 Conventional Milling (Up)

 Feed Direction for Milling Operations

Conventional Milling (Up)

 The tool starts with a cut of chip of no thickness
before attaining maximum thickness at the end of
the cut near and at the part surface
 High clamping and horsepower is required
especially for hard outer scales material.
 Recommended in cases where the a tool length
used may cause unacceptable chattering of the
cutter if using climb milling
 Cutter are prone to be dull as the cut can create
high tool impact
Comparison Between Up Milling and
Down Milling
 CNC Tooling

CNC Tooling

N10 M06 T5
Manual Tool Change
N15 G01 X10 Y20
N20 G02 X30 Y20 R10
Automatic Tool Change N25 M06 T7
N30 G01 X50 Y40
N35 G03 X50 Y60 R10
 Manual Tool Change

• In a manual machine, the tools are changed manually

whenever required.
 Automatic Tool Change (ATC)

• The CNC machines are designed to perform a number of

operations in a single setting of the job.
• A number of tools may be required for making a complex part.
• In a CNC machine, tools are changed through program
instructions.
• The tools are fitted in a tool magazine or drum.
• When a tool needs to be changed, the drum rotates to an
empty position, approaches the old tool and pulls it.
• Then it again rotates to position the new tool, fits it and then
retracts.
• This is a typical tool changing sequence of an automatic tool
changer (ATC).
 Drum Type

• For holding small number of tools usually not more than

30, stored on periphery of drum and tool search speed is
faster.
 Chain Type

• For more number of tools (40 or more), tools search

speed is less.
 Tool Holder

• The design of the tool holders ensures an accurate fit

 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 20th century saw soap added to water
 Soluble oils came in 1936
 Chemical cutting fluids introduced in 1944
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
Zone of Heat Generation
 Heat Generated During Machining

 Heat find its way into one of three places

 Workpiece, tool, chips

Act as disposable
heat sink

Too much, cutting edge Too much, work

will break down rapidly, will expand
reducing tool life
 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
 Characteristics of a Good Cutting
Fluid

1. Good cooling 6. Rust resistance

capacity 7. Nontoxic
2. Good lubricating
8. Transparent
qualities
3. Resistance to 9. Nonflammable
rancidity
4. Relatively low
viscosity
5. Stability (long life)
 Types of Cutting Fluids

There are several different types of CNC cutting fluid available,

including:
 Water-based fluids: These are the most common type of cutting
fluid and are typically made from water mixed with additives such as
oil or glycol.
 Synthetic fluids: These are made from chemical compounds and
are designed to be longer-lasting than water-based fluids.
 Oil-based fluids: These are made from petroleum-based oils and
are typically used for heavy-duty machining operations.
 Semi-synthetic fluids: These are a combination of oil-based and
water-based fluids and provide a balance between lubrication and
cooling.
 Vegetable-based fluids: These are made from vegetable oils and
are an eco-friendly alternative to petroleum-based fluids.
 Functions of a Cutting Fluid

 Prime functions
 Provide cooling

 Provide lubrication

 Other functions
 Prolong cutting-tool life

 Provide rust control

 Resist rancidity
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)
 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)