21.

DESIGN OF SINGLE POINT

CUTTING TOOLS . .

The work of a tool designer consists of following steps:

(i) Detennine the forces acting on the cutting surfaces of the tool and
detennining the optimum tool geometry. ·
(ii) Finding tlie most producible shapes of the cutting tool and determining
the tolerances on the. dimensions of the cutting and mounting elements of the
tools. ,
(iii) Calculating the rigidity of the cutting and mounting elements of the tool.
(iv) Making a working dfclwing of the tool and computing the manufacturing
dimensions. ·
. -
21.01 RIGIDITY 'CONSIDERATIONS FOR A SINGLE POINT·
- ·TURNING TOOL~ :
Th~:rshank-of a si_ngle point tool may be rectangular, square or round in section.
The. i-ectangular cross-section ,is the most popular as reduction in its strength is
much .less than when a seat is cut 'into it for the tip. In most of the cases, fig.
21.0 li:H/8 varies between I ._25 to 1.6. It is desirable to use tools having H/8 =
.1.6.'for-- semi-finishing and ·finishing operatiQns and those with H/8 = 1.25 for .
roughing. Square shank tools are ·used for boring, turret and automatic lathes.
· Round shank tools are used for boring and-thread cutting.

The permissible size of the shank cross-section is determined on the · strength ·

basis. For this purpose the actual bending moment (Mb) acting on the tool is
equated to the-moment of resistance of tool s_hank (M'b).i.e.
Mb = M\ ----(21.01)
 From Fig. 21.01 ..;--(21.02)
Mb= Fe•1
----(21 .03)
M'b=pZ
Where 1= tool overhang ,(mm)
p =penriissible bending stress of the shank materials. F~r
unhardened steel having tensile strength · in the range of 60-70
kg/mm2, p = 20kg/mm2• -
2
Z = Section Modulus of the tool shank (mm ) .

Fe
Fig.21.01.

. . BH 2 ·
For rectangular cross-section Z = - -
6
For circular cross-section-of diameter·d (mm) .
. mi3
Z=~ -
32
Hence substituting from Eqns. (21.02) and (21.03) into (21 .0 l) we hav~ for a
rectangular cross-section tool holder .
BH 2 . ,,
Fl= .6 p
C .
---(21.04)
. ·{

BH2 = 6~/ ----(21.05) · ·

p
•
Taking H/B = I .6, we get

8=3 . ~/ -~--(21.06)
2.56p
Similarly for a square shank
 - ·· - "•UL_'--unmg Tools

B= 3 . ---(21.07)

And for a circular shank .

.,- .
,
d=3 (mm) t 2F,i
Hp
/

----(21.08)

The tool overhang I, is usually taken as (1-

· 1.5) H. . . · .
nd
The to?l cross-sectional area calculated on the basis of the pernussible be mg
stre_ss is not sufficient. The maximum deflection .which the tool undergoes
durmg the machining operatio,i should.also be limited. · ·
The maximum deflection of the tool would occur at the cutting point and could
be fou nd by assuming the tool ·shank to be a·cantilever loaded at the free end .
For a tool having rectangular cross section the deflection 6 of the tool point is
then given be: · _
<>·= 4Fc/3
EBH 3 ----(21.09)
-where Eis the Young's Modulus of tool steel.
The deflection 'O' would directly govern the natural frequency of vibration of
the tool, Eqn. 21.09. If this frequency of vibration happens to coincide with the
frequency of cutting chatter would result. Under all circumstances ,chatter
· should be eliminated as this leads to poor surface, poor tool life and may also
damage the machine tool itself. .
a ro)
_ Th~ natural frequency of vibration of c·antilever ( having a deflection 0
. (mm) at the free end is given be
0.625 1·
0) = · C S ----(21.10)
.·/;f
Example: A. 6° b~ck rake ~olid lathe tool is to be employed for machining
-of stee] at 50m/min, feed 0.05 mm/rev and .at a depth of cut 2.0 mm. The
maximum pennissible deflection at th~ tool poipt is 0.01 mm and the
maximum. aJJowable stress in the tool point is 6kg/mm2• Find the ·cross--
• I .

section of a rectangular tool shank. The cutting forcet can. be obtained

from the fonnulae Fe · ·256 -~ f· d (kg) and the work diameter is 150mm.
18

Assuming a rectangular shank with H/B = 1.6 and tool over hang l =
· 1.25H. , , ·
For the cutting condition, fc = 256 x 0.05°· 18 x 2-; 300kg
Assuming J= 1.25 H
-' =1.25 x l ;6 x B
=2B
~nd-as given p = 6 kg/mm 3
 I

Ii We have from Eqn. (21.05)

6x300x2B
B=
256x6
Or B = 15.3mm
H=24.5mm
I
The dimensions B and H·as found above will have to be checked so .that the
ii
deflection at the free end does not exceed 0.0lmm.The deflection at the free end
/ from Eqn.21.09 is given by

-(4F/
11
I 3
0= C
)
. · EBH 3

4 X 300 X (2 X 15.3 y
20 X 103 X 15.3 X 24.5 3
(E ~o X 103 kg /mm2)
6 = 0.00408 mm
As·the actual 6 is less than the specified value of 0.01 -mm hence,the·dimensions
B and H already chosen are safe. _ ·
1000V
Cutting - frequency -
jz-D x 60

-------
1000 X 50
,,. X 150 X 60

= 1.77 c/s.
_
Natural frequency of the cutting_tool Eqn. 2 l. l Ois given by
. 0 .625 ,-
OJ = · C S
" .Jo .
0.625
1,,:·
- 0 .0058 •
= 8.4 c/s
As the natural frequency of the cutting tool is much higher than the c~ting
frequency therefore the cross section 8=12.mm and H=20.4mm with an
overhang of 25mm is satisfactory.

CAltBIDE TIPPED SINGLE POINT TOOLS.

Carbi.de tipped tools can be classed as
(a) Tip brazed to the shank,
(b) Mechanically held tips, and
(c) Tip bn12ed to the shank
 The carb~de tiP' can be brazed directly to the shank of the tool induction heati1,1g.
T~e brazmg filler material may either be electrolytic copperor an alloy_ofbrass
with ~% e3:ch of nickel and ferro~anganese. The thickness of the filler material
. layer 10 the brazed point should be approximately 0.1 mm. · .
· In order to facilitate brazing the tool shank has to be provided with a seat. Some
of the common types of seats are shown in Fig. "21.02 (a), (b). It is a good
practice to make the seat angle equal to alpha+5° ·where alpha is the to9l .rake
angle and for strength. Fig 21.02 (a). The tip thickness te is mainly selected on
the consideration of strength and the permissible number of tool regrinds, which
can be had. For heavy cutting a thicker tip is preferable. ·

SEC A-A~

Fig.21.02a

A'
A

Fig.21.02b
 21.02 TOOLS HAVING MECHANICALLY CLAMPED TIPS.

Brazing the tool tip to the sh~ has .g~t certain disadv~tages. Sometimes
cracks appear within the carbide -tip. This 1s ~ue .to non-:~mfonn cooling of the
tip and also due to difference in the coefficients of thermal expansion of the
carbide and the shank ~aterial-. In additi~n scales are formed on the carbide tip
during brazing. Mechanically clamped tips overcome the defects of the brazed
tip tools and also reduce the cost of manufacture. Hence, they are more popular.
Some of the typical methods for clamping the tool bit to the shank are shown in
Figs 21.03,21.04 and 21.0S. Table XXXII also compares machining cost
obtained with brazed and clamped tools.

( )

Fig.21.03: 1

SEC .. A-A

Hexagonal
too I t'I p
Tool holder
,
.e
_t

Fig.21.04.
 TABLEXXXII.

Particulars. Throw Brazed

away Tool
tool.
Brazed Tool.
Purchase cost Rs. 25.00 each
No. of regrinds possible .10
Tool cost per cutting edge •....... Rs 2.28
Clamped Tool
Cost of each tip .............. Rs 6 .00
No. of cutting edge per tip 6 I
· Tool tip cost per edge 1.0 6.00
Holder for the throw away tip ... Rs 76.00
No. of cutting edges per holder ..... 4.00
Holder cost per cutting edge: ...... Rs 0.19
Regrinding Cost
Tool regrinding labour rate Rs. 15.00/hr
Grinding time per edge .... ·.... 10.0 min.
: Grinding cost per tool edge .......Rs 2.50
Tool Setting Cost
Tool setting costper hr ........Rs. 15.00 ·
Tool setting time per tool edge ....... . 5mm Imm
Setting cost/cutting edge, Rs ... . . . 0.25 1.25
Total cost per cutting edge, Rs 1.44 6.03

Weld

SEC A ·A

Chip bre_oker
Seal

J
Fig.21.05.
21.04.DES.IGN CHIP BREAKERS.
 Production Engineering Sciences
548 .
bee discussed in Chapter 5 . The types .
Importance of chip breakers has already I ned are by the use of (i) groove type
of chip breaking fI!ethods cormn~,nl~ er!: rs or (iii) Dynamic chip breakers.
chip breakers or (ii) clamped type chip e - ·

GROOVE TYPE CHIP er:~:~ld act as an obstruction to the chip

th
G~ves or step fonned on ~ excessive curling leading of the fracture of the
flow and hence wo~d re~ult
hi The usual dimension
::Ois is shown in Fig. 21.06. Such grc>Qves bay~_
. bo . . r-t d
c ps. ful · operations like turnmg, _ nng, 1acmg e c., un er
proved to be success ."!- -- - _ __ - . •
.d range working condition. . · .
WI e timum size of the groove depends upon the ~Q_rk gi~~erial- and the-cu.tt1n_& ..
The ed However this method of chip breaking suffers from the
conditions emp1oy · ' __ __ - _ - - -- --- ·- - --- -
following two advantages: . . ·
(i)Grinding of the grooves ts expens1v~. . . . ..
(ii)The groove size has to be altered with a change 1n the cutting cond1t1ons.

The fonner objections could be overcome by providing . groove during

sintering of the tool bits. Whereas the latter defect could only be overcome by
use of adjustable types chip breakers. c ' /

--t~
·1 '

Fig21.06.
.,

_ADJUSTABLE or CLAMPED CHIP BREAKERS.

Adjustable type chip breaker is shown in.Fig 21.05. The chip breaker has found
t.o work efficiently in steel turning whilst employing a depth of cut between 110
mm feed ranging between 0.08 to 2mnilrev. and speed varying between 50-6
00 m per mip. The chip breakers are usually made of high strength steel often
hardened and ground of faced with stiletto to give increased hardness.
Typical ~imensions of the chip breaker groove whilst turning structural steel
with tungsten carbide tools.
 Design of Single Point Cutting Tools 549
n = 0.1 - 0.2 mm less than the feed rate for feed 0.6 mm/rev.
rr= feed for feed> 0.6 mm/rev.
n = 0.1-0.6 mm
I = width of the chip + O.S -1.S rnm.

21.03. DYNAMIC CIDP.BREAKING.

Chips can also be broken into short pieces by oscillation the tool in the f~
direction at the controlled frequency and amplitude. This method of chip
breaking if still in experimental stage but has proved to be advantageous owing
to the case of adjusbnent for varied cutting conditions. ·

21.04.DESIGNING AND APPLYING TOOLS FOR . INTERRUPTED

CUTS. . . .
When interrupted cuts are to be ~en with a single point carbide tool th~
following precautions be observed: ··
(I) Use largest possible shank size. For internal cutting use carbide
shanks instead of usual carbon.steel shanks. This would improve the
rigidity of the tooL .
(2) Use tough, shock-resistant carbide grade;
(3) -Use thicker tips than WQuld normally be used for continuous cutting.
(4) Use largest nose radius possible
·cs) Use large side cutting edge angle and minimum end cutting edge
angle. .
(6) Use .· minimum relief and clearance angle to give the cutting edge
· maximum support. ·
(7) When conditions pennit use negative rake tools.
(8) .If possible design .or apply the tool so that .the interruption contacts
. the rake surface' back of the nose. (Fig. 21.07)
(9) Keep the tool overliailg to a maximum.
(I0)Make everything in the set up as rigid as possible.
(11).For steel machining hone the cutting edge heavily.

Fig.21.07.
 JJV

21.05 FORM TOOLS.

In turning operations a fonn tool can produce the desired contour on the
piece. Use of such a tool ensures high output ace~ dimensions and unifoWork
of the worlc: produced. These tools are common 10 mass production. The ~y

Circular form tool ,Fig. 21.08 (a).

Radial feed flat form tool, _Fig.2 I.08(b)
End form tool,Fig.21.08©.
Tangential tool, Fig 21.08 (d).

. Fig.il.08(a)

Fig.21., 08(b)
 ·.a Work axis

Fig.21.08· (C)

Fig.21.08(d).
Mostly, form tools are made of H.S.S. but carbides are also becoming
as
· popular a form tool material. The carbide form tools like turning tools
can either be brazed or clamped. A form tool should be provided with
proper ··rake and relief angles. Table XXXIII shows the recommended
angles for the form tools.

TABLE XXXlII
Material BHN Rake angle deg.
Mild steel Upto 150 25
Hard steel 235-290 12-20
Soft C.I. Upto 150 15
Aluminium 20-25
 The clearance angle depends upon the type of fonn tool. It usually varies
between 10,.-150,

ll.06 DETERMINING PROFILE OF FORM TOOL.

&

(a) Out side diameter of the circular fonn tool having positive rake angle.
Fig. 21.09 shows a job which has to be produced by means of a circular form
tool. It is required to detennine the radius R of the tool. In order to determine R
a graphical method has been described here.
- Through the point P We draw a line PR' at an angle "a"the tool rank angle. The -
horizontal -distance QR is set depending upon the chip flow considerations
(usually between 312 mm.). R' and the vertical tine PR'. In order to determine
the center Q2 of the form tool another · ·
·Line B02 inclined at an angle equal to the tool clearance angle is drawn.

Work

Fig.21.09.
 In order to locate the center 0 2 of the form tool another line P02 inclined ,
at an angle equal to .the tool clearance angle beta in drawn. In order to
locate the center 0 2 of the tool, through the point R' a line R'O2S is
drawn inclined at an form angle (9o+ a )/2 with respect to the tool face,
the intersection of the lines R'O2S and PO2T determines the center 0 2•
Having known 0 2 the tool radius R can be determined.
(b)Profile of th.e rorm tool~ _
For the work shown in Fig.2l.10 let it be required to determine the profile
of the form tool. The first step in this direction would be·to determined
the radius R of the form tool and the position of its center 0 2 we get a
series of right angled triangles such as POO 1,h'OO 1 etc.
In the /l POO1, we have X2 = r 1cosa ·
·- In the fl P'OO1; we have X2 = r2cosa 1
Where

Tool
Oi

Tool prof II•

Sectionx-x

. Fig.21.10. - . .
Calculations are usually made for a large number of pomts on ~e bne
PP'R' and calculating the dimensions X1, X2, X3. ••·•••• .. etc. 1n .the
manner described above.
 .1. 1 uuu\,,,,11.• v•• A,,.,/&&o •& • - -& -·o - - .. - · · -"'~

To construct the tool profile in radial directioq draw the ·radial line·.xx and
measure the d~mension "l" perpendicular to the line XX the dimension t is equal
toi R1-R2) which fixes the tool profile in the radial direction.

21.07 DESIGN OF MILLING CIJ;TTERS.

Milling is comparative~y faster method of metal removal than is possible with

single point cutting tools. The reason being multiple number of cutting teeth an
· intermittent nature of the tool work contact. Like a single point tool the milling
cutters are -also provided with the various cutting angles. The various angles for
two types of milling cutters are shown in Fig. 1.13 ·

Helix angle: All milling cutters in practice have their tenth set along a helical
path. For light cuts helix angle of 15° is quite common.but for heavy duty_work
helix angle in the range of 45-50° is more common.

Number of Teeth (N):

For HSS cutter above 3 diameter (75 mm) N is given by
N=2D+8 -
D = cutter diameter in inches.
Sometimes for helical mills the number, of teeth could be obtained by the
relation

12.56D . p
N=---cos
D+4d
P = helix angle .
D = depth ofcut-

For cutters having carbide inserts upon the work material.

= 1.5 for C.I.
= 2.5 for Aluminum
= 0.65 for steel
H = H.P. used in cutting
N = cutter speed 'in ,r.p.m.
W = width of cut in inches.
In general the .cutter should be designed so that not more •than two teeth
are e~gag~-in cuttin_g at ~y time. The commonly employed cutter angles
used 10 mllhng are given m the Table XXXIV. · ·
 TABLE -XXXIV
R. ake an2·1es ior milli02 cu tters.
Work H.S.S. Cost alloy Carbide Relief
..
Material
I
cutters cutters cutters anlge,
. de2.
. .
Radial Radial rake Radial rake
rake deg. deg. de2.
Soft CI .10-15 .6-8 · 3--6 4 7
-Soft CI 10 3-6 0-3 .
MS 10-15 3-6 .!!=(--15) 3-5
Al alloys 20-35 1~15 10-15 10-20