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Machine Tools Cutting Tool Classification

A power-driven machine that performs a machining
1. Single-Point Tools
operation, including grinding
– One dominant cutting edge
• Functions in machining: – Point is usually rounded to form a nose radius
– Turning uses single point tools
– Holds workpart
2. Multiple Cutting Edge Tools
– Positions tool relative to work
– More than one cutting edge
– Provides power at speed, feed, and depth that – Motion relative to work achieved by rotating
have been set – Drilling and milling use rotating multiple cutting edge tools
• The term is also applied to machines that perform
metal forming operations

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Roughing vs. Finishing

In production, several roughing cuts are usually taken on
the part, followed by one or two finishing cuts

• Roughing - removes large amounts of material from

starting workpart
– Creates shape close to desired geometry, but
leaves some material for finish cutting
– High feeds and depths, low speeds

• Finishing - completes part geometry

– Final dimensions, tolerances, and finish
– Low feeds and depths, high cutting speeds
Surface roughness and tolerances obtained in various machining processes.
Note the wide range within each process.
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Source: Machining Data Handbook, 3rd ed. Copyright © 1980. Used by permission of Metcut Research Associates, Inc. 4
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Range of dimensional tolerances obtained in various machining processes as

a function of workpiece size.
The range of surface roughnesses obtained in various machining processes.
Note that there is an order of magnitude difference between small and large
Note the wide range within each group, especially in turning and boring.
5 workpieces. 6

Typical production rates for various machining operations

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Disadvantages with machining

• Wasteful of material
– Chips generated in machining are wasted material, at
least in the unit operation
• Time consuming
– A machining operation generally takes more time to
shape a given part than alternative shaping processes,
such as casting, powder metallurgy, or forming

Machining in manufacturing sequence

• Generally performed after other manufacturing processes,
such as casting, forging, and bar drawing
– Other processes create the general shape of the starting workpart
– Machining provides the final shape, dimensions, finish, and
Components manufactured using plastically forming, casting, sintering,
special geometric details that other processes cannot create
and molding and generally resolved using machining operation.
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Why Machining is Important Turning

Operation
• Variety of work materials can be machined
– Most frequently used to cut metals
• Variety of part shapes and special geometric
features possible, such as:
– Screw threads
– Accurate round holes
– Very straight edges and surfaces
• Good dimensional accuracy and surface finish Figure : Schematic illustration of the basic turning
operation, showing depth-of-cut, d; feed, f; and
spindle rotational speed, N in rev/min. Cutting
speed is the surface speed of the workpiece at the
11 tool tip.
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Lathe
General view of
a typical lathe
Operations

Turret Lathe

FIGURE Various cutting

operations that can be
Numerical Control performed on a lathe.

Lathe and Turret

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There are 4 common methods to hold the workpiece in a lathe as

shown in the figure below: (a) mounting between centers, (b) chuck,
Terminology in a turning operation
(c) collet, and (d) face plate.

zoom

FIGURE : Terminology used in a turning operation on a lathe, where f is the feed (in./rev or mm/rev)
and d is the depth of cut. Note that feed in turning is equivalent to the depth of cut in orthogonal
cutting (Fig. 8.2), and the depth of cut in turning is equivalent to the turning is equivalent to the
width of cut in orthogonal cutting.

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Micrographs of feed marks for turning of

austenitic stainless steel The description of feed marks in turning process
under different cutting parameters

using the using the

cutting tool cutting tool
of of
uncoated uncoated
carbide carbide
MC7025 UTi20T
insert  In cutting with a single point cutting tool (such as turning), the tool forming a
insert
spiral profile on machined surfaces when crossing the workpiece, this is
referred to as the feed marks.
 Height of the feed marks can be regarded as the height of surface roughness
and assumed equal to Ra.
 From the figure, it is proven that the feed and cutting tool geometry establish
the Ra value.
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Cutting Conditions
Three dimensions of a machining process:
Cutting parameters
– Cutting speed (v) – primary motion
on turning
– Feed (f )– secondary motion
– Depth of cut (a) – penetration of tool below original work surface
operations

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Cutting Speeds in Turning

WORKPIECE MATERIAL CUTTING SPEED

m/min ft/min
Aluminum alloys 200-1000 650-3300
Cast iron, gray 60-900 200-3000
Copper alloys 50-700 160-2300

Elemen High-temperature alloys

Steels
20-400
50-500
65-1300
160-1600
Stainless steels 50-300 160-1000
Kedalaman potong (a, depth of cut): dasar Thermoplastics and thermosets 90-240 300-800
tebal bagian benda kerja yang dibuang dari benda kerja Titanium alloys 10-100 30-330
proses Tungsten alloys 60-150 200-500

bubut Note: (a) These speeds are for carbides and ceramic cutting tools. Speeds for high-speed steel
tool are lower than indicated. The higher ranges are for coated carbides and cermets. Speeds for
diamond tools are significantly higher than those indicated.
(b) Depths of cut, d, are generally in the range of 0.5-12 mm (0.02-0.5 in.)
(c) Feeds, f, are generally in the range of 0.15-1 mm/rev (0.006-0.040 in./rev).

TABLE : Approximate range of recommended cutting speeds for turning operations.

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FIGURE : The range of applicable cutting speeds and fees for a variety of tool
23 materials. Source: Valenite, Inc. 24