Final Report Perfect

National Institute of Technology, Warangal
Dept. Of Mechanical Engineering
CHAPTER 1
INTRODUCTION
Material removal is one of the major and oldest shaping processes for the economic
production of machine components. Because of the wide use of engineering materials and
alloy steels with high hardness in the aerospace industry, fast and precise machining problems
have attracted much attention in manufacturing. Rapid failure of cutting tool leads to
deterioration of the work piece surface integrity, loss of geometrical tolerances and increase
of machining times.
Consideration of cutting tool life suggests that the following conditions of tool
performance would be highly desirable when attempting to cut metal at a high rate of cutting
speed. [4]
1. A large effective rake angle in so far as the shear process is concerned, a

small actual rake angle from the stand point of strength and heat flow.
2. Positive means for carrying the fluid to the tool point at high cutting speeds as in
the case of journal bearing.
Computer Integrated Manufacturing
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3. The possibility of increasing chip velocity without necessitating a corresponding

increase in cutting speed.
The first item could be accomplished by means of inclination of the tool relative to the
work velocity vector. The second two items can be achieved by providing a sidewise motion
of the tool relative to the work
One of the main features of any material removal process is that a significant portion
of the mechanical energy generated by the interaction of the tool and the workpiece is
converted into heat. In metal cutting, this energy is mainly created by shearing and friction
and is dissipated through conduction of heat into the tool, the workpiece and the chip. This
results in an increase in tool temperature which accelerates the tool wear. Tool wear is not
desirable because both tool life and the accuracy of the machined surface are adversely
affected.
Several methods have been investigated by researchers in order to lower the tool
temperature. In particular, the use of cutting fluids that serve as both a heat transport
mechanism and as a lubricant at the tool-chip interface has been studied and used in practice
today. However, in some cases, its effectiveness is limited by its inability to penetrate the
tool-chip interface. Furthermore, these days, the use of cutting fluids is less desirable because
of its adverse effect on the environment. Some investigations have reported that exposure to
particles generated by evaporation of cutting fluids can cause breathing trouble and skin
irritation.
A novel method to get the sidewise motion is to use a rotating cutting edge in the form
of a disk. This type of device is known as a rotary tool and it provides a rest period for the
cutting edge thereby allowing for the edge to be cooled and a continuously fresh portion of
the edge to be engaged with the workpiece. This enables the tool to get
kinematically induced inclination angle and it is the predominant variable that controls
performance of rotary machining operation.
Page 2
Fig 1-1: Self Propelled Rotary Cutting Process. [6]

Though there is a rapid development of advanced aerospace materials like titanium and
composite materials with improved properties such as strength to weight ratio, the difficulties
in machining of these materials economically and effectively are limiting their applications.
As the development of new cutting tool materials are reaching an optimum level, the attention
of manufacturers all over the world is focused on novel tool designs. One such development
is the rotary tool machining operations i.e. self-propelled rotary tool turning and selfpropelled rotary tool milling operations in which the tool life increases enormously and
aerospace materials can be machined at a faster rate at lesser tool cost than that of
conventional machining operations.
Radial rake angle is considered to be inclination angle in rotary milling cutter which
has great importance while dealing with the mechanics of rotary machining. In face milling
operation lead angle has importance in chip thinning action and this lead angle is variable due
to the circular edge of the insert and depends upon the depth of cut provided.
Fig 1-2: Variation of effective lead angle and average chip thickness with variation in
depth of cut while using round inserts.
Page 3
However, the lead angle of a round insert cannot be truly defined. The effective lead
angle will change throughout the cutting depth. A 3/4-inch diameter (inscribed circle) insert is
shown in Fig 1-2 at a depth of cut of 0.375, 0.250 and 0.125 inch respectively.
As the lead angle changes, the cutting forces are also changing. Where the insert is at
the maximum depth of cut (one half the insert diameter), the axial and radial forces are
balanced. When the depth of cut is reduced, the radial forces decrease and the axial forces
increase. At a very light depth of cut, the forces would be almost totally in the axial direction.
Thus, depending on the setup and part parameters, maximum productivity can be gained with
a round insert cutter by selecting the optimum depth of cut that best controls the cutting
forces.
Ceramic inserts are preferred for rotary milling cutters where ceramic inserts are
capable of machining hardened steels at much higher speeds than conventional carbide cutting
tools due to its high melting point. Rotary milling cutters are built for security and
repeatability at ceramic milling speeds. Modern whisker-reinforced ceramics have a melting
point of more than 2000o C, which means that ceramic inserts can operate at speeds well
beyond the point where carbide tools fail. In fact, whisker-reinforced ceramics work better
above the melting temperature of carbide inserts. Coolant is not recommended for hard
milling applications with ceramic inserts. Ceramic inserts have more strength in compression
and weak in tension due to its high brittleness and it is suggested to provide negative axial
rake angle
Fig 1-3: Rotary milling cutter with single inclination angle [17]
(Rotary Technology Corporation, U.S.A)
Page 4
In DRDL extensive research has been carried out [16] on the performance of rotary
milling operation using the single inclination commercial milling cutter having inclination
angle of 18.5 degrees. Models are predicted and established for the forces and surface
roughness using the milling cutter show in fig 1-3. Inclination angle of the rotary insert is the
major parameter which governs the cutting forces, surface roughness and chip flow direction.
Models can be predicted for the cutting force and surface roughness accurately if we take the
variation of inclination angle in to consideration.
In this thesis an attempt has been made to design and develop a rotary milling cutter
having a provision to accommodate four inclination angles such as 20, 30, 40 and 50 for
the catridge assembly carrying circular insert. Cutter was designed to machine difficult-to-cut
materials like titanium alloys and hardened steels.
Page 5
Chapter 2
LITERATURE REVIEW
2.1. Generalities
Generally, rotary tool turning is a cutting process in which the cutting edge of a round
insert rotates about its axis, so that a continuously indexed cutting edge is fed into the cutting
zone. Compared to a conventional stationary tool or non-rotating circular tool, rotary tool
allows each portion of the cutting edge to be cooled between engagements and makes use of
the entire circumference of the edge which has a positive influence on lowering overall tool
temperature.
Insert rotation can be either externally driven (Driven Rotary Tool) or generated by a
self-propelling action induced by chip formation (Self-Propelled Rotary Tool). Venuvinod et
al. (1981) [25] studied the mechanics of the DRT process. Shaw et al. (1952) [4] investigated
the DRT process and measured the average tool-chip interface temperatures using the toolwork thermocouple technique. Armarego et al. (1994) [10]
investigated the mechanics of both DRT and SPRT processes theoretically and
experimentally.
Like conventional cutting processes, the rotary tool cutting process is classified as
orthogonal or oblique depending on whether the workpiece velocity is perpendicular to the
rotary tool cutting edge or not, respectively. The DRT can be both, whereas the SPRT
Page 6
requires the cutting edge to be at an oblique angle to the cutting speed in order to derive its
motion. The insert rotation about its axis is derived from the cutting force parallel to the
workpiece velocity. Consequently, the static inclination angle i must be non-zero for the tool
to rotate.
In self-propelled tool cutting process, another way to explain the reduction of
temperature could be given. Indeed, in metal cutting the temperature in the tool-chip interface
depends on the balance between the generation and the dissipation of heat. In conventional
cutting, the consumed power is largely converted into heat. In rotary tool cutting, some energy
is required to drive the tool and is turned into kinetic energy. Thus, the heat generation is
reduced.
2.2. Kinematics
Like stationary tools, two motions are important in a rotary tool turning process:
Cutting motion, rotational speed of the workpiece.
Feed motion of the tool into the work piece.
The main feature of a rotary tool is that the cutting insert also rotates. Thus, a third
motion, i.e. rotational speed of the tool, Nr occurs in this process. The consequences of this
characteristic concern the kinematics and the mechanics of the chip formation process.
Indeed, it is obvious that the spin of the round insert deviates the chip flow velocity vector.
Also, the effect of feed rate Vf can be ignored because its value is much smaller than the
cutting speed Vw and Vr. Thus, the following relations between the different velocities can be
derived.
= Vw Vr
Vcr = Vc Vr
Page 7
Consequently, the mechanism is studied in the frame of the tool where the cutting
edge is assumed to be a straight line since the tool radius is large compared to other geometric
parameters (Fig 2-1).
Fig 2-1: Rotary cutting process as observed from fixed point (a) in space,
(b) on tool. (Armarego et al., 1994) [10]
Armarego et al. (1994) carried out investigations in order to understand the
fundamentals of the rotary tool cutting processes. Studying operations for machining a tube,
they related rotary tool processes to the better known orthogonal and oblique cutting
processes and developed mechanics of cutting models for these new processes. They
performed a theoretical investigation and validated their model trough experimental
investigation. When the rotary tool and the tube diameters are large compared to the tube
thickness and the feed speed is negligible compared to the cutting speed, the rotary tool can be
represented by a straight cutting wedge tool of constant normal rake angle.
As pointed out earlier, all rotary tool processes can be classified into three basic types:
driven orthogonal rotary operation, driven oblique rotary operation and selfpropelled rotary
operation. If the angle between the cutting velocity Vw and the normal plane Pn (called static
inclination angle) is equal to zero then it is called orthogonal otherwise, it is called oblique.
Thus, there exists only one way to get a driven orthogonal rotary operation, i.e. the
tool has to be on centre. For the self-propelled, there are two possibilities. On one hand, the
tool can be tilted. On the other hand, it can be set above or below centre. For the driven
oblique process, the tool is not inclined but is set above or below centre. The different cases
are presented in Figure 2-2, 2-3 and 2-4.
Page 8
Nationnal Institute of
o Technology
y, Warangal
Dept. O
Of Mechanical Engineeringg
Fig 2-2:: Tool on ceentre, orthoggonal driven

n rotary too
ol cutting roocess (Armaarego et al.,
1994) [10]
Fig 2-3: Tool abo

ove and beloow centre, driven
d
or sellf-propelledd Oblique ro
otary tool
Proccesses (Arm
marego et al, 1994) [10]
Fig 2-4:
2 Tilted to
ool, self-proopelled obliique rotary tool
t processs
(Armaregoo et al., 1994
4). [10]
Compputer Integrateed Manufacturring
Page 9
o Technology
y, Warangal
Dept. O
22.2.1. Drivven obliqu

ue rotary tool cuttiing proceess
T
The kinemattics of this process is studied firsst. Indeed, it may be coonsidered as
a a generall
case for reasonss explained later. As m
mentioned earlier, the mechanism
m
has to be studied bothh
s
and in
n the framee of the tooll. In Fig 2-3
3, the tool iis set abovee centre andd
in the absolute space
driveen in a clocckwise direection as viiewed from
m the top. In this casee Vr is assu
umed to bee
posittive. Thus, the
t workpieece velocityy Vw and th
he walls of the tube (aassumed to be straight))
are innclined to the
t normal plane Pn bby the staticc inclination
n angle is; the processs is obliquee
rotarry. The orieentation off the relativve or resulttant workpiece velociity V is giv
ven by thee
inclinnation anglee i with resp
pect to Pn. IIn Fig 2-5(aa) to (e), configurationns of the driv
ven obliquee
rotarry tool are simulated ass Vr varies ffrom a posittive value to
o a negativee value (thee spin of thee
tool iis reversed)). When Vr is equal to zero, the ro
otary tool beecomes a staationary too
ol as shownn
in Fig 2-5(b). Also,
A
in this case, the drriven obliqu
ue process is identical tto the classiical obliquee
cuttinng process as
a in Fig 2-5(b) & (g).
Fig 2-5: Driven oblique rotary tool and co

orresponding
g equivalenntclassical
marego et all., 1994). [10]
processes (Arm
Page 100
o Technology
y, Warangal
Dept. O
22.2.2. Drivven orthogonal rottary tool cutting

c
prrocess
When thhe rotary too
ol is set on centre (i.e. static inclin
nation anglle is equal to zero) andd
driveen, the proccess is considered to bee a driven orthogonal
o
rotary tool process. Th
he absolutee
veloccity Vw is parallel to Pn but the relative velocity V is inclined too Pn by the inclinationn
anglee i whose both
b
magnittude and diirection dep
pend on tho
ose of the to
tool rotation
nal velocityy
Vr. In Figure 2-6,
2
both driven
d
orthoogonal rotaary tool pro
ocess and itts equivalen
nt classicall
orthoogonal cutting process are shown aas Vr variess from a possitive value to a negativ
ve value.
When thhe tool is seet on centre and not driiven but freee to rotate about its ax
xis, the tooll
couldd be self-prropelled. Ho
owever, as shown in Fig
F 2-6(b) & (e), this phenomeno
on does nott
occuur. In this caase, the driven orthogonnal rotary prrocess is peerfectly equiivalent to
the cclassical orthhogonal cuttting processs and the reesultant forcce lies in thhe normal plane so thatt
no siide force along
a
the cu
utting edge can propel the tool. Thus, the oorthogonal rotary tooll
proceess must bee driven by an
a external source.
Figg 2-6: Driveen orthogon

nal rotary toool and corresponding equivalent
e
classical processes
p
(Armaarego et al.,, 1994). [10
0]
Page 11
2.2.3. Self-propelled oblique rotary tool cutting process

Contrary to the former process, this process has to be oblique in order to allow the
rotation of the tool. As pointed out earlier, one way to get tool motion is to set it above or
below centre. If the rotary tool is free to rotate and is set above centre so that is not equal to
zero, the cutting action will result in a force along the cutting edge which will propel the tool
counter-clockwise (negative Vr) until an equilibrium position is achieved where no side force
acts along the tool edge (assuming the rotary tool axis can rotate freely with no friction and
chip transportation requires no additional energy). This condition occurs when the relative
velocity V lies in the normal plane (inclination angle is zero) as shown in Fig 2-6. Thus, the
equivalent process is a classical orthogonal process. When the tool is set below centre, the
static inclination angle is becomes negative, the inclination angle i is zero, and the tool is
propelled clockwise.
The other way to propel the tool is to give an effective negative rake angle to the
tool. Thus, the tool is again driven by the chip in a counter-clockwise direction. This tilted
position of the tool is similar to the one where it is set above centre. Also, some tools are
inclined in two directions, around the workpiece axis and around the axis normal to the latter
(effective negative rake angle).
Table 2-1: Rotary tool and corresponding equivalent classical processes.
Self-propelled
Rotary tool processes
Driven oblique
Corresponding
equivalent classical
cutting processes
Oblique
Driven Orthogonal
Oblique;
(Oblique)
Orthogonal
Orthogonal if Vr=0
Page 12
2.3. Machining of Difficult-To-Cut Materials

Conventional methods of machining hardened materials usually involve rough
machining of the annealed workpiece followed by heat treatment, grinding and superfinishing
or honing. The main issues with this multi-step process are obviously its high cost and time.
Also, this process requires several machines for each operation. Hard turning refers to single
point machining of materials approximately 45 HRC and higher using extremely hard, wearresistant cutting tools such as polycrystalline cubic boron nitride (PCBN) or ceramics. This
process can yield material removal rates close to rough machining and surface characteristics
comparable to grinding, using a single machine tool. This provides an attractive alternative to
the conventional machining sequence because the number of operations is reduced and the
entire machining process can be performed after heat treatment. Moreover, machine tools
used for hard milling are typically cheaper than those used for grinding and chips generated
during hard milling are easier to recycle than grinding swarf. Therefore, hard machining
provides cost savings and environmental advantages when used as a replacement for grinding
operations.
Titanium alloys are considered to be difficult-to-cut materials. Properties of EN24 (alloy
steel) like low specific heat, and tendency to strain-harden and diffuse between tool and work
material, give rise to certain problems in its machining such as large cutting forces, high
cutting-tool temperatures, poor surface finish and built-up- edge formation and EN24 at
hardened state, above 40 HRC considered as difficult-to-cut material.
2.4. Importance of Round and Ceramic Inserts

The shape of an insert has a major influence on the impact resistance of the carbide.
The weakest section of a milling insert is the corner, which is exposed to constant interrupted
cuts and extreme heat changes. Since a round insert has no corners, it is more secure than any
other shape.
Consider the tremendous forces that are placed on a milling insert in a typical cut. As
the insert enters the cut, it is subjected to a large compressive load. The initial contact
between the cutting edge and the workpiece may be very unfavorable depending on the
position of the cutter in relation to the workpiece. As the insert moves through the cut, the
Page 13
chip thickness is constantly changing, varying the radial and axial cutting forces. Finally, as
the insert leaves the workpiece, it is subjected to tensile stresses that break down the carbide.
The chip bending away from the insert places large tensile or "ripping" stress on the face of
the carbide.
One major reason for the success of the round insert in so many applications is that the
axial and radial cutting forces can be managed by changing the axial depth of cut. A high
radial cutting force can cause vibration and chatter. Conversely, a high axial force can cause
the workpiece to move in its fixturing and cause poor tolerances. With the use of traditional
milling cutters, the lead angle dictates the kind of cutting force produced.
Another reason the round insert cutter is so widely used is the high table feeds that can
be attained. This is due to the chip thinning effect of the round cutting edge. Chip thinning is
what happens when you increase lead angle of the tool. The greater the lead angle, the thinner
the chip since it is distributed over a greater length of the cutting edge. Therefore the insert
load will be reduced allowing for higher feeds per tooth and superior metal removal rates. In a
tool with no lead, the chip thickness is equal to the feed per tooth. Round insert cutters, like
all lead angle cutters, have a change in chip thickness when feed per tooth is changed. But
unlike other lead angle cutters, the chip thickness for a round insert is also affected by a
change in depth of cut. High velocity milling cutters are built for security and repeatability at
ceramic milling speeds. Modern whisker-reinforced ceramics have a melting point of more
than 2000o C, which means that ceramic inserts can operate at speeds well beyond the point
where carbide tools fail. In fact, whisker-reinforced ceramics work better above the melting
temperature of carbide inserts. Coolant is not recommended for hard milling applications with
ceramic inserts.
Ceramic inserts are capable of machining hardened steel at much higher speeds than
conventional carbide cutting tools. Combine the higher operating speed with the proper
feedrate and a healthy step-over and the shop can achieve some impressive metal removal
rates. Another key factor in increased production rates when hard milling is the cutter density.
Every additional tooth in a cutter increases the cross feedrate. Higher speed and more feed
add up to lower cycle times.
Page 14
The surface finish achieved by rough milling with ceramics leaves less work for a
finish milling operation, and reduces finishing and polishing time. Milling at relatively light
feedrates in hardened steel with carbide usually leaves a good finish, but many times with
ceramic inserts the rough finish is even better than the required finish. In some cases,
additional milling, grinding and polishing can be eliminated.
2.5. Hard Milling with Ceramic Inserts

Proper application of speed and feed for the material hardness are critical factors for
good tool life when hard milling with ceramic inserts. Unfortunately, depth- and width-of-cut,
as well as cutter lead angle, are commonly overlooked. A basic understanding of how these
factors influence tool life can make a huge difference in metal removal rates. If a tool is
running with the incorrect chip load or at inefficient speeds and feeds, it not only sacrifices
tool life, but productivity as well. When considering all of the factors, productivity increases
and decreases can be astounding with small changes in cutting parameters. [11]
2.5.1. Cutting speed

The cutting speed necessary for successful hard milling with ceramics is based on the
actual material hardness, usually in the 4565 Rockwell C hardness range. At elevated
temperatures the metal being machined becomes plasticized, or softened, which lessens the
cutting forces, and aids in chip separation. To take advantage of the strength and hardness of a
whisker-reinforced ceramic insert, it is necessary to run at a surface speed
high enough to create sufficient heat in the cutting zone, which may be as much as five times
the cutting speed of conventional carbide.
Successful cutting with ceramic inserts demands high surface speed coupled with
balanced feed rates. High speed cutting is necessary to generate the high heat within the
cutting zone and to assure that the heat propagates into the workpiece immediately ahead of
the cutter.
This is not to suggest that hard milling with ceramic inserts requires a new high-speed
machining center with 50 horsepower and the latest advanced processor. The speed necessary
Page 15
for milling hardened materials with ceramics is within the range of many of the machines in a
modern shop. The horsepower consumption is actually quite low due to the low cutting forces
being generated.
In general, a conservative approach to cutting speeds and feeds is the single largest
contributor to process failure when trying to implement ceramic cutters. When cutting speeds
are too slow, insufficient heat is generated. Because heat cannot be transferred ahead of the
cutter, in effect, to anneal the already hardened workpiece, cutting forces become too high and
insert failure occurs.
2.5.2. Feed
Before programming a hardened part, it is important to consider the factors that
influence the difference between the programmed feedrate per tooth and the actual thickness
of the chip being formed. The feed per tooth specified in the program can be dramatically
reduced by the cutting conditions. The actual thickness of a chip being formed is affected by
the depth- and width-of-cut as well as the insert radius or the lead angle of the tool.
Actual chip thickness is a crucial factor for heat dispersion (i.e., the chip must have
enough mass to carry away a majority of the heat). When the depth- and/or width-of-cut is
below an acceptable level, the chip generated will not be thick enough to carry away all of the
heat being produced by the cut. Heat that is not absorbed by a thin chip has to go somewhere.
It will be pushed into the part, the inserts, the cutter and the fixture. It is much more efficient
to send the largest portion of the heat away with the chips.
Page 16
2.6 Different Angles in Face Milling and their Importance
Table 2-2: Function and effects of different angles in face milling
Type of Angle
Function
Axial Rake Angle
Determines chip disposal

direction.
Positive: Excellent machinability.
Radial Rake Angle
Determines sharpness.
Negative: Excellent chip disposal.
Corner Angle
Determines chip thickness.
Large: Thin chips and small cutting impact.

Large back force.
True Rake Angle
Determines actual sharpness.
Positive (large): Excellent machinability.

Minimal welding. Negative (large): Poor
machinability. Strong cutting edge.
Cutting Edge
Inclination
Determines chip disposal

direction.
Positive (large): Excellent chip disposal.

Low cutting edge strength.
Effect
Page 17
2.6.1. Lead angle

The lead angle of a round insert cannot be truly defined. When the tool is used at
different depths of cuts, the lead angle changes with the depth of cut. The lead angle can be
measured at the depth-of-cut line.
Fig 2-8: Variation of cutting forces and effective lead angle

with variation in depth of cut while using round inserts
As the lead angle changes, the cutting forces are also changing. Where the insert is at
the maximum depth-of-cut (one half the insert diameter), the axial and radial forces are
balanced. When the depth of cut is reduced, the radial forces decrease and the axial forces
increase. At a very light depth of cut, the forces would be almost totally in the axial direction.
Thus, depending on the setup and part parameters, maximum productivity can be gained with
a round insert cutter by selecting the optimum depth of cut that best controls the cutting
forces.
2.6.2. Radial rake angle

Generally more radial rake angles are provided to the rotary milling cutters and climb
Milling is especially desirable with milling cutters having a high radial rake angle. The high
radial rake angle weakens the tooth because it is relatively thin. The forces imposed on the
tooth during conventional milling are in a direction that will cause the tooth to deflect because
it has no support to oppose the forces. On the other hand the forces imposed on the insert
during the climb milling are in a direction more parallel to the tooth body, thus giving added
support to prevent deflection to the cutters designed for high metal removal rates.
Page 18
2.7. Rotating Inserts

Rotating inserts have been around for fifty years or so. The inserts are mounted on
thrust and radial bearings, which allow them to rotate freely. This rotation creates a slicing
action that, combined with the continuous change of the cutting edge zone exposed to the
metal-removal process, leads to lower temperature, improved tool life resulting from
distribution of tool wear around the entire insert circumference, lower machining forces and
power requirements, and better surface finish. [13]
Limitations of the tooling have been reliability issues arising from the bearing system,
excessive size of the insert-holding cartridges, higher initial cost of the cutter and inserts, and
a lack of effective analytical tools for cutting tool design.
Fig 2-9: Rotating Insert [13]

Rotary Technologies' development is a compact cartridge system for housing the
bearings consisting of a stator surrounded by a thrust bearing and needle roller bearing. The
bearings allow the rotor to rotate under the action of cutting forces. Inserts are mounted on the
rotor and locked in place using a lock nut. A dovetail on the bottom of the stator enables the
cartridge to be guided in the tool and locked in place using a clamping mechanism. Cartridges
are sealed using O-rings that prevent contamination of the bearings by cutting fluids or chips.
The advantages of rotary-insert tools depend entirely on the fact that the insert rotates
during the cutting process, propelled by forces generated during the machining process.
Rotary-insert tool design is complicated by the fact that the machining forces creating the
insert torque are a complex function of a number of variables and need to be high enough to
overcome the friction inherent in the cartridge bearings.
Page 19
2.8. Geometrical Analysis of Rotary Machining and Influence of

Inclination Angle
2.8.1.
Effect of feed rate on the chip cross-sectional area
Feed
r
Depth of cut
Fig 2-10: Model to demonstrate the effect of

feed rate on the chip cross-sectional area [2]
The feed rate influences the both cutting force and feed force components
significantly. An increase in the maximum cutting and feed forces with increasing feed rate is
analogous to the traditional relationship during machining with stationary tools [2]. It could
be due to an increase in the cross-sectional area of the uncut chip. In Fig 2-10 variation of
uncut chip cross-sectional area with feed rate was demonstrated.
2.8.2. Effect of depth of cut on surface irregularities

Rotary insert
Machined surface
Depth of
cut=1mm
Height of surface
irregularities
Feed
Depth of cut = 0.5mm
Fig 2-11: Model to demonstrate the effect of depth of cut on surface irregularities
Page 20
The influence of depth of cut can be explained with the help of a model for surface
irregularities shown in Fig 2-11. As evident from the model, a change in depth of cut does not
contribute directly to the change in height of surface irregularities and hence the surface
roughness [7], but increase in depth of cut after certain limits will lead to vibrations during
machining and deteriorates the surface finish significantly.
2.8.3. Differences in the cutting action of stationary and rotary inserts

The rotary inserts differ from that of the stationary inserts on three accounts.
1. Geometry of insert
2. Geometry of the cutter
3. Insert rotation
1. Geometry of insert: The diameter of the round insert used in a rotary tool operation is
analogous to the tool nose radius of a stationary insert. Usually, the diameter of a round insert
is very large (27 mm) as compared to the tool nose radius (usually of the order of 0.8 mm). It
changes the geometry of cut and the lead angle on the milling cutter and consequently
influences the cutting forces. [3]
2. Geometry of cutter: The rake angle provided on the round insert is analogous to the axial
rake angle on a stationary insert. Similarly, the inclination angle of a round insert is analogous
to the radial rake angle on a stationary insert. It also changes the geometry of cut and
consequently the cutting forces.
3. Insert rotation: It changes the nature of friction at the tool-chip and tool-work interfaces
and hence the cutting forces. In rotary tools, as the insert rotates, the rake surface is
continuously moved under the chip unlike the stationary rake face in a conventional milling
cutter. Similarly, at the tool-work interface, a rotary insert has two relative motions, one, due
to the rotation of milling cutter and the other due to the insert rotation. In the case of
stationary inserts, the second motion is not present.
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2.8.4. Effect of inclination angle on the magnitude of cutting forces

It is observed from the schematic in Fig 2-12 that the inclination angle influences two
(Fx and Fy) of the three force components. The third force component, Fz remains unaffected.
Therefore, the modified equations to predict cutting forces after incorporating effect of
inclination angle are given as below: [3]
---------------
(i)
The instantaneous X, Y and Z-force components at the cutter (considering only

one round insert) will now be given as:
--------------
( ii )
By substituting Eq. ( i ) in Eq. ( ii ) we will get a set of basic equations to predict cutting
forces, which includes the effect of inclination angle.
FT
FR
Rotary Insert
FR
Y
FT
X
Z
Fig 2-12: Effect of inclination angle on cutting forces in rotary face-milling
Page 22
Chapter 3
MODELING OF ROTARY MILLING
CUTTER ASSEMBLY
3.1. Conceptual Design

Inclination angle is the major parameter to study the rotary milling performance
profoundly and inclination angle is equal to the radial rake angle in face milling insert
geometry. Four inclination angles 15, 25, 35 and 45 degrees are considered and a model is
proposed as follows. Cutter body has to hold a round insert which is able to rotate around its
own axis. Initially milling cutter body model is proposed to accommodate four inclination
angles without considering provision to hold the rotary inserts.
Fig 3-1: Proposed model with different inclination angles
Page 23
This model has to hold the rotating catridge assembly designed by rotary corporation
technology [17]. Model proposed is changed to suit the catridge assembly by providing the
dove tail slot and v-groove. These dimensions are extracted from the commercial rotary
milling cutter by inspecting it under flash microscope and coordinate measuring machine in
metrology department. Cutter body model concept is designed by considering the importance
of different inclination angles and radial distance of the cutting tip from the centre (55mm).
Pockets are provided on the cutter to get some similarities and uniform ness in slot
dimensions for the clamps. Axial rake angle of 4.5 was provided on the catridge and fixed.
Internal bore diameter was fixed by considering the weight of the cutter and it is designed to
suit 40mm morse taper shank.
3.2. Components of the Rotary Milling Cutter Assembly
Rotary milling cutter body has to hold the catridge assembly which requires two
clamps, front clamp and rear clamp respectively having internal left hand threads. Studs with
left hand and right hand M6 threads on respective sides are provided to make sure the clamps
are tightly holding the catridge by locking mechanism. Front clamp is designed to push the
catridge towards the cutter body to overcome the inevitable play in dovetail slot and rear
clamp will hold the catridge tightly. Rotary corporation technology designed the catridge
assembly with advanced bearing materials which assures negligible wear inside the bearing
system.
1. Cutter body
2. Front clamp rear clamps
3. Studs (2)
4. Catridge Assembly
3.3. Pro-E Model

Pro-E is the modeling software used to develop the 3-D models of the cutter assembly
components. All the components are modelled according to the designed dimensions and
assembled. Components are assembled with 10-2microns to ensure the gluing operation should
be done during stress analysis. Care was taken during model cutter body to ensure the cutting
tip should be at constant radial distance from the center.
Page 24
Proper planes are created and slots are made to ensure the forces on to the clamps
should be axial and minimum bending moment occurs. Threaded holes are drilled to the
maximum possible deep. All the manufacturing drawings for the cutter body are extracted
from this model and for other components manufacturing drawings drawn in AUTO
CAD2010. Catridge assembly is modeled to replicate the original catridge. Rotary milling
cutter assembly model is shown in Fig 3-2 and exploded view was shown in Fig 5-7.
3.4. Work Material for the Cutter Components

EN24 (BS 970 817M40) (SAE 4340)
EN24 is a high quality alloy steel and it combines high tensile strength, shock
resistance, good ductility and resistance to wear at defined hardness. It is supplied as black
round shape in annealed condition and readily machineable and hardness of the raw material
is around 20 HRC. It is nickel chromium molybdenum steel with high strength and toughness
used for heavy duty gears, axles and high strength studs. Due to its extreme resistance to
impact loads at 32 HRC we choose it as work material for cutter components.
Page 25
3.4.1. Composition
Table 3-1: Composition of EN24
Table 3-2: Strength and impact values of EN24 at different hardness values
Tensile Strength Yield Stress

2
( N/mm )
Impact Izod (J) Impact KCV (J) Hardness HB
(N/mm)
850/1000
654
40
35
248/302
850/1000
680
54
50
248/302
925/1075
755
47
54
269/331
1000/1150
850
47
42
293/352
1075/1225
940
40
35
311/375
1150/1300
1020
34
28
345/401
1550
1235
10
444
Milling cutter should have resistance to impact loads and EN24 is having maximum
resistance to impact at the hardness around 32 HRC according to the table 3-2. Heat treatment
cycle for EN24 was hardening followed by tempering to 32 HRC and it requires through
hardening process to attain uniform hardness throughout the volume.
3.4.2. Through Hardening

Through Hardening is a process used to produce high strength and good toughness
when the entire part needs to be hardened. In through hardening, the metal is heated to form
Page 26
austenite, and then quenched to transform the austenite to martensite, which has a much
harder microstructure. Then the part is tempered to the defined temperature to attain the
required hardness. Tempering between 250C-375C is not recommended as this can
seriously reduce the steels impact value.
Page 27
Chapter 4
STRESS ANALYSIS OF MILLING
CUTTER ASSEMBLY
Rotary milling cutters are designed to machine difficult-to-cut materials and for
intermittent cutting operations. Impact loads coming on to the cutter are significant.
Theoretically basic rotary machining operation is studied for rotary milling cutters and forces
are calculated using standard values of the specific cutting energy values (Appendix-1) of the
different materials. Cutter assembly model in CATIA V5 is imported to ANSYS9 and stress
analysis was carried out. Stress analysis was carried out in static condition of the cutter body
and factor of safety six to seven is provided. All the dimensions are fixed to minimize the
weight of the cutter and it is 4.2 kg.
Specifications of Milling Cutter
1. Outside diameter
150 mm
2. Effective diameter
110 mm
3. Bore diameter
40 mm
4. Thickness
52 mm
5. Insert diameter
28 mm
6. Inclination Angles
15, 25, 35 and 45
Page 28
o Technology
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Dept. O
4.1. Theoretical Calcu

ulation of Forces
Forces inn rotary millling operattion are low
w when com
mpared to the
he conventio
onal millingg
me conditions due to thhe rotary motion
m
of the insert. Frrictional forrce betweenn
operaation at sam
chip and insert are negligiible due to the insert rotation. Paart of the taangential fo
orce on thee
hree componnents Tangential forcee
inserrt is used too rotate the insert. Forcces are diviided into th
(Ft), Radial forcce (Fr) and Axial
A
Forcee (Fa). Ratio
o of the cuttting forces vary with the depth off
cut ddue to the vaariable lead
d angles but here we fix
xed the max
ximum depthh of cut as the
t 25 % off
the m
maximum poossible deptth.
S Area Chipp cross-sectiional area
Cuutting Force (Ft) = Speecific Cuttinng Pressuree x Chip C/S
Fig 4-1:
4 Geomeetry of chip in rotary miilling
4..1.1. Areaa of chip cross

c
sectiion in rottary millin
ng operattion
and
Page 299
o Technology
y, Warangal
Dept. O
W
Where,
C
Cutting Forcce (Ft)
ft
= feed/inserrt
= Depth of cut
Di
=
=Diameter of Insert
=
=Inclination
n Angle
Specific Cutting Preessure x Chiip C/S Areaa
KFss *
Coss (i)
(K
KFs of diffeerent materiaals are ment
ntioned in APPENDIXA
-1)
F
Ft: Fr: Fa
= 1: 0.7: 00.4
R
Radial Forcee (Fr)
= 0.7 (Ft);;
Axiial Force (Fa) = 0.4 (FFt)
4.2. Stress An
nalysis off the Assem
mbly
Rotaary milling cutter
c
assem
mbly model from PRO--E is importted to the AN
ANSYS914.5
5 and in pree
proceessor all thee material properties
p
aare given an
nd all the co
omponents aare glued according too
the pphysical relaationship off respective componentts. Tetrahed
dral elementt was chosen
n due to thee
compplexity of thhe componeent. Elemennt side length is taken according tto the comp
ponent suchh
that ttotal numbeer of elemen
nts not to exxceed 2, 00,000.
Distortioon energy th
heory was cconsidered for
f compon
nent failure. The distorrtion energyy
perr unit volum
me at a poin
nt is a functiion of singlle stress com
mponent caalled von-miises normall
streess. This is the
t single descriptor
d
off the stress condition
c
att a point.
Page 300
Work material
EN24
Youngs modulus
2.12e MPa
Poisons ratio
0.3
Tensile strength of the material
1050 MPa
Yield stress
755 MPa
Fig 4-2: Meshed view of rotary milling cutter using Hypermesh.
4.2.1. Boundary Conditions

All degrees of freedom for the surfaces coming into direct contact to the milling shank
are fixed i.e. surfaces on the shank which are taking load from cutter body.
Page 31
4.2.2. Load Conditions

Fc = 2550 N
Fr = 1785 N
Fa = 1020N
Where,
Fc = Force Component Perpendicular to Insert,
Fr = Force Component Tangential to Insert,
Fa = Force Component Perpendicular to Fc & Fr
4.2.3. Maximum Load Conditions

Initially a set of experiments are conducted using
the imported rotary milling cutter
developed by Rotary Technologies Corporation. The experiments are conducted based on

minimum and maximum levels of cutting speed and feed, keeping depth of cut constant. The
experimental values of various cutting forces are shown below in the table
The experiments are performed using the rotary and vertical milling machining centre (VMC).
The radius of the rotary insert considered is 14 mm (nearly).
Experiment
No.
Speed
(rpm)
Feed
(mm/min)
Depth of cut
(mm)
Force Fx
(N)
Force Fx
(N)
Force Fz
(N)
40
40
0.9
2157
1561
1358
40
80
0.9
3946
2758
2355
100
40
0.9
1161
871
827
100
80
0.9
2039
1504
1363
From the table it can be observed that maximum cutting forces obtained for Fx, Fy and
Fz are 3946 N, 2758 N and 2355 N respectively. Hence the maximum cutting forces are
Fx = Ft = 3946 N
Fy = Fr = 2758 N
Fz = Fa = 2355 N
Page 32
By comparing both theoretical and practical load conditions, it is clear that the maximum
load conditions from experiments are higher. So we take these forces into account while stress
calculations in our ansys analysis.
4.2.5. Stresses in cutter body (Von-mises stresses)

Maximum Stress = 119.28MPa
4.2.6. Stresses in front clamp (Von-mises stresses)

Maximum stress= 12.16 MPa
Maximum stress = 83.78 MPa
Page 33
4.2.7. Stresses in stud (Von-mises stresses)

Maximum stress= 14.26MPa
4.2.8. Stresses in Pin (Von-mises stresses)

Maximum stress= 14.19MPa
Page 34
The maximum stress developed on the cutter body with single rotary cartridge was
very minimum and found to be around 120 MPa where as the yield strength of the cutter
body material is 755 MPa. Hence the design of cutter is having a factor of safety of about 6.3
and the design is found to be very safe.
Page 35
Chapter 5
MANUFACTURING OF ROTARY MILLING CUTTER
COMPONENTS
Rotary milling cutter is designed and modeled to hold the catridge assembly at
different inclination angles. Manufacturing drawings (APPENDIX-2) are extracted from the
model by freezing the model at different stages and close tolerances were provided. Sequence
of operations (APPENDIX-3) prepared according to the different stages of manufacturing.
Rotary milling cutter assembly comprises cutter body, catridge assembly, rear clamp, front
clamp and studs.
Generally milling cutter is subjected to impact loads and cutter components should
have enough resistance to impact loads. EN24 (SAE 4340) is the work material and it is a high
quality alloy steel supplied readily in machineable condition. It combines high tensile strength,
shock resistance, good ductility and resistance to wear after proper heat treatment. We can
achieve required hardness more precisely and accurately.
Page 36
Machine tools allotted in process plan

1. Center Lathe
2. Vertical milling machine
3. Surface grinding machine
4. Cylindrical grinding machine
5. Universal milling machine
6. Vertical machining center (VMC)
7. CNC milling machine
8. Schaublin CNC lathe
9. Wire electric discharge machine (WEDM)
10. Jig grinding machine
11. Conventional milling machine
12. Copy milling machine
Different Stages of Manufacturing:

5.1.1 Stage one operations
Operations Involved: Turning, Facing, Taper Turning, Drilling,

Reaming, Boring, Counter Boring, Slot Milling,
Surface Grinding and Cylindrical Grinding
Page 37
5.1.2 Stage two operations
Operations Involved: pocket milling using mastercamon

bridgeportVertical machining Center
5.1.3 Stage three operations
Operations Involved: Drilling, End Milling, Flat Drilling,

Reaming and Tapping
Page 38
5.1.4 Stage four operations
Operations Involved: Wire EDM Using AUTOCAD Drawing,

Welding and Jig Grinding
5.2 Important Machining Operations

5.2.1 Vertical Machining Centre: End milling operation was done on this machine
using Mastercam to produce the pockets. 4-pockets on the component dont have any proper
references to do manually. Model of the component is given at this stage and uploaded to the
computer connected to the VMC.
Pocket
Fig 5-1: Model given to the shop floor for pocketing operation
Page 39
Program was developed using mastercam and after positioning the component on the
table similar to the position of model in computer by dialing the bore & reference holes
provided on the component machining was done.
5.2.2 Universal Milling Machine: All 8-slotted holes are radially at different angles
and different offsets. Each hole is at different offset from radial axis. On universal milling
machine we can do this operation by swiveling the table about both the axes.
Fig 5-2: Threaded hole and slot whose axis is offset to the radial axis.
Fig 5-3: Cross section of the cutter body
Page 40
5.2.3 Heat Treatment Cycles: Milling cutter should have resistance to impact loads
and EN24 is having maximum resistance to impact loads at the hardness around 32 HRC
according to the table 3-1. Heat treatment cycle for EN24 was hardening followed by
tempering to 32 HRC and it requires through hardening.
Through Hardening is a process used to produce high strength and good toughness when
the entire part needs to be hardened. In through hardening, the metal is heated to form
austenite, and then quenched to transform the austenite to martensite, which has a much
harder microstructure. Then the part is tempered to the defined temperature to attain the
required hardness.
Heat Treatment Cycle for EN24 to get 32 HRC
Hardening:
Heat the component to 840/860C in electric furnace. Soak the component for two hours to
attain uniform temperature. Quench in oil. Now it is in martensite state and material has
extreme brittleness and hardness. Internal holes and slots should have to fill with chalk
powder to avoid oxidation during heat treatment. Furnaces are controlled by digital process
controllers to ensure accurate process temperatures and reproducible results.
Tempering:
Heat the component to 600C temperature and hold the temperature for two hours to attain
uniform hardness. Take out the component from the furnace and allow the component to cool
in standstill air to attain ambient temperature. Pickling operation is carried out to clean the
oxides formed on the surface of the components.
5.2.4 Wire Electric Discharge Machine (WEDM): Wire cut operation is next to heat
treatment to avoid inevitable distortions to the dove-tail slot which suits the standard catridge
assembly. Profile of the wire cut path in Auto CAD file was uploaded to the machine
according to the true scale. Component is positioned on the frame of the WEDM similar to
the position in uploaded drawing by dialing the internal bore and reference holes.
Page 41
Fig 5-4: Slot produced in wire cut operation
During wire cut speed of the wire is in the range of (0.35-0.80) mm/minute. For each slot
it took 3 to 4hrs. Accuracy depends upon the position of the component clamped respective to
the position of the input drawing.
5.3 Manufacturing of Clamps and Studs

EN24 is the work material for the components. Round 30 40 mm work pieces are
machined on FN2 milling machine to get the size 201236 mm for the clamps and Round
10 120 mm size directly taken for the studs.
Clamps 2-D profile is given as the path of the tool in program and uploaded to the
machine. 6mm end mill is used for the machining. After machining the required height of the
clamp, left hand tap is rotated. Remaining part of the block is removed from the clamp using
saw in fitting shop and surface is grounded on the surface grinding machine. For rear clamp vgroove is suited to the drawing in fitting shop.
Studs are having left hand and right hand threads on respective side. Initially
workpiece is machined to size of outer diameter of the threads on precision lathe. Studs are
designed to uniform strength and hence remaining length in between the RH & LH threads
machined to inner diameter of threads. Using the standard 1mm pitch special purpose insert,
Page 42
threads are machined on schaublin CNC lathe by uploading the program and are matched with
the standard M6 thread gauges. Slot on the stud is machined on the copy milling machine
using 2mm end mill.
Rear Clamp
Front Clamp
Stud (LH/RH)
Fig 5-5: Rear clamp, Front clamp and Stud.
5.4 Milling Cutter Assembly and Components
Fig 5-6: Exploded view of the rotary milling cutter assembly
Page 43
5.5. Scheme of Measuring the Inclination Angle (i) on CMM
In rotary face milling operation inclination angle (i) is defined as the angle between
cutting velocity vector and axis of rotation of the insert. Cutting velocity vector is tangential
to the effective diameter of the cutter at the tool workpiece contact point. Geometrically this
inclination angle is equal to the angle between the plane containing the cutting edge and radial
axis passing through the point of intersection of plane containing cutting edge and axis of
insert rotation as shown in Fig. Inclination angle was measured for the 30 slot in fabricated
rotary milling cutter using Coordinate Measuring Machine (CMM).
Axis of Insert Rotation
i = Inclination Angle
Fig 5-7: Inclination angle in rotary face milling cutter

Step1: Selection of reference plane. By touching the probe on different points of the grounded
surface of the cutter body reference plane was selected.
Page 44
Step2: Location of vertical axis of cutter body. By touching the different points on the inner
bore of the cutter axis was located.
Step3: Location of insert rotating axis. By touching the different points on cylindrical part of
the catridge body axis was located.
Step4: Location of cutting edge plane. By touching the probe on different points on the
circular cutting edge, plane containing cutting edge was located.
Step5: From the plane of cutting edge and axis of insert rotation intersection point was
located. Vertical axis passing through this point is the axis to change the inclination angle of
the insert. This is the neutral axis for all slots to guide catridge assembly and passing through
the pitch circle of 110mm diameter.
Step6: Inclination angle was measured between the plane of cutting edge and radial line
passing through the intersection point of cutting edge plane and axis of insert rotation.
Measured Inclination Angle (i) on CMM for 30 slot = 29 degrees 34 minutes
Error in inclination angle (e) = (30) - (2934)
= 26 minutes
This error in inclination angle is due to the off-set of the plane containing the cutting edge
in model. The cutting edge plane is measured roughly and model built for catridge assembly,
that error causes the variation in inclination angle and was geometrically demonstrated.
Page 45
CHAPTER 6
CONCLUSIONS AND SCOPE OF
FUTURE WORK
6.1. Conclusions
Concepts of rotary milling are studied profoundly and it is clear that inclination angle
is the predominant variable to study the performance of rotary milling operation and directly
it will effects the chip formation and surface roughness produced. A model of rotary milling
cutter with different inclination angles was proposed and developed.
Physical and mechanical properties of different materials are studied and alloy steel
EN24 (SAE 4340) was chosen as the work material for cutter components and it combines
high tensile strength, shock resistance, good ductility and wear resistance.
Solid model was developed using CATIA V5 to suit the catridge assembly
manufactured by rotary technology corporation. Theoretically forces are calculated to
machine difficult-to-cut materials like alloy steels, hard cast iron and titanium alloys. Using
ANSYS9 stress analysis was done under static conditions on milling cutter model and cutter
dimensions are optimized to minimize the weight.
Page 46
Manufacturing drawings and process plans were prepared and machining carried out
in shop floor at different stages to complete the components. Components are heat treated to
32 HRC where EN24 will get the maximum resistance to impact loads. Scheme of measuring
inclination angle on CMM was explained and inclination angle for 30 slot was measured and
it is 2934. This error is due to the offset of cutting edge plane in model from the original
catridge assembly. Models can be predicted for cutting forces and surface roughness
accurately in rotary milling using the cutter fabricated.
6.2. Scope of future work

Rotary tools application in face milling has received limited attention and research
work is going on to study the performance of rotary milling. Using the cutter developed we
can predict models for cutting forces and surface roughness and we can optimize the process
parameters more precisely.
Mathematical models for rotary face milling are not yet developed appropriately and it
requires lot of attention to develop a mathematical model for rotary face milling.
Machining with rotary milling cutter using ceramic inserts is different from using
carbide inserts due to the differences in cutting velocities and mechanics of machining. There
is need to optimize the process parameters separately.
Depth of cut has different and significant role in machining with round inserts due its
variable lead angles at different depth of cuts. It will be interesting if we consider the
variations in lead angles while predicting the models for cutting forces as it causes the
variations in the ratios of force components.
Chip formation in rotary face milling is the another scope to study as chip control has
the special importance in modern automated manufacturing due to its direct effect on the
productivity and quality of the produced surface.
Page 47
APPENDIX-1
Table: A-1 Specific cutting energies of materials during face milling operation at different
feeds
Work Material
Tensile Strength
(Mpa) & Hardness
0.1mm/tooth
0.2mm/tooth
0.3mm/tooth
0.4mm/tooth
0.6mm/tooth
Mild Steel
520
2200
1950
1820
1700
1580
Medium Steel
620
1980
1800
1730
1600
1570
Hard Steel
720
2520
2200
2040
1850
1740
Tool Steel
770
2030
1800
1750
1700
1580
Cr Mn Steel
630
2750
2300
2060
1800
1780
Cr Mo Steel
730
2540
2250
2140
2000
1800
Ni Cr Mo Steel
940
2000
1800
1680
1600
1500
Ni Cr Mo Steel
352 HB
2100
1900
1760
1700
1530
Cast Iron
520
2800
2500
2320
2200
2040
Hard Cast Iron
46 HRC
3000
2700
2500
2400
2200
Gray Cast Iron
200 HB
1750
1400
1240
1050
970
Brass
500
1150
950
800
700
630
Light Alloy
(Al-mg)
160
580
480
400
350
320
Light Alloy
(Al-Si)
200
700
600
490
450
390
Specific Cutting Pressure KFs

2
(N/mm )
Page 48
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Dept. O
APPEND
DIX-2
MANUFA
ACTURING DRAWIN
NGS
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Page 69

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1. A large effective rake angle in so far as the shear process is concerned, a

Computer Integrated Manufacturing

National Institute of Technology, Warangal

Dept. Of Mechanical Engineering

3. The possibility of increasing chip velocity without necessitating a corresponding

Computer Integrated Manufacturing

National Institute of Technology, Warangal

Dept. Of Mechanical Engineering

Fig 1-1: Self Propelled Rotary Cutting Process. [6]

National Institute of Technology, Warangal

Dept. Of Mechanical Engineering

National Institute of Technology, Warangal

Dept. Of Mechanical Engineering

Computer Integrated Manufacturing

National Institute of Technology, Warangal

Dept. Of Mechanical Engineering

National Institute of Technology, Warangal

Dept. Of Mechanical Engineering

Computer Integrated Manufacturing

National Institute of Technology, Warangal

Dept. Of Mechanical Engineering

Computer Integrated Manufacturing

Fig 2-2:: Tool on ceentre, orthoggonal driven

Fig 2-3: Tool abo

Compputer Integrateed Manufacturring

22.2.1. Drivven obliqu

Fig 2-5: Driven oblique rotary tool and co

Compputer Integrateed Manufacturring

22.2.2. Drivven orthogonal rottary tool cutting

Figg 2-6: Driveen orthogon

Compputer Integrateed Manufacturring

National Institute of Technology, Warangal

Dept. Of Mechanical Engineering

2.2.3. Self-propelled oblique rotary tool cutting process

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National Institute of Technology, Warangal

Dept. Of Mechanical Engineering

2.3. Machining of Difficult-To-Cut Materials

2.4. Importance of Round and Ceramic Inserts

National Institute of Technology, Warangal

Dept. Of Mechanical Engineering

Computer Integrated Manufacturing

National Institute of Technology, Warangal

Dept. Of Mechanical Engineering

2.5. Hard Milling with Ceramic Inserts

2.5.1. Cutting speed

National Institute of Technology, Warangal

Dept. Of Mechanical Engineering

Computer Integrated Manufacturing

National Institute of Technology, Warangal

Dept. Of Mechanical Engineering

2.6 Different Angles in Face Milling and their Importance

Table 2-2: Function and effects of different angles in face milling

Axial Rake Angle

Determines chip disposal

Positive: Excellent machinability.

Radial Rake Angle

Negative: Excellent chip disposal.

Determines chip thickness.

Large: Thin chips and small cutting impact.

True Rake Angle