INFLUENCE OF CUTTING TOOL GEOMETRY ON CUTTING FORCES.

Tool geometry and cutting parameters of machining tools, are important aspects in the
design and optimization of several characteristics involved in general machining
processes, such as cutting forces, chip formation, quality of the machined piece, time vs
cost, etc. It is specially of great importance to define and study the influences of tool
geometry and cutting parameters on cutting forces, because this is a good way to estimate
mechanically the overall cutting forces involved in a machining process using standard
terms and determine the effects such forces may cause in the outcome of the machining
and those aspect related to the life-cycle of the cutting tool, Thus, valuable information can
be provided for prolonging the tool life and reducing machining cost.
Sustainability of the machining processes is of vital importance because normally the
machining of materials such as A70 steel requires consuming great amounts of energy.
Reducing the energy consumption during machining process can significantly improve the
manufacturing systems performance, thus a first approach to this optimization can be done
by analyzing the correlation between cutting geometry and cutting forces, which provide
tools to determine efficient conditions for a machining process. First it is necessary to
define the basic concepts of cutting geometry.
Rake angle

Fig 1
Figure 1 shows the machining of a chip from the surface of a material by a cutting tool the
tool is stationary and the plate moves towards it, so there is a cutting speed, which is the
relative speed between the material and the tool (from now on Uwork). In figure 1 it is
shown the tool rake angle a as the angle between the rake face and the normal to both the
cutting edge and Uwork. This angle by convention is positive. The cutting energy
consumption in high speed machining process is greatly affected by the tool rake angle. A
study conducted in HSM chip formation of 7050-T7451 aluminum alloy in high speed
machining [1] shows that changing the angle from 10 to 10, the total cutting energy
consumption increases. Negative angles, cause more compression on the uncut part of
the material which causes large friction and higher stresses.

Cutting edge angle (r)

The cutting edge angle is set to avoid the interference between the machine piece and the
tool. Decreasing the end cutting edge angle increases the strength of the cutting edge, but
it also increases temperature. It may also cause vibration in the process. Usually small
angle is used for rough machining and a large angle in finishing.
Cutting edge inclination ()

Cutting edge inclination indicates inclination of the rake face. A simulation conducted on the
Selection of the Machining Inclination Angle in High-Speed Ball End Milling, shows that a
machining inclination angle of 15 was good enough from the point view of machineability,
and this value was verified by a cutting experiment using high-speed ball end milling.
Tool nose radius
Refers to the radius of the tip of the tool.

It is an important factor in turning operations and its

Selection of nose radius depends on the depth cut, feed and influences the chip breaking,
the surface finish and it is used to determine the strength of the tool.

The radial forces that act against the insert from the cutting surface become axial as the depth of cut
increases; but it is recommendable to have axial forces instead of radial, which have a negative effects
on the cutting action, such as tendency to vibration and bad surface finish with increased radial forces.
The nose radius also affects the chip formation. Generally, chip breaking improves with a smaller
radius.

Tool nose radius effects on finish turning of hardened AISI 52100 steels have
been investigated. Surface finish, tool wear, cutting forces, and, particularly,
white layer (phase transformation structures) were evaluated at different
machining conditions. Results show that large tool nose radii only give finer
surface finish, but comparable tool wear compared to small nose radius tools
Forces involved in the machining processes:
In orthogonal cutting, the total cutting force has two components, which can be
measured using a dynamometer. We can represent this forces at the tip of the
tool for practical purposes.

Cutting force (Fc): it is the component of the force that goes in the machining direction,
usually constitute a great amount of the total force roughly to 80%, and is important
determining this force to calculate the power P, required to perform the cutting process.
In three-dimensional oblique cutting, one more force component appears along the third
axis. The thrust force FD is further resolved into two more components, one in the direction

of feed motion called feed force Ff , and the other perpendicular to it and to the cutting
force FC called back force F p , which is in the direction of the cutting tool axis.

[1]Wang, B., & Liua Z, & Songa Q., & Wana Y., & Shia Z.. (2016,
agosto 15). Proper selection of cutting parameters and cutting
tool angle to lower the specific cutting energy during high speed
machining of 7050-T7451 aluminum alloy. Journal of cleaner
production , 129, 292-304. 206, septiembre 6, De ScienceDirect
Base de datos.
[2]T.J. Ko, H.S. Kim, S.S. Lee. (2001, Enero). Selection of the
Machining Inclination Angle in High-Speed Ball End Milling. The
international journal of advanced manufacturing technology, 17,
163-170. 2016, septiembre 6, De Springer Link Base de datos.

[3]Chou Y., & Song H . (2003, octubre 30). Tool nose radius effect
on finish hard turning. Journal of materials processal technology,
148, 259-268. 2016, septiembre 6, De Elsevier Base de datos.