THEORY OF CUTTING TOOL

 Both material and geometry of the cutting tools play

very important roles on their performances in achieving
effectiveness, efficiency and overall economy of
machining.
 Cutting tools may be classified according to the number
of major cutting edges (points) involved as follows:
 Single point: e.g., turning tools, shaping, planning and
slotting tools and boring tools
 Double (two) point: e.g., drills
 Multipoint (more than two): e.g., milling cutters,
broaching tools, hobs, gear shaping cutters etc.
 PARTS OF SINGLE POINT
CUTTING TOOL

1.SHANK
2. FACE
3. CUTTING EDGE
a] End cutting edge
b] Side cutting edge
4. FLANK
5. NOSE
6. NOSE RADIUS
SHANK: It is the main part of the cutting tool, and is also the part of the
tool is gripped in the tool holder.

FACE: It is the top portion or surface of the tool over which the chip flows
during the cutting.

CUTTING EDGE: Cutting edge is the portion of the face edge that
separates the chip from the workpiece.

END CUTTING EDGE: It is the cutting edge formed at the end face of the
tool.

SIDE CUTTING EDGE: It is the cutting edge on the side face of the tool.

FLANK: It is the surface adjacent to, and below the cutting edge when tool
lies in a horizontal position.

NOSE: It is the tip of the cutting tool, and formed by the intersection of the
side cutting edge and the end cutting edge.
SINGLE POINT CUTTING TOOL
 Rake Angle: Angle of inclination of rake surface from
reference plane.
 Clearance angle (α): Angle of inclination of clearance or
flank surface from the finished surface.
– Rake angle is provided for ease of chip flow and overall
machining.
– Rake angle may be positive, or negative or even zero.
Relative advantages of such rake angles are:
➢ Positive rake – helps reduce cutting force and thus cutting
power requirement.

➢ Negative rake – to increase edge-strength and life of the tool

➢ Zero rake – to simplify design and manufacture of the form

tools.
➢ Clearance angle is essentially provided to avoid rubbing of the tool
(flank) with the machined surface which causes loss of energy and
damages of both the tool and the job surface.

➢ Hence, clearance angle is a must and must be positive (3o to 15o

depending upon tool-work materials and type of the machining
operations like turning, drilling, boring etc.)
ANGLES OF SINGLE POINT CUTTING TOOL
(i) Back rake angle:
Back rake angle is the angle between the face of the single point cutting tool
and a line parallel with base of the tool measured in a perpendicular plane
through the side cutting edge. If the slope face is downward toward the nose,
it is negative back rake angle and if it is upward toward nose, it is positive back
rake angle. Back rake angle helps in removing the chips away from work piece.
(ii) Side rake angle:
Side rake angle is the angle by which the face of tool is inclined
side ways. Side rake angle is the angle between the surface the flank
immediately below the point and the line down from the point
perpendicular to the base. Side rake angle of cutting tool determines
the thickness of the tool behind the cutting edge. It is provided on
tool to provide clearance between work piece and tool so as to
prevent the rubbing of work piece with end flake of tool.
(iii) End relief angle:
End relief angle is defined as the angle between the portion of the
end flank immediately below the cutting edge and a line
perpendicular to the base of the tool, measured at right angles to the
flank. End relief angle allows the tool to cut without rubbing on the
workpiece.
iv) Side relief angle:
Side rake angle is the angle between the portion of the side flank
immediately below the side edge and a line perpendicular to the
base of the tool measured at right angles to the side. Side relief
angle is the angle that prevents the interference as the tool enters the
material. It is incorporated on the tool to provide relief between its
flank and the workpiece surface.
v) End cutting edge angle:
End cutting edge angle is the angle between the end cutting edge
and a line perpendicular to the shank of the tool. It provides
clearance between tool cutting edge and work piece.
vi) Side cutting edge angle:
Side cutting edge angle is the angle between straight cutting edge
on the side of tool and the side of the shank. It is responsible for
turning the chip away from the finished surface.
TOOL REFERENCE SYSTEM
To determine the orientation and inclination of the rake face and flank
surfaces, a coordinate system is essential, resulting in a set of planes
with reference to which the orientation or inclination can be
determined.
Two planes are of significance
i)Tool reference plane or principal plane , which is perpendicular to the
cutting velocity vector
ii) Cutting plane, which is tangential to the cutting edge and contains
the velocity vector. The cutting plane is also perpendicular to the
principal plane or the tool reference plane.
Three types of co-ordinate system are:
i) Machine Reference System(ASA)
ii) Orthogonal tool Reference System (ORS)
iii) Oblique or Normal tool Reference System (NRS)
ASA SYSTEM
This system is also called ASA system; ASA stands for American Standards
Association. Geometry of a cutting tool refers mainly to its several angles or
slope of its salient working surfaces and cutting edges. Those angles are
expressed w.r.t. some planes of reference. In Machine Reference System
(ASA), the three planes of reference and the coordinates are chosen based on
the configuration and axes of the machine tool concerned.
For example in a Lathe, XX is the spindle axis or workpiece axis, YY is the
tool axis and ZZ is the vertical axis. Figure 4 depicts the xyz coordinates of
machine
 The planes of reference and the coordinates used in ASA system for tool geometry
are : πR - πX - πY and Xm – Ym – Zm
πR = Reference plane; plane perpendicular to the velocity vector
πX = Machine longitudinal plane; plane perpendicular to πR and taken in the
direction of assumed longitudinal feed
πY = Machine Transverse plane; plane perpendicular to both πR and πX [This plane
is taken in the direction of assumed cross feed]
 The axes Xm, Ym and Zm are in the direction of longitudinal feed, cross feed and
cutting velocity (vector) respectively.
ORS SYSTEM
Generally referred to as ORS (orthogonal rake system). This system is also
known as ISO (International standard organization) – old.
The principal or tool reference plane πR , which is the same as for the
machine reference plane
The cutting plane πC , which contains the cutting edge, normal to πR plane
The cutting plane πo , which contains the cutting edge, normal to πR plane.
Figure 6 shows the orientation of the rake face and flank surfaces with
respect to the orthogonal tool reference system and tool angles in symbolic
form.
 ASA system—It utilizes three mutually perpendicular planes namely
Machine longitudinal plane, Machine transverse plane and Reference
plane. Reference plane is a plane perpendicular to cutting velocity
vector in turning. Machine longitudinal plane is perpendicular to
reference plane and is along longitudinal axis of lathe. As the name
suggests, machine transverse plane is along the transverse axis of the
lathe and is perpendicular to other two planes.
 ORS system—It also utilizes three mutually perpendicular planes
namely Reference plane, Cutting plane, and Orthogonal plane. As
usual, reference plane is a plane perpendicular to cutting velocity vector
in turning. Cutting plane contains principal cutting edge of the tool and
is perpendicular to reference plane. Orthogonal plane is perpendicular
to other two planes.
 NRS system—It also utilizes three planes for reference purpose
(Reference plane, Cutting plane, and Normal plane) but they may
not be mutually perpendicular. Here normal plane is a plane
perpendicular to the principal cutting edge and is inclined with the
orthogonal plane by an angle equals to inclination angle (λ) of the
tool. So if λ = 0º, then both normal plane and orthogonal plane will
coincide.
TYPES OF SINGLE POINT CUTTING TOOL

➢ Solid type tool

➢ Brazed type tool
➢ Insert bit with holder tool

SOLID TYPE TOOL

Material used are mostly High carbon steel
And High speed steel
BRAZED TYPE TOOL
Shank is made of ordinary
Material and tip is of Tungsten
Carbide and is brazed with
shank.

INSERT BIT WITH HOLDER TOOL

Shank is made of ordinary
Material and insert is made of
Different kind of hard material
And can be used for different kind
Of work.
 ORTHOGONAL & OBLIQUE CUTTING
 Orthogonal cutting is a type of metal cutting in which the cutting
edge of wedge shape cutting tool is perpendicular to the direction of
tool motion. In this cutting the cutting edge is wider than width of
cut. This cutting is also known as 2D cutting because the force
develop during cutting can be plot on a plane.
 Oblique cutting is another type of cutting in which the cutting edge
of wedge shape cutting tool make a angle except right angle to the
direction of tool motion. This will affect the cutting conditions. It is
also known as 3D cutting because the cutting force develop during
cutting cannot be represent by 2D coordinate or used 3D coordinate
to represent.
MERCHANT CIRCLE DIAGRAM
F=Fc sinα + Ft cos α
N=Fc cosα - Ft sin α
µ= F/N
On shear plane,
Fs = Fc cosø - Ft sinø
Fn = Fc sinø + Ft cosø
To find shear angle:
tanø = rcosα/(1-rsinα)
r = t/tc
t = uncut chip thickness
tc = chip thickness after cut
TWIST DRILL BIT CUTTING TOOL
1. SHANK
2. BODY
3. POINT
4. LIPS
5. FACE
6. FLANK
7. LAND OR MARGIN
8. WEB
9. CHISEL EDGE
10.BODY CLEARANCE
11.AXIS
12.HELIX ANGLE
13.POINT ANGLE
14.LIP RELIEF ANGLE
15.CHISEL EDGE ANGLE
16.NECK
 PARTS OF TWIST DRILL BIT
1. SHANK: The shank is the portion of the drill bit which is held and driven.
2. BODY: The body is the portion of drill bit that forms the main cutting unit.
3. POINT: The point is the cutting end of the drill bit. It is a cone shaped surface
consisting of lips, faces, flanks and chisel edge
4. LIPS: The lips are the primary cutting edges of the drill extending from the chisel
point to the periphery of the drill.
5. FACE: The curved surface of the flute near the lip is called face.
6. FLANK: It is the conical surface of the drill point, which extends behind the lip to
the following flute.
7. LAND: It is a narrow flat surface which runs all along the flutes of the drill on its
leading edges.
8. WEB: The web is the central portion of the drill body that connects the lands.
9. CHISEL EDGE: It is the short edge ground on the tool point along the web.
ANGLES OF TWIST DRILL BIT

HELIX ANGLE: It is the angle between the leading edge of the land and
the axis of the drill bit.
(16-320)
2. POINT ANGLE: The angle between the drill lips is called the point or
cutting angle.(80-1400)
3. LIP RELIEF ANGLE: it is the axial relief angle at the outer corner of the
lip and varies from
8-150
4. CHISEL EDGE ANGLE: It is the angle between the lip and the chisel
edge, as seen from the end
of the drill (130-1450)
PLAIN MILLING CUTTER
CUTTING TOOL
1. BODY
2. CUTTING EDGE
3. FLUTE
4. FILLET
5. TOOTH
6. FACE
7. LAND
8. OUTSIDE DIAMETER
9. ROOT DIAMETER
10.HOLE DIAMETER
11.CLEARANCE ANGLE
 ANGLES OF PLAIN MILLING
CUTTER
1. PRIMARY CLEARANCE ANGLE:
It is the angle formed by the back
of the tooth with a line drawn tangent
through the periphery cutting edge.
2. SECONDARY CLEARANCE ANGLE:
It is the angle formed by the
secondary clearance surface of the tooth
and a line drawn tangent through the
periphery cutting edge.
3. RELIEF ANGLE: It is the angle measured between the
land and the tangent drawn to the
periphery cutting edge.
4. RAKE ANGLE: It is the angle measured between the
tooth face and the center line of the cutter.
TYPES OF MILLING CUTTER
CUTTING TOOL MATERIALS

◼HIGH CARBON STEEL

◼HIGH SPEED STEEL
◼CAST ALLOY
◼CEMENTED CARBIDE
◼CERAMICS
◼SIALON
◼DIAMOND
◼CBN(CUBIC BORON NITRIDE)
HIGH CARBON STEEL

The hardness of the tool is determined by the carbon contents

which ranges from 0.65 to 1.5%.The higher the carbon
content ,greater the wear resistance of the tool. This tools are
used for low cutting speed.
Eg:-hand tools, hack saw blades, milling cutters, twist drills,
reamer, turning tools and form tools etc.
HSS CUTTING TOOL
 H.S.S is used for drills, milling cutters, single point
cutting tools, dies, reamers etc.
 It looses hardness above 600°C.
 Some times tungsten is completely replaced by
Molybdenum.
 Molybdenum based H.S.S is cheaper than Tungsten
based H.S.S and also slightly greater toughness but less
water resistance.
 HIGH SPEEDSTEEL

HIGH TUNGSTUN T-TYPE HIGH MOLYBDENUM(M-TYPE TUNGESTUN MOLYBDENUM

 COMPOSITION OF HSS
TYPE W Cr V Mo C Fe
HIGH BAL
TUNGSTU
18 4 1 ___ 0.7 ANC
N (T-TYP) E
HIGH BAL
MOLYBDEN 1.5 4 1 8.5 0.8 ANC
UM (M- E
TYP)

TUNGSTUN BAL
MOLYBDEN 6 4 2 5 0.8 ANC
UM E
 SUPER HIGH SPEED STEEL
Cobalt 12% is added which results in increase of hot hardness
of that of hss(18:4:1) and is called super high steel.

MATERIAL PROPERTIES
Cobalt gives hot hardness and greater resistance to shock.

Vanadium increase hardness, wear resistance and strength

when it works as an alloy of iron.

Tungsten has high wear resistance properties and high

melting point. When it is added to steel it increases
strength and heat resistance and works as a super alloys.
CAST ALLOY (STELLITES)

 This is an alloy of chromium, tungsten and

cobalt.
 A number of non-ferous material alloys high in
cobalt have been developed for cutting tool
material.
 These materials are used as a cast.
 These contains cobalt 40-50%, chromium 27-
32%, carbon 2-4%.
 CAST ALLOY
 Stellite is harder than hss at temp.500 °c.
 It maintain its hardness and cutting edge even at red heat
(750°c.)
 These are used for making for form tools.

CEMENTED CARBIDE
Tungsten carbide crystal when mixed with cobalt
powder could be sintered at a temperature near melting
point of cobalt(1980c)to provide a strong material for
use in certain machining operation.
 Speed can be used 3 to 8 times that of H.S.S.
 Can withstand up to 1000°C.
 High compressive strength is more than tensile strength.
 They are very stiff and their young’s modulus is about 3 times
that of the steel.
 High wear resistance.
 High modulus of elasticity.
 Low coefficient of thermal expansion.
 High thermal conductivity, low specific heat, low thermal
expansion.
 These are the products of carbides of tungsten, titanium and
tantalum with certain percentage of cobalt.
 Cemented carbide is a typical powder metallurgy product.
 Cemented carbide have high hardness over a wide range of
temperature ,very stiff, exibit no plastic flow, low thermal
expansion, high thermal conductivity which enables them for
faster cutting speed .

TITANIUM CARBIDE (0-16%)

TANTANUM CARBIDE(0-10%)
TUNGSTUN CARBIDE(82%)
COBALT (3-16%)
 CERAMICS
 These materials basically aluminum oxide.
 (80% aluminium oxide and other oxides of
ti,mg,tungstun)
 It is produced same manner as sintered carbide.
 It is harder than cemented carbide hss.
 Cutting speed 2-3 times faster than carbide.
 Vibration and chatter are fatal to these tool.
 Ceramics and sintered oxides are basically made
of Al2O3, These are made by powder metallurgy
technique.
 Used for very high speed (500m/min).
 Used for continuous cutting only.
 Can withstand upto 1200°C.
 Have very abrasion resistance.
 Used for machining CI and plastics.
 Has less tendency to weld metals during
machining.
 Another ceramic tool material is silicon nitride
which is mainly used for CI.
 CERMETS
 Cermates are combination of ceramic
and metal
 It is manufactured by same p/m
process
 Aluminiumoxide+metal(w,mo,boron,ti)
 Cermets is the combination
of ceramics and metals and produced
by Powder Metallurgy process.
 When they combine ceramics will give
high refractoriness and metals will give
high toughness and thermal shock
resistance.
 For cutting tools usual combination as
Al2O3 + W + Mo + boron + Ti etc.
 Usual combination 90% ceramic, 10%
metals.
 Increase in % of metals reduces
brittleness some extent and also
reduces wear resistance.
 CBN

 It is called cubic boron nitride

 Consist of atoms of boron and
nitrogen
 Hardest material available
 Substitute for diamond for
machining steel
 It is used for grinding carbide
 The trade name is Borozone.
 Consists of atoms of Nitrogen and Boron and
produced by power metallurgy process.
 Used as a substitute for diamond during
machining of steel.
 Used as a grinding wheel on H.S.S tools.
 Excellent surface finish is obtained.
 DIAMOND
 HARDEST OF ALL CUTTING
TOOL
 USED WHEN HIGH SURFACE
FINISH AND DIMENSIONAL
ACCURACY IS REQUIRED
 GOOD FOR MACHINING
CO,BRASS,ZINK,ALUMINIUM
 CUTTING SPEED 200-500M/MIN
 Diamond has
◦ Extreme hardness
◦ Low thermal expansion.
◦ High thermal conductivity.
◦ Very low coefficient of friction.
 Cutting tool material made of diamond can withstand speeds ranging
from 1500 to 2000m/min.
 Can withstand above 1500°C.
 A synthetic (man made) diamond with polycrystalline structure is
recently introduced and made by powder metallurgy process.
 SIALON
 It is a silicon nitride based material
with aluminum and oxygen addition
 It is tougher than alumina
 Aerospace alloys and nickel gas
turbine blades are machined