SINGLE POINT CUTTING TOOL -

The single point cutting tool is mainly used to metal remove from work piece become with require shape
and size of product. It remove large amount of metal in quickly again rotating the work piece. Boring,
turning are performed by using single point cutting tool in lathe machine.

PARTS OF SINGLE POINT CUTTING TOOL -

Shank: It is a body of tools, which is not Grained is known as shank.

Face: The surface over the chip of metal side is known as face.

Flank: The Cutting tool surface is facing the work metal is known as Flank. There are two types like as
end flank and side flank.
Base: It is a bottom surface of shank. Generally it having flat farming in naturally.

Nose: It is a Junction of side and end of cutting edge is known as nose.

Cutting edge : It is a junction of face and Flank.It having two types,

• end cutting edge

• side cutting edge

VARIOUS ANGLES IN 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 the workpiece.

(ii) Side rake angle : Side rake angle is the angle by which the face of tool is inclined sideways. 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 workpiece and tool so as to
prevent the rubbing of workpiece 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 workpiece.

(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.

(vii)Nose radius : The nose radius is the angle between side of cutting edge and end of cutting edge.
Which the side cutting edge and end cutting edge to joining a line by point lead to high heat
concentration.When the joining by means of the small radius is good configuration to increase in the
cutting tool life and to obtain better surface finish. By the large radius, strengthening the tool and it used
on cast iron and also the casting where the cuts are interrupted.

Effects of back rake angle:

The angle size selection depends upon the material to be machined. If the material having softer, greater
angle will be given. When the material is harder, the smaller of angle will be required. For example, the
aluminium require more back angle than cast iron. Which back rack angle may be positive or negative or
neutral according to the material selection.

For consider the above diagram show the tool with positive, neutral and negative back rack angle
respectively. When the back Rake angle is higher of value the cutting edge will be weaken together. The
negative back angle will be increase the tool forces to some extending. This type of difficult may be
rectified by give additional support to cutting edge. For generally the carbide tools designed with negative
rake angle.

The positive rake Angle whereas used as follows,

• To machining the hardened work material.

• To machining the low strength of ferrous and nonferrous material.
• To turn the long shaft with small diameter
• Machining the metals having lesser recommended the cutting speed
 • The machining the job metal using small machine tool include low horsepower

The negative rake Angle whereas used followed by,

• Machining the high strength alloy

• Machine tools are more rigid
• To given the heavy and interrupted cuts
• The feed rate will be highly

Effects of side rake angle:-

During the machining operation the chip curling or amount of chip bends depends upon the side rake
angle. If the side rake angle is larger, cut and bending of chip and power requirement will be
decreased. Hence that providing better surface finish of machining surface.

Signature of metal cutting tool:-

The tool angle given in definite pattern is called tool signature. It tool angle have standardized by
American standard Association (ASA). As per American standard Association the tool signature are
presented as follows

• Back rake angle

• Side rake angle
• End relief angle
• Side relief angle
• End cutting edge angle
• Side cutting edge
• Nose radius

There are presenting in degree and mm.

Example:

The tool having the signature forming like as 8, 8, 5, 5, 6, 6 and 1 as per ASA. So the angle of tool
explained for,

• Back rake angle = 8 degree

 • Side rake angle = 8 degree
• End relief angle = 5 degree
• Side relief angle = 5 degree
• End cutting edge angle = 6 degree
• Side cutting edge = 6 degree
• Nose radius = 1 mm

Mechanics of metal cutting -

Mechanics of metal cutting consists of study of machining process and accurate estimation of dynamic
cutting forces by the use of suitable analytical models. Different Scientist have prepared different models
and advanced their own theory and analysis of metal cutting action. There are certain basic concepts used
by most of them. A Wedge shaped tool with a straight cutting edge is made to move relative to the
workpiece and a layer of metal called chip is removed. The model of cutting forces is shown in fig. The
chip is formed by a continuous shearing action of workpiece and there is friction between the flowing
chip and face of the tool.

Chip Formation -

In any machining operation, the material is removed from the workpiece in the form of chips, the nature
of which differs from operation to operation. As the form and dimensions of a chip from any process can
reveal lot of information about the nature and loyalty of process, the analysis of chip formation is very
important. Chips are formed due to tearing and shearing.

In the process of chip formation by tear, the workpiece material adjacent to tool face is compressed and a
crack runs ahead of cutting tool and towards the body of the workpiece. The chip is highly deformed and
workpiece material is relatively under-formed. Cutting takes place intermittently and there is no
movement of the work-piece material over the tool face. In chip formation by shear, there is general
movement of the chip over tool face.

As the tool advances into the work-piece, the metal ahead of the tool is severely stressed. The cutting tool
causes internal shearing action in the metal, such that the metal below the cutting edge yields and flows
plastically in the form of chip. Firstly compression of the metal under the tool edge takes place and then
follows separation of metal, when compression limit of that metal has been exceeded.Plastic flow takes
place in a localized region called shear plane, which extends from the cutting edge obliquely upto the
uncut surface ahead of the tool. When the metal is sheared the crystals are elongated, the direction of
elongation being different than from that of the shear.

It may be mentioned that the deformation of metal in the process of separation of chip, does not occur
sharply across the shear-plane. The grains of the metal ahead of cutting edge of tool start elongating along
the line AB and continue to do so until they are completely deformed along the line CD.

The region between the lines AB and CD is called shear-zone. After passing out the shear-zone, the
deformed metal slides along the tool face due to the velocity of the cutting tool. For all mathematical
analysis this shear zone is treated as a plane and is called a shear-plane.

The angle made by plane of shear with the direction of tool travel is known as shear angle (f). Its value
depends on the material being cut and the cutting conditions. If (f) is small, path of shear will be long,
chips will be thick, and the force required to remove the layer of metal of given thickness will be high and
vice versa.
Types of Chips -

Whatever the cutting conditions can be, the chips produced may belong to one of the following three
types.

1. Discontinuous chips:
2. Continuous chips.
3. Continuous chips with build up edge (BUE).

Discontinuous Chips

These types of chips are usually produced when cutting more brittle materials like grey cast iron, bronze
and hard brass. These materials lack the ductility necessary for appreciable plastic chips formation. The
material ahead of the tool edge fails in a brittle fracture manner along the shear zone. This produces small
fragments of discontinuous chips. Since the chips break up into small segments, the friction between the
tool and the chips reduces, resulting in better surface finish. These chips are convenient to collect, handle
and dispose off. Discontinuous chips are also produced when cutting more ductile materials under the
following conditions:

(i) large chip thickness. (ii) low cutting speed. (iii) cutting with the use of a cutting fluid. (iv) small rake
angle of the tool.
Continuous Chips.

These types of chips are produced when, machining more ductile materials. Due to large plastic
deformations possible with ductile materials, longer continuous chips are produced. This type of chip is
the most desirable, since it is stable cutting, resulting in generally good surface finish. On the other hand,
these chips are difficult to handle and dispose off. The chips coil in a helix (chip curl) and curl around the
work and the tool and may injure the operator when break loose. Also, this type of chip remains in contact
with the tool face for a longer period, resulting in more frictional heat. These difficulties are usually
avoided by attaching to the tool face or machine on the tool face, a 'chip breaker', The function of chip
breaker is to reduce 1 curvature of the chip and thus break it. The following cutting conditions also help
in the production of continuous chips :

1) Small chip thickness.

2) High cutting speed.
3) Large rake angle of the cutting tool.
4) Reducing the friction of the chip along the tool face, by: imparting high surface finish to the tool face,
use of tool material with low co-efficient of friction, and use of good cutting fluid.

Continuous chips with built up edge (BUE). -

When machining ductile materials, conditions of high local temperature and extreme pressure in the
cutting zone and also high friction in the tool-chip interface, may cause the work material to adhere or
weld to the cutting edge of then tool forming the builtup edge.

- Successive layers of work material are then added to the built up edge. When this edge becomes larger
and unstable, it breaks up and part of it is carried up the face of the tool along with the chip while the
remaining is left over the surface being machined, which contributes to the roughness of the surface.

- The built-up edge changes its size during the cutting operation. It first increases, then decreases, then
again increases etc. This cycle is a source of vibration and poor surface finish.

- Although, the built-up edge protects the cutting edge of the tool, changes the geometry of the cutting
tool. Low cutting speed also contributes to the formation of the built-up edge.

- Increasing the cutting speed, increasing the rake angle and using a cutting fluid contribute to the
reduction or elimination of the built-up edge.