Lecturer Name : S.

Kareemulla
Subject
: Machine Tools
Class
: III B.Tech I semester
Section
: M.E-A
Academic Year : 2014-15

S.Kareemulla
Assistant Professor
M.E Dept, MITS
email id:kareem.mech316@gmail.com
kareemullas@mits.ac.in

Text books for Machine Tools

1.Title:Elements of work shop technology
Vol=II(Machine tools)
Authors: A.K. Hajra Choudhury
S.K. Hajra Choudhury
Nirjhar Roy
2. Title: A Course in Work shop Technology
Vol=II(Machine Tools)
Author: B.S.Raghuwanshi

Text Books Continued

3.Title:Production Technology
Authors: R.K.Jain and
S.C.Gupta
4. Title: Manufacturing Technology
Authors: Kalpakzian ,
Publications: Pearson
Publications
5.Title: Machine Tools
Authors: Dr.R.Kesavan,B.Vijaya

Text Books Continued

6. Title: A Text book of Manufacturing
Technology = II
Author: P.C.Sharma

UNIT-1

INTRODUCTION TO METAL
CUTTING

Machine Tool

A Machine tool is power driven

machine for making articles of given
shape, size and good dimensional
accuracy by removing metal from
work piece in the form of chips

Metal cutting (or)Machining

A machining is a one type of metal
removal process from the blank of
material for getting good shape, size
and good dimensional accuracy
unwanted material can be removed
in the form of chips

Mother of all Machines

Machine tools is called as the mother
of all machines because of all types
of
machine
components
and
instruments can be manufactured by
machine tool so that this is called
mother of all machines

Types of cutting processes

1.
2.

Non cutting shaping process

Cutting shaping process

1. Non cutting shaping process: The metal is

shaped under the action of heat, pressure or

both. Here there is no chip formation.
eg: forging, drawing, spinning, extruding,
rolling.
2. Cutting shaping process:
The required shape of material is obtained
by removing the unwanted material from the
work piece in the form of chips.
eg: Turning ,boring, drilling, milling , shaping.

Elements of cutting process

Tool
Work piece
Chip
Tool:
A cutting tool may be used either for cutting apart, as
with a knife or, for removing chips. parts are produced by
removing metal mostly in the form of small chips.
Work piece:
Work piece is nothing but parent metal
Chip:
The unwanted material removed from the work piece is
called as chip.

ELEMENTS OF CUTTING PROCESS

Metal cutting action

The metal cutting is done by a relative motion
between the work piece and the hard edge of a
cutting tool. The relative motion between the
work piece and the cutting tool may be
obtained by :
1.Rotation of work against the tool(turning)
2.Rotation of tool against the work( Milling, Drilling)
3.Linear movement of the work against tool(planning)
4.Linear movement of the tool against work(shaping)

What is a Cutting Tool

A cutting tool is any tool that is used to
remove metal from the work piece by
means of shear deformation.
It is one of most important components
in machining process
It must be made of a material harder
than the material which is to be cut,
and the tool must be able to withstand
the heat generated in the metal cutting
process.
Two basic types
Single point cutting Tool
Multiple point cutting Tool

13

Single point cutting tool

A cutting tool which is having
one cutting point is known as
single point cutting tool.
Eg: Lathe Tools, shaper tools,
planer tools etc.,

Single Point Cutting Tool

Multi point cutting tool

A cutting tool which is having
two and more cutting points
is known as multi point
cutting tool.
Eg: Milling tools, drilling tools
etc.,

Orthogonal and oblique cutting

Geometry of single point cutting tool continued

Single point cutting tool

Geometry of single point cutting tool

Three views of single point cutting tools

Cutting-Tool Materials
Cutting tool bits generally made
High-speed steel
Cast alloys
Cemented carbides
Ceramics
Cermets
Cubic Boron Nitride
Polycrystalline Diamond

24

CUTTING TOOL PROPERTIES

Hardness
Cutting tool material must be 1 1/2 times harder
than the material it is being used to machine.

Capable of maintaining a red hardness

during machining operation
Red hardness: ability of cutting tool to maintain
sharp cutting edge at elevated temp.
It is also sometimes referred to as hot hardness
or hot strength

25

Cutting Tool Properties

Wear Resistance
Able to maintain sharpened edge
throughout the cutting operation
Same as abrasive resistance

Shock Resistance
Able to take the cutting loads and
forces

Shape and Configuration

Must be available for use in different
sizes and shapes.
26

Single Point Cutting Tool

30

Single Point
Cutting Tool

31

Know the Single Point Cutting Tool

Shank: Main body of tool, it is part of

tool which is gripped in tool holder
Face: Top surface of tool b/w shank
and point of tool. Chips flow along this
surface
Flank: Portion tool which faces the work. It is surface
adjacent to & below the cutting edge when tool lies in a
horizontal position.
Point: Wedge shaped portion where face & flank of tool
meet.
Base: Bearing surface of tool on which it is held in a tool
holder.
Nose radius: Cutting tip, which carries a sharp cutting
point. Nose provided with radius to enable greater
strength, increase tool life & surface life.
Typical Value : 0.4 mm 1.6 mm

SPC Tool
Geometry

SIDE RELIEF
SIDE CLEARANCE

33

Nomenclature of Single Point Lathe Tool

The most significant terms in the

geometry of a cutting tool angles
are:
Relief or clearance angle
Side relief
End relief

Rake angle
Back Rake angle
Side Rake angle

Cutting edge angle

Side Cutting edge angle
End Cutting edge angl
Nose Radius

34

Cutting-Tool Terms
Relief or Clearance angle:
Ground on the end and side faces
of a tool to prevent it from rubbing
on the work piece.
To enable only the cutting edge to
work piece.
Sidetouch
Reliefthe
angle:
Angle ground
directly below
the cutting edge
on the flank of
the tool

End Relief angle:

Angle ground
from the nose of

35

Cutting-Tool Terms
Cutting edge angle

Ground on a tool so that it can be

mounted in the correct position for
operations.
Sidevarious
Cuttingmachining
edge
angle
Allows flank of the tool
to approach the work
piece first
Spreads the material
over a greater
distance on the
cutting edge, thereby
thinning out the chip.
Approximately 150

End Cutting edge

angle

Allows the cutting tool

to machine close to

36

Cutting-Tool Terms
Rake angle:
Ground on a tool to provide a smooth flow of the chip over the
tool so as to move it away from the work piece

Back Rake angle

Ground on the face of

the tool
Influences the angle
at which chip leaves
the nose of the tool
Generally 8 - 100

Side Rake angle

Ground on the tool

face away from the
cutting edge
Influences the angle
at which the chip
leaves the work piece
0

37

Side Rake
Large as possible to allow
chips to escape
Amount determined
Type and grade of cutting tool
Type of material being cut
Feed per revolution

Angle of keenness
Formed by side rake and side
clearance
38

Back Rake
Angle formed between top face of
tool and top of tool shank
Positive
Top face slopes downward
away from point

Negative
Top face slopes upward
away from point

Neutral
39

Rake Angles
Small to medium rake angles cause:
high compression
high tool forces
high friction
result = Thickhighly deformedhot
chips

Negative Rake Tools

Typical tool materials which utilize negative
rakes are:
Carbide
Diamonds
Ceramics

These materials tend to be much more brittle

than HSS but they hold superior hardness at
high temperatures. The negative rake angles
transfer the cutting forces to the tool which help
to provide added support to the cutting edge.

Cutting-Tool Terms
Nose Radius:
Rounded tip on the point of the
tool
Functions:
Strengthens
finishing point of
tool
Improves surface
finish on work
Should be twice
amount of feed
per revolution
Too large chatter;
too small
weakens point

42

Tool Angle Application

Factors to consider for tool angles
The hardness of the metal
Type of cutting operation
Material and shape of the cutting tool
The strength of the cutting edge

Chip formation
The type of chip produced during metal
cutting depends upon the machining
condition and material being cut. The
variables which influence the type of chip
produced are as follows:
1. Properties of material cut especially
ductility
2. Depth of cut
3. Feed rate
4. Effective rake angle of tool
5. Cutting speed
6. Type and quantity of cutting fluid

Different types of chips

Three different types of chips

formed during metal cutting
are as follows:
1.Continuous chips
2.Discontinuous chips
3.Continuous chips with a built
up edge.

Continuous chips
A continuous chip is obtained when
cutting ductile materials such as low
carbon steel, aluminum and copper.
This chip is several deformed and
either comes often in the form of a
long string or curl in to a coil.

Work piece

Continuous chip forms when

a. Machining ductile materials
b. Fine feed
c. Sharp cutting edge
d. Higher cutting speed
e. Large rake angles

Discontinuous chips
Brittle materials such as grey cast iron lack of ductility
necessary for appreciable plastic chips formation
consequently the compressed material ahead of tool fails in
a brittle manner along the shear zone producing small
fragments. Such chips are discontinuous chips.
Discontinuous chips from due to following factors.
a. Machining Brittle materials
b. Lower cutting speeds
c. Insufficient rake angle
Continuous chips with a built up edge
when during cutting, the temperature and pressure is
quite high it causes the chip material to weld itself to the
tool face near the nose. This is called built up edge . This

This accumulated build up of chip

material will then break away, part
adhering to the under side of the
chip and part to the work piece. The
process gives rise to poor finish on
the
machining
surface
and
accelerate wear on the tool face.

Built up edge forms due to

a high friction at tool face
Coarse feed
Low rake angle
Ineffective use of cutting fluid
produce such chips.
Effect of Built up edge
a) Poor finish on the machined
surface
b) wear on the tool surface

Chip thickness ratio and Shear

angle

The outward flow of the metal causes the chip

to be thicker after separation from the parent
metal . Metal prior to being cut is much longer
than the chip which is removed
let
t1= chip thick ness before
cutting
t2= chip thickness after
cutting
= shear angle
= back rake angle
Chip thickness ratio

CHIP MECHANISM

Basic configuration of multi spindle automatic vertical lathe

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