Escolar Documentos
Profissional Documentos
Cultura Documentos
PRACTICAL NO: 11
AIM: To study the design and selection of the single point cutting tool.
INTRODUCTION:
The tool having only one cutting point or edge is called single
point cutting tool such as tool used for turning, boring shaping or
planning, while the tool having more than one cutting point or edge is
called multi point cutting tool such as tool used for drilling, milling
broaching.
2. Mechanically clamped tip tools. In these tools, the tips or inserts are
clamped mechanically on to the tool shank. These tips are known as
indexable because these have more than one cutting edges which are
used one by one by indexing the tip and these tips are known as
throwaway type because once all the edges of the tip have been used,
the tip or insert is removed from the tool shank and thrown away.
The most common shapes in which these tips are available are : square,
triangular, and diamond. In the first case, the tips will provide a negative
rake angle because these will have to be clamped on to shank with the
seating sloping downwards to provide a clearance angle.
Prac 11 5
• CHIP BREAKER
TABLE – 11.1
M = Fc × l
1. MILLING CUTTERS
DESIGN FEATURES
D = d + 2t + 2h
Generally the cutter diameter, D, is taken about 2.5 to 3 times
the arbor diameter. The face width of the cutter should be adequate so as
to give sufficient support to the cutting edges. The arbor is usually
selected from the commercially available standard arbor sizes: 16, 22, 27,
32, 40, 50 and 60 mm.
n = f / (f t × N)
n = (K × hp c ) / (ft × N × h × w)
Where hp c = horse power available at cutter
K =machinability factor, mm 3 / min/ hp c
2. BROACH DESIGN
(b) TOOTH ELEMENT. The front rake angle refers to rake angle of a
single point cutting tool and the back off angle is provided to prevent
rubbing of tool with work piece.
(c) MATERIAL. H.S.S. is far by the most widely used material for the
broaches. Brazes carbides or disposable inserts are sometimes used for the
cutting edges when machining cast iron parts which require close
tolerances and production rates. Carbide tools are also used to an
advantage on steel casting to offset the damaging effect of local hard
spots.
The ratio of gullet area to chip cross section is taken as = 3 to 5 for rough
= 8 for finishing
(g) RAKE AND RELIEF ANGLES. The front rake angle falls in the
same range as used for another tools, but, the back off angle is quite low,
(0.5 to3.5). A large relief angle weakens the tooth.
(h) DEPTH OF CUT PER TOOTH. Depth of cut per tooth or chip
thickness or rise per tooth depends upon the shape of hole, size of hole,
type oh material being cut and the force available at the machine. It is
generally very small, of the order of 0.025 mm for finishing to 0.15 mm
for roughing. In progressive broaching, the cut per tooth can be made
more and may be between 0.1 to 0.35 mm or even more.
w = (0.25 to 0.333) × p
Land at zero clearance, that is, parallel to the broach axis is taken as 0.13
mm to 0.50 mm.
h = (0.35 to 0.40) × p
Prac 11 12
The depth of tooth gullet can also be found in the following manner:
When the job is getting broached, the metal chips get collected
in the gullet space. It is highly desirable that the chips don’t get
compressed and thereby jams up the entire gullet space. Now, the
effective cross sectional area of the gullet space can be taken as,
A g = π/4 × h 2
Now to allow for clearance between the coils of continuous
chips and for free formation of the discontinuous chips, the effective
gullet section is taken to be 3 to 6 times the actual chip section. Thus, if
the uncut chip thickness is‘t’, and job length is L, the chip section area A c
is,
Ac = L × t
Ag = K A c
Where K is 3 to 6, is the volume factor. Its value depends upon chip
thickness and material.
Depth of gullet will be given as, h = (4×k×L×t/π) ½
r = (0.20 to 0.35) × p
= (0.40 to 0.60) × h
= 1/3 × (land width) +1/2 × (tooth depth) + ¼(pitch)
n c = T/s + (2 to 4)
Where T = metal thickness to be removed
= A b /2, for round broaches.
Prac 11 13
(o) LOAD ON BROACH. The load on the broach or the force needed
for broaching may be found by the simple relation.
F = Area of metal removed by the teeth in contact with the work × shear
strength of the material being cut.
= n × A × τs
Where n = number of teeth at a time
A = cross sectional area of cut.
The above relation does not consider the fact that the resistance
to broaching varies with rise per tooth, being higher for lower values of
rise per tooth. Considering this fact, the relation becomes,
F = n A C
Where C = specific cutting force, that is, force remove 1 mm 2 of metal at a
given size per tooth.
Considering the blunt broach factor, the expression finally becomes,
F = n A C B
Where B = Blunt broach factor (1.25 to 1.40)
For round broaches, F = n × πDs × C × B
For surface broaching, F = n × s × b × C × B
For spline broaching, F = n × z × s × w × C × B
Where D = finish diameter of hole
b = width of contact of each tooth
z = number of splines
w = width of splines.
3. DRILL DESIGN.
(c) DRILL SIZE. Standard drills are available in four size series, the
size indicating the diameter of the drill body:
1. Fractional size. Size range is 1/64” to ¼” with increments of 1/64”.
2. Millimeter size. Size range is 0.50 to 10 mm with increments of 0.1
mm.
3. Numbered size. Size range is 0.0135” to 0.228” with very slight
increment.
4. Lettered size. Size range is 0.234” to 0.413” with very slight
increment. The diameter should always be slightly smaller than that of the
hole it is to be drilled, since drills always cut oversize.
(d) LIP RELIEF ANGLE. The heel of the drill point is backed off
when ground to give relief behind the cutting lips. This will allow the
cutting edges to cut without interference. This is equivalent to end relief
angle of a single point cutting tool. It is kept 12º to 15º.
(e) POINT ANGLE. The point angle is selected to suit the hardness
and brittleness of the material being drilled. It is 116º to 118º for medium
Prac 11 15
hard steel and cast iron, 125º for hardened steel and 130º to 140º for
brass and bronze. It is only 60º for wood and fiber. This angle refers to
side cutting edge angle of the single point cutting tool.
(h) CHIESEL ANGLE. This is the angle which the raised line at the
dead center makes with cutting edge. It is 120º to 135º.
(i) LAND WIDTH. Land width affects the strength and rigidity of the
drill body. It is usually taken to be equal to the flute width if drill
diameter is more than 20 mm. for smaller diameter drills; the land width is
made larger than the flute width. As a guide, the following values for land
width should be taken:
Land width = 0.62 × drill diameter, for drill diameter 3 to 8 mm
= 0.59 × drill diameter, for drill diameter 8 to 20 mm
= 0.58 × drill diameter, for drill diameter > 20 mm
(j) MARGIN. Margin is usually kept as 0.06 to0.07 times the drill
diameter. Its height is from 0.03 to 0.02 of the diameter.
(k) BACK TAPER. As mentioned above, the back taper is usually kept
as 0.0075 mm per cm of drill body. The usual values are given below:
Back taper (mm per 100 mm length of drill)
= 0.03 to 0.07 for drill diameter 1 to 6 mm
= 0.04 to 0.08 for drill diameter 6 to 18 mm
= 0.05 to 0.10 for drill diameter > 18 mm
M = (σ c × D 2 × f) ÷ g = (H B × D 2 × f) ÷ 8
The thrust force T 1 due to cutting edges can be estimated if the mean rake
angle is known. However, the effective rake angle goes from a positive
value near the outer radius to a negative value near the chisel edge.
Taking F t / F p = 0.05 to 1.0
T 1 = (0.5 to 1.0) × 2 × sin α p × (f/2) × (D/2) × σ c
For 2α p = 118º
T 1 = (0.21 to 0.42) × σ c D × f
= (1.7 to 3.5) M/D
It is difficult to estimate T 2 as it is difficult to ascertain the
area of contact between the chisel edge and metal. The web thickness w, is
w = 0.2 D for D < 3.2 mm
= 0.1 D for D > 25.4 mm
As mentioned above, the cutting action of chisel point is very similar to a
hardness test, so.
T2 = (0.1 to 0.2) × π/4 × w 2 × H B
T = (0.7 to 3.5) × M/D + (0.1 to 0.2) × π/4 × w 2 × H B
Power required for a drilling by a two flute drill can be calculated from
the following empirical formula:
4. REAMERS DESIGN.
DESIGN FEATURES.
1. Reaming Allowance. Reaming is a finishing operation and hence the
reaming allowance or the cutting allowance, that is, the material to be
removed is very small. Following are the average values:
(a) Machine Reaming:
Reaming allowance = 0.125 to 0.25 mm for up to 6.25 mm hole
= 0.25 to 0.375 mm for up to 12.5 mm hole
= 0.375 to 0.75 mm for up to 37.5 mm hole.
(b) Hand Reaming:
Reaming allowance = 0.025 to 0.125 mm
FIGURE 11.11
Recommended tolerance values for the reamer diameters are shown.
Maximum diameter of the reamer = Maximum diameter of hole – 0.15 IT
Minimum diameter of the reamer = minimum diameter of hole – 0.35 IT
5. Front end. The front end of the reamer should be smaller than the hole
diameter by 0.3 to 0.4 times the reaming allowance to ensure the free
entry of the reamer into the drilled or bored hole.
6. Shape of the teeth. The reamers may be straight helical fluted, with
straight fluted reamers being more common. Helical fluted reamers are
Prac 11 19
used for holes with straight slots or with sheet metal. The helix angle
varies from 30º to 45º. Hand of flute is generally opposite to the hand of
cut in order to avoid the screwing action.
7. Number of teeth. The number of teeth on reamer can be found out as,
Z = 1.5 × (D) ½ + 4, for cutting brittle material (C.I. and Bronze)
= 1.5 × (D) ½ + 2, for cutting other materials. (D is the diameter)
TABLE 11.5
8. Various angles.
(a) Rake angle. Reamers are generally provided with a zero rake. But
proper rake angle can be chosen depending on the work piece material.
Following are the average values of the rake angles:
.
TABLE 11.6
0º to 5º For steel
5º to 8º For grey C.I.
5º For brass
8º to 12º For aluminium
(c) Taper lead angle or Plan approach angle. The cutting edges of the
starting taper on a reamer make an angle with the tool axis (point or
included angle 2φ). The angle is called the taper lead angle or plan
approach angle. It is taken as:
2φ = 1º to 3º for hand reamers
= 30º for machine reamers in reaming through holes in ductile material
Prac 11 20
= 10º for reaming through holes in C.I.
= 60º to 90º for carbide tipped reamers
= 90º to 120º in reaming blind holes as well as through holes to the 3 r d
accuracy grade.
(d) Chamfer or bevel angle. The chamfer forms a truncated cone on the
starting end of the reamer. It is provided to further facilitate the entry of
the reamer into the hole and make the cutting action more convenient. The
chamfer angle generally used is 45º.
9. Material. The common materials for reamers are H.S.S. and cemented
carbide tipped. Reamers are frequently tipped with cemented carbides to
increase their production capacity.
5. FORM TOOLS.
DESIGN FEATURES.
Prac 11 21
Most form tools are made of H.S.S. however cemented
carbides are increasingly being used for this purpose. The use of
contoured cemented carbide tips for form tools enables the productivity to
be raised by 30 to 40 percent, as compared to H.S.S. form tools.
A form tool should have the proper rake and relief angles, so
that, the metal is cut under sufficiently advantageous conditions.
The relief angle depends upon the type of the form tool. Relief
angle is:
= 10º to 12º on circular form tools.
= 10º to 15º on flat form tools.
= 25º to 30º on form tools used for relieving form milling
cutters.
TABLE 11.7
1. With O as centre of the work piece, draw two concentric circles with
radii equal to the maximum and minimum radii of the contour to be
machined.
4. From the point of intersection C of the vertical line and the line of
action of the tool face, draw a line bisecting angle β.