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Contents Cutting Tools and Cutting Materials CONTENTS 1. Cutting tools and cutting materials 1.1 cutting tools- various types of single point cutting tools and their uses, single point cutting too geometry, tool signature and its effect, heat produced during cutting and its effect, cutting speed, feed and depth of cut and their effect 1.2 Cutting tool materials- properties of cutting tool material, study of various cutting tool materials viz. high-speed steel, tungsten carbide, cobalt steel cemented carbides, satellite, ceramics and diamond CUTTING TOOLS AND CUTTING MATERIALS 1.1 INTRODUCTION Cutting material are shaped with the help of cutting tool into usable forms through various processes. The work pieces of most different shapes and sizes and of different materials are worked. 1.2 CUTTING TOOLS The tools which are used for the purpose of cutting the metals in the desired shape and size are called cutting tools. 1.2.1 Classification of cutting tools: Cutting tools are classified into groups. 1. Single point cutting tool. 2. Multi point cutting tool. 1.2.2 Various types of single point cutting tools: Tools for lathe machines On a lathe machine to perform different operations different tools are required. i. Turning tool ii. Facing tool iii. Chamfering tool iv. External threading tool v. Internal threading tool vi. Boring tool vii. Grooving tool, etc. Tool for planer The planer tools are made of high speed steel. Cemented carbide tipped tools are also used. The shape of the tool depends on the type of operation to be performed. Different single point cutting tools are given below: i. Straight and bent roughing tools ii. Straight, roundness and goose neck tools. 1.2.3 Single point cutting tool Geometry Cutting tool geometry concerns with basic tool angles i.e. angles ground on tool to make it efficient in cutting. Parts of a single point cutting tool The different parts of a single point cutting tool are as follow: 1. Shank 2. Face 3. Flank 4. Heel 5. Base 6. Nose 7. Point. Principal angles of a single point cutting tool The different angles provided on a single point cutting tool have a great signification role to play in successful and efficient machining of different metals. 1. Back rake angle 2. Front clearance angle 3. Side rake angle 4. Side clearance angle 5. Side cutting edge angle 6. End cutting edge angle 7. Nose radius 1.2.4 Tool signature: The term ‘tool signature’ is used to denote a standardised system of specifying the principal tool angles of a single point cutting tool. The seven elements that comprise the signature of a single point cutting tool are always staed in the following order: i. Back rake angle ii. Side rake angle iii. End relief angle iv. Side relief angle v. End cutting edge angle vi. Side cutting edge angle vii. Nose radius. 1.2.5 Heat produced during cutting Considerable heat during machining process is generated at the cutting edge of the tool due to friction between tool and work and the plastic shearing of the metal in the form of chips when the tool is machining metal on a machine tool. The three different zones are named as follow: 1. Zone A is the shear zone 2. Zone B is the friction zone 3. Zone C is the work-tool contact zone 1.2.6 Cutting speed, feed and depth of cut Cutting speed: The cutting speed of the cutting tool is defined as the speed at which the cutting edge passes over the material and it is expressed in meter per minute. Feed: The feed of a cutting tool is defined as the distance the tool advances into or along the work piece each time the tool point passes a certain position in its travel over the surface. Depth of cut: The depth of cut is defined as the perpendicular distance measured from the machined surface to the under cut surface of the work piece. 1.3 CUTTING TOOL MATERIALS With a great variety of machines and machining operations in use, there is no single tool material, which fulfils all the factors encountered during machining process. The relative importance of each item shifts with the nature of product machined. 1.3.1 Properties of cutting tool material i. It should be easily available. ii. It should have the ability to resist shock called toughness. iii. It should be harder than the material of work piece. iv. IT should have ability to retain its hardness at high temperatures called hot hardness. v. It should be cheap. vi. IT should be able to be fabricated and shaped easily. 1.3.2 Study of various cutting tool materials The following materials are commonly used for manufacturing of the cutting tools. i. High sped steel ii. Tungsten carbide iii. Cobalt steel iv. Cemented carbides v. Stellite vi. Cemented oxides or ceramics vii. Diamond. CONTENTS 2. Drilling 2.1 Principle of drilling 2.2 Classification of drilling machines and their description. 2.3 Various operation performed on drilling machine – drilling, spot facing, reaming, boring, counter sinking, hole, milling, tapping. 2.4 Speeds and feeds during drilling, impact of these parameters on drilling, machining time. 2.5 Types of drills and their features, nomenclature of a drill. 2.6 Drill holding devices. 2.7 Types of reamers. DRILLING INTRODUCTION Drilling is a metal cutting process performed by a rotating cutting tool to make a circular hole in solid materials. The cutting tool is named as a twist drill, since it has sharp twisted edges formed around a cylindrical tool provided with a helical groove along its length to allow the cut material to escape through it during drilling. 2.1 PRINCIPAL OF DRILLING It is defined as to generate a hole by the rotating edge of a cutting tool and exerting a large force on the work piece clamped on the table. 2.2 CLASSIFICATION OF DRILLING MACHINE There is a wide variety of drilling machines. These are manufactured in various sizes to suit the different types of work. They are either hand operated or power driven. The different types of drilling machines are classified as giver below. i. Portable drilling machine: As the name implies, portable drilling machine is a small drilling machine which can be easily carried to work piece or any where in the workshop. It is used for drilling holes in any position which cannot be performed with a standard drilling machine. The portable drilling machines are operated either by hand or power. Depending upon the source of power i.e. manual, electric or pneumatic the machines are of different types which are given below. a. Hand brace, b. Breast drill and c. Electric or Pneumatic drilling machine. ii. Sensitive or bench drilling machine: This drill machine is used for light work. It is usually fitted on a bench so it is called bench drilling machine as shown in fig. iii. Upright drilling machine: The upright pillar drilling machine is shown in fig. It is designed for handling medium sized work pieces. The constructional feature are very close to a sensitive drilling machine for having a vertical column mounted on the base with a difference that it is larger and heavier than a sensitive drill and is supplied with power feed arrangement. The upright drilling machine is of two general classes: a. Round column section or pillar drilling machine. b. Box column section. iv. Radial drilling machine: The radial drilling machine is shown in figure. It is intended for drilling medium to large and heavy work pieces. With the use of this machine, the tool is moved to the desired position instead of moving the work for drilling. The machine has a base on which a cylindrical vertical column is mounted. The column carries a radial arm which is raised or lowered by a separate motor and locked at a desired height with the help of clamping levers. v. Multiple drilling machine: this drilling machine is provided with many spindles or drill heads. These may vary from four to twelve or mare. All are driven from one spindle drive gear in one head fitted with one motor so that at a time four, six, eight or twelve holes can be drilled, reamed or tapped. This drilling machine is also named as cluster drilling machine. vi. Gang drilling machine: The gang drilling machine as shown in figure is a type of multiple spindle drilling machine in which the spindles are arranged in a row. These spindles are driven either separately. In this machine a number of operations like drilling, reaming , counter boring and tapping, etc. vii. Deep hole drilling machine: The deep hole drilling machine used where very long holes of relatively smaller diameter are required to be drilled as in refle barrels, long spindles, crank shafts and long shafts etc. The machine is operated at high speed with low feed. While drilling sufficient quantity of lubricant is pumped to the cutting points for removal of chips and cooling the cutting edges of the drill. For long jobs several supports are provided to prevent deflection. viii. Automatic drilling machine: It is used to perform a series of machining operations at successive units and to transfer the work from one unit to the other automatically. When the work is loaded at the first machine agter finish it moves to the other where different operations can be performed and the finished product comes out from the last unit. 2.3 VARIOUS OPERATIONS PERFORMED ON DRILLING MACHINE 1. Drilling 2. Spot facing 3. Reaming 4. Boring 5. Counter boring 6. Counter sinking 7. Hole milling 8.
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