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Tool Design Cutting Tool Design Basic Tool Angles (Tool Signature)

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Tool Design Cutting Tool Design Basic Tool Angles (Tool Signature) Tool Design Cutting Tool Design Nageswara Rao Posinasetti Guidelines for Cutting tool Design Rigidity Strength Weak links Force limitations Speed, feed and size Related force components Chip disposal Uneven motions Chatter January 31, 2008 Nageswara Rao Posinasetti 2 Basic tool angles (Tool Signature) Back rake angle Side rake angle End relief angle Side relief angle End cutting edge angle Side cutting edge angle Nose radius January 31, 2008 Nageswara Rao Posinasetti 3 1 January 31, 2008 Nageswara Rao Posinasetti 4 January 31, 2008 Nageswara Rao Posinasetti 5 January 31, 2008 Nageswara Rao Posinasetti 6 2 January 31, 2008 Nageswara Rao Posinasetti 7 January 31, 2008 Nageswara Rao Posinasetti 8 January 31, 2008 Nageswara Rao Posinasetti 9 3 Selecting carbide Tools Establish the operating conditions Select the –Cemented carbide grade –Nose radius –Insert shape –Insert size –Insert thickness –Tool style –Rake angle –Shank size –Chip breaker January 31, 2008 Nageswara Rao Posinasetti 10 Establish the operating conditions Feed, speed and depth of cut greatly influence the machining performance. Also lead angle affects the performance January 31, 2008 Nageswara Rao Posinasetti 11 FIGURE F-27 The difference in style A and style D holders for depth of cut and cutting edge engagement length (copyright © General Electric Company). Richard R. Kibbe, JohnJanuary E. Neely, 31, 2008 Nageswara Rao Posinasetti 12 Roland O. Meyer, and Warren T. Copyright ©2002 by Pearson Education, Inc. White Upper Saddle River, New Jersey 07458 Machine Tool Practices, 7e All rights reserved. 4 FIGURE F-28 Large, well-formed chips were produced by this tool with built-in chip breaker (Kennametal, Inc., Latrobe, PA). Large depth of cut Richard R. Kibbe, JohnJanuary E. Neely, 31, 2008 Nageswara Rao Posinasetti 13 Roland O. Meyer, and Warren T. Copyright ©2002 by Pearson Education, Inc. White Upper Saddle River, New Jersey 07458 Machine Tool Practices, 7e All rights reserved. To reduce cutting edge chipping Increase the speed Decrease the feed and/or depth of cut Change to a tougher grade carbide insert Use a negative rake Hone the cutting edge before use Check the rigidity and tool overhang January 31, 2008 Nageswara Rao Posinasetti 14 Select the cemented carbide grade Straight carbides - Cast iron, Resistance to Tungsten carbide nonferrous and edge wear (WC) and cobalt nonmetallic binder materials January 31, 2008 Nageswara Rao Posinasetti 15 5 Select the cemented carbide grade Straight carbides - Cast iron, Resistance to Tungsten carbide nonferrous and edge wear (WC) and cobalt nonmetallic binder materials WC + Titanium Steels Resistance to carbide + Tantalum cratering carbide with cobalt binder Coated carbides January 31, 2008 Nageswara Rao Posinasetti 16 January 31, 2008 Nageswara Rao Posinasetti 17 January 31, 2008 Nageswara Rao Posinasetti 18 6 January 31, 2008 Nageswara Rao Posinasetti 19 Select the nose radius Based on surface finish January 31, 2008 Nageswara Rao Posinasetti 20 FIGURE F-34 Surface finish versus nose radius (copyright © General Electric Company). Richard R. Kibbe, JohnJanuary E. Neely, 31, 2008 Nageswara Rao Posinasetti 21 Roland O. Meyer, and Warren T. Copyright ©2002 by Pearson Education, Inc. White Upper Saddle River, New Jersey 07458 Machine Tool Practices, 7e All rights reserved. 7 Select the insert shape Round – strong and large radius, good for higher feed rates Square – medium stronger Traingular – least stronger, less number of cutting edges, but more versatile in use January 31, 2008 Nageswara Rao Posinasetti 22 FIGURE F-35 Insert shapes for various applications (Kennametal, Inc., Latrobe, PA) Richard R. Kibbe, JohnJanuary E. Neely, 31, 2008 Nageswara Rao Posinasetti 23 Roland O. Meyer, and Warren T. Copyright ©2002 by Pearson Education, Inc. White Upper Saddle River, New Jersey 07458 Machine Tool Practices, 7e All rights reserved. January 31, 2008 Nageswara Rao Posinasetti 24 8 January 31, 2008 Nageswara Rao Posinasetti 25 FIGURE F-36 A 38-degree triangular insert used for a tracing operation (copyright © General Electric Company). Richard R. Kibbe, JohnJanuary E. Neely, 31, 2008 Nageswara Rao Posinasetti 26 Roland O. Meyer, and Warren T. Copyright ©2002 by Pearson Education, Inc. White Upper Saddle River, New Jersey 07458 Machine Tool Practices, 7e All rights reserved. Select the insert size Smallest size based on the depth of cut used Cutting edge should be 1.5 times that of the length of cutting edge engagement. January 31, 2008 Nageswara Rao Posinasetti 27 9 Select the insert thickness Gives the strength of the tool January 31, 2008 Nageswara Rao Posinasetti 28 FIGURE F-37 Insert thickness as determined by length of cutting edge engagement and feed rate (copyright © General Electric Company). Richard R. Kibbe, JohnJanuary E. Neely, 31, 2008 Nageswara Rao Posinasetti 29 Roland O. Meyer, and Warren T. Copyright ©2002 by Pearson Education, Inc. White Upper Saddle River, New Jersey 07458 Machine Tool Practices, 7e All rights reserved. Select the tool style Based on the geometry of the operation to be performed. January 31, 2008 Nageswara Rao Posinasetti 30 10 FIGURE F-38 Several of the many tool styles available (Kennametal, Inc., Latrobe, PA). Richard R. Kibbe, JohnJanuary E. Neely, 31, 2008 Nageswara Rao Posinasetti 31 Roland O. Meyer, and Warren T. Copyright ©2002 by Pearson Education, Inc. White Upper Saddle River, New Jersey 07458 Machine Tool Practices, 7e All rights reserved. January 31, 2008 Nageswara Rao Posinasetti 32 January 31, 2008 Nageswara Rao Posinasetti 33 11 January 31, 2008 Nageswara Rao Posinasetti 34 January 31, 2008 Nageswara Rao Posinasetti 35 January 31, 2008 Nageswara Rao Posinasetti 36 12 January 31, 2008 Nageswara Rao Posinasetti 37 Select the rake angle January 31, 2008 Nageswara Rao Posinasetti 38 FIGURE F-39 Side view of back rake angles. Richard R. Kibbe, JohnJanuary E. Neely, 31, 2008 Nageswara Rao Posinasetti 39 Roland O. Meyer, and Warren T. Copyright ©2002 by Pearson Education, Inc. White Upper Saddle River, New Jersey 07458 Machine Tool Practices, 7e All rights reserved. 13 Select the shank size January 31, 2008 Nageswara Rao Posinasetti 40 FIGURE F-40 Determining shank size according to depth of cut, feed rate, and tool overhang (copyright © General Electric Company). Richard R. Kibbe, JohnJanuary E. Neely, 31, 2008 Nageswara Rao Posinasetti 41 Roland O. Meyer, and Warren T. Copyright ©2002 by Pearson Education, Inc. White Upper Saddle River, New Jersey 07458 Machine Tool Practices, 7e All rights reserved. FIGURE F-41 A boring bar with various interchangeable adjustable heads (Kennametal, Inc., Latrobe, PA). Richard R. Kibbe, JohnJanuary E. Neely, 31, 2008 Nageswara Rao Posinasetti 42 Roland O. Meyer, and Warren T. Copyright ©2002 by Pearson Education, Inc. White Upper Saddle River, New Jersey 07458 Machine Tool Practices, 7e All rights reserved. 14 Select the chip breaker January 31, 2008 Nageswara Rao Posinasetti 43 FIGURE F-42 Chip breakers used are the adjustable chip deflator (center) with a straight insert and the type with the built-in chip control groove. Richard R. Kibbe, JohnJanuary E. Neely, 31, 2008 Nageswara Rao Posinasetti 44 Roland O. Meyer, and Warren T. Copyright ©2002 by Pearson Education, Inc. White Upper Saddle River, New Jersey 07458 Machine Tool Practices, 7e All rights reserved. FIGURE F-43(b, c) (a) Negative rake two-sided Kenloc inserts; *Maximum D.O.C. and feed rates (ipr) are limited by the insert thickness and cutting edge length. Application ranges are for AISI 1045 steel at 180 to 220 BHN (Kennametal, Inc., Latrobe, PA.) Richard R. Kibbe, JohnJanuary E. Neely, 31, 2008 Nageswara Rao Posinasetti 45 Roland O. Meyer, and Warren T. Copyright ©2002 by Pearson Education, Inc. White Upper Saddle River, New Jersey 07458 Machine Tool Practices, 7e All rights reserved. 15 Tool Holder Identification January 31, 2008 Nageswara Rao Posinasetti 46 FIGURE F-44 ASA tool identification system (Tool Application Handbook; data courtesy of Kennametal, Inc., Latrobe, PA, 1973.) Richard R. Kibbe, JohnJanuary E. Neely, 31, 2008 Nageswara Rao Posinasetti 47 Roland O. Meyer, and Warren T. Copyright ©2002 by Pearson Education, Inc. White Upper Saddle River, New Jersey 07458 Machine Tool Practices, 7e All rights reserved. Carbide Insert Identification January 31, 2008 Nageswara Rao Posinasetti 48 16 FIGURE F-45 ASA carbide insert identification (Tool Application Handbook; data courtesy of Kennametal, Inc., Latrobe, PA, 1973.) Richard R. Kibbe, JohnJanuary E. Neely, 31, 2008 Nageswara Rao Posinasetti 49 Roland O. Meyer, and Warren T. Copyright ©2002 by Pearson Education, Inc. White Upper Saddle River, New Jersey 07458 Machine Tool Practices, 7e All rights reserved. January 31, 2008 Nageswara Rao Posinasetti 50 January 31, 2008 Nageswara Rao Posinasetti 51 17 January 31, 2008 Nageswara Rao Posinasetti 52 January 31, 2008 Nageswara Rao Posinasetti 53 Multiple-Point Cutting Tools Drilling Reaming Milling Gear cutting January 31, 2008 Nageswara Rao Posinasetti 54 18 January 31, 2008 Nageswara Rao Posinasetti 55 Power requirement for Drilling Torque, M = 25,200 f 0.8 d 1.8 Thrust, T =57,500 f 0.8 d 0.8 + 625 d 2 d = drill diameter, in f = feed in/rev January 31, 2008 Nageswara Rao Posinasetti 56 January 31, 2008 Nageswara Rao Posinasetti 57 19 January 31, 2008 Nageswara Rao Posinasetti 58 Power requirement for Reaming 2 ⎡ ⎛ d ⎞ ⎤ ⎢ 1 − ⎜ 1 ⎟ ⎥ 0.8 1.8 ⎢ ⎝ d ⎠ ⎥ M = 23,300 k f d 0.2 ⎢ ⎛ d ⎞ ⎥ ⎢1 + ⎜ 1 ⎟ ⎥ ⎣ ⎝ d ⎠ ⎦ ⎡ ⎛ d ⎞ ⎤ ⎢ 1 − ⎜ 1 ⎟ ⎥ 0.8 0.8
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