Copyright 2008 Society of Manufacturing Engineers. FUNDAMENTALS OF TOOL DESIGN Cutting Tool Design

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1 FUNDAMENTALS OF TOOL DESIGN Cutting Tool Design SCENE 1. CT25A, CGS: Single-Point Cutting Tool Design white text, centered on background FTD01B, motion background SCENE 2. CT26A, tape FTD21, 01:03:22:00-01:03:33:00 zoom out, single point contour turning NEARLY ALL TURNING OPERATIONS USE SINGLE POINT CUTTING TOOLS. SCENE 3. continue previous shot CT27A, ANI: tool signature CT27B, CGS: Various Angles Significant Dimensions Special Features Nose Radius Size THE TOOL SIGNATURE OR NOMENCLATURE FOR A SINGLE-POINT CUTTING TOOL IS A SEQUENCE OF ALPHA AND NUMERIC CHARACTERS REPRESENTING THE VARIOUS ANGLES, SIGNIFICANT DIMENSIONS, SPECIAL FEATURES, AND NOSE RADIUS SIZE. SCENE 4. continue previous shot CT28A, tape FTD19, 20:31:30:00-20:31:40:00 zoom in, cutting tool case CT28B, ansi page CT28C, tape FTD07, 06:19:09:00-06:19:30:00 zoom out, turning operation THIS METHOD OF IDENTIFICATION HAS BEEN STANDARDIZED BY THE AMERICAN NATIONAL STANDARDS INSTITUTE, OR ANSI, FOR CARBIDE AND HIGH-SPEED-STEEL TOOLS. THIS ANSI CLASSIFICATION SYSTEM DOES NOT CATEGORIZE EVERYTHING. FOR EXAMPLE, THE VARIETIES OF CHIPBREAKER GEOMETRIES IN CARBIDE TURNING INSERTS ARE NOT REQUIRED TO BE COVERED. SCENE 5. CT29A, tape FTD21, 01:12:24:00-01:12:52:00

2 finish turning operation CT29B, CGS: Back-Rake Angle Side-Rake Angle End-Relief Angle Side-Relief Angle End-Cutting-Edge Angle Lead Angle Nose Radius Chipbreaker Design MANY OF THE CUTTING-TOOL ANGLES CLASSIFIED IN A TOOL S SIGNATURE INCLUDE: THE BACK-RAKE ANGLE, THE SIDE-RAKE ANGLE, THE END-RELIEF ANGLE, THE SIDE-RELIEF ANGLE, THE END-CUTTING-EDGE ANGLE, THE LEAD ANGLE, AND THE NOSE RADIUS. ADDITIONALLY, MANY MANUFACTURER S ALSO ADD A CHIPBREAKER DESIGN CODE TO A TOOL S SIGNATURE. SCENE 6. CT30A, CGS: Back-Rake Angle CT30B, CGS: Top-Rake Angle CT30C, ANI: top/back rake angle movie THE BACK-RAKE ANGLE, WHICH IS ALSO REFERRED TO AS THE TOP-RAKE ANGLE, IS THE ANGLE BETWEEN THE FACE OF THE CUTTING TOOL AND A LINE PARALLEL TO THE TOOLHOLDER BASE. SCENE 7. CT31A, tape FTD21, 01:05:10:00-01:05:20:00 turning operation CT31B, ANI: positive rake tool movie CT31C, ANI: negative rake tool movie VARIATIONS IN THE BACK-RAKE ANGLE INFLUENCE CHIP-FLOW DIRECTION AND CUTTING FORCE. A TOOL WITH A POSITIVE BACK-RAKE CUTS FREELY, WITH REDUCED POWER REQUIREMENTS AND REDUCED TEMPERATURES. CUTTING-EDGE STRENGTH DECREASES CONSIDERABLY THOUGH, AS POSITIVE BACK-RAKE ANGLES INCREASE ABOVE

3 5 DEGREES. A TOOL HAVING A NEGATIVE BACK-RAKE IS GENERALLY STRONGER, BUT IT GENERATES MORE FORCE AND REQUIRES MORE POWER. SCENE 8. CT32A, tape 227, 02:05:39:00-02:05:55:00 cast iron rough cut A TOOL HAVING A NEGATIVE OR A NEUTRAL BACK-RAKE IS PREFERRED FOR ROUGH TURNING OPERATIONS, PARTICULARLY FOR CAST IRON. SCENE 9. CT33A, CGS: Side-Rake Angle CT33B, ANI: side-rake angle movie THE SIDE-RAKE ANGLE IS THE ANGLE BETWEEN THE CUTTING-TOOL FACE AND A PLANE PARALLEL TO THE TOOL BASE. SCENE 10. CT34A, tape 227, 02:15:01:00-02:15:18:00 turning operation with good chip flow CT34B, tape 216, 01:04:39:00-01:05:01:00 turning operation with good chip flow VARIATIONS IN THE SIDE-RAKE ANGLE HAVE THE LARGEST EFFECT ON CUTTING FORCE AND, TO SOME EXTENT, AFFECT CHIP-FLOW DIRECTION. AS THIS ANGLE INCREASES, FORCES REDUCE ABOUT 1 PERCENT PER DEGREE OF POSITIVE SIDE RAKE BECAUSE WORKPIECE TEAR LESSENS. NEGATIVE SIDE RAKE INCREASES EDGE STRENGTH, WHICH IS RECOMMENDED FOR MOST STEELS. SCENE 11. CT35A, CGS: End-Relief Angle CT35B, end-relief angle movie CT35E, tape FTD12, 11:23:34:00-11:23:50:00 turning operation THE END-RELIEF ANGLE LIES BETWEEN THE END FLANK AND A LINE PERPENDICULAR TO THE CUTTING-TOOL BASE. ITS PURPOSE IS TO

4 PROVIDE CLEARANCE TO PREVENT RUBBING BETWEEN THE WORKPIECE AND THE TOOL END FLANK. EXCESSIVE CLEARANCE OR RELIEF ANGLE REDUCES TOOL STRENGTH, THUS THIS ANGLE SHOULD NOT EXCEED 5 TO 7 DEGREES. SCENE 12. CT36A, CGS: Side-Relief Angle CT36B, ANI: side-relief angle movie THE SIDE-RELIEF ANGLE RUNS BETWEEN THE CUTTING-TOOL SIDE FLANK AND A LINE PERPENDICULAR TO THE BASE. LIKE THE END- RELIEF ANGLE, THIS ANGLE ALSO PROVIDES CLEARANCE IN THE CUT. SCENE 13. CT37A, CGS: End-Cutting-Edge Angle CT37B, ANI: end-cutting-edge angle movie CT37E, tape 216, 01:09:32:00-01:09:52:00 turning operation THE END-CUTTING EDGE ANGLE LIES BETWEEN THE EDGE ON THE END OF THE CUTTING TOOL AND A PLANE PERPENDICULAR TO THE TOOL- SHANK SIDE. ITS PURPOSE IS TO AVOID RUBBING BETWEEN THE TOOL EDGE AND WORKPIECE. AS WITH END-RELIEF ANGLES, EXCESSIVE END-CUTTING EDGE ANGLES REDUCE TOOL STRENGTH. SCENE 14. CT38A, CGS: Lead Angle CT38B, CGS: Side-Cutting Edge Angle CT38C, ANI: lead angle movie CT38F, tape FTD22, 02:18:05:00-02:18:14:00 turning with lead angle THE LEAD ANGLE, WHICH IS ALSO COMMONLY REFERRED TO AS THE SIDE-CUTTING EDGE ANGLE, IS BETWEEN THE STRAIGHT CUTTING EDGE ON THE TOOL SIDE AND THE TOOL-SHANK SIDE. THIS EDGE PROVIDES THE PRINCIPAL CUTTING ACTION AND SHOULD BE KEPT AS

5 SHARP AS POSSIBLE. SCENE 15. CT39A, tape 227, 02:28:37:00-02:28:55:00 c.u. insert entering cut, cutting INCREASING THE LEAD ANGLE TENDS TO WIDEN AND THIN THE CHIP AND INFLUENCES CHIP- FLOW DIRECTION. TOO LARGE A LEAD ANGLE, HOWEVER, REDIRECTS FEED FORCE RADIALLY, WHICH MAY CAUSE CHATTER. SCENE 16. CT40A, CGS: Nose Radius CT40B, ANI: tool nose radius CT40C, ANI: arrow CT40D, ANI: tool nose radius in equal radius cut CT40E, tape FTD12, 11:25:05:00-11:25:35:00 c.u. turning operation emphasizing tool nose radius CT40F, ANI: tool nose radius highlight A CUTTING TOOL S NOSE RADIUS CONNECTS THE SIDE- AND END-CUTTING EDGES, AND MUST BE EQUAL TO OR SMALLER THAN THE SMALLEST RADIUS ON THE WORKPIECE FOR CUTS MADE WITH THAT TOOL. OTHER FACTORS INFLUENCING TOOL NOSE RADIUS SELECTION INCLUDE: THE SURFACE FINISH REQUIREMENTS, AND THE TOOL STRENGTH, WITH THE LARGEST TOOL NOSE-RADIUS PERMISSIBLE GIVING THE GREATEST STRENGTH. SCENE 17. CT41A, tape 227, 02:23:43:00-02:24:27:00 c.u. round tool nose radius CT41B, tape 239, 07:01:44:00-07:02:03:00 c.u. large tool nose radius in cut CT41C, tape 239, 07:00:42:00-07:00:48:00 c.u. large tool nose radius in cut part turned, completed, stops THE LARGER THE TOOL S NOSE RADIUS AND THE STRONGER THE CORNER THE GREATER THE CUTTING TOOLS ABILITY TO ABSORB HEAT, AND PRODUCE A SMOOTHER SURFACE. HOWEVER, A LARGER RADIUS ALSO GENERATES GREATER RADIAL CUTTING FORCES AND RUNS THE RISK OF VIBRATION. THE QUALITY OF THE

6 FINISHED TURNED SURFACE IS MAINLY FROM A COMBINATION OF THE CUTTING TOOLS NOSE RADIUS AND THE FEED PER REVOLUTION. SCENE 18. CT42A, CGS: Chipbreaker Design CT42B, tape FTD12, 11:11:17:00-11:11:40:00 zoom out, chipbreaking turning operation CT42C, CGS: Feed Rate Depth of Cut Chipbreaker Geometry IN TURNING, EFFECTIVELY BREAKING A CHIP IS JUST AS IMPORTANT AS MAKING THE CHIP. PROPER CHIP BREAKING RESULTS FROM A BALANCE BETWEEN FEEDRATE, DEPTH OF CUT, AND CHIPBREAKER GEOMETRY IN THE CUTTING TOOL. SCENE 19. CT43A, tape FTD14, 13:47:11:00-13:47:21:00 grinding of insert CT43B, tape FTD14, 13:26:08:00-13:26:22:00 pressing of insert CT43C, tape FTD21, 01:24:02:00-01:24:12:00 CT43D, tape FTD21, 01:24:52:00-01:25:02:00 CT43E, tape FTD21, 01:25:25:00-01:25:35:00 CT43F, tape FTD21, 01:26:44:00-01:26:54:00 CT43G, tape FTD21, 01:27:22:00-01:27:32:00 CT43H, tape FTD21, 01:28:02:00-01:28:12:00 CT43I, tape FTD21, 01:28:33:00-01:28:43:00 CT43J, tape FTD21, 01:01:24:00-01:01:43:00 zoom out, turning operation, chip breaking well CHIPBREAKING GEOMETRIES CAN BE GROUND INTO THE CUTTING SURFACE OF A TOOL OR PRESSED-IN USING MECHANICAL PRESSING. PRESSED-IN CHIPBREAKER DESIGNS OFFER A WIDE VARIETY OF PROPRIETARY GEOMETRIES THAT INCORPORATE GROOVES, BUMPS, WAVES, DIMPLES, AND ALL SORTS OF SHAPES. CHIPBREAKER GEOMETRIES ARE ALL DESIGNED TO PROVIDE CHIP CONTROL AND FORCE REDUCTIONS FOR SPECIFIC APPLICATIONS AT DESIGNATED FEED RATES AND DEPTH OF CUT. --- TOUCH BLACK --- SCENE 20. CT44A, tape FTD12, 11:17:50:00-11:18:06:00 zoom out, insert in toolholder, cutting WHEN TURNING WITH INSERTS, MUCH OF THE REQUIRED GEOMETRY, SUCH AS CLEARANCE ANGLES, IS BUILT INTO THE TOOLHOLDER

7 RATHER THAN THE INSERT ITSELF. SCENE 21. CT45A, tape 239, 07:12:00:00-07:12:29:00 medium shot of toolholder CT45B, CGS: Shank CT45C, CGS: Head CT45D, CGS: Pocket INSERT-TYPE TOOLHOLDERS FOR TURNING ARE MADE OF STEEL AND CONSIST OF A SHANK..., HEAD..., POCKET..., AND CLAMPING HARDWARE. SCENE 22. CT46A, tape FTD21, 01:25:54:00-01:26:13:00 c.u., insert secured in pocket with carbide seat TOOLHOLDER POCKETS ARE MACHINED TO ACCURATELY LOCATE AND ORIENT THE INSERT. SOMETIMES A CARBIDE SEAT IS USED BETWEEN THE POCKET AND THE INSERT. SCENE 23. CT47A, tape 239, 07:11:16:00-07:11:26:00 left-handed toolholder CT47B, tape 239, 07:09:46:00-07:09:56:00 right-handed toolholder CT47C, tape 239, 07:10:47:00-07:10:57:00 neutral toolholder TOOLHOLDERS ARE ALSO EITHER LEFT- HANDED..., RIGHT-HANDED..., OR NEUTRAL. SCENE 24. CT48A, tape 239, 07:17:14:00-07:17:24:00 55 degree toolholder CT48B, tape 239, 07:15:14:00-07:15:24:00 triangle toolholder CT48C, tape 239, 07:16:00:00-07:16:08:00 round tool holder CT48D, tape 239, 07:17:43:00-07:17:53:00 trigon toolholder CT48E, tape 239, 07:18:13:00-07:18:37:00 35 degree toolholder CT48F, CGS: Shank Size Hand of Tool Clamping Method Insert Shape Insert Size Insert Style Rake Angle TOOLHOLDERS ARE OFFERED IN A WIDE VARIETY AND ARE DESIGNATED BY SHANK SIZE, HAND OF TOOL, CLAMPING METHOD, INSERT SHAPE, INSERT SIZE, INSERT STYLE, AND RAKE ANGLE. --- FADE TO BLACK ---

FUNDAMENTAL MANUFACTURING PROCESSES CUTTING TOOL GEOMETRIES MUSIC UP AND UNDER NARRATION (VO): PRECISION MANUFACTURING.

FUNDAMENTAL MANUFACTURING PROCESSES CUTTING TOOL GEOMETRIES SCENE 1. CG: FBI warning SCENE 2. Tape 40, 01:00:00-01:00:12 ANI: SME logo SCENE 3. tape 25, 01:01:06-01:01:20 series opening title: FUNDAMENTAL