International Journal of Engineering Trends and Technology (IJETT) – Volume 27 Number 4 - September 2015
Optimization of Selecting Tool Materials under Different
Tool Geometry in a Single Point Cutting Tool - a Review
Ashok Atulkar 1, Ashish Soni2*
1 Assistant Professor, SGSITS, 23, Park Road, Indore, MP, India
2 Research Scholar, Department of Mechanical Engineering, SGSITS, Indore, MP, India
ABSTRACT
In the latter half of the nineteenth century the demand
in the manufacturing industry have led to the
development of improved machine tools. Also cutting
tools and production processes have been improved
during the course of time. Cutting tool material and
its geometry plays an important role in utilizing the
full potential of any machining process. Further with
the increase in the demand for economic competition
in the past few years have motivated a lot of
researches in the field of tool material as a result
improvement over the material properties have been
achieved. Carbon tool steel, high speed steel and cast
alloys were replaced by carbides and ceramics
because of high hardness and abrasive resistance has
facilitated the application of greater and wider range
of cutting speed. By improving cutting tool materials
and tool geometries effective improvement in the
machining efficiency has been delivered. With the
advent of carbide and ceramics tools radical changes
have been made in the design of tool cutters and
holders . Selection of suitable material for a cutting
tool and geometry are important for desirable
material removal rate, production rate, machined
surface, rigidity of the setup, accuracy, finish etc.
Though there is no fixed rule for selecting tool
material, the overall economy and demand for
specific cutting tool property decides the type of
material to be selected. This review aims fully to
describe the development in the cutting material and
also highlights some previous analysis which have
been made over cutting tool geometry in the past few
years. The history and principal of metal cutting are
also outlined.
Keywords: Finite element method, von misses stress,
back rake angle, ANSYS, edge radius.
performance of a tool material one of the most
important factor for consideration is tool life.
Till 1900, High carbon steel was only the material
which was used for machining. High carbon steel are
plain carbon steel without appreciable alloying
element. They have high surface hardness, develops
keen cutting edge and are easily machinable , but as
temperature reaches at
C or above plain
carbon steel tools losses its hardness and dimensional
stability[1]. Shortly after 1900, some alloying
element like Vanadium (Vd), Chromium (Cr), Cobalt
(Co), Molybdenum (Mo) and Tungsten have been
added to plain carbon steel giving rise to several
types of tools of higher cutting spe
C[1] thus can be used at
higher cutting speed. It was found that certain
combination of tungsten, chromium and cobalt forms
cast cobalt alloy, having red hardness , wear
resistance and toughness. In 1920, with the advent of
Cemented Carbide as a cutting tool material a major
breakthrough come. Most of the tools produced
earlier were by molten metallurgy thus hardness
depends on proper heat treatment
whereas,
cemented carbide were produced by powder
metallurgy. Cemented carbide can be used at higher
cutting speed,
C[1] and posses better wear
resistance. Some of the problems encountered with
the carbide tools were low tensile strength, rapid
flank wear,
catering, spalling etc. Further
improvement in the tool material leds to the
introduction of Ceramics , which was produced by
processing Bauxite into a de
INTRODUCTION:
Over the years the economic competition in the
field of manufacturing industries has increased a lot
and metal cutting forms the basis of industrial
engineering as a result lot of researchers are
motivated in the field of metal cutting. A wedge
shaped tool is constrained to move relative to the
work piece and metal is removed in the form of chips.
Properties of cutting tool material and tool geometry
have considerable influence on the tool wear, which
causes a tool to lose its original shape and has adverse
effect in production. Also for assessing the
ISSN: 2231-5381
C[1] thus can be used at higher
cutting speed and at elevated temperature. Ceramics
aids in increasing the production and lowering cost.
Ceramics provide good surface finish .However
owing to brittleness and lack of strength their
application was limited .UCON a new material
consisting of Tungsten ,Columbium and Titanium
was introduced. It was developed by Union Carbide
,USA. UCON cuts very cool. It has excellent thermal
shock resistance, high hardness and toughness.
UCON is primarly recommended for roughing and
finishing cuts in turning, facing and boring. Next to
UCON, Diamond of various forms comes which
because of exponentially high hardness, inertness and
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International Journal of Engineering Trends and Technology (IJETT) – Volume 27 Number 4 - September 2015
modulus of elasticity found to be ideal material for
obtaining fine surface finish and accuracy. But
Diamond is extremely brittle also it starts to oxide at
a temp
C[1] .Further to improve
shock and to increase strength
polycrystalline
diamond has been introduced. Problem of oxidation
has been overcome with the introduction of Cubic
Boron Nitride. It was successfully used for grinding
wheel on High Speed Steel which provides better
surface finish and higher output.
and tools. There are two groups of carbides available
for machining tungsten carbide and titanium carbide.
Titanium carbide have higher wear resistance but
lacks in toughness. For machining steels, cast irons
and abrasive non-ferrous materials mostly uses
tungsten carbide. It is used for machining at higher
speed as compared to tungsten carbide.
CUTTING TOOL MATERIAL
6. Ceramics : Ceramics are hard and have high
degree of compressive strength till a temperature of
1400°C and their strength is becomes uniform at
1200°C. Ceramics are highly reactive on the work
piece. Ceramics are used in the applications where
good surface finish is a requirement .Ceramics
permits higher cutting speed than Carbide.
The tool is a wedge shape material. The main
requirement of tool is hardness .It must be hard to
resist forces during cutting, applied to the work piece.
Hot hardness, thermal conductivity, toughness, wear
resistance and specific heat, coefficient of friction are
the other requirement of a tool material. The different
materials for cutting tool are
1. Carbonsteels: Carbon generally varies from 0.6 %
to 1.5 %[1] and hardened to about 62Rc.[2]Properties
varies with the change in carbon percentage. At low
carbon content, tools are tough and shock resistant
whereas at high carbon content they are abrasive
resistant. But carbon steel start to soften at a
temperature of 180°C.[2] Therefore such tools are
operated at low cutting speed and take only light
loads. They are widely used for woodworking.
2. High Speed Steel: They were developed to cut at
higher speed as compared to carbon steel which is
about 28-30 m/min. and are most highly alloyed tool
steel tools. It contain 12-18 % Tungsten, 4%
Chromium and 1-5 % Vanadium. Most of grade
contain 0.5% Molybdenum and some other contain 412% Cobalt.[2] Later it was found that Molybdenum
can be used as a substitute for Tungsten, which
results in better abrasion resistance. There cutting
edge can withstand at a temperature of 600°C.
HSS tools are tough and therefore is much suitable
for interrupted cutting. HSS are used to manufacture
drills, reamers, taps, dies and gear cutters.
3. Cast Cobalt alloys: It contain about 40-55 % of
Cobalt, 30% Chromium and 10-20 % Tungsten.[2]
Addition of Cobalt with Tungsten and Chromium
forms an alloy which has properties of higher wear
resistance, red hardness, toughness. Maximum
hardness values varies from 55 to 64Rc. Cast Cobalt
alloys has better wear resistance but lacks in
toughness.
4. Carbides: Carbides are known as cemented or
sintered carbides. Maximum cutting speed is
150m/min. For such type of tool carbide chip is made
by powder metallurgy and then it is fixed over the
tool by brazing. They have high hardness and high
thermal conductivity and hence used for making dies
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5. Cermets: Cermets contain 30% Titanium and 70%
Aluminum oxide. [2]
(a) Alumina : There are two classes available for
cutting tools: Fine grained Aluminium oxide of high
purity and Silicon nitride , these are pressed into tip.
These tips have high abrasion resistance, hot hardness
and more chemical resistance as compared to HSS,
but low in toughness. Cutting speed varies from 150650m/min.
(b) Silicon Nitride : Silicon Nitride have affinity for
iron and it is not suitable for machining steels.
7. Cubic Boron Nitride: Boron has a hexagonal
structure but on heating in the presence of catalyst it
get converted into cubic structure, which is very hard
and it is the second hardest material after diamond. It
is chemically inert. CBN is used in the form of solid
tips or as a thick layer of polycrystalline boron nitride
which is sintered carbide substrate under pressure.
CBN coated tools are widely used for machining
stainless steel and high speed steel.
8. Diamond: It is the hardest substance known, its
hardness value is about 7500HV and cutting speed is
nearly 1000m/min. A single diamond crystal is brittle
and it needs to be mounted at correct crystal
orientation. Single crystal diamond tool is replaced by
polycrystalline diamond in which small synthetic
crystal is fused at high temperature and pressure to a
thickness of between 0.5-1 mm[2] and bounded to a
carbide substrate. It is mostly used for finishing at
any speed mainly at high for machining of aluminumsilicon, composites and other metallic materials.
9. UCON: UCON is developed by Union carbide,
USA and it is a material. It has a composition of 50%
Columbium, 30% Titanium.[1] UCON has excellent
high hardness, toughness and possess high thermal
shock resistance. Cutting range varies from 250 to
500m/ min. Its edge life is 3-5 times than that of
Carbides.
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Base :
It is support of the tool shank which takes the
tangential cutting force.
Face :
It is the surface over which the chip flows when
separates from the work piece.
Flank :
It is the end surface, when the tool is horizontal
position.
Cutting Edge :
10. Coatings: Coatings are applied to carbide tool tips
to enable higher cutting speed. Some mostly used
materials for coating are nitride and carbide of
titanium and oxide of aluminium and thickness varies
from 2-15 micro-m .
PRINCIPLE OF METAL CUTTING
The chip formation process in the cutting of brittle
and elastic-plastic work piece material is considered
as a result of the dynamic interaction of the system
components. The system consideration reveals that:
1. The formation of chip is caused by bending stress
when it is combined with the shear stress in the
deformation zones.
Cutting edge separates chip from the work piece. The
cutting edge consists of side cutting edge , the nose
and the cutting edge.
In a study, six different model of cutting tool have
taken having edge radii (0.01,0.05,0.1,0.15,0.2 and
0.25)mm and the effect on cutting forces , stress
distribution were studied at rake face and tool chip
contact length was summarized. The optimum edge
radius which was found is 0.05 mm because for this
radius the value for stress is minimum .Also it is
observed during analysis if the cutting edge is 0.01
mm , the tangential and feed force is minimum [3].
Tool Point :
Cutting edge and the face are produced by shaping
the tool point.
2. Chip formation is cyclic.
The Nose :
DESCRIPTION OF
CUTTING TOOL:
A
SINGLE
POINT
It relates to top of cutting edge. As the nose radius is
increased the value for required cutting force also
increases.
Geometry of a single point cutting tool :
Tool geometry takes its approach with the basic tool
angle. A single point cutting tool has only one cutting
edge and is most widely used in machining operation
and there are two forms of such tool , in one form it is
solid tool and in other form it is tipped tool.
Neck :
Size :
Side cutting edge angle :
Size is determined by height , width and overall
length of tool.
It is also called lead angle or principal angle. Side
cutting edge angle is the angle between side of
cutting of cutting edge and tool shank.
Neck is small cross section behind the point.
TOOL ANGLES:
Shank :
End cutting edge :
It is the main body of tool on which the cutting edge
is formed and it is generally analyzed for strength and
rigidity.
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It is the angle between the cutting edge on the side of
tool and shank, it should be kept as sharp as possible.
It provides major cutting action.
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International Journal of Engineering Trends and Technology (IJETT) – Volume 27 Number 4 - September 2015
It is responsible for turning the chip away from the
finish surface. Smaller is the value of this angle larger
is the force required to machine surface and tool may
chatter. Generally value ranges from 8°-15°.
Side relief angle :
It is the angle between the surface of the flank and a
plane at right angle to the centre line of the point of
the tool. Due to elastic recovery the work piece
material which is going to be removed will try to hit
side flank to avoid this rubbing side relief angle is
provided. It provides clearance thus prevent
interference.
End relief angle :
It is the angle formed between a line drawn
perpendicular to the base and surface of the flank. It
is provided on the tool to provide clearance between
the work piece and the tool.
Back rake angle :
The angle between the face of the tool and a line
parallel to the tool base, measured in a perpendicular
plane through the side cutting edge is called back
rake angle. It measures the slope of the face of the
tool from the nose towards the rear. Increase in the
value of back rake angle facilities the chip flow,
consequently there will be decrease in the drag hence
tool wear out. Initially by increasing the back rake
angle tool life increases but at a particular value lip
angle of the tool decreases which decreases the
strength of the tool hence tool life. Optimum value
ranges from 10-15°.
Fig 1. Representation of various angles in different
views of single point cutting tool
In a study three different rake angle of values
2°,9°,and 11° were used to find out the variation in
the value of vonmises stresses for a specified applied
force. From study it was found the vonmises stress
decreases as the value of rake angle increases as a
result tool life increases. On further increase in rake
angle it was found that although tool force go on
decreasing, tool life decreases.[4]
Fig 2. Variation of back rake angle with respect to
tool life
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International Journal of Engineering Trends and Technology (IJETT) – Volume 27 Number 4 - September 2015
CONCLUSION:
A review of history of cutting tool reveals that a new
tool material seldom fully replaces the old one . The
performance of a cutting in any machining operation
is mainly determined by wear resistance, hot hardness
and toughness. A material which permits high cutting
speed will produce better surface finish, thus the
order would be carbon steel , HSS, Cast alloy
Sintered Carbide tool. Diamond produced best
surface finish due to smaller built up edge as a result
low friction of material on the face of diamond. Tool
life and surface finish are are influence by tool
geometry. The important tool characteristic
considered are the nose radius , rake angle and tool
edge geometry. Surface finish is improved by
increasing nose radius. Machining is significantly
influence by heat generation . It escalates tool wear
and reduces tool life, Also the failure mechanism
developing during cutting are influence by
temperature. It is observed that the maximum
interface temperature exist in the first part of tool chip contact and at higher cutting speed surface
temperature is decreased . Cutting forces has been
found to be an important variable in generating
surface temperature . So, to prevent wear and failure
characteristic of a tool , it is necessary to quantify the
temperature limit .
6. Mr. Yash R. Bhoyar1, Prof. P. D. Kamble2. "Finite element
analysis on temperature distribution." International Journal of
Modern Engineering Research (IJMER) Issue.1, Jan-Feb.
2013.
7. Lalitha Babu1, M. Kumara Swamy, "Finite element analysis of a
plane; milling cutter" International Journal of Modern
Engineering Research (IJMER) :Vol. 2, Issue. 6, Nov-Dec.
2012.
8. Vivek Varia, and Prof. Jegadeeshwarwn. "Finite element
analysis of deformation of single point cutting tool "
International journal on Innovation in engineering and
Technology Dec 25-26 2013.
9. P.C.Sharma, “Production Engineering”, S.Chand publisher, New
Delhi, pp 149-155. [12] P.N.Rao,
10. Manufacturing technology-Metal Cutting and Manufacturing
Tools, Tata McGraw-Hill Publishing Company Limited, New
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11. Production Technology R. K. Jain ,Khanna publishers .
12. NBV Lakshmi Kumari, S. Irfan Sadaq G. Prasana Kumar
''Analysis of Single Point Cutting Tool of a Lathe Machine
Using FEA ''International Journal of Engineering Trends and
Technology (IJETT) – Volume 20 Number 5 – Feb 2015
13. Olugboji Oluwafemi Ayodeji1, Matthew Sunday Abolarin,Jiya
Jonathan Yisa, Popoola Solomon Olaoluwa, Ajani Clement
Kehinde ''Effect of Cutting Speed and Feed Rate on Tool
Wear Rate and Surface Roughness in Lathe Turning Process
''International Journal of Engineering Trends and Technology
(IJETT) – Volume22 Number 4- April 2015
14. Mr.MangesR.Phate,Dr.V.H.Tatwawadi''Modeling of Power
Consumption in Turning of Ferrous and Nonferrous Materials
using Artificial Neural Network ''International Journal of
Engineering Trends and Technology- Volume4Issue3- 2013
ACKNOWLEDGEMENT:
I extend my courtesy to all authors and publishers of
the journal from where I have collected my
information. I am deeply privileged to be a part of
SHRI GOVINDRAM SEKSARIA INSTITUTE OF
TECHNOLOGY AND SCIENCE for the course of
my work on this paper. I am highly thankful to Prof.
Dr. Smita ManePatil, Professor and Head Of the
Department, Mechanical Department, for her expert
advice, technical suggestions and moral support
during in this work.
In addition, I would like to thank my friends for
sharing their experience in CATIA, ANSYS. Finally,
I would like to thank my family for their support and
putting up with me for these past few months moral
and financial support during my studies.
REFERENCES:
1. Production Technology, Tata McGraw- Hill Publishing
Company Ltd.; New Delhi.
2. Dr David J Grieve, Manufacture and Materials -2.7 Materials
for Cutting Tools 23-03-2009.
3. Dr. Maan Aabid Tawfiq and Suha Kareem Shahab "Analysis of
single point cutting tool using different tool edge
geometry."Eng. & Technology, Vol.25, No.4, 2007.
4. Deepak Bhardwaj, B. Kumar "Study and analysis of single point
cutting tool under variable rake angle" International Journal
of Scientific and Innovative Research 2014.
5. Maheshwari, N Patil Shreepad Sarange, Dr. D. Y. Patil
"Analysis of von mises stress and deformation at the tip of
cutting tool." International Journal of Innovative Research in
Advanced Engineering (IJIRAE) Volume 1 Issue 1 (April
2014.
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