BASICS OF CUTTING
TOOLS
IN INDUSTRIES ,WE ARE USING DIFFERENT
TYPES OF CUTTING
TOOLS.IN WHICH,THE PRIMARY CUTTING
TOOL IS ,
TIPS (OR) INSERTS
INSERT SPECIFICATION
EXAMPLE – DNMG 110408
1. D – INSERT SHAPE
D - DIAMOND 55
C - DIAMOND 80
R - ROUND
S – SQUARE
T – TRIANGLE
V – DIAMOND 35
W – TRIGON 80
H - HEXAGON 60
EXAMPLE – DNMG 110408
2. N – INSERT CLEARANCE ANGLE
CLEARANCE ANGLE
A - 3 DEGREE
B – 5 DEGREE
C – 7 DEGREE
E – 20 DEGREE
N – 0 DEGREE
P – 11 DEQREE
D – 15 DEGREE
EXAMPLE – DNMG 110408
3. M – TOLERANCE CLASS
LETTER SYMBOL I.C THICKNESS
A - 0.025 A - 0.025
B – 0.025 B – 0.127
C – 0.025 C – 0.025
D – 0.025 D – 0.127
E – 0.025 E – 0.025
F – 0.013 F – 0.025
G – 0.025 G – 0.0127
H – 0.013 H – 0.013
J,K,L – 0.05- J,K,L – 0.025
0.13 M – 0.127
M – 0.05-0.10 U – 0.127
U – 0.13-0.25 N – 0.025
N – 0.05-0.10
EXAMPLE – DNMG 110408
4. G – TYPE OF INSERT
TYPE OF THE INSERT INCLUDES CHIP BREAKER
AND RELIEF OF THE INSERT.
TYPES ARE,
A P
B R
G S
H T
M W
N X(SPL DESIGN)
EXAMPLE – DNMG 110408
5. 11 – LENGTH OF THE INSERT IN MM
DIFFERENT TYPES OF
LENGTH,
05
06
09
11
12
16
EXAMPLE – DNMG 110408
5. 04 – THICKNESS OF THE INSERT IN MM
DIFFERENT TYPES OF THICKNESS ARE,
01
02
03
04
T3
06
EXAMPLE – DNMG 110408
5. 08 – NOSE RADIUS OF THE INSERT IN MM
DIFFERENT TYPES OF RADIUS ARE,
02
04
08
1.2
1.4
1.6
TOOL HOLDER SPECIFICATION
EXAMPLE – MDJNL 2525 M11
1. M – CLAMPING TYPE
OVER HANG NOT EXEED – 1.5H
CLAMPING TYPES,
M – LEVER,TOP,WEDGE TYPE
P - LEVER TYPE
S - SCREW TYPE
C - TOP CLAMP TYPE
D - INSERT CENTRE CLAMP TYPE
TOOL HOLDER SPECIFICATION
EXAMPLE – MDJNL 2525 M11
1. D – INSERT SHAPE
D - DIAMOND 55
C - DIAMOND 80
R - ROUND
S – SQUARE
T – TRIANGLE
V – DIAMOND 35
W – TRIGON 80
1
TOOL HOLDER SPECIFICATION
EXAMPLE – MDJNL 2525 M11
1. J – LEAD ANGLE
LEAD ANGLES
15 0
1
TOOL HOLDER SPECIFICATION
EXAMPLE – MDJNL 2525 M11
1. N – INSERT CLEARANCE ANGLE
TOOL HOLDER SPECIFICATION
TYPES OF CLEARANCE ANGLE ;
A - 3 DEGREE
B – 5 DEGREE
C – 7 DEGREE
E – 20 DEGREE
N – 0 DEGREE
P – 11 DEQREE
D – 15 DEGREE
TOOL HOLDER SPECIFICATION
EXAMPLE – MDJNL 2525 M11
1. L – HAND OF TOOL
TOOL HOLDER SPECIFICATION
L – LEFT HAND TOOL HOLDER FOR CCW
R – RIGHT HAND TOOL HOLDER FOR CW
TOOL HOLDER SPECIFICATION
EXAMPLE – MDJNL 2525 M11
1. 2525 – HOLDER SHANK SIZE
TOOL HOLDER SPECIFICATION
DIFFERENT TYPES OF SHANK SIZES,
HEIGHTXWIDTH
1010
1212
2525
2020
1616
THE SHANK SIZE,DEPENDS UPON THE CENTRE HEIGHT.
TOOL HOLDER SPECIFICATION
EXAMPLE – MDJNL 2525 M11
1. M – HOLDER SHANK LENGTH
TOOL HOLDER SPECIFICATION
DIFFERENT TYPES OF SHANK LENGTH,
W – 450 MM
V – 400 MM
U – 350 MM
S – 250 MM
R – 200 MM
M – 150 MM
K – 125 MM
J – 120 MM
H – 100 MM
TOOL HOLDER SPECIFICATION
EXAMPLE – MDJNL 2525 M11
1. 11 – INSERT LENGTH
TOOL HOLDER SPECIFICATION
DIFFERENT TYPES OF
LENGTH,
05
06
09
11
12
16
BORING BAR SPECIFICATION
S 20 S SCLCR 09
S – MATERIAL OF BORING BAR (S-STEEL,C-CARBIDE)
20 – BAR DIAMETER
S – LENGTH OF BORING BAR
S – METHOD OF HOLDING INSERT
C – INSERT SHAPE
L – BORING BAR STYLE
R – HAND OF BORING BAR
09 – LENGTH OF THE INSERT
MECHANICS OF METAL CUTTING
MAIN THREE ELEMENTS ARE ,
1.RAKE ANGLES
2.LEAD ANGLES
3.CLEARANCE ANGLES
MECHANICS OF METAL CUTTING
TWO TYPES OF RAKEANGLES ARE ,
1.POSITIVE RAKE ANGLE
2.NEGATIVE RAKE ANGLE
RAKE ANGLES
+6
-5
NEGATIVE POSITIVE
LEAD ANGLES
15 0
1
CLEARANCE ANGLES
NEGATIVE
POSITIVE
5 6
CUTTING SPEED Vc = 3.14XDXN/1000
FEED RATE (mm/rev) = mm/min/RPM
RPM = VcX1000/3.14XD
CUT TIME = LENGTH OF CUT/MM/REVXRPM
Material Removal Rate(MRR) = Vc(m/min) X DOC mmXFmm/rev
CUTTING TOOLS
CUTTING TOOLS ARE GRADED FOR DIFFERENT
WORK MATERIALS. ( ISO STANDARD)
P – STEEL
M – STAINLESS STEEL
K – CAST IRON
N – NON FERROUS
S – SUPER ALLOYS
H – HARDENED STEEL
CUTTING TOOLS
CUTTING TOOLS ARE PREPARD BY POWDER METALLERGY
SYSTEM.THE INGREDIENTS OF THE CUTTING TOOLS ARE,
TUNGSTEN CARBIDE – WC about 80 %
COBALT (BINDING MATERIAL) 3 – 12 %
TiC
TaC
T15
M42
HSS
GRAIN SIZE ; 1 – 5 um
CUTTING TOOLS
CUTTING TOOLS ARE NEED COATINGS FOR,
1.PROLONG TOOL LIFE
2.IMPROVE MACHINING PRODUCTIVITY
3.IMPROVED SURFACE FINISH
TYPES OF COATINGS,
1. CVD ( CHEMICAL VAPOUR DEPOSITION)
2. PVD (PHYSICAL VAPOUR DEPOSITION)
3. DIAMOND COATING
CVD COATING
COMMON CVD COATING TYPES,
•TiC (Titanium Carbide)
•TiCN (Titanium Carbo-Nitride)
•ZrCN (Zirconium Carbo-Nitride)
•TiN (Titanium Nitride)
•Al2O3 (Aluminium Oxide)
THICKNESS - 5 to 25 Microns.
LAYERS – UP to 25 layers.
ANODE – INSERT
CATHODE – POWDER
TEMP - 600 To 1000 degree
CVD NOT POSSIBLE FOR LESSER RADIUS.
PVD COATING
COMMON PVD COATING TYPES,
•TiAlN (Titanium Aluminium Nitride)
•TiCN (Titanium Carbo-Nitride)
•ZrN (Zirconium Nitride)
•TiN (Titanium Nitride)
•TiB2 (Titanium Boron)
• CrN (Cromic Nitride)
THICKNESS - 2 to 8 Microns.
LAYERS – 5 to 6 layers.
TEMP – 300 to 600 degree
DIAMOND COATING
COATING THICKNESS - 5 To 30 Microns
TOOL FAILURE ANALYSIS
CATEGORIES OF TOOL FAILURE
1.ABRASIVE WEAR
2.MECHANICAL FAILURE
3.HEAT FAILURE
TOOL FAILURE ANALYSIS
TYPES OF ABRASIVE WEAR,
1.FLANK WEAR
IT IS OBSERVED ON THE TOOL CLEARANCE FACE.
UP TO 0.203 mm.
TOOL FAILURE ANALYSIS
TYPES OF MECHANICAL FAILURE,
1.CHIPPING (FLANK CHIPPING,RAKE FACE CHIPPING)
2.DEPTH OF CUT NOTCHING
3.FRACTURE
TOOL FAILURE ANALYSIS
TYPES OF HEAT FAILURE,
1.BUILT UP EDGE
2.THERMAL CRACKING
3.CRATER WEAR
4.THERMAL DEFORMATION
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