#3 Cutting Tool

MKP
Proses Permesinan
Kuliah # 3. Cutting Tool
Rusnaldy, PhD
Tool Selection Process
Cutting Tool
 Cutting Tool Geometry

 Cutting Tool Materials
Cutting Tool Geometry
Tool Geometry
• The geometry of a cutting tool is
determined by (3) factors:
– Properties of the tool material
– Properties of the workpiece
– Type of cut
Tool – in – Hand system
• The most important geometry’s to
consider on a cutting tool are
– Back Rake Angles
– End Relief Angles
– Side Relief Angles
A
Ashi 
sin 
Fs  Ashi shi
Fs cos   o 
Fc 
cos     o 
• Small to medium rake angles cause:
– high compression
– high tool forces
– high friction
– result = Thick—highly deformed—hot chips
• Larger positive rake angles
– Reduce compression
and less chance of a
discontinuous chip
– Reduce forces
– Reduce friction
– Result = A thinner, less
deformed, and cooler
chip.
• Problems….as we increase the angle:
– Reduce strength of tool
– Reduce the capacity of the tool to conduct
heat away from the cutting edge.
– To increase the strength of the tool and
allow it to conduct heat better, in some
tools, zero to negative rake angles are
used.
Negative Rake Tools
• Typical tool materials which utilize negative rakes are:
• Carbide
• Diamonds
• Ceramics
• These materials tend to be much more brittle than HSS but they hold
superior hardness at high temperatures. The negative rake angles
transfer the cutting forces to the tool which help to provide added support
to the cutting edge.
Summary Positive vs. Negative Rake
Angles
• Positive rake angles
– Reduced cutting forces
– Smaller deflection of work, tool holder, and
machine
– Considered by some to be the most efficient way
to cut metal
– Creates large shear angle, reduced friction and
heat
– Allows chip to move freely up the chip-tool zone
– Generally used for continuous cuts on ductile
materials which are not to hard or brittle
• Negative rake angles
– Initial shock of work to tool is on the face of
the tool and not on the point or edge. This
prolongs the life of the tool.
– Higher cutting speeds/feeds can be
employed
Cutting Tool Materials
Persyaratan Cutting Tool
 Hardness (Hot Hardness)

 Toughness
 Wear Resistance
 Chemical Stability or Inertness
Tool Materials
 Carbon steels
 High Speed Steels
 Carbide
 Coated Tools
 Cubic Boron Nitride
 Diamond
Carbon Steels
 The oldest of tool materials (1880s)

 Do not have sufficient hot hardness and wear resistance at high speed
 Limited to very low speed cutting operations
High-Speed Steels
 First produced in 1900s
 Have good resistance and high toughness
 Suitable for high positive rake angle
Two Basic types : M series: 10% molybdenum) and T series (12-18%
Tungsten)
 Relatively low cutting speeds when compared to carbide tools
Carbide
 Introduced in the 1930s
 Have high hardness over a wide range of temperature
 High elastic modulus and high thermal conductivity
 Low thermal expansion
 Two basic : tungsten carbide (WC) and titanium carbide
 Tungsten carbide
- a composite material : WC particle and Cobalt matrix
- manufactured by powder metallurgy techniques
- generally used for cutting steels, cast irons, abrasive nonferrous
 Titanium carbide
- has higher wear resistance than WC
- a composite material : Ni-Mo as the matrix and TiC particle
- for cutting at speeds higher than WC
- for cutting hard materials, steels and cast irons
Coated Tools
Tools may be coated for many reasons:

• Chemically inert
• Temperature resistance
• Surface energy/specific energy
• Low friction
Coated Tools
 Can be used at high cutting speeds

 Reducing the time required for machining operations
 Being used for cutting operations with tool life as much as 10 times
that of uncoated tools
Common coatings
• Titanium nitride (TiN)
• Cubic boron nitride (cBN)
• Multi-phase coatings
Cubic Boron Nitride
 Introduced in 1962
 The hardest material presently available
 Made by bonding a 0.5-1 mm layer of PCBN to a carbide substrate by
sintering under pressure
 Carbide provides shock resistance, CBN provides very high wear
resistance and cutting edge strength
Diamond
 The hardest substance of all known materials

 Has low friction, high wear resistance, and the ability to maintain a
sharp cutting edge
 Used when good surface finish and dimensional accuracy are required
 Is not recommended for machining plain-carbon steels, titanium, nickel
and cobalt base alloys

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MKP

Kuliah # 3. Cutting Tool

 Cutting Tool Geometry

 Hardness (Hot Hardness)

 The oldest of tool materials (1880s)

Tools may be coated for many reasons:

 Can be used at high cutting speeds

 The hardest substance of all known materials

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