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Advantages</a></p></header><div class="excerpt"><p>Taper turning by using taper turning attachment | Advantages
Fig.  schematically shows a taper turning attachment. It consists of a bracket or frame which is attached to the rear end of the lathe...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/taper-turning-by-using-taper-turning-attachment-advantages/" aria-label="View Post: Taper turning by using taper turning attachment | Advantages">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Taper turning by using taper turning attachment | Advantages","url":"\/\/www.gunkrazy.com\/taper-turning-by-using-taper-turning-attachment-advantages\/","articleBody":"Taper turning by using taper turning attachment | Advantages\r\nFig.\u00a0 schematically shows a taper turning attachment. It consists of a bracket or frame which is attached to the rear end of the lathe bed and supports a guide bar pivoted at the centre. The guide bar having graduations in degrees may be swiveled on either side of the zero graduation and is set at the desired angle with the lathe axis. When this attachment is used the cross slide is delinked from the saddle by removing the binder screw. The rear end of the cross slide is then tightened with the guide block by means of a bolt. When the longitudinal feed is engaged, the tool mounted on the cross slide will follow the angular path, as the guide block will slide on the guide bar set at an angle to the lathe axis.\r\nThe required depth of cut is given by the compound slide which is placed at right angles to the lathe axis. The guide bar must be set at half taper angle and the taper on the work must be converted in degrees. The maximum angle through which the guide bar may be swiveled is 100 to 120 on either side of the centre line. The angle of swiveling the guide bar can be determined from the equation .\r\n\r\nThe angle is determined by using the formula, tan\u03b1 = ( D-d) \/l\r\n\r\nWhere ,\u00a0\r\n\r\nD - Large diameter of the taper.\r\nd - Small diameter of the taper.\r\nl - Length of tapered part.\r\n\u03b1 - Half angle of taper.\r\n\r\n taper turning attachment diagram\r\n\r\nThe advantages of using a taper turning attachment are:\r\n\r\n \tThe alignment of live and dead centres being not disturbed; both straight and taper turning may be performed on a work piece in one setting without much loss of time.\r\n \tOnce the taper is set, any length of work piece may be turned taper within its limit.\r\n \tVery steep taper on a long work piece may be turned, which cannot be done by any other method.\r\n \tAccurate taper on a large number of work pieces may be turned.\r\n \tInternal tapers can be turned with ease.","headline":"Taper turning by using taper turning attachment | Advantages","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-03-29","mainEntityOfPage":"False","dateModified":"February 20, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/03\/taper-turning-attachment-diagram-300x168.jpg","height":168,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/types-of-cutting-fluids-and-their-application-selection-of-cutting-fluid/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2019/03/cutting-fluid-selectiion-300x200.jpg')"></div><span class="sr-only">link to Types of cutting fluids and their application | Selection of cutting fluid</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/types-of-cutting-fluids-and-their-application-selection-of-cutting-fluid/">Types of cutting fluids and their application | Selection of cutting fluid</a></p></header><div class="excerpt"><p>Types of cutting fluids and their application | Selection of cutting fluid
Types of cutting fluids and their application  Generally, cutting fluids are employed in liquid form but occasionally...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/types-of-cutting-fluids-and-their-application-selection-of-cutting-fluid/" aria-label="View Post: Types of cutting fluids and their application | Selection of cutting fluid">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Types of cutting fluids and their application | Selection of cutting fluid","url":"\/\/www.gunkrazy.com\/types-of-cutting-fluids-and-their-application-selection-of-cutting-fluid\/","articleBody":"Types of cutting fluids and their application | Selection of cutting fluid\r\nTypes of cutting fluids and their application\r\n\r\nGenerally, cutting fluids are employed in liquid form but occasionally also employed in gaseous form. Only for lubricating purpose, often solid lubricants are also employed in machining and grinding.\r\n\r\nRead MORE :\u00a0What are the purposes, properties and types of cutting fluids?\r\n\r\nThe cutting fluids, which are commonly used, are:\r\nAir blast or compressed air only\r\nMachining of some materials like grey cast iron become inconvenient or difficult if any cutting fluid is employed in liquid form. In such case only air blast is recommended for cooling and cleaning.\r\nSolid or semi-solid lubricant\r\nPaste, waxes, soaps, graphite, Moly-disulphide (MoS2) may also often be used, either applied directly to the workpiece or as an impregnant in the tool to reduce friction and thus cutting forces, temperature and tool wear.\r\nWater\r\nFor its good wetting and spreading properties and very high specific heat, water is considered as the best coolant and hence employed where cooling is most urgent.\r\nSoluble oil\r\nWater acts as the best coolant but does not lubricate. Besides, use of only water may impair the machine-fixture-tool-work system by rusting. So oil containing some emulsifying agent and additive like EPA, together called cutting compound, is mixed with water in a suitable ratio ( 1 ~ 2 in 20 ~ 50). This milk like white emulsion, called soluble oil, is very common and widely used in machining and grinding.\r\nCutting oils\r\nCutting oils are generally compounds of mineral oil to which are added desired type and amount of vegetable, animal or marine oils for improving spreading, wetting and lubricating properties. As and when required some EP additive is also mixed to reduce friction, adhesion and BUE formation in heavy cuts.\r\nChemical fluids\r\nThese are occasionally used fluids which are water based where some organic and or inorganic materials are dissolved in water to enable desired cutting fluid action.\r\nThere are two types of such cutting fluid:\r\n\r\n \tChemically inactive type - high cooling, anti-rusting and wetting but less lubricating.\r\n \tActive (surface) type - moderate cooling and lubricating.\r\n\r\nCryogenic cutting fluid\r\nExtremely cold (cryogenic) fluids (often in the form of gases) like liquid CO2 or N2 are used in some special cases for effective cooling without creating much environmental pollution and health hazards.\r\n\r\ncutting fluid selection\r\nSelection of cutting fluid\r\nThe benefits of application of cutting fluid largely depend upon proper selection of the type of the cutting fluid depending upon the work material, tool material and the machining condition. As for example, for high speed machining of not-difficult-to-machine materials greater cooling type fluids are preferred and for low speed machining of both conventional and difficult-to-machine materials greater\r\nlubricating type fluid is preferred.\r\nSelection of cutting fluids for machining some common engineering materials and operations are presented as follows:\r\nGrey cast iron:\r\n\r\n \tGenerally dry for its self lubricating property.\r\n \tAir blast for cooling and flushing chips.\r\n \tSoluble oil for cooling and flushing chips in high speed machining and grinding.\r\n\r\nSteels:\r\n\r\n \tIf machined by HSS tools, sol. Oil (1: 20 ~30) for low carbon and alloy steels and neat oil with EPA for heavy cuts.\r\n \tIf machined by carbide tools thinner sol. Oil for low strength steel, thicker sol. Oil ( 1:10 ~ 20) for stronger steels and straight sulphurised oil for heavy and low speed cuts and EP cutting oil for high alloy steel.\r\n \tOften steels are machined dry by carbide tools for preventing thermal shocks.\r\n\r\nAluminium and its alloys:\r\n\r\n \tPreferably machined dry.\r\n \tLight but oily soluble oil.\r\n \tStraight neat oil or kerosene oil for stringent cuts.\r\n\r\nCopper and its alloys:\r\n\r\n \tWater based fluids are generally used.\r\n \tOil with or without inactive EPA for tougher grades of Cu-alloy.\r\n\r\nStainless steels and Heat resistant alloys:\r\n\r\n \tHigh performance soluble oil or neat oil with high concentration with chlorinated EP additive.\r\n \tThe brittle ceramics and cermets should be used either under dry condition or light neat oil in case of fine finishing.\r\n \tGrinding at high speed needs cooling (1: 50 ~ 100) soluble oil. For finish grinding of metals and alloys low viscosity neat oil is also used.","headline":"Types of cutting fluids and their application | Selection of cutting fluid","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-03-29","mainEntityOfPage":"False","dateModified":"February 20, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/03\/cutting-fluid-selectiion-300x200.jpg","height":200,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/machinability-concept-definition-machinability-rating/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2019/03/what-is-machinability-300x276.jpg')"></div><span class="sr-only">link to Machinability | Concept , Definition , Machinability rating</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/machinability-concept-definition-machinability-rating/">Machinability | Concept , Definition , Machinability rating</a></p></header><div class="excerpt"><p>Machinability | Concept , Definition , Machinability rating
Concept, definition and criteria of judgement of machinability
The term; ‘Machinability’ has been introduced for gradation of work...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/machinability-concept-definition-machinability-rating/" aria-label="View Post: Machinability | Concept , Definition , Machinability rating">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Machinability | Concept , Definition , Machinability rating","url":"\/\/www.gunkrazy.com\/machinability-concept-definition-machinability-rating\/","articleBody":"Machinability | Concept , Definition , Machinability rating\r\nConcept, definition and criteria of judgement of machinability\r\nThe term; \u2018Machinability\u2019 has been introduced for gradation of work materials with respect to machining characteristics. But truly speaking, there is no unique or clear meaning of the term machinability. People tried to describe \u201cMachinability\u201d in several ways such as:\r\n\r\n \tIt is generally applied to the machining properties of work material.\r\n \tIt refers to material (work) response to machining.\r\n \tIt is the ability of the work material to be machined.\r\n \tIt indicates how easily and fast a material can be machined.\r\n\r\nBut it has been agreed, in general, that it is difficult to clearly define and quantify Machinability. For instance, saying \u2018material A is more machinable than material B\u2019 may mean that compared to \u2018B\u2019:\r\n\r\n \t\u2018A\u2019 causes lesser tool wear or longer tool life.\r\n \t\u2018A\u2019 requires lesser cutting forces and power.\r\n \t\u2018A\u2019 provides better surface finish.\r\n\r\nwhat is machinability\r\n\r\nAttempts were made to measure or quantify machinability and it was done mostly in terms of:\r\n\r\n \tTool life which substantially influences productivity and economy in machining.\r\n \tMagnitude of cutting forces which affects power consumption and dimensional accuracy.\r\n \tSurface finish which plays role on performance and service life of the product.\r\n\r\nOften cutting temperature and chip form are also considered for assessing machinability.\r\n\r\nMachinability rating (MR) =\u00a0\r\n\r\nThe machinability index KM is defined by\r\nKM = V60\/V60R\r\nwhere ,\r\n\r\n \tV60 is the cutting speed for the target material that ensures tool life of 60 min,\r\n \tV60R is the same for the reference material. Reference materials are selected for each group of work materials (ferrous and non-ferrous) among the most popular and widely used brands.\r\n\r\nIf KM Greater than 1, the machinability of the target material is better that this of the reference material, and vice versa. Note that this system can be misleading because the index is different for different machining processes.\r\n\r\nRead More : What Is Machinability Index | Ways Of Improving Machinability\r\n\r\nMachinability can be tentatively defined as \u201cability of being machined\u201d and more reasonably as \u201cease of machining\u201d.\r\n\r\nSuch ease of machining or machinability characteristics of any tool-work pair is to be judged by:\r\n\r\n \tMagnitude of the cutting forces.\r\n \tTool wear or tool life.\r\n \tSurface finish.\r\n \tMagnitude of cutting temperature.\r\n \tChip forms.\r\n\r\nMachinability will be considered desirably high when cutting forces, temperature, surface roughness and tool wear are less, tool life is long and chips are ideally uniform and short enabling short chip-tool contact length and less friction.\r\n\r\nRole of the properties of the work material on machinability\r\n\r\nThe work material properties that generally govern machinability in varying extent are:\r\n\r\n \t\u00a0The basic nature - brittleness or ductility etc.\r\n \tMicrostructure.\r\n \tMechanical strength - fracture or yield.\r\n \tHardness and hot hardness, hot strength.\r\n \tWork hardenability.\r\n \tThermal conductivity.\r\n \tChemical reactivity.\r\n \tStickiness \/ self lubricity.","headline":"Machinability | Concept , Definition , Machinability rating","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-03-28","mainEntityOfPage":"False","dateModified":"February 20, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/03\/what-is-machinability-300x276.jpg","height":276,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/merchants-circle-diagram-advantages-and-disadvantages/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2019/03/merchant-circle-diagram-300x159.jpg')"></div><span class="sr-only">link to Merchant’s circle diagram | Advantages and Disadvantages</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/merchants-circle-diagram-advantages-and-disadvantages/">Merchant’s circle diagram | Advantages and Disadvantages</a></p></header><div class="excerpt"><p>Merchant’s circle diagram | Advantages and Disadvantages
Merchant’s Circle Diagram and its use  In orthogonal cutting when the chip flows along the orthogonal plane, π0, the cutting force...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/merchants-circle-diagram-advantages-and-disadvantages/" aria-label="View Post: Merchant’s circle diagram | Advantages and Disadvantages">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Merchant\u2019s circle diagram | Advantages and Disadvantages","url":"\/\/www.gunkrazy.com\/merchants-circle-diagram-advantages-and-disadvantages\/","articleBody":"Merchant\u2019s circle diagram | Advantages and Disadvantages\r\nMerchant\u2019s Circle Diagram and its use\r\n\r\nIn orthogonal cutting when the chip flows along the orthogonal plane, \u03c00, the cutting force (resultant) and its components PZ and PXY remain in the orthogonal plane. Fig.\u00a0 is schematically showing the forces acting on a piece of continuous chip coming out from the shear zone at a constant speed. That chip is apparently in a state of equilibrium.\r\n\r\n merchant circle diagram\r\n\r\nThe forces in the chip segment are:\r\n\r\n \tFrom job-side:\r\n \tPs - Shear force.\r\n \tPn - force normal to the shear force.\r\n\r\nFrom the tool side:\r\n\r\nR1 = R (in state of equilibrium) where, R1 = F + N\r\n\r\nN - Force normal to rake face.\r\nF - Friction force at chip tool interface.\r\n\r\nThe resulting cutting force R or R1 can be resolved further as,\r\n\r\nR1 = PZ + PXY \r\n\r\nwhere, PZ - Force along the velocity vector.\r\n\r\nPXY - force along orthogonal plane.\r\n\r\nThe circle(s) drawn taking R or R1 as diameter is called Merchant\u2019s circle which contains all the force components concerned as intercepts. The two circles with their forces are combined into one circle having all the forces contained in that as shown by the diagram called \r\n\r\nMerchant\u2019s Circle Diagram (MCD) in Fig.\r\n\r\nThe significance of the forces displayed in the Merchant\u2019s Circle Diagram is:\r\n\r\nPs - The shear force essentially required to produce or separate the chip from the parent body by shear.\r\nPn - Inherently exists along with Ps.\r\nF - Friction force at the chip tool interface.\r\n\r\nN - Force acting normal to the rake surface.\r\n\r\nPZ = PXY \u2013 PX + PY = main force or power component acting in the direction of cutting velocity.\r\n\r\nThe magnitude of PS provides the yield shear strength of the work material under the cutting action. The values of F and the ratio of F and N indicate the nature and degree of interaction like friction at the chip tool interface. The force components PX, PY, PZ are generally obtained by direct measurement. Again PZ helps in determining cutting power and specific energy requirement. The force components are also required to design the cutting tool and the machine tool.\r\n\r\nAdvantageous use of Merchant\u2019s circle diagram\r\n\r\nProper use of MCD enables the followings:\r\n\r\n \tEasy, quick and reasonably accurate determination of several other forces from a few known forces involved in machining.\r\n \tFriction at chip tool interface and dynamic yield shear strength can be easily determined.\r\n \tEquations relating the different forces are easily developed.\r\n\r\nSome limitations of use of MCD:\r\n\r\n \tMerchant\u2019s circle diagram (MCD) is only valid for orthogonal cutting.\r\n \tBy the ratio, F\/N, the MCD gives apparent (not actual) coefficient of friction.\r\n \tIt is based on single shear plane theory.","headline":"Merchant\u2019s circle diagram | Advantages and Disadvantages","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-03-28","mainEntityOfPage":"False","dateModified":"February 20, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/03\/merchant-circle-diagram-300x159.jpg","height":159,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/chip-breakers-need-purpose-principles-of-chip-breaking/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2019/03/self-breaking-chips-300x121.jpg')"></div><span class="sr-only">link to Chip breakers | Need , Purpose , Principles of chip-breaking</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/chip-breakers-need-purpose-principles-of-chip-breaking/">Chip breakers | Need , Purpose , Principles of chip-breaking</a></p></header><div class="excerpt"><p>Chip breakers | Need , Purpose , Principles of chip-breaking
Chip breakers
Need and purpose of chip-breaking
Continuous machining like turning of ductile metals, unlike brittle metals like grey...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/chip-breakers-need-purpose-principles-of-chip-breaking/" aria-label="View Post: Chip breakers | Need , Purpose , Principles of chip-breaking">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Chip breakers | Need , Purpose , Principles of chip-breaking","url":"\/\/www.gunkrazy.com\/chip-breakers-need-purpose-principles-of-chip-breaking\/","articleBody":"Chip breakers | Need , Purpose , Principles of chip-breaking\r\nChip breakers\r\nNeed and purpose of chip-breaking\r\nContinuous machining like turning of ductile metals, unlike brittle metals like grey cast iron, produce continuous chips, which leads to their handling and disposal problems. The problems become acute when ductile but strong metals like steels are machined at high cutting velocity for high MRR by flat rake face type carbide or ceramic inserts. The sharp edged hot continuous chip that comes out at very high speed:\r\n\r\n \tBecomes dangerous to the operator and the other people working in the vicinity.\r\n \tMay impair the finished surface by entangling with the rotating job.\r\n \tCreates difficulties in chip disposal.\r\n\r\nTherefore it is essentially needed to break such continuous chips into small regular pieces for:\r\n\r\n \tSafety of the working people.\r\n \tPrevention of damage of the product.\r\n \tEasy collection and disposal of chips.\r\n\r\nChip breaking is done in proper way also for the additional purpose of improving machinability by reducing the chip-tool contact area, cutting forces and crater wear of the cutting tool.\r\nPrinciples of chip-breaking\r\nIn respect of convenience and safety, closed coil type chips of short length and \u2018coma\u2019 shaped broken-to-half turn chips are ideal in machining of ductile metals and alloys at high speed.\r\n\r\nThe principles and methods of chip breaking are generally classified as follows:\r\n\r\n\u00a0Self chip breaking - This is accomplished without using a separate chip-breaker either as an attachment or an additional geometrical modification of the tool.\r\n\r\nForced chip breaking - This is accomplished by additional tool geometrical features or devices.\r\n\r\n\r\n\r\na) Self breaking of chips\r\nDuctile chips usually become curled or tend to curl (like clock spring) even in machining by tools with flat rake surface due to unequal speed of flow of the chip at its free and generated (rubbed) surfaces and unequal temperature and cooling rate at those two surfaces. With the increase in cutting velocity and rake angle (positive) the radius of curvature increases, which is more dangerous.\r\n\r\nIn case of oblique cutting due to presence of inclination angle, restricted cutting effect etc. the curled chips deviate laterally resulting helical coiling of the chips. The curled chips may self break:\r\n\r\n \tBy natural fracturing of the strain hardened outgoing chip after sufficient cooling and spring back as indicated in Fig. 1.27 (a). This kind of chip breaking is generally observed under the condition close to that which favors formation of jointed or segmented chips.\r\n \tBy striking against the cutting surface of the job, as shown in Fig. 1.27 (b), mostly under pure orthogonal cutting.\r\n \tBy striking against the tool flank after each half to full turn as indicated in Fig. 1.27 (c).\r\n\r\n self breaking chips\r\nb) Forced chip-breaking\r\nThe hot continuous chip becomes hard and brittle at a distance from its origin due to work hardening and cooling. If the running chip does not become enough curled and work hardened, it may not break. In that case the running chip is forced to bend or closely curl so that it breaks into pieces at regular intervals. Such broken chips are of regular size and shape depending upon the configuration of the chip breaker. \r\n\r\nChip breakers are basically of two types:\r\n\r\n \tIn-built type.\r\n \tClamped or attachment type.\r\n\r\nIn-built breakers are in the form of step or groove at the rake surface near the cutting edges of the tools. Such chip breakers are provided either:\r\n\r\nAfter their manufacture - in case of HSS tools like drills, milling cutters, broaches etc and brazed type carbide inserts.\r\n\r\nDuring their manufacture by powder metallurgical process - e.g., throw away type inserts of carbides, ceramics and cermets.\r\n\r\nOverall effects of chip breaking\r\n\r\nFavorable effects:\r\n\r\n \tSafety of the operator(s) from the hot, sharp continuous chip flowing out at high speed.\r\n \tConvenience of collection and disposal of chips.\r\n \tA chance of damage of the finished surface by entangling or rubbing with the chip is eliminated.\r\n \tMore effective cutting fluid action due to shorter and varying chip tool contact length.\r\n\r\nUnfavorable effects:\r\n\r\n \tChances of harmful vibration due to frequent chip breaking and hitting at the heel or flank of the tool bit.\r\n \tMore heat and stress concentration near the sharp cutting edge and hence chances of its rapid failure.\r\n \tSurface finish may deteriorate.","headline":"Chip breakers | Need , Purpose , Principles of chip-breaking","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-03-28","mainEntityOfPage":"False","dateModified":"February 20, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/03\/self-breaking-chips-300x121.jpg","height":121,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/cutting-tool-angles-function-and-effects-of-cutting-tool-angles/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2019/03/tool-geometry-of-single-point-cutting-tool-300x208.jpg')"></div><span class="sr-only">link to Cutting tool Angles | Function and Effects Of Cutting Tool angles</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/cutting-tool-angles-function-and-effects-of-cutting-tool-angles/">Cutting tool Angles | Function and Effects Of Cutting Tool angles</a></p></header><div class="excerpt"><p>Cutting tool Angles | Function and Effects Of Cutting Tool angles
The face and the flank are pain surfaces, the cutting edge can be assumed to be a line. These surfaces and the edges are inclined...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/cutting-tool-angles-function-and-effects-of-cutting-tool-angles/" aria-label="View Post: Cutting tool Angles | Function and Effects Of Cutting Tool angles">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Cutting tool Angles | Function and Effects Of Cutting Tool angles","url":"\/\/www.gunkrazy.com\/cutting-tool-angles-function-and-effects-of-cutting-tool-angles\/","articleBody":"Cutting tool Angles | Function and Effects Of Cutting Tool angles\r\nThe face and the flank are pain surfaces, the cutting edge can be assumed to be a line. These surfaces and the edges are inclined with respect to some reference plan or line. The inclinations are called tool angles.\r\n\r\nThese angles are defined by various names. They are provided for various purposes. Consider the case of the face abgf, as shown in Fig. It is a plane surface no doubt, but can have some inclinations. This surface may be parallel to the base or say to horizontal surface, or it can be inclined upward or downward with respect to the horizontal plane. Again it may have inclination sideward also. So in general the face can have two inclinations simultaneously, backward and sideward. Similarly the flank (Principal flank abed or auxiliary flank adef) can have two inclinations.\r\n\r\ntool geometry of single point cutting tool 2\r\n\r\nFrom the geometry of cutting tool the various cutting tool angles are:\r\n\r\nRake Angle (\u03b1):\r\n\r\n(a) Black rake angle.\r\n\r\n(b) Side rake angle.\r\n\r\nClearance or Relief Angle (\u03b3):\r\n\r\n(a) End clearance relief angle.\r\n\r\n(b) Side clearance relief angle.\r\n\r\nCutting Edge Angle:\r\n\r\n(a) End cutting edge angle.\r\n\r\n(b) Side cutting edge angle.\r\n\r\n(i) Back Rake Angle:\r\n\r\nIt is the angle between the face of the tool and plane parallel to its base. It is also known as front rake angle or top rake angle.\r\n\r\n(ii)\u00a0Side Rake Angle:\r\n\r\nIt is the angle between the face of the tool and the shank of the tool.\r\n\r\n(iii)\u00a0End Clearance (Relief) Angle:\r\n\r\nIt is the angle between the front surface of the tool and a line normal to the base of the tool. It is also known as front clearance angle.\r\n\r\n(iv)\u00a0Side Clearance (Relief) Angle:\r\n\r\nIt is the angle between the side surface of the tool and a line normal to the base of the tool.\r\n\r\n(v)\u00a0End Cutting Edge Angle:\r\n\r\nIt is the angle between the end cutting edge of the tool and a line perpendicular to its shank.\r\n\r\n(vi)\u00a0Side Cutting Edge Angle:\r\n\r\nIt is the angle between the side cutting edge of the tool and shank of the tool.\r\n\r\n(vii)\u00a0Nose Radius:\r\n\r\nNose radius is one which connects the side and end cutting edge. \r\n\r\nNow, we will discuss the functions and effects of cutting tool angles on cutting process.\r\n\r\nFunctions of Back Rake Angle:\r\n\r\n(a) It helps to control the chip flow in a convenient direction.\r\n\r\n(b) It reduces the cutting force required to shear the metal and consequently helps to reduces power requirements and increase tool life.\r\n\r\n(c) It also helps counteract the pressure against the cutting tool from the work by pulling the tool into the work.\r\n\r\n(d) It provides keenness to the cutting edge and improves the surface finish.\r\n\r\nFunctions of Side Rake angle:\r\n\r\n(a) It performs similar functions as performed by back rake angle.\r\n\r\n(b) Side rake angle along with back rake angle controls the chip flow direction.\r\n\r\n(c) It partly counteracts the resistance of the work to the movement of the cutter.\r\n\r\n(d) For example, brass requires a back and side rake angle of almost 0\u00b0, while aluminum uses a back rake of 35\u00b0 and a side rake of 15\u00b0.\r\n\r\nFunctions of End Clearance (relief) Angle:\r\n\r\n(a) It allows the tool to cut freely without rubbing against the work surface.\r\n\r\n(b) This angle varies from 0\u00b0 to 15\u00b0, and usually 8\u00b0.\r\n\r\n(c) Excessive relief angle reduces strength of the tool.\r\n\r\nFunctions of Side Clearance (relief) Angle:\r\n\r\ni. It avoids the rubbing of flank against the work piece when the tool is fed longitudinally.\r\n\r\nii. This angle is 6\u00b0 to 10\u00b0 for steel, 8\u00b0 for aluminum.\r\n\r\niii. It maintains that no part of the tool besides the actual cutting edge can touch the work.\r\n\r\nFunctions of End Cutting Edge Angle:\r\n\r\ni. It avoids rubbing between the edge of the tool and workspace.\r\n\r\nii. It influences the direction of chip flow.\r\n\r\nFunctions of Side Cutting Edge Angle:\r\n\r\ni. Increase in side cutting edge angle tends to widen and thin the chip.\r\n\r\nii. An excessive side cutting edge angle redirects feed forces in radial direction which may cause chatter.\r\n\r\nFunctions of Nose Radius:\r\n\r\ni. A sharp point at the end of tool is undesirable, because it is highly stressed, short lived and leaves groove in the path of cut.\r\n\r\nii. Therefore Nose Radius is favourable for long tool life and good surface quality.\r\n\r\niii. It affects the tool life, radial force, and surface quality of work piece.\r\n\r\niv. If nose radius is too large chatter will occur.\r\n\r\nv. There is an optimum value of the nose radius at which the tool life is maximum.\r\n\r\nvi. If the nose radius exceeds optimum value, the tool life decreases.\r\n\r\nvii. Larger nose radius means larger area of contact between tool and work piece. Resulting more frictional heat is generated. Also, cutting force increases due to which the work part may start vibrating and chattering, if work part holding is not very tight.\r\n\r\nviii. The recommendations for use of more nose radius are.\r\n\r\nR= 0.4 mm for delicate components.\r\n\r\nR = 0.4 mm to 1.2 mm for disposable carbide inserts for common use.\r\n\r\nR = 1.2 mm to 1.5 mm for heavy duty inserts.\r\n\r\nR \u2265 1.5 mm for heavy depth of cut, interrupted cuts and heavy feeds.\r\n\r\nSignificance of Rake Angle:\r\n\r\n1. The rake angles may be positive, zero or negative.\r\n\r\n2. An increased rake angle will reduce the strength of the cutting edge.\r\n\r\n3. Rake angle affects the values of cutting angle and the shear angle.\r\n\r\n4. Larger the rake angle, smaller the cutting angle (and larger the shear angle).\r\n\r\n5. In general, the small rake angle is used for cutting hard metals and a larger rake angle is used for cutting soft and ductile metals.\r\n\r\n6. The use of negative rake angle started with the employment of carbide cutting tools. When positive rake angle is used, the force on the tool is directed towards the cutting edge, tending to chip or break it, as shown in Fig.\u00a0\r\n\r\n7. Since the carbide material is brittle and lacks shock resistance, it will fail if positive rake angles are used with it. Using negative rake angles, directs the force back into the body of the tool away from the cutting edge, which protects to the cutting edge, as shown in Fig.\r\n\r\ntool geometry of single point cutting tool\r\n\r\n8. The use of negative rake angle increases the cutting force. This can compensate by higher cutting speeds. Therefore, high cutting speeds are always used with negative rake angles. High cutting speeds require high power of the machine tool.\r\n\r\n9. The use of index able inserts also need the use of negative rake angles.\r\n\r\n10. A negative rake angle insert has twice life than an equivalent positive rake angle insert.\r\n\r\n11. Negative rake angle increases cutting edge strength, because the cutting force acts on the middle of cutting edge.\r\n\r\n12. Positive rake angle decreases cutting edge strength, because the cutting force acts on the end or corner of the cutting edge.\r\n\r\n13. Positive rake angle recommendations are:\r\n\r\n(a) When machining low strength metals and alloys, such as aluminum and copper alloys, mild steel, etc.\r\n\r\n(b) Where cutting at low speeds.\r\n\r\n(c) When set up has low strength and rigidity.\r\n\r\n(d) When low power machines used.\r\n\r\n(e) When tool materials are H.S.S. and cast alloys.\r\n\r\n14. Negative rake angle recommendations are:\r\n\r\n(a) When machining high strength metal and alloys, such as stainless steel, alloy tool steel, titanium alloys, etc.","headline":"Cutting tool Angles | Function and Effects Of Cutting Tool angles","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-03-28","mainEntityOfPage":"False","dateModified":"February 20, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/03\/tool-geometry-of-single-point-cutting-tool-300x208.jpg","height":208,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <nav class="pagination-wrapper" aria-label="article pagination"> <a class="prev page-numbers" href="?page_num=90">&laquo; PREV</a> <a class="page-numbers" href="?page_num=1"><span class="screen-reader-text">Page </span>1</a> <span class="page-numbers dots">&hellip;</span> <a class="page-numbers" href="?page_num=89"><span class="screen-reader-text">Page </span>89</a> <a class="page-numbers" href="?page_num=90"><span class="screen-reader-text">Page </span>90</a> <span aria-current="page" class="page-numbers current"><span class="screen-reader-text">Page </span>91</span> <a class="page-numbers" href="?page_num=92"><span class="screen-reader-text">Page </span>92</a> <a class="page-numbers" href="?page_num=93"><span class="screen-reader-text">Page </span>93</a> <span class="page-numbers dots">&hellip;</span> <a class="page-numbers" href="?page_num=338"><span class="screen-reader-text">Page </span>338</a> <a class="next page-numbers" href="?page_num=92">NEXT &raquo;</a></nav></section></main><aside id="secondary" class="widget-area"><div class="about-wrapper"><h2 class="widget-title" style="background: #d693c6; color: #ff392e">About Us</h2><div class="about-image" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2020/03/Sachin-Thorat-300x300-min.png')"></div><p class="about-copy">LearnMech.Com is a Mechanical Project-oriented platform run by Sachin Thorat who is a B-Tech Graduate in Mechanical Engineering. 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