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ELSEVIER Journal of Materials Processing Technology 61 (1996) 231-237

Developing New Trends of Cutting Tool Geometry


I. A. Kattan and K. R. Currie
College of Engineering, Tennessee Technological University
Cookeville, Tennessee 38505, USA, E-mall ia5833@tntech.edu

Abstract

The objective of this research is to use an analytical and experimental approach to develop new trends of cutting tool geometry with
negative Side Cutting Edge Angle (SCEA). The first task of this research is to conduct experimental tests for different SCEAs, cutting
speeds, feed rates and depths of cut. This is accomplished as follows. One set of these experimental results will be used as a feedback
to develop new empirical formulae required to predict cutting forces and other machining parameters. A second set of experimental tests
will be conducted in this study to ensure the validity of the empirical relationships associated with the mathematical model. The second
task is to develop a mathematical model to predict cutting forces for the three dimensional oblique cutting operation. New cutting tools
will be proposed by using the results of the expanded mathematical model.

Keywords: metal cutting, cutting tool geometry, oblique cutting operation

1. Introduction forces [1-5]. One of the most important parameters in tool


geometry is the Side Cutting Edge Angle (SCEA). With the
The work of Taylor in 1906 [1,3, 8] set a milestone in the advent of numericaUy controlled machines, the problem of facing
practical development of machining with his now famous tool life and turning with the same tool may be solved by the use of
equation (V7~ = C) and his contribution to the development of negative SCEAs. The development of an 80 ° diamond-shaped
high speed tools. Since the pioneering work by Taylor, research inserts has made them more versatile not only for use with -5 ° but
in metal cutting has expanded in scope and complexity. Metal also with 0 ° and +15" SCEAs and the corresponding three End
cutting has, by its nature, more dynamic variables than any other Cutting Edge Angles (ECEAs), 5 °, 10 °, 5 °, respectively.
manufacturing operation. Over the past decades, researchers have Chattering and vibration in metal cutting may be controlled by
found that the analysis of the oblique cutting process is difficult providing appropriate SCEAs and ECEAs in the tool geometry
to model [1-6]. Notable contributors in the field of metal cutting design. The value of SCEAs and ECEAs can directly affect the
include Merchant in 1944 [8, 12], Finnier in 1956 [1, 2, 13], quahty of surface finish, dimensional accuracy, and tool fife.
Zorev in 1962 [6], Armarego and Brown in 1964 [1], Kronenberg Although considerable research has been done to investigate the
in 1966 [7] and Shaw in 1984 [3]. Piispanen and Merchant [8, effect of positive SCEAs, the effect of negative SCEAs has not
12] carried out independent research which completely analyzed been discussed in any leading journals or textbooks [1-9].
the process in terms of the geometry and stress strain conditions. However, some tool manufacturing industries have designed tools
In a series of three articles, Usi et al. [15, 16, 17], used Shaw's with negative SCEAs, and, despite their success, their
energy model to develop a three.-dimensional curing model for performance has not been discussed in the open literature. The
single-point tools. Many other techniques such as dynamic following are some hypotheses why negative SCEAs have not
modeling [21], kinematic equivalence [22], neural networks [23], been investigated [26]:
and simulation [24,25] have been conducted to embrace a wide 1. The trend of the main cutting force and feed force are
range of orthogonal and oblique cutting for a specific area of increased as the SCEA angle approaches 0 °. Even with a SCEA
metal cutting and only for positive SCEAs. In this study, some of-5 ° the same increasing trend was observed in both cutting and
of the thoughts presented in these papers have been taken into feed force. The radial force, as expected, was observed to
account, but the novelty of this model is the use of negative decrease, as shown in Figure 1. However, the reduction in the
SCEAs and the consideration of primary shear in addition to radial force could not be justified in terms of the increasing values
secondary shear zone. of both cutting force and feed force. The experimental results of
In metal cutting operations a cutting tool is driven this research will show that all cutting forces were decreased as
through a workpiece material to remove chips from the machined the negative SCEA drops below -5 °, as shown in Figure 2.
part. The kind of surface roughness produced by the turning 2. A positive SCEA helps to increase the diamond angle. The
operation depends on the cutting tool geometry and the path it larger the diamond angle, the stronger the area surrounding the
traverses throughout the workpiece material. The geometry of the tool tip. However, the advancement of cutting tool materials has
cutting tool plays an important role in the projection of all cutting enhanced the tool's strength and allowed for decreasing diamond

0924-0136/96/$15.00 © 1996 Elsevier Science S A All rights reserved


PII 0924-0136(96)02492-2
232 I.A. Kattan, K.R. Currie/Journal of Materials Processing Technology 61 (1996) 231-237

angles, while maintaining a strong tool tip. As shown through the


experiments, the 8 0 ° diamond-shaped CVD triphase coated A Mechanical Quick Stop Device (MQSD) was used to
carbides are a good example. remove material from the tube with a thickness of 0.254 meters
3. Past studies on metal cutting tools have focused on increased corresponding to the depth of cut for a solidbar. A M Q S D was
material removal rate. With Positive SCEAs a larger depth of cut used on the tube to produce in-process chips. The term, in-
could be used, resulting in higher productivity. The results of this process chips, is used as the chips were obtained in real-time
research will demonstrate that negative SCEAs require a relatively machining conditions. The post-process chips produced without
lower depth of cut, but produces a better quality of surface finish, using a MQSD were obtained from the solid bar. Each of the
and more precise geometric toleraneing. experiments was repeated several times. Chips for solid, chips
This research is two fold; first experimental, the second for tube, and chip roots for tube were mounted, polished, and
analytical. The foUowing procedures have been considered to etched. Micrographs for chips and chip roots were developed.
conduct the research: Mierographs of in-process chips for the first set of the experiment
1. Two sets of experiments will be conducted, with each set are shown in Figure 4, where the thickness of the secondary shear
producing measurements for various cutting conditions such as zone of each cutting condition is indicated in micrometers. It is
forces, machining parameters, surface finish, and tool wear. The clear from these micrographs that the flow lines of the material
first set of experiments will use SCEAs of -5 °, 0 °, 15 ° and near the tool tip was seized by the tool, as shown in Figure 5,
cutting speeds of 140, 170, and 220 m/rain. The results wiU be These experiments were conducted for aLlcutting conditions using
used as feedback to derive the empirical relationships used in the a solid bar for post-process and a tube for in-process machining.
model. The second set of experiments will be conducted using Figure 3 shows that, the values for tangential force, the feed
tool geometry with SCEA of -17.50, _10 o, _5° ' -3", 0 °, 15 ° and force are increasing as the SCEA decreases to -5 °. New
45 ° for validation of the mathematical model. interesting results were obtained, that these forces start to
2. The development of the empirical equations as a function of decrease as the SCEA decreases below -5 °. The value of the
SCEAs and cutting speed to predict the value of cutting force radial force is decreasing as the SCEA decreases to 00. The
components. The main parameters required for prediction of radial force decreases sharply and changes its direction (became
cutting force components are chip flow angle, ~ , chip thickness a negative value) as soon as the SCEA became negative, and
ratio, r~, normal shear angle, ~,., and normal friction angle, ft,. continue to decrease as SCEA decreases. A large amount of
positive or negative radial force is undesirable. A large positive
2. Experimental Procedure radial force causes the workpiece to deflect, while a large
negative radial force causes chattering by dcllecting the tool.
In thisresearch severalmetal cuttingexperiments for turned Cutting forces, chip thickness, normal shear angle, surface
parts were carried out on the Leblond C N C lathe machine. For roughness, roundness, and tool wear were measured. These
the firstset of experiments an 80" diamond-shaped insertwas measurements were used to calculate the remaining machining
used and clamped on three tool holders creatingthree SCEAs of- parameters.
5°,0°,+15 °, corresponding three ECEAs, 5", 10 °, 5 °,
respectively. For the second set of experiments a 55" diamond-
shaped insertwas clamped on two tool holders with SCEAs of- 3. The Development Process of the Empirical Equations
17.5° and -3°, and E C E A s at 17.5 ° and 32 °, respectively. All
inserts selected in this research are Chemical Vapor Deposition One of the most irnpottantfactorsnecessary for investigation
(CVD) type because they are the most commonly used coated of the effectof side cuttingedge angles on machining parameters
insertsin metal cuttingtoday. The C V D triphasecoated carbides, is the relationshipof cutting force components as a function of
K C grade 850 (TiCfricNfriN), of C N M G - 4 3 2 and D N M G - 4 3 2 SCEAs and theirvalues. The cutting force components could be
category of Kennametal, for 80" and 55 ° diamond-shaped insert, found either by direct measurement using a dynamometer for
respectively. CVD coated carbides were used as these type of differentSCEAs, or by predictingthe cutting forces analytically.
inserts are recommended for 1018 steels by the automotive steel Calculating the values of cutting forces in oblique cutting
company. The three cutting forces (the feed force, the radial analytically is extremely difficultdue to the complexity of the
force, and the tangential force) were measured using a metal cuttingprocess. Therefore, empirical equations have to be
dynamometer for the first set of experiments with three SCEAs of utilized as a function of S C E A s to predict the value of cutting
-5",0",+15", at speeds of 140, 170, and 220 m/rain, at a feed force components. The main parameters required for prediction
rate of 0.0254 mpr, and a depth of cut of 0.254 m. ALso, the of cutting force components are chip flow angle, ~ , chip
three cutting forces were measured for the second set of thickness ratio, r c, normal shear angle, ~,, and normal friction
experiments with two SCEAs of-17.5 ° and -3", at speeds of 140, angle, ft.. Figure 6 illustrates these angles and SCEAs in
170, and 220 m/rain, at a feed rate of 0.0254 mpr and a depth of Merchant's circle diagram [8, 12]. Jiang [10] has developed an
cut of 0.254 m. For each cutting condition several readings were empirical formula to predict chip flow angle th as a function of
conducted. In addition to these cutting conditions, other side cutting edge angle. For the first time the following empirical
experiments were conducted using the same toolholder and insert equations have been developed, for oblique cutting operations as
by rotating the base on which the cutting tool and dynamometer a function of side cutting edge angles in this research.
were placed and adjusted for different SCEAs -17.5°, _10 o, -5° _ chip thickness ratio,r, normal shear angle, ~,
3", 0 °, +15" and 45 °. The average of each cutting condition normal frictionangle, r. main cutting force Fp
was recorded and plotted in Figure 3. A solid bar workpiece feed force Ff,,d radial force F ~
material and tube were used to conduct all cutting conditions. Several differentapproaches have been considered in developing
I.A. Kattan, K.R. Currie/Journal of Materials Processing Technology 61 (1996) 231-237 233

o 0 IO
. . 20 . 30 . 40 o 0-20 -~0 0 I0 20 30 40 O

,• § - ; ~ " ' ~ " ~ ............. ; ......... i ..................


! i o
: .......... 7 °
,o ....... ............................................
..., ..............
..-__._.j_~
!
. . . . . . . . . . . . . . . . . . . . . . . .
~oi ...........
o ,
m ~
.o Ij_ I
o .... ,. . . . . . . . . . ~EC,E"IO . . F°
. . . . . . . . .

•' 7tonq |
o i 7~anai :o ,.~ .
~
o . - ' ° ' " '." " . . . . . . . . . FF,~e~ . .....' / L
o ..... ,~, ..... r ............................. = ~ ........... o - ...... F-ac
o ! .... ~o~ Io
r k.p

0 I0 20 ]0 40 1-2o 40 ~b :o :'o ;o '


SCFA K DEGREE SCEA K DEGREE

FIGURE THE TREND O F C U T T I N G FORCES VS SCEA'~ F I G U R E 2 /~AEASURED C U T T I N G FORCFS VS SCEA'~

V • L~O V .170 y .220


FORCE MEASUREMENTS , . ,

~. / . . . . . . . :',,.. ~ . , . . . . . . . . . :.-~

24.52 l.'m 3Z.31 pm ?,8.41 um

, --.

i
K.15 ~

? . . . . . _ . ?

-2o -,o o SC-A'K OEG~E= :o ,o z3.~ ~, 31.,7 ~ ~6:9Z


Figure4 Post-processchip roots t'or nine conditions (k=-5, 0 and + I5~
~md at tbt¢,- diffP.rc~t JIpccds V = 140, tTO'~nd 220 mJmin)
the insP.r~is CN'MG 432 KC$50 ~nd the m a ~ i A[SI-ASE I015
FIGURE 3 FORC--S VS SCSA A T V=220 m/rain ~ v'aJ~ 0 f SSZ i'~ indicated un~e.~ ~ chip too{, magnifi,'~don (22,..~')
,234 LA. Kattan, K.R. Currie/Journal of Materials Processing Technology 61 (1996) 231 237

the empirical equations in this work. However, because of the insert clamped on tool holders to produce different SCEAs and
limited amount of experimental data due to the small variety of ECEAs. The proposed scheme of new inserts and tool holders
the tool inserts on the market, a combination of curve fitting, has the same dimensions and properties similar to the CNGM -
trend analysis, interpolation, and iteration of the computer 432 insert used in the research. ALso, the proposed scheme has
program using the theoretical equations of similar conditions have very good flexibility as each proposed insert could be used for
been considered to develop empirical equations using the seven operations similar to the 80 degree diamond-shaped insert
following steps: which has been used in the experiments. End Cutting Edge Angle
1. The existing equations for geometrical relationship of (ECEA) should not be less than 2.5 degree due to dynamic
oRhogonal cutting were used as the basis for developing the condition of metal cutting, as additional criteria imposed in the
empirical equations for geometrical parameters. designing process. The tool insert may be installed in different
2. The theoretical equations developed by Armarcgo [1] for toolholders with different SCEA's and ECEA's. The CNMG -432
cutting forces were used as basis equations to derive empirical insert and DCLNR, DCGNR, and DCRNR toolholders developed
equations for the cutting forces. However, these equations, arc by Kennametal have been used in this rcsearoh.
function of chip flow angle Vc, normal friction angle ~,, and In metal cutting, the occurrence of chattering and vibration
normal shear angle ~bn,which have been empirically developed as may be controlled by providing appropriate End Cutting Edge
functions of side cutting edge angles. These empirical equations Angle (ECEA) in the tool geometry design. The value of ECEA
arc vital in the mathematical model to predict the cutting forces. can directly affect surface finish, dimensional accuracy, and tool
Having the predicted values of these forces, then, it is possible to life. The ECEA is provided in tool design to prevent the
predict all other machining parameters. auxiliary cutting edge from cutting, scratching or rubbing,
3. The first estimate of SCEA was introduced as an independent thereby reducing the friction of the auxiliary flank on the
variable in the basis equations. The program was run to begin an machined surface of work-piece. In the case of negative $CEA
iterative operation in which the results of each run were compared with -5 ° the diamond angle has to be reduced. The smaller the
with the associated plotted curve. An acceptable deviation diamond angle is, the weaker the area surrounding the finishing
(_T10%) was set by iterativc operations. point of the insert. The experimental tests at large negative
4. The second independent variable (cutting speed V) was SCEA should be avoided due to a wedging action on the cutting
introduced into the empirical equations in the same manner. The edge that often causes severe edge breakage. The diamond angle
program was run to obtain an acceptable deviation (_T_10%) using may be increased by decreasing ECEA; however, the size of
both independent variables (SCEA and cutting speed) in each ECEA should not be less than 3" due to the dynamic condition of
equation. metal cutting. As ECEA is increased, the maximum roughness
In oblique cutting the cutting speed V, forms an angle with height R,,~ increases which means the quality of surface is
the plane normal to the cutting edge called the inclination angle expected to deteriorate. However, a reduction in ECEA increases
(i). The main cutting edge forms side cutting edge angle ~, and the radial force because the auxiliary cutting edge becomes more
the secondary edge forms the end cutting edge as shown in Figure active and may cause chattering and vibration. An ECEA angle
7 [1-6]. A mathematical model was designed to use the input of 5 ° to 15 ° has been found satisfactory in most tool design cases
parameters of tool geometry, tool material and work-piece [1].
material, cutting condition and machine specifications. The modal
has included mathematical relationships and empirical formulae 5. Conclusions and Remarks
developed for oblique cutting to calculate the main output
parameters of metal cutting such as; three cutting forces (feed, Direct experimental evidence shows that the values of all
tangential and radial), coefficient of friction, shear force, shear three curing forces (the main cutting or tangential, the feed and
energy, friction force, and friction energy. The model is designed the radial forces) wen: decreased as negative $CEA decreases
to run a wide range of input data to test the effect of side cutting below -5 °. The measurements of cutting forces for tool geometry
edge angle on the performance of cutting, quality of surface finish with SCEA of -17.5 ° indicated lower values than tool geometry
and cutting condition parameters. A computer program has bccn with SCEA of 0 ° and -5". The color of the chip root with SCEA
written for this model, tested and verified. A sample of the of-17.5 ° was light brown compared to the color of the chip with
output of the mathematical model is illustrated in Figures 8. For SCEA of 4..15" was a dark blue, which indicate lower cutting
more details of the mathematical model the reader should refer to temperature with SCEA of -17.5". However, the color of the
Kattan [27]. chip with $CEA of 4..45" was light blue and brown, which
indicates lower cutting temperature with SCEA of 4-45 °
4. The Proposed New Cutting Tools compared to the tool with $CEA of 4-15 °. The radial force has
increased for SCEA at 4..45° over the radial force at SCEA 4-15"
A new scheme of tool geometry with negative SCEA has but the magnitude of both the tangential and the feed forces were
been proposed. The following diamond-shaped inseRs with decreased sharply. These results arc consistent with all color of
diamond angles of 85 °, 75 °, 70 °, 65 ° and 60 ° have been the chips corresponding to the tool geometry with negative SCEA.
designed. Each tool insert may be installed in different tool The thickness of Secondary Shear Zone (SSZ) with cutting tool
holders to produce different SCEAs and ECEAs. Figure 9, with SCEA of-5" was less than the thickness of SSZ with cutting
shows the geometry of proposed inserts with respect to the tool has $CEA 0 °, another indicator for cutting temperature. The
workpicce material in the cutting operations. Table 1 illustrates temperature in the $SZ depends on the heat evolved and the heat
the proposed new tool geometry for different diamond-shaped dissipated. The specific heat evolved in the $SZ is proportional
1.A, Kattan, K,R. Currie/Journal of Materials Processing Technology 61 (1996) 231-237 235

Worksuriac~

MacldnedsudacQ
~Sh oaring
vc--'-Flow Ilnos
C~,~p
~,

~T/'/122~;'/7~12Z~'/tti4/llliilillii//

/ Depthol '
cut (d)
MAIN CUTTING
EDGE
X4
~ FIEFEREIqCE
/~/CUTTING
PLANE
/I TO MAIN
EDGE
Fx
xy

FIGURE 7 S H O W S T H E GBOL4EFRY OP OBLIQUE CLrFI3NG

FIGURE 5 THE FLOW LINES OF MJCROSTRUCTURE SCEA K - -25.00 SPEED V- 140.0 m/min
OF A CH~-ROOT AND T ~ TOOL TIP
THY.SE V A L U E S A R E C A L C U L A T E D BY THE MODEL
AND COMPARED WITH THE EXPERIMENTAL RESULTS

TRUE BACK RAKE ANGLE ,L A M D A T O R I = -6.63166


TRUE SIDE RAKE ANGLE , GAMAT -2.42312
NORMAL SIDE RAKE ANGLE , ALPHAN -2.4069229459236
CHIP FLOW ANGLE , ETAC = 6.0433659667053
CHIP THICKNESS RATIO rc = 0.24554145496930
CAL. DEFORMED CHIP THICKNESS, tc = 4.07263E-02
NORMAL SHEAR ANGLE, phin = 13.6485
FRICTION ANGLE ON THE TOOL, betan - 45.5736
MERCHANT MACHINABILITY ANGLE , C = 72.0000
SHEAR FLOW ANGLE , e~as - 7.8398499863644
NORMAL COMPRESSIVE STRESS , Sn = 1190.083999 []~Pa]
YEILD STRENGTH , sO - 478.223328 [KPa]
SHEAR STRESS INPUT VALUE ssm = 697.40902 [KPa]
Max SHEAR STRESS (ORTHOGONAL) = 1073.341619 [l~Pa]

THESE ARE THE VALUES FOR FORCES AND STRESS

MAIN CUTTING FORCE Fp = 469.3785122 [N]

RADIAL FORCE Frad - -612.872996 IN 3

FEED FORCE Freed = 508.095645 IN]

FRICTION FORCE Ff = 1717.049682 [N]

NORMAL FORCE N m 1932.640591 IN]

COEFFICIENT OF FRICTION Mu - 0.88844901323318

SHEAR FORCE Fs - 1541.0032706 [N]

SHF.ARAREA As = 2.752562195 [mm^2]


V b SHF~%R S T R E S S (OBLIQUE) Ss - 808.983165162 [KPa]

NORMAL STRESS {OBLIQUE) Sn - I089.69935312 [KPa]

FIGURE 6 MERCHANT'S cn%CLB DIAGRAM FIGURE 8 AN OUTPUT OF THE MATHEMATICAL MODEL


236 I.A. Kattan, K.R. Currie/Journal of Materials Processing Technology 61 (1996) 231-237

K--15 K2-+15 K--12.5 K2-+12.5 K--15 K2-+10

I 15.0" 12.5" - 110.0"


15.0" ~O ~ ` ~ ~ 12.5.~ ~ 15.0.~
~
K--15 K2=+5 K--12.5 K2-7.5 K-- 10 K2=-,-10
5 O"
I 10.0"

12.5"~_~ 10.0"

K--IO K2-+5 K--7.5 K2=+7.5 K--2.5 K2=+2.5

10.0"
t 2 .5"

Figure 9 The proposed new tool geometry.

Table 1 The Proposed New Cutting Tool Geometry


I

Diam. SCEA ECEA Imert Installation on


No. A.g/c (Deg) (Deg) the Toolholder Rcmar~

1 85 -2.50 2.5 Symmetrical Small ECEA may cause rubbing


2 75 -7.50 7.5 Symmetrical Good at high feed rate
3 75 -10.0 5.0 AsymmeU-ical General purpose
4 75 -5.0 10.0 Syrmne~'ical General purpos©
5 70 -5.0 15.0 AsymmeU-ical (Heavy Roughing)
6 70 -10.0 10.0 Symmetrical Gencral purpose, low DOC
7 70 -7.5 12.5 AsyrnmeU-ical High feed rate, low DOC
8 70 -12.5 7.5 A~ymmelrical High feed rate, low DOC
9 65 -12.5 12.5 Symm~dcal High fee~ rate, low DOC
10 60 -10.0 20.0 Asymmetrical very low DOC, High fred rate
I.A. Kattan, K.R. Currw/Journalof Mater/alsProcessingTechnology61 (1996)231~37 237

to the shear deformation and the tangential force. The heat [12] Merchant, M.E., "Mechanics of the Metal Cutting Process.
dissipation conditions are basically determined by the curing I. Orthogonal Cutting and a Type 2 Chip," Journal of
speed, the depth of cut, the thermal conductivity of the workpiece Applied Physics, Vol. 16, No. 5, 1945, pp. 267-275.
material and the cooling system. The temperature of the moving [13] Lee, E. H., and Shaffer, B. W., "The Theory of Plasticity
surface of the chip depends on the heat generated along the lower Applied to a Problem of Machining," Journal of Applied
surface of the chip, the dissipation conditions and the heating of Mechanics, Vol. 22, Transaction ASME, Vol. 73, 1951,
the chip during plastic deformation in the chip formation zone. pp. 405-413.
The rate of the tool wear is generally observed to increase with [14] Stabler, G. N., "The Fundamental Geometry of Cutting
higher cutting temperature. Tools," Proceedings Institute of Mechanical Engineering,
The measurements of quality of surface finish show that the No. 63, 1951, p. 165.
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waviness is obtained with a tool geometry having an SCEA angle Prediction of Three-Dimensional Cutting Process. Part 1
of-5 degrees. A relatively poor surface finish was obtained at an Basic Cutting Model and Energy Approach," Journal of
SCEA of + 15 degrees. This is due to the effect of high radial Engineering for Industry, Vol. 100, Transactions ASME,
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quality of surface finish, large samples with 210 readings for Dimensional Cutting Process. Part 2 Chip Formation and
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life. The other objectives of this study are to investigate the Journal of Engineeringfor lndustry , Vol. 100, Transcations
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292.
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