A

Project Report
On

ANALYSIS OF SINGLE POINT CUTTING TOOL

Submitted By

THOMSON RODRIGUES 201271

SUJOY LUCAS 201269

KEVIN KOTIAN 201268

SAVIO SEQUEIRA 201272

TEJAS YADAV 201264

Under the guidance of

Dr. C.M. CHOUDHARI

(ASST. Professor, mechanical engineering department)

DEPARTMENT OF MECHANICAL ENGINEERING

FR. CONCEICAO RODRIGUES INSTITUTE OF TECHNOLOGY

SECTOR-9A VASHI, NAVI MUMBAI-400703

UNIVERSITY OF MUMBAI

2014-2015

1
 ABSTRACT
In this project, cutting forces at single point cutting tool-tip interface is determined, generated
in high-speed machining operations.

An investigation of cutting forces acting on the tool is carried out by subjecting it to the
maximum possible working stress during a cutting operation. It is also determined that change
in cutting speed and depth of cut has the maximum effect on increasing cutting forces.

By varying the material the effect of those on cutting forces are compared with the experimental
results and FEA results.

The experimental results reveal that the main factors responsible for increasing cutting forces
are cutting speed (v), feed rate (f), and depth of cut (d), respectively.

In this report, an FEM simulation technique is utilized to investigate the physical cutting and
deformation of tip of single point cutting tool under the influence of cutting forces.

2
 INDEX
TITLE PAGE NO.
Chapter 1: Introduction 4
1.1 Introduction to single point cutting tool 5
Chapter 1.2: objective of present work 7
Chapter 2: Modeling of cutting tool on inventor 8
Chapter 3: Element analysis of single point tool 11
3.1 Steps involved in ANSYS solution 12
3.2 Meshing of tool 14
3.3 Important Results in ANSYS solution 18
Chapter 4: Analysis of tool using tungsten carbide 19
4.1 Results 23
4.2 Comparison of results from ANSYS solution 24
Chapter 5: Conclusions 25
Chapter 6: References 26

3
 Chapter:1
INTRODUCTION
Machining, the most widespread process for shaping metal, has become a very significant
aspect of modern society and industry. The importance of the machining process is evident by
the observation that nearly every device used by humanity in day-to-day life has at least one
machined part or surface. From a materials viewpoint, high speed machining is a relative term,
since different materials should be machined with different cutting speeds to insure acceptable
tool life. Because of this difference and the fact that cutting speed determines whether a
material will form continuous or segmented chips, one way to define high-speed machining is
to relate it to the chip formation mechanism. Machining is a common fabrication technique
where material removed from a part using a tool with a small, hard tip. Usually the material
being cut is a metal, such as aluminum or steel. In order to fabricate a part quickly, a high
cutting speed desired. These higher speeds, however, lead to a faster degradation of the tool tip,
which requires that the tool tip replaced more frequently. Over the history of machining,
guidelines and conventions have arisen based on empirical information of tradeoffs between
cutting speed and tool replacement time. Machining is a term covering a large collection of
manufacturing processes designed to remove material from a work piece.

The purpose of this report is to provide a review of efforts related to single-point cutting tool
and finite element analysis. The review is done to offer insight to how the cutting tool behaves
when it is acted upon by various loads.

The use of the software, ANSYS has been very helpful for determining the deformation of the
cutting tool under the influence of maximum possible loads.

4
 1.1 INTRODUCTION OF SINGLE POINT CUTTING TOOL

The single point cutting tool used for turning, boring, shaping and planning operations, that is,
tool used on Lathes, boring machines, shaper, planer etc. are single point cutting tool.
A solid model of Single point cutting tool as shown in figure It is generated using the below
parameters and values by INVENTOR software.

5
Sr No. Parameters Value
1. Back Rake Angle 8
2. Side Rake Angle 10
3. End Relief Angle 6-8
4. Side Relief Angle 7-9
5. Standard Shank Bxh=16x20
6. Tool length depends on cross section 100 to 500mm
7. Nose Radius 1.2-1.6

6
1.2 OBJECTIVE OF PRESENT WORK

The objective of the project is;

 To detect cutting forces acting on tool for various materials

 Modeling by using AUTODESK INVENTOR

 Importing the modeled tool into ANSYS

 Discretization of tool into domains by meshing

 Finite Element Analysis using ANSYS

 Comparison of Experimental data with FEA data for the tool.

7
 Chapter:2

MODELLING OF SINGLE POINT CUTTING TOOL ON AUTODESK

INVENTOR

Fig 3.1

Standard cutting tool dimensions are selected according to requirements.

Tool bit cross-section profile is extruded as per the standard tool length.

Fig 3.2

8
 For single point thread cutting tool, flank angle of 60˚ is used .

Fig 3.3

Plane offset selected for providing rake angle of 10˚.

Fig 3.5

Top rake angle of 10˚ provided for easy flow and breakage of chips during thread cutting.

9
 Chapter:4

ELEMENT ANALYSIS OF SINGLE POINT CUTTING TOOL

4.1 STEPS INVOLVED IN ANSYS SOLUTION:

1. Click SAVE.
2. Drag and Drop Static Structure in PROJECT.
3. Double click Engineering Data>Add Material>Enter values for Young’s modulus,
Poisson’s ratio, ultimate stress and permissible stress.
4. Click RETURN PROJECT.
5. Right click GEOMETRY and click IMPORT>BROWSE>select CAD file made in IGES
format.
6. Right click MODEL and select UPDATE AND REFRESH.
7. Right click GEOMETRY and click ASSIGN MATERIAL.
8. Click STATIC STRUCTURED >loads>force and apply force on cutting face enter apply
2000N
9. Click Loads>Force and apply in cutting edge, enter 5000N.
10.Click Support>apply fixed support click on the top face of the cutting tool blank
11.Click on SOLUTION>Deformation>Total Deformation, also add Stress> Maximum
Shear and Equivalent Stress.
12.Click on SOLUTION and Verify results.

10
4.2MESHING

Fig 4.1 MESHING OF GEOMETRY

11
PROPERTIES OF MATERIALS SELECTED

VALUES FOR TUNGSTEN CARBIDE

VALUES FOR HSS

12
 4.3 IMPORTANT RESULTS FOUND IN ANSYS SOLUTION
 TOOL MATERIAL USED: HSS (High Speed Steel)
 DENSITY: 7972 kg/m3
 E= 3400 MPa
 ⱱ= 0.3
 Fs= 2000N
 Fc= 5000N

Fig 4.3.1 Applying shear force on edge of cutting tool

13
Fig 4.3.2 APPLY CUTTING FORCE ON FACE OF TOOL

Fig 4.3.3 APPLY SHEAR FORCE ON HSS

TOOL
14
 Fig 4.3.4 EQUIVALENT ELASTIC STRAIN
ON HSS TOOL

Fig 4.3.5 TOTAL DEFORMATION

15
 Fig 4.3.6 EQUIVALENT STRESS ON TOOL

Fig 4.3.6 MAXIMUM SHEAR STRESS ACTING ON

TOOL
16
 4.4 RESULTS FOR HSS CUTTING TOOL
1. MAXIMUM SHEAR STRESS: 328.5 N/mm^2

2. DISPLACEMENT: 4.11X10^-2mm

3. EQUIVALENT STRESS: 573 MPa

4. TOOL MATERIAL USED: TUNGSTEN CARBIDE

5. DENSITY: 155.85 kg/m3

6. E= 550 GPa

7. ⱱ= 0.25

8. σt: 400N/mm2

17
 Chapter 6
ANALYSIS OF TOOL USING TUNGSTEN CARBIDE

Fig 5.1 APPLY SHEAR FORCE ON TUNGSTEN CARBIDE TOOL

Fig 5.2 CUTTING FORCE ON TUNGSTEN CARBIDE TOOL

18
 Fig 5.3 APPLYING SHEAR FORCE ON EDGE OF CUTTING
TOOL

Fig 5.4 EQUIVALENT STRESS INDUCED IN TUNGSTEN CARBIDE TOOL

19
Fig 5.4 EQUIVALENT STRESS ON CARBIDE TOOL

20
Fig 5.4 MAXIMUM SHEAR STRESS ACTING ON CARBIDE TOOL

Fig 5.5EQUIVALENT ELASTIC STRAIN

21
 4.1RESULTS

1. MAXIMUM SHEAR STRESS: 276 N/mm^2

2. DISPLACEMENT: 9.438^-6mm
3. EQUIVALENT STRESS: 505 MPa

22
 5.2 COMPARISON OF RESULTS FROM ANSYS

TOOL EQUIVALENT SHEAR DISPLACEMENT

MATERIAL
STRESS STRESS

HSS 573 MPa 328.5MPa 4.11*10^-2mm

TUNGSTEN 505 MPa 276 MPa 9.438*10^-6mm
CARBIDE

23
 Chapter 5
CONCLUSIONS
The Analysis of Single point cutting tool was carried out in ANSYS© and results were
accumulated. Under Static Structural Simulations of High Speed Steel Tools and Tungsten
Carbide Cutting tool we found various parameters like Equivalent stress, Max. Shear Stress and
Total Deformation experienced in cutting operation. These results are portrayed in the above
report and we draw these conclusion based on the aforementioned table that Carbide tools
perform better than HSS cutting tools by very high magnitudes.

24
 Chapter 6
REFERENCES

1. Production Technology(P C Sharma)

2. En.m.wikipedia.org/wiki/Tungsten_carbide

3.www.iaeng.org/publication/WCE2010/WCE2010_p
p218

4. AME10084.April14.39

25