Design and Manufacturing of Tool

Contents
1 INTRODUCTION.................................................................................................................2
1.1 Problem Statement...................................................................................................2
1.2 Objectives.................................................................................................................2
1.3 Scope........................................................................................................................2
1.4 Methodology............................................................................................................2
2 LITERATURE REVIEW.........................................................................................................3
2.1 INITIAL CONSIDERATIONS FOR TURNING -................................................................3
2.2 AFTER CONSIDERING THE FEATURES :......................................................................3
2.2.1 Machine considerations include:......................................................................4
3 RECENT DEVELOPMENTS IN METALWORKING INDUSTRY AND TURNING TOOLS.............4
3.1 Innovation to Reduce cycle times and produce more parts in turning processes.....4
3.2 Vibration reduction in turning processes..................................................................5
3.3 3D Printing in manufacturing....................................................................................6
4 HEAT GENERATION ON CUTTING TOOLS..........................................................................6

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 Design and Manufacturing of Tool

1 INTRODUCTION
1.1 Problem Statement
Design of a special turning tool according to given constraints or requirements by the
customer.

1.2 Objectives
• Enhance production by designing tools that have faster production rates.
• To reduce setup space of the machines.
• Enhance the quality of the product by designing tools which consistently
produce good parts.
• To design and manufacture tool according to time constraints and within
• the acceptable limits at the lowest possible cost.
• Design tools that are easy, safe to use and operate.

1.3 Scope
1.4 Methodology
Special tools are designed according to time constraints and requirements given
by the customer.
• Planning Process is divided into viz.
o Raw material planning
o Process planning

Global tool design department prepares proposal drawing and rough quotation
after receiving the customer requirements from the sales representative. Rough
quotation is prepared with the help of the Global Quotation system. After
verification, the proposal offer is sent to the customer (which is valid for six
months).
• Proposal offers contents :
o Material planning :
 Blank
 Spare parts
 Coolant
 Packaging
o Process planning :
 NC preparation
 Cutting the material
 Box preparation
 Blank preparation
 MCPL
 Induction hardening
 MCPL
 Inspection
 Blackening

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 Design and Manufacturing of Tool

 Laser Marking
 Assembly
• Design requirements are further sent to the design department where they
prepare 3D models and manufacturing drawings.
• Further the 3D model is cross verified by the customer before the actual
manufacturing.
• Once verified the drawings are sent to the production department.

2 LITERATURE REVIEW

Figure 1

Turning generates cylindrical and rounded forms with a single point tool. The turning
definition is that the tool is stationary with the workpiece rotating.
A turning operation is the most common process for metal cutting and is a highly
optimized process, requiring thorough consideration of the various factors in the turning
application.
Turning can be broken down into several basic applications (longitudinal turning, facing
and profiling), requiring specific types of tools, cutting data and programming for the
operation to be performed in the most efficient way.
2.1 INITIAL CONSIDERATIONS FOR TURNING -
Consider the following dimensions and quality demands of the component to be
machined:
 Type of applications, for example, longitudinal or profiling, internal or external
 Type of methods, for example, roughing or finishing.
 Large, stable component
 Small, long, slender, thin-walled component
 Corner radius
 Quality demands (tolerance, surface finish etc.)

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 Design and Manufacturing of Tool

2.2 AFTER CONSIDERING THE FEATURES :

 Does the material have good chip-breaking qualities?
 Is chip evacuation a critical issue? Mass production justifies an optimized Tailor-
Made tool to maximize productivity.
 Batch size, a single component or mass production?
 Can the component be fixed securely?
2.2.1 Machine considerations include:

Figure 2

 Stability, power, and torque, especially for larger components

 Coolant supply or dry machining
 Is high pressure coolant for chip breaking in long-chipping materials necessary?
 Tool changing times/number of tools in turret.
 Limitations in rpm, especially for bar feed magazine
 Sub-spindle, or tail stock available?

3 RECENT DEVELOPMENTS IN METALWORKING

INDUSTRY AND TURNING TOOLS
• Innovation to Reduce cycle times and produce more parts in turning
processes.
• Vibration reduction in turning processes.
• 3D printing in manufacturing

3.1 Innovation to Reduce cycle times and produce more parts in turning
processes.
Sandvik Coromant’s innovative Prime Turning tools can rough and finish parts in
simultaneous passes allowing production levels to increase.
The Prime Turning methodology enables you to do turning in all directions in a
much more efficient and productive way compared to conventional turning.
This latest innovation let users cut not just in a forward motion, but also in
reverse and away from the chuck. You can go in one direction and perform high
feed roughing and you can come back with the front of the tool and traditionally
turn to finish the part.

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 Design and Manufacturing of Tool

Prime Turning is more useful to shops in the aerospace and automotive

industries, though it is applicable, in any shop where large-batch productions
require external turning operations.

Figure 3

3.2 Vibration reduction in turning processes.

Silent Tool Plus enables data from the machining process to be collected and
sent to a dashboard, giving the operator a valuable insight into what is
happening inside slender tubular components.
The Silent Tools Plus vibration indicator can detect issues with machining at an
early stage, helping to prevent vibration-associated issues such as noise, poor
surface quality and accelerated tool wear.
The range of Silent Tools from Sandvik Coromant is designed to minimize
vibration through a pre-tuned damper inside the tool body that consists of a
heavy mass supported by rubber spring elements.
The benefits of this design are multi-faceted, allowing machine shops to increase
metal removal rates, improve surface finish, secure the process, or reduce
production costs.

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 Design and Manufacturing of Tool

Figure 4

3.3 3D Printing in manufacturing

The 3D printed carrier or tool holder is often better than the steel one. When the
parts are being machined, developing complex carrier designs become
impractical.
Creating tooling to hold the inserts at precise orientations requires five-axis
machining and/or additional setups to machine the needed angles into the
carrier.
3D printing is unaffected by complexity—it simply prints a tangible model of
whatever CAD geometry is provided. 3D printing has the main advantage to have
a very short lead time production. Manufacturing a tool in a few days or even a
few hours is made very simple.
3D printing also reduces cost as there are no costs related to machine setup and
finishing as in traditional manufacturing and allows to improve and optimize the
existing tools with new features.

Figure 5

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4 HEAT GENERATION ON CUTTING TOOLS

During machining heat is generated at the cutting point. The heat generated is
shared by the chip, cutting tool and the blank.
The effect of the cutting temperature, particularly when it is high, is mostly
detrimental to both the tool and the job. The major portion of the heat is taken
away by the chips. But it does not matter because chips are thrown out.
So, attempts should be made such that the chips takeaway more and more heat
leaving a small amount of heat to harm the tool and the job.
The possible detrimental effects of the high cutting tool temperature on cutting
(edge) are:-
i. rapid tool wear, which reduces tool life.
ii. plastic deformation of the cutting edge if the tool material is not enough
hot-hard and hot-strong.
iii. thermal flaking and fracturing of the cutting edges due to thermal shocks.
iv. built-up-edge formation.
The possible detrimental effects of cutting temperature on the machined job are:
i. dimensional inaccuracy of the job due to thermal distortion and expansion-
contraction during and after machining
ii. surface damage by oxidation, rapid corrosion, burning etc.
The magnitude of cutting temperature is governed or influenced by all the
machining parameters like :

Figure 6

It is already seen that high cutting temperature is mostly detrimental in

several respects. Therefore, it is necessary to control or reduce the cutting
temperature as far as possible. Cutting temperature can be controlled in
varying extent by the following general methods:
i. proper selection of material and geometry of the cutting tool(s)
ii. optimum selection of VC – so combination without sacrificing MRR.
iii. proper selection and application of cutting fluid application of special
technique, if required and feasible.

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