Design of a Single Point Cutting Tool

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 04 | Apr 2022 www.irjet.net p-ISSN: 2395-0072
© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 1070
Design of a Single Point Cutting Tool
Bhairab Prasad Kantu1
1Undergraduate Mechanical Engineering student at Veer Surendra Sai University of Technology, Burla
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Abstract – Single point cutting tool is a tool which touches
the workpiece only at a single point. This paper deals with
design of a single point cutting tool for machining medium
carbon steel with a cutting velocity of 400 m/min, feed of 0.5
mm per revolution and depth of cut of 0.5mm. Studyanddesign
of single point cutting tool is an important aspect of tool
engineering. In this paper we have discussed the design aspect
of shank, the tool geometries, the power required by the lathe
and the stresses developed in the tool due to machining. Single
point cutting tool is used for important operation in the lathe
like facing and turning hence study of geometry of a single
point cutting tool is very essential part of study required for
manufacturing. Design of single point cutting tool involves
collecting data from design data book and usingthe datatoget
the final design. It is an iterative processwhichinvolvesvarying
the angle within a certain limit provided by the data book to
get an optimum result.
Key Words: Single point cutting tool, design, mediumcarbon
steel, carbide tool, power consumed, lathe, American
standard association, orthogonal rake system,vectormethod
of conversion.
1. INTRODUCTION
Single point cutting tool is a tool which touches the
workpiece at only on point. Operation like turning, facing,
shaping, planing , boring etc use single point cutting tool.
Gradually the price of tool material is increasing which has
increased the need of less costly tool body i.e., shank. As the
price of tool is increasing the durability and life of tool
material is an important factor while making a tool. A small
change of even 1: in the tool parameters can alter the force
encountered by the tool by more than ten times. Hence the
proper design of tool is very essential.
Fig -1: Single point cutting tool
In this paper we have designed a tool based on a specific
condition that can be extended to any variation of data. In
this paper we have estimated the following prerequisite -:
 Workpiece material -: Medium carbon steel
 Cutting velocity (Vc)-: 400 m/min
 Feed (S₀) -: 0.5 mm/rev
 Depth of cut (t) -:0.5 mm

The properties of the workpiece are listed below-:
 Ultimate tensile strength -: 565 MPa
 Tensile strength yield -: 310 Mpa
 Modulus of elasticity -: 200 GPa
 Density -: 7.87*10³ kg/m³
 Brinell hardness number -: 163
 Shear modulus -: 80 GPa
Before designing the tool we must be aware of the
requirements of a cutting tool. The requirements of cutting
tool are listed below-:
 The tool and the workpiece mustbeheldrigidlysoas
to allow the tool to penetrate the workpiece when
forces are applied.
 The shank of the tool must be properly analyzed for
strength and rigidity.
 The deflection of the tool must be within prescribed
limit.
 The tool must withstand forces encountered by it
when it penetrates through the workpiece.
2. MATERIAL SELECTION
The required properties of tool material are listed below
 The tool material must be harder than the
workpiece.
 The tool material should be chemically inert.
 The material must be able to resist wear and
tear.
 The material should be thermally stable.
 The material should have good thermal
conductivity and less coefficient of thermal
expansion.
Tool material most widely used are -:
 Carbide

 Ceramic
 Cubic Boron Nitride
 Diamond
 High speed steel
 Tool with coating of Titanium Carbide(TiC)
and Titanium Nitride(TiN).
In this paper we have selected Carbide tool with a coating of
TiC as BHN of Carbide is much higher than that of medium
carbon steel. HSS is also an good alternative but it is not good
for machining at such high speed.
3. DETERMINATION OF ANGLES
From the design data book we get the recommended angles
for carbide tool in ASA system.
 Back rake angle (Υy) -: 0:
 Side rake angle (Υx) -:6:
 End clearance angle ( αy) -:5:
 Side clearance angle (αx) -:5:
 Side cutting edge angle (ϕs) -:15:
 Approach angle (ϕ)-: -: 75:
 Nose Radius (r) -:1 mm
3.1 Conversion from ASA system ORS
There are four methods for conversion from one system
of angle to the other -:
 Geometrical Method
 Graphical Method
 Transformation Matrix Method
 Vector Method
We have used vector method of conversion from ASA
system to ORS
a) Tan(Υ₀) = Tan(Υx) Sin(ϕ) + Tan (Υy)Cos(ϕ)
 Tan(Υ₀) = Tan (6) Sin (75) + Tan(0)Cos(75)
 Tan(Υ₀) =0.1015
 Υ₀ = Tan⁻¹(0.1015)
 Υ₀=5.795:
b) Tan (λ)= Tan (Υy ) Sin(ϕ)- Tan(Υx) Cos(ϕ)
 Tan (λ) = Tan (0) Sin (75) -Tan (6) Cos (75)
 Tan (λ) =-0.0272
 λ= Tan⁻¹ (-0.0272)
 λ= -1.568:
c) Cot(α₀) = Cot (αx) Sin(ϕ)+ Cot(αy) Cos(ϕ)
 Cot(α₀) = Cot (5) Sin (75) + Cot (5) Cos (75)
 Cot(α₀) =13.998
 Tan(α₀) =0.0714
 α₀= Tan⁻¹ (0.0714)
 α₀= 4.083:
Hence the angles in ORS (Orthogonal Rake System) are-:
 λ -Inclination Angle - -1.558:
 Υ₀ -Orthogonal Rake Angle -5.795:
 α₀ -Orthogonal Clearance Angle- 4.083:
 α₀’-Auxiliary Clearance Angle- 2:
 ϕe – Auxiliary Cutting Edge Angle- 15:
 ϕ- End Cutting Edge Angle- 75:
 r- Nose Radius-1 mm
4. CALCULATION OF DYNAMIC SHEAR STRESS
Dynamic shear stress is given by the product of Brinell
hardness number and 0.186.
We know, τ=0.186*BHN
=0.186*163
= 30.318 kg/mm²
=303.18 N/ mm²
5. DETERMINATION OF CHIP REDUCTION
COEFFICIENT (ζ)
Chip Reduction Coefficient is defined as the ratio of
uncut chip thickness to the cut chip thickness. It
indicates the degree of deformation.
Assuming it to be rough turning cycle the chip reduction
coefficient (ζ) is assuming to be 2.5 and Factor of safety
(FOS) is assumed as 10.
6. CALCULATION OF TANGENTIAL FORCE
Tangential force is defined as the component of force
which acts on the edge of the cutting tool along a tangent
to cutting tool body.
PZ = t s₀ τs(ζ - Tan(Υ₀) +1)
Here,
t is the thickness of the workpiece
s₀ is the feed
Hence,
PZ =0.5*0.5*303.18(2.5-0.1015+1)
= 257.596N
7. CALCULATION OF LONGITUDINAL FEED FORCE
Px = t s₀ τs (ζ - Tan(Υ₀) -1) Sin(ϕ)
Here,
t is the thickness of the workpiece
s₀ is the feed
=0.5*0.5*303.18(2.5-0.1015-1) Sin (75)
=102.394 N

8. CALCULATION OF RADIAL FORCE
Py = t s₀ τs (ζ - Tan(Υ₀) -1) Cos(ϕ)
=0.5*0.5*303.18(2.5-0.1015-1) Cos (75)
=27.436 N
9. CALCULATIONOFCROSS-SECTIONALDIMENSION
We know H/B must be between 1.25-1.6, Here
 H is the height the tool
 B is the breadth of the tool
The effective length Le of the tool mustbebetween25-30
mm for proper holding of the tool.
So, we assume H/B = 1.5 and Le =30 mm
We Know,
Total stress is given by the sum of principal stresses i.e.,
σ = σ ₁+ σ₂
Also,
…………….(ii)
Now, from (i) and (ii) we have,
56.5 =
B= 8.35 mm
Rounding it off to the nearest standard value of
integer we get B =10 mm
From the recommended set of cross section 10*16 is
available.
Hence the Cross-Section of the cutting Tool is 10*16
mm.
10. POWER CONSUMED
The power consumed in the cutting the workpiece is
given by the equation
P= Pz*Vc
Here,
Pz is the Tangential Force
Vc is the cutting velocity
= {(257.596*400)/60} Watt
= 1717.306 Watt
=1.717 KW
11. DEFLECTION
= 0.00396 mm
=3.96 microns
12. TOOL SIGNATURE
The expected tool signature in ORS System is
-1.558-5.795-4.083-2-15-75-1
13. ROUGH DIAGRAM
14. CONCLUSION
This research work deals with the design of single point
cutting tool and after the determination of forces the effect of
these forces were studied. With all theanalysisoftheseforces
it can be concluded that design of the single point cutting tool
is strong enough to bear cutting forces during all kindoflathe
operation.

REFERENCES
[1] Dr. P.C.Sharma, A Textbook of Production Engineering
Technology .
[2] Pradeep Kumar Patil, A.I. Khandwawala Design of single
point cutting tool , International Journal of Engineering
Science Invention Research & Development; Vol. I Issue I
[3] Hemanth ,Muralidharan,Predictiveanalysisofmill cutters
for improved surfacefinish quality and effects of coolant
on carbide tools,Advanced Research Journals Of Science
And Technology,Volume: I, Issue : II
[4] U.Pradeep Kumar, C Fakrunnisha, Experimental
Investigation of Optimizing En8 and En19 Steels Using
Cryogenic Technique With Ansys Results,
Journal of Mechanical and Civil Engineering ,Volume
15 ,Issue 4
[5] Shiv Prakash Singh, Tanweer Alam, Somnath
Chattopadhyaya, A Review on the Excavator Tool Bits
Wear, Proceedings of the 1st International and 16
th National Conference on Machines and Mechanisms
(iNaCoMM2013), IIT Roorkee, India, Dec 18-20 2013

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