Advances in Science and Technology

Research Journal
Volume 9, No. 28, Dec. 2015, pages 107111 Research Article
DOI: 10.12913/22998624/60796

COMPUTER AIDED DESIGN OF CUTTING TOOLS

Jakub Matuszak1, Marcin Barszcz2

1
Department of Production Engineering, Mechanical Engineering Faculty, Lublin University of Technology,
Nadbystrzycka 36 Str., 20-618 Lublin, Poland, e-mail: j.matuszak@pollub.pl
2
Department of Fundamentals of Technology, Technology Fundamentals Faculty, Lublin University of
Technology, Nadbystrzycka 38 Str., 20-618 Lublin, Poland, e-mail: m.barszcz@pollub.pl

Received: 2015.10.05 ABSTRACT

Accepted: 2015.11.14 Correct and stable machining process requires an appropriate cutting tool. In most
Published: 2015.12.04 cases the tool can be selected by using special tool catalogs often available in online
version. But in some cases there is a need to design unusual tools, for special treat-
ment, which are not available in tool manufacturers catalogs. Proper tool design re-
quires strength and geometric calculations. Moreover, in many cases specific technical
documentation is required. By using Computer Aided Design of cutting tools this task
can be carried out quickly and with high accuracy. Cutting tool visualization in CAD
programs gives a clear overview of the design process. Besides, these programs pro-
vide the ability to simulate real machining process. Nowadays, 3D modeling in CAD
programs is a fundamental tool for engineers. Therefore, it is important to use them in
the education process.

Keywords: cutting tools, computer aided design.

INTRODUCTION sessed and controlled by the person responsible

for the project. The combination of CAD CAM
Workstation with the appropriate software is allows reducing the time between design and
a fundamental designing system, which, thanks manufacturing process. This secures quick and
to its capabilities, is able to encompass the entire easy transition to the new structure and enables
process of product design, production prepara- efficient and low-cost production of short series,
tion, manufacturing and management together and even piece production [5, 10].
with controlling the manufacturing machines, Recently there has been a tendency to imple-
and other devices in real time. In enterprises ment additional modules into the environment of
through internal computer networks, one project the CAD / CAM, e.g. the Finite Element Method
can be carried out by a larger number of design- FEM, allowing the use of advanced strength eval-
ers who form a team, which minimizes the time uation for component models and whole assem-
from design to manufacturing the finished prod- blies. For example, Solid Edge software allows to
uct and reduces the risk of errors in the design analyze stresses and strains, check the structure
process. CAD systems that interact with CAD for buckling and to determine the frequency of
and CAE are programs that due to their structure vibrations. Advanced tools for the results visu-
allow the simultaneous work on a project of the alization, may allow to precisely and accurately
whole team of designers. They give the oppor- optimize the construction (for instance: to reduce
tunity to introduce changes at any stage of the weight) and evaluate the place where the parts are
design, which, in turn, are automatically updated most strenuous.
on all the team members computers. Advanced Forming machine parts by machining process
graphic systems allow to use the computer for plays the leading role in the production, while
presenting information to be conveniently as- cutting tools occupy the predominant position in

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manufacturing engineering, thanks to its wide ap- first of these is the setup surface roughness (this
plication in industrial processes of manufacturing is especially important for high accuracy require-
machine parts. Cutting tools development leads ments, e.g. using heat tool holders). The second
to direct development of machining centers. The issue is the roughness of the rake and flank faces
introduction of new, durable tool materials, al- affecting the adhesive properties (e.g. during ap-
lows for high speed machining of materials after plying coatings), but also built-up edge effect and
heat treatment. This, in turn, leads to the produc- the friction coefficient between the tool material
tion of machine having the necessary rigidity, and the formed chip.
sufficient feeds and power high-speed spindles to Re. 2. Depending on the type of workpiece
ensure high rate of metal removal. Through this, material, tool material is selected and adequate
machining can be the final step in the process of strength calculations are carried out. The calcu-
making the product. In addition to tool materi- lation takes into account the previously selected
als development of cutting tools, construction is tool geometry and the designated force and cut-
the subject of optimization, so as to ensure maxi- ting resistance. During machining the tool should
mum efficiency of the cutting edge and ensure the be considered as an element that is subject to
greatest possible tool life. Tool life is important complex forces and torques. Adequate strength
during machining of materials with high strength analysis will give the answer whether there is a
and hardness, like titanium and nickel alloys, be- risk of catastrophic tool wear. The tool wear may
cause the costs of cutting tools have the biggest affect cutting edges, but also the tool body, which,
share in the total cost of production of the prod- in the case of indexable tools is made of less re-
uct. Furthermore, it is possible to influence and sistant material than the inserts. Strength calcu-
control surface layer as well as the properties of lations should include a number of aspects such
the workpiece by the cutting tool [2, 4, 9]. as mechanical strength, vibration and machining
accuracy. If failure condition is not fulfilled, one
should either change the tool material, or go back
STAGES OF THE DESIGN OF CUTTING to step one and redesign its geometry.
TOOLS Re. 3. Depending on the complexity of the
tool appropriate drawings should be prepared.
Cutting tools can be divided into two groups. They can be assembly drawings for indexable
The first group consists of commercial cutting tools or work in conjunction with a dedicated tool
tools. They are used for typical machining opera- holder and working drawings fully illustrating the
tions and the size and tool geometry are described shape of the tool. Design solid models and then
in detail in relevant standards and catalogs. In the automatically generating 2D technical documen-
second group there are special tools dedicated to tation is currently available in most design pro-
specific objects. The geometry and dimensions grams such as: Solid Edge, I-DEAS, NX, T-Flex,
of these tools depend on the desired shape and SolidWorks, Catia ect. In addition the kinematics
the material of the workpiece [1, 6, 7]. In such a of machining can be simulated to illustrate the
situation, during the design of special tools, there operation of the tool even better. Moreover, these
is a need to prepare technical documentation and programs have built-in modules for advanced
perform the necessary calculations each time. De- rendering providing photorealistic visualization.
signing cutting tools can be divided into several
stages [3]:
1) geometric and stereometric calculations, EXAMPLES OF COMPUTER-DESIGNED
2) strength calculations,
SPECIAL CUTTING TOOLS
3) execution of tool drawings, models (3D and
2D) and simulations.
In the case of forming tools, it is very im-
Re. 1. At this stage the assumptions associ- portant to properly determine the outline of the
ated with overall dimensions of tools should be cutting edge. The cutting edge is reflected in the
taken into account, e.g. the type and variety of workpiece as it is shown in Figure 1. Therefore,
tools. In the case of special forming tools, dimen- the accuracy of the edge contour directly affects
sions depend on the shape of workpiece. As for the dimensional and shape accuracy of the fin-
the surface roughness of the tool, it is necessary ished object. There are two methods of determin-
to distinguish between two important issues. The ing the outline of the cutting edge. The first is

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an analytical method which consists of calculat- input data for the design are the module and num-
ing the position of the individual characteristic ber of gear teeth. Cutting edge of gear cutting hob
points of edge contour. The second diagrammatic is formed by the intersection of the helical tooth
method, which consists of traditional (not us- profile and outline chip grooves. The visual as-
ing a computer) determining the contour edge sessment of the entire model makes it possible to
is not precise. This restricts its use to cases that verify the correctness of an operation in which
do not require high shape accuracy. However, in the cutting edges are formed. Figure 2 shows the
such situations the use of computer-aided design photorealistic visualization prepared in the Key-
is very helpful. It simplifies diagrammatic meth- Shot compared to the view of model from ISO
ods and allows the simultaneous maintain the ac- part module of Solid Edge ST7.
curacy of the analytical method. In this way, the The advantage of the software is that the
forming tool presented in Figure 1 was designed. initial rendering is done in real time. How-
During the operation of contour turning tool and ever, the final preparation of visualization re-
toolholder constitute a set and therefore they must quires high-speed graphic processor dedicated
be designed jointly. Toolholder enforces proper to computer graphics. For example, it took two
setting of the forming tool in a working system [8]. minutes to prepare photorealistic visualizations
Another example of a tool that requires a presented in Figure 2a with the use of a stan-
comprehensive design is gear cutting hob. The dard PC computer.

Fig. 1. Visualization of tool orientation relative to the workpiece during machining

a) b)

Fig. 2. The example of visualization capabilities: a) rendering in Keyshot 5 software,

b) view from the ISO part module of Solid Edge ST7

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Example of automatically generated technical As it was mentioned above, one of the stages
documentation showing view and cross section of of cutting tools design is strength calculations.
the gear cutting hob is presented in Figure 3. The way to expand and verify the analytical cal-
Another example of the special tool is a pull culations may be the finite element method imple-
broach presented in Figure 4. As shown in the fig- ment in Solid Edge ST7. Highest stresses occur in
ure, pathfinder containing a set of operations the area of the holder and at the location of chip
is not very extensive because all the geometry is groove just before the first blade. After imposing
contained in one sketch presented in Fig. 4a. Pull the boundary conditions finite element mesh is
broach is almost finished after revolved protru- generated. The results of stress and strain can be
sion using the sketch. Additional operations are presented as color scale as it is shown in Figure 5.
performed only to create chipbreakers (Fig. 4b). This method is time consuming and requires pow-

Fig. 3. Automatically generated technical documentation in ISO draft module in Solid Edge ST7

Fig. 4. View of pull broach: a) sketch, b) chipbreakers

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Fig. 5. Strength analysis using finite element method

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