KEVOS® MAKEOS · Manufacturing
Forming Tool Step Depths and Angles
What depth and angle must I grind on a flat or circular forming tool to produce these steps on the work?
Forming tool dimensions by the handbook methods: step depth and angle on a flat tool with front clearance, step depth on a tool with both rake and clearance from the work radii, and the radius of each step on a circular forming tool whose cutting face sits below centre.
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How this tool works
Inputs, units and where to find them
| Input | Unit | Typical source |
|---|---|---|
| Tool | choice | Type of forming tool. |
| Radial step depth on the work (flat, circular) | mm | Difference in radius between two steps on the work. |
| Front clearance angle (flat) | ° | Front clearance angle of the flat tool. |
| Angle on the work (flat) | ° | Angle of a flank on the work (for its reduced angle on the tool). |
| Larger work radius (rake) | mm | Larger radius on the work. |
| Smaller work radius (rake) | mm | Smaller radius on the work. |
| Rake angle (rake) | ° | Top rake angle of the tool. |
| Clearance angle (rake) | ° | Front clearance angle of the tool. |
| Largest radius of the circular tool | mm | Radius of the circular tool at its largest step. |
| Cutting face below centre (circular) | mm | Distance of the cutting face below the tool’s horizontal centre line (set by the machine). |
Method and formulas
- Flat tool: depth d = D cos C; angle in plane x-x: tan A′ = tan A × cos C.
- Rake and clearance: A = 180° − F; sin B = r sin A ÷ R; C = 180° − (A + B); y = R sin C ÷ sin A; tool angle D = 90° − (E + F); depth x = y sin D (handbook example: 16 and 10 mm radii, 10° rake, 15° clearance → 5.490 mm).
- Circular tool: r = √[(√(R² − C²) − D)² + C²], with C the offset of the cutting face.
- Example: a 12.7 mm step with 15° clearance is 12.267 mm deep on a flat tool.
Limitations
- Straight radial steps; curved profiles need point-by-point correction.
- Machine-specific tool radius and offset come from the machine maker.
- Example values are illustrations. Replace them with values for your actual task.
Typical uses
- Grind a dovetail or circular form tool for a profile
- Correct form depths for rake and clearance
- Check a supplier’s form tool drawing
Who it is for
- Machinists
- Toolmakers
- Manufacturing engineers
What you get
- Step depth on the tool
- Angle or radius on the tool
- Correction from the work dimension
Interpreting the result
- Without correction, a raked or offset tool cuts steps shallower than intended.
References
- Machinery’s Handbook, 29th edition (Industrial Press, 2012), printed pp. 797–801. Topic reference; no source tables or recommended settings are reproduced.
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