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Training Handbook Sandvik
Training Handbook Sandvik
Training Handbook
x D m x n
π
vc = 1000
Content
Turning Drilling
Theory A 4 Theory E 6
Selection procedure A 12 Selection procedure E 15
System overview A 16 System overview E 20
Choice of inserts A 22 How to apply E 26
Choice of tools Hole quality and tolerances E 37
- External A 50 Troubleshooting E 42
- Internal A 56
Code keys A 66
Boring
Troubleshooting A 70
Theory F 4
Selection procedure F 9
Parting & Grooving
System overview F 14
Theory B 4 Choice of tools F 16
Selection procedure B 7 How to apply F 21
System overview B 11 Troubleshooting F 26
Parting & grooving - how to apply B 15
- Parting off B 22
Tool holding
- General grooving B 25
- Circlip grooving B 27 History and background G 4
- Face grooving B 28 Why modular tooling G 7
- Profiling B 31 Turning centers G 15
- Turning B 33 Machining centers G 23
- Undercutting B 35 Multi-task machines G 29
Troubleshooting B 36 Chucks G 33
Threading Machinability
Theory C 4 Workpiece materials H 4
Selection procedure C 9 The cutting edge H 18
System overview C 13 Cutting tool materials H 29
How to apply C 19 Manufacturing of cemented carbide H 44
Troubleshooting C 25
Other information
Milling
Machining economy H 55
Theory D 4 Maintenance & tool wear H 68
Selection procedure D 9 Formulas and definitions H 75
System overview D 13 Cutting data calculator H 84
Choice of insert – how to apply D 24
Choice of tools – how to apply D 29
Troubleshooting D 36
1
A2
Turning
• Theory A4
• Selection procedure A 12
• System overview A 16
•C
hoice of tools – how to apply
- External A 50
- Internal A 56
• Code keys A 66
• Troubleshooting A 70
A3
A Theory
E
Drilling
F
Boring
- Facing
- Profiling.
H
Other information
Machinability
A4
Theory
A
Definitions of terms
Turning
Spindle speed
B
n (rpm) The spindle speed rpm (revolution per
minute) is the rotation of the chuck and
Parting and
workpiece.
grooving
C
Threading
Cutting speed
D
The cutting speed is the surface speed,
ft/min (m/min), at which the tool moves
vc (ft/min) along the workpiece in feet (meters) per
(m/min) minute.
Milling
E
Drilling
n The definition of cutting speed as the result
of the diameter, pi (π) and spindle speed in
revolutions per minute (rpm). The circumfer- F
ence (C) is the distance the cutting edge
moves in a revolution. Boring
Inch Metric
π × Dm × n ft/min
π × Dm × n m/min
H
vc = vc =
Other information
12 1000
Machinability
A5
A Theory
•C
ircumference = π x diameter (inch)
(mm)
B • π (pi) = 3.14
Parting and
Example:
grooving
Dm2 = 3
.937 inch (100 mm)
Circumference = 3.14 x 3.937
C
= 12.362 inch
Circumference = 3.14 x 100
= 314 mm
Threading
Dm1 = 1
.969 inch (50 mm)
Circumference = 3.14 x 1.969
D = 6.183 inch
Circumference = 3.14 x 50
= 157 mm
Milling
Given:
Spindle speed, n = 2000 rpm
Drilling
Inch Metric
π × Dm × n π × Dm × n
G vc = ft/min vc = m/min
12 1000
Tool holding
A6
Theory
A
Definitions of terms
Turning
Spindle speed
The workpiece rotates in the lathe, with
a certain spindle speed (n), at a certain B
number of revolutions per minute (rpm).
Parting and
grooving
Surface/cutting speed
The cutting speed (vc) in ft/min (m/min) at
which the periphery of the cut workpiece C
diameter passes the cutting edge.
Threading
Feed
The cutting feed (fn) in inch/r (mm/r) is
n = spindle speed (rpm) the movement of the tool in relation to the D
revolving workpiece. This is a key value
vc = cutting speed (ft/min) (m/min)
in determining the quality of the surface
fn = cutting feed (inch/r) (mm/r) being machined and for ensuring that the
chip formation is within the scope of the
Milling
ap = depth of cut (inch) (mm)
tool geometry. This value influences, not
κr = entering angle only how thick the chip is, but also how the
chip forms against the insert geometry. E
ψr = lead angle
Depth of cut
Drilling
The cutting depth (ap) in inch (mm) is half
of the difference between the un-cut and
cut diameter of the workpiece. The cutting F
depth is always measured at right angles
Lead angle = 0° to the feed direction of the tool.
Entering angle = 90°
Boring
A7
A Theory
Cutting speed
Example of how to calculate the spindle speed (n) from cutting speed (vc).
B
Parting and
grooving
Given:
Cutting speed, vc = 1312 ft/min (400 m/min)
C Diameter Dm = 3.937 inch (100 mm)
Threading
D Inch Metric
vc × 12 vc × 1000
n= r/min n= r/min
π × Dm π × Dm
Milling
Rake angle
F The rake angle gamma (γ) is a measure
of the edge in relation to the cut. The rake
angle of the insert itself is usually positive
λ and the clearance face is in the form of
a radius, chamfer or land and affects tool
Boring
Inclination angle
Tool holding
A8
Theory
A
Turning
ap B
ap
κr
Parting and
grooving
C
The cutting depth (ap) is the length the Chip formation varies with depth of cut,
edge goes into the workpiece. lead (entering) angle, feed, material and
Threading
insert geometry.
Milling
E
Drilling
F
H
Other information
Machinability
A9
A Theory
The lead angle, ψr (entering angle κr), of the tool and the
B nose radius (re) of the insert affect the chip formation in
that the chip cross-section changes. The chip thickness is
reduced and the width increased with a larger lead angle
Parting and
C
CNMG DNMG WNMG
VNMG
hex ≈ fn x 0.71
Machinability
A 10
Theory
A
Turning
Maximum chip thickness hex reduces relative to the feed
rate as the lead angle increases (entering angle reduces).
B
Parting and
grooving
κr κr κr κr
C
Lead angle ψr −5° 15° 30° 45° 0° min
Entering angle κr 95° 75° 60° 45° 90° max
Threading
Chip thickness
compared to feed, .039 (1) .038 (0.96) .034 (0.87) .028 (0.71) Variable
inch (mm)
D
Contact length la,
inch (mm) at ap .079 (2) .082 (2.08) .091 (2.3) .111 (2.82) Variable
.079 inch (2 mm)
Milling
Calculating power consumption
E
The net power (Pc) in HP (kW) required for
metal cutting is mainly of interest when n = spindle speed (rpm)
roughing, where it is essential to ensure
vc = cutting speed (ft/min) (m/min)
that the machine has sufficient power for
Drilling
the operation. The efficiency factor of the fn = cutting feed (inch/rev) (mm/rev)
machine is also of great importance.
ap = depth of cut (inch) (mm) F
For information about the kc value, see
kc = s
pecific cutting force (lbs/in2)
page H 16.
(N/mm2)
Pc = net power (HP) (kW)
Boring
G
vc × ap × fn × kc
Pc = HP
Tool holding
33 × 103
vc × ap × fn × kc
Pc = kW H
60 × 103
Other information
Machinability
A 11
A Selection procedure
Selection procedure
Turning
1 Component
Workpiece material and
Threading
quantity
Machine parameters
2
Milling
Machine
E
Type of turning tool:
- External/internal
- Longitudinal
3
Drilling
How to apply
G
Tool holding
A 12
Selection procedure
A
Turning
Parameters to be considered
Component B
•A nalyze the dimensions and quality demands of the
surface to be machined.
Parting and
grooving
• Type of operation (longitudinal, profiling and facing).
• External, internal
• Roughing, medium or finishing
• Tool paths
C
• Number of passes
• Tolerances
Threading
D
P M K Material
N S H • achinability
M
Milling
• Cast or pre-machined
• Chip breaking
• Hardness E
• Alloy elements
2. Machine parameters
Drilling
Condition of the machine
F
Some important machine considerations:
- Stability, power and torque, especially for
larger diameters
- Component clamping
Boring
- Tool position
- Tool changing times/number of tools in turret G
- Spindle speed (rpm) limitations, bar feed magazine
- Sub spindle, or tail stock available?
Tool holding
A 13
A Selection procedure
3. Choice of tools
Turning
H
Other information
Machinability
A 14
Selection procedure
A
4. How to apply
Turning
Important application considerations
Parting and
- Chip control
grooving
- Insert wear
- Surface quality
- Tool life. C
Threading
influences the cycle time and productivity
considerably.
D
5. Troubleshooting
Milling
Some areas to consider
E
Insert style
•U
se positive inserts for lower cutting forces in
general and for internal turning.
Drilling
Chip breaking
•O
ptimize the chip breaking by changing the
Negative style Positive style depth of cut, the feed or the insert geometry. F
Nose radius
• T he depth of cut should be no less than 2/3
of the nose radius (re).
Boring
Insert wear
•M
ake sure that the flank wear does not G
exceed the general recommendation of .012
inch (0.3 mm).
Tool holding
ap re H
Other information
Machinability
A 15
A System overview
1. Longitudinal turning
B
2. Profiling
3. Facing
Parting and
grooving
1 2
Threading
D
Milling
F
Boring
G
•N egative insert •N egative insert
Tool holding
H
Other information
Machinability
A 16
System overview
A
Turning
1. Longitudinal turning
B
2. Profiling
3. Facing
Parting and
grooving
C
1
2
Threading
3
D
Milling
E
Drilling
F
Boring
A 17
A System overview
1. Longitudinal turning
B
2. Profiling
2 3. Longitudinal turning
1
Parting and
“Mini bars”
3
grooving
C
Threading
D
Overview of internal tool holders
Milling
G
Tool holding
• egative/positive insert
N • ositive insert
P •D ampened boring bars
• All clamping systems • Screw clamping system • Min. hole .512 inch
• Cutting heads • Cutting heads (13 mm)
• Min. hole .787 inch • Min. hole .236 inch • Boring bars
H (6 mm)
(20 mm)
Other information
boring bars
A 18
System overview
A
Turning
1. External turning
B
2. External turning
(Sliding head machines)
Parting and
1 3. Internal turning
grooving
2 (Exchangeable inserts)
4. Internal turning
C
5. Internal turning
5 (Carbide rods)
Threading
4 3
D
Overview of tool holders
External tools
Milling
E
Drilling
• Screw clamping system • Positive insert • Screw clamping system
• Shank tools • Screw clamping system
F
Internal tools
Boring
G
Tool holding
A 19
A System overview
C
Rigid clamping system Lever clamping system
Threading
D
Milling
T-rails
H
Other information
A 20
System overview
A
Turning
Rigid clamping
• Negative inserts B
• Excellent clamping
Parting and
• Easy indexing
grooving
C
Lever clamping
Threading
• Negative inserts
• Free chip flow D
• Easy indexing
Milling
E
Screw clamping
• Positive inserts
Drilling
•S
ecure clamping of
the insert
F
• Free chip flow
Boring
• Positive inserts
Tool holding
A 21
A Choice of inserts
Choice of inserts
Turning
• Basic factors A 23
Parting and
grooving
• Insert geometries A 32
C
• Insert grades A 39
Threading
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
A 22
Choice of inserts – basic factors
A
Turning
Getting metal cutting processes right means knowing
the workpiece material, then choosing the correct insert B
geometry and grade to suit the specific application.
Parting and
grooving
Workpiece material
• T he interaction between
an optimized insert C
geometry and grade for a
certain workpiece mate-
rial is the key to success-
Threading
ful machining.
• T hese three main basic
factors must be carefully D
considered and adapted
for the machining opera-
tion in question.
Milling
• T he knowledge and
understanding of how
to work with and employ E
these factors is of vital
importance.
Drilling
Grade Geometry
G
Tool holding
H
Typical chip breaking
Other information
imaging.
A 23
A Choice of inserts – basic factors
In the metal cutting industry there is an Workpiece materials are divided into 6
incredibly broad range of component major groups in accordance with the ISO-
B designs made from different materials. standard, where each group has unique
Each material has its own unique char- properties regarding machinability.
acteristics influenced by the alloying ele-
ments, heat treatment, hardness, etc. This
Parting and
grooving
M steel
alloyed with a minimum of 12% chro-
mium; other alloys are, e.g., nickel and
G molybdenum. Different conditions such
as ferritic, martensitic, austenitic and
austenitic-ferritic (duplex), makes this an
Tool holding
A 24
Choice of inserts – basic factors
A
Turning
iron (GCI) and malleable cast irons (MCI)
are quite easy to machine, while nodular
cast iron (NCI), compact cast iron (CGI) B
and austempered cast iron (ADI) are
more difficult. All cast irons contain sili-
con carbide (SiC) which is very abrasive
Parting and
grooving
to the cutting edge.
Threading
per, brass, etc. Aluminum with a silicon
content (Si) of 13% is very abrasive.
Generally high cutting speeds and long
tool life can be expected for inserts with D
sharp edges.
Milling
E
Heat resistant • ISO S – Heat Resistant Super Alloys
S alloys include a great number of high-alloyed
iron, nickel, cobalt and titanium-based
Drilling
materials. They are sticky, create built-up
edge, workharden and generate heat,
very similar to the ISO M-area, but they
are much more difficult to cut, leading to F
shorter tool life for the cutting edges.
Boring
A 25
A Choice of inserts – basic factors
Cutting forces
Turning
Another expression of the differences tion of how much power is needed for an
in the six material groups is through the operation.
B force (FT) needed to shear off a specific
kc1 = specific cutting force for average
chip cross-section in certain conditions.
chip thickness .039 inch (1 mm).
This value, the specific cutting force value
Parting and
C
P Steel
Threading
•P
materials have a kc1 variation of:
217,500-449,500 lbs/inch2
Milling
(1500-3100 N/mm2).
E M Stainless steel
Drilling
F
materials have a kc1 variation of:
•M
261,000-413,250 lbs/inch2
(1800-2850 N/mm2).
Boring
K Cast iron
G
Tool holding
H •K
materials have a kc1 variation of:
114,550-195,750 lbs/inch2
Other information
(790-1350 N/mm2).
Machinability
A 26
Choice of inserts – basic factors
A
Turning
N Aluminum
Parting and
grooving
•N
materials have a kc1 variation of:
50,750-195,750 lbs/inch2 C
(350-1350 N/mm2).
Threading
S Heat resistant super alloys
Milling
•S
materials have a kc1 variation of:
- 348,000-449,500 lbs/inch2 E
(2400-3100 N/mm2) for HRSA
- 188,500-203,000 lbs/inch2
(1300-1400 N/mm2) for titanium alloys
Drilling
H Hardened material
F
Boring
H
Other information
Machinability
A 27
A Choice of inserts – basic factors
Chip formation
Turning
C
Threading
D
Milling
Self-breaking, where the Chips breaking against the Chips breaking against the
material, in combina- tool, where the chip curves workpiece, where the chip
Drilling
tion with how the chip is around until it makes snaps when making con-
curved, leads to the chips contact with the clearance tact with the surface that
F being parted as they come face of the insert or tool has just been machined.
off the insert. holder, and the resulting This type of chip breaking
strain snaps it. Although is usually not suitable in
often accepted, this applications where a good
Boring
H
Other information
Machinability
A 28
Choice of inserts – basic factors
A
Turning
Chip formation varies with depth of cut, feed, material
and tool geometry.
B
Parting and
grooving
ap
ap
κr C
Threading
D
Milling
The rake angle (γ) can be either negative or positive.
Based on this, there are negative and positive inserts, E
where the clearance angles are either zero or several de-
grees plus. This determines how the insert can be tilted
in the tool holder, giving rise to a negative or positive
cutting action.
Drilling
F
γ γ G
Tool holding
H
Other information
Machinability
A 29
A Choice of inserts – basic factors
C Negative style
• ouble/single sided
D Note: The clearance
• Edge strength angle is the angle
between the front
Threading
Positive style
• ingle sided
S
Milling
Insert geometries
A 30
Choice of inserts – geometries
A
Turning
Definitions of terms and geometry design
B
Parting and
grooving
.010 in.
(0.25 mm) 20° C
5°
Macro geometry with
chip breaker •C
utting edge rein-
Threading
forcement .010 inch
(0.25 mm)
Geometry for small • Rake angle 20°
cutting depths D
• Primary land 5°
Milling
E
The reinforcement of the cutting edge
The ER-treatment (Edge Roundness) gives the cutting
Drilling
edge the final micro-geometry.
H
Other information
Machinability
A 31
A Choice of inserts – geometries
Cutting depth,
•C
utting depth (ap) and feed (fn) must be
grooving
ap inch (mm)
adapted to the chipbreaking area of the
geometry to get acceptable chip control.
C
•C
hip breaking which is too hard can lead
to insert breakage.
•C
hips which are too long can lead to
Threading
Finishing
• Small cutting depths and low feed rates.
A 32
Choice of inserts – geometries
A
Turning
Turning of low alloy steel
Roughing – R
Cutting depth, High depth of cut and feed rate combina- B
ap inch (mm)
tions. Operations requiring the highest
CNMG 432 (CNMG 120408) edge security.
Parting and
grooving
.236 (6.0)
Medium – M
Medium operations to light roughing.
.157 (4.0) C
Wide range of depth of cut and feed rate
combinations.
.079 .(2.0)
Threading
Finishing – F
Operations at light depths of cut and low
(0.1) (0.4) (0.8) D
.004 .016 .031 feed rates.
Feed, fn inch/r (mm/r) Operations requiring low cutting forces.
Milling
Chip breaking diagram
E
Roughing of low alloy Chip breaking area:
steel
P R
ap = .197 (.039 - .295) inch
fn = .020 (.010 - .028) inch/r
Drilling
CNMM 432-PR ap = 5.0 (1.0 - 7.5 ) mm
Cutting depth, (CNMM 120412-PR) fn = 0.5 (0.25 - 0.7) mm/r
ap inch (mm) F
The area marked
in red indicates the
area which gives
Boring
.039 (1.0)
.020 (0.5)
H
Other information
(0.1) (0.2) (0.3) (0.4) (0.5) (0.6) (0.7) Feed, fn inch/r (mm/r)
.004 .008 .012 .016 .020 .024 .028
Machinability
A 33
A Choice of inserts – geometries
.236 (6.0)
C
.118 (3.0)
Threading
.059 (1.5)
.039 (1.0)
D
.020 (0.5)
E
Finishing of low alloy Chip breaking area:
steel
P F ap = .016 (.010 - .059) inch
fn = .006 (.003 - .012) inch/r
Drilling
.059 (1.5)
Boring
.049 (1.25)
G .039 (1.0)
.030 (0.75)
Tool holding
.020 (0.5)
.010 (0.25)
H
(0.1) (0.15) (0.2) (0.25) (0.3) (0.35) Feed, fn inch/r (mm/r)
Other information
A 34
Choice of inserts – geometries
A
Selection of inserts
Turning
Considerations when selecting inserts
It is important to select the correct insert
size, insert shape, geometry and insert B
nose radius to achieve good chip control.
•S
elect the largest possible point angle
Parting and
grooving
on the insert for strength and economy.
•S
elect the largest possible nose radius
l for insert strength. C
•S
elect a smaller nose radius if there is a
tendency for vibration.
re
Threading
l = cutting edge length (insert size)
re = nose radius D
Milling
Dedicated inserts for the ISO P, M and K area E
The different micro and macro-geometries are adapted to the
various requirements in the applications.
Drilling
Workpiece Finishing Medium Roughing
material
F
.003 in. .008 in. .013 in.
(0.07 mm) (0.2 mm) (0.32 mm) Boring
A 35
A Choice of inserts – geometries
Geometry description
Turning
area description
grooving
(0.1) (0.2) (0.3) (0.4) (0.5) (0.6) (0.7) (0.8) (0.9) fn inch (mm)
.004 .008 .012 .016 .020 .024 .028 .031 .035
• Universal geometry.
F • Optimizing with grades.
• Performance compromised.
Boring
Application area
G
Optimized inserts
Tool holding
•D
edicated geometries
and grades.
H •O
ptimized performance
according to workpiece
Other information
machinability.
Machinability
Application area
A 36
Choice of inserts – geometries
A
Turning
super alloys and hardened steel.
Parting and
Negative basic-shape inserts Positive basic-shape inserts
grooving
ISO Finishing Medium Roughing Finishing Medium Roughing
C
Threading
D
M
Milling
K E
Drilling
N
F
S
Boring
H
Tool holding
H
Other information
Machinability
A 37
A Choice of inserts – geometries
•A
vailable as double/single-
sided inserts with P-hole or
plain.
C Double Single Without With hole
sided sided hole
Threading
deformation.
- be tough to resist bulk breakage.
G
-n
ot chemically interact with the workpiece
material.
Tool holding
-b
e chemically stable to resist oxidation
and diffusion.
Temperatures given -h
ave good resistance to sudden thermal
H in Celsius
changes.
Other information
Machinability
A 38
Choice of inserts – grades
A
Turning
The most common cutting tool materials are divided into
the following main groups: B
- Uncoated cemented carbide (HW) • CN N
itride ceramics containing prima-
rily silicon nitride (Si3N4).
Parting and
- Coated cemented carbides (HC)
grooving
• CC Ceramics as above, but coated.
- Cermets (HT, HC)
- Cubic boron nitrides (BN)
• HT U
ncoated cermet containing
C
primarily titanium carbides (TiC) - Polycrystalline diamonds (DP, HC)
or titanium nitrides (TiN) or both
• HC P
olycrystalline diamonds, but
•HC Cermet as above, but coated coated.
Threading
- Ceramics (CA, CM, CN, CC)
• CA O
xide ceramics containing primar-
D
ily aluminum oxide (Al2O3).
• CM M
ixed ceramics containing
primarily aluminum oxide (Al2O3)
but containing components other
Milling
than oxides.
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
A 39
A Choice of inserts – grades
Wear resistance
Parting and
Good
grooving
C
Average
Threading
Difficult
D
Milling
E Machining conditions
Good conditions
• Continuous cuts
Drilling
• High speeds
• Pre-machined workpiece
F • Excellent component clamping
• Small overhangs
Average conditions
Boring
• Profiling cuts
• Moderate speeds
G • Forged or cast workpiece
• Good component clamping
Tool holding
Difficult conditions
• Interrupted cuts
• Low speeds
H • Heavy cast or forged skin on workpiece
Other information
A 40
Choice of inserts – grades
A
Turning
Dedicated grades minimize tool wear development
The workpiece material influences the wear during the B
cutting action in different ways. Therefore dedicated
grades have been developed to cope with the basic wear
Parting and
mechanisms, e.g.:
grooving
- Flank wear, crater wear and plastic deformation in steel
- Built-up edge and notch wear in stainless steel
C
- Flank wear and plastic deformation in cast iron.
Threading
D
Select geometry and grade depending on the type of the
workpiece material and type of application.
Milling
E
Drilling
F
Boring
G
ISO GC 4200 ISO GC 2000 ISO GC 3200
P M K
Tool holding
H
Other information
Machinability
A 41
A Choice of inserts – shape
B The insert shape and point angle varies Each shape also has unique limitations.
considerably from the smallest, at 35°, to For example:
the round insert. - high edge accessibility during machining
Parting and
Cutting edge
Accessibility
strength
Drilling
Vibration Power
F tendency consumption
Boring
H
Other information
Machinability
A 42
Choice of inserts – shape
A
Turning
Insert shape should be selected relative to the lead
(entering) angle accessibility required of the tool. The
largest possible point angle should be applied to give
B
insert strength and reliability.
= Most suitable
Parting and
grooving
= Suitable
C
Insert shape
Threading
Roughing strength
Light roughing/semi-
finishing D
Finishing
Milling
Longitudinal turning
E
Profiling
Facing
Drilling
Operational versatility
F
Limited machine power Boring
Vibration tendencies
Hard material G
Tool holding
Intermittent machining
A 43
A Choice of inserts – shape
Insert shape
B
Number of edges,
4/8 2/4 3/6 3/6 2/4 2/4
negative inserts
C
Number of edges,
4 2 3 3 2 2
positive inserts
Threading
re
E re
re
Drilling
H
Other information
Machinability
A 44
Choice of inserts – nose radius
A
Turning
With a small nose radius, the radial cutting forces can
be kept to a minimum, while utilizing the advantages of a
larger nose radius leads to a stronger cutting edge, better B
surface texture and more even pressure on the cutting
edge.
Parting and
grooving
C
DOC
DOC
Threading
DOC
D
• T he relationship between nose radius and DOC (depth
of cut) affects vibration tendencies.
It is often an advantage to choose a nose radius which
Milling
is smaller than the DOC.
Drilling
The radial force exerted on the workpiece However with a round insert, radial pres-
grows linearly until the nose radius of the sure will never stabilize because the
insert is less than the depth of cut where theoretical nose radius is half the insert
F
it stabilizes at the maximum value. diameter (iC).
Boring
G
Tool holding
H
Other information
Machinability
A 45
A Choice of inserts – nose radius
rWiper
grooving
E
Wiper – Technical solution
•O
ne wiper cutting edge is based on
Drilling
3-9 radii.
•C
ontact surface between insert and
F component is longer with wipers.
• L onger contact surface makes a better
surface finish.
• L onger contact surface increases cutting
Boring
H
Other information
A 46
Choice of inserts – nose radius
A
Turning
Traditional
insert
B
Rule of thumb
Parting and
grooving
• T wo times feed with a wiper will
generate as good surface as con-
Wiper insert ventional geometries with normal
Twice the feed. C
feed, same Ra • T he same feed with a wiper will
generate twice as good surface
Threading
compared with conventional
geometries.
D
Wiper insert
Same feed,
half Ra
Rt = Maximum value peak-to-valley height
Milling
Ra = A
rithmetic average height of the
profile E
Drilling
Achieved surface – traditional ISO inserts and wipers
Ra F
(µm)
236 (6.00)
79 (2.00)
Wiper -WMX
39 (1.00)
0 (0.00) H
(0.20) (0.35) (0.50) (0.65) Feed, fn inch/r (mm/r)
Other information
A 47
A Choice of inserts – speed and tool life
B
Use the potential of:
Parting and
Cutting speed
Tool life
D
vc – large effect on tool life.
Adjust vc for best economy.
Milling
E Cutting speed vc
Drilling
Feed
Tool life
Feed fn
Cutting depth
Tool life
Tool holding
H
Other information
Machinability
Cutting depth ap
A 48
Choice of inserts – speeds and tool life
A
Turning
The single largest factor determining tool life
Parting and
• Poor finish • Uneconomical
grooving
• Rapid cratering
• Plastic deformation
C
Threading
Effects of feed rate
D
The single largest factor determining productivity
Milling
• Loss of chip control • Stringers
• Poor surface finish • Uneconomical
E
•C
ratering, plastic defor-
mation
• High power consumption
Drilling
• Chip welding
• Chip hammering F
Boring
A 49
A Choice of tools – external turning
External turning
Turning
•S
ecure insert and tool holder clamping is
grooving
F
Boring
H Insert shape
Other information
A 50
Choice of tools – external turning
A
Turning
Longitudinal turning/facing
B
The most common turning operation.
• Rhombic shape C-style (80°) insert is frequently used.
Parting and
• Holders with lead angles of –5° and –3° (entering angles of
grooving
95° and 93°) are commonly used.
• Alternatives to the C-style insert are D-style (55°), W-style (80°)
and T-style (60°). C
Threading
Profiling
Versatility and accessibility is the determining factor.
Milling
V-style (35°) and T-style (60°) inserts.
E
Facing
The tool is fed in towards the center.
Drilling
•P
ay attention to the cutting speed which will change progres-
sively when feeding towards the centre.
• L ead angles of 15° and –5°/–1° (entering angles of 75° and
95°/91°) are commonly used.
F
• C-style (80°), S-style (90°), and T-style (60°) inserts are fre-
quently used.
Boring
Plunging
G
A method to produce or widen shallow grooves.
•R
ound inserts are very suitable for plunge turning as they can
Tool holding
H
Other information
Machinability
A 51
A Choice of tools – external turning
Features / Benefits
• Cutting forces directed towards chuck.
B
• Can turn against a shoulder.
• Higher cutting forces at entrance and exit of cut.
Parting and
grooving
C
Threading
Features / Benefits
Milling
F
Boring
G
Tool holding
H
Other information
Machinability
A 52
Choice of tools – external turning
A
Turning
Important consideration in profile turning
B
In-copying Longitudinal turning Out-copying
Parting and
ψr
grooving
ψr
ψr β
C
Threading
• T he effective lead angle (ψr) should also be considered
for satisfactory machining when the operation involves
profiling. D
β • T he maximum in-copying angle beta (β) is recommend-
ed for each tool type and is specified in the catalogs.
Milling
E
Axial and radial cutting forces
Small lead angle Large lead angle
Drilling
F
Ff = axial
Ff = axial
Fp = radial
Boring
Fp = radial
G
• Forces directed toward the chuck. Less • Forces are directed both axially and
tendency for vibration. radially.
Tool holding
A 53
A Choice of tools – external turning
Tooling system
Longitudinal
B
Plunging
Profiling
turning
Facing
++
Parting and
= Recommended tool
grooving
holder system
+ = Alternative system
Rigid clamp
design ++ ++ ++
Threading
Negative inserts
D Lever
design + + + +
Milling
Wedge
E clamp + + +
design
Drilling
Screw
clamp + ++ + ++
Positive inserts
design
F
Screw
clamp + ++
Boring
design T-rail
G
Rigid clamp
++ ++ ++
Ceramic and CBN
design
Tool holding
inserts
H Top clamp
design + + + ++
Other information
Machinability
A 54
Choice of tools – external turning
A
Turning
Insert shape
Longitudinal
B
Plunging
Profiling
turning
Facing
Parting and
++ =
grooving
Recommended insert shape
+= Alternative shape
C
C Rhombic 80° ++ +
Threading
D Rhombic 55° + ++ +
R Round + + + ++ D
S Square + ++
+ + + +
Milling
T Triangular
W Trigon 80° + + E
V Rhombic 35° +
Drilling
K Rhombic 55° + + +
F
Screw clamping, G
Rigid clamping “P lever style” Screw clamping
T-rail
Tool holding
H
Other information
Machinability
A 55
A Choice of tools - internal turning
Internal turning
Turning
-C
hip evacuation is a critical factor for
successful boring.
- T he clamping method has a decisive ef-
D
fect on the performance and result.
Milling
E
Drilling
F
Selection factors
Tool and insert geometry Chip evacuation Tool requirements
Boring
• Nose radius
• Clamping
H
Other information
Machinability
A 56
Choice of tools – internal turning
A
Turning
Radial and tangential cutting forces deflect the boring bar
B
Tangential cutting force, Ft
• Forces the tool down, away from the
Parting and
center line.
grooving
• Gives a reduced clearance angle.
C
Radial cutting force, Fr
• Alters cutting depth and chip thickness.
Threading
• Gives out of tolerance dimension and
risk of vibration.
Fr
D
Feed force, Fa
Fa
• Directed along the feed of the tool.
Milling
Ft F
E
Drilling
• Select a lead angle close to 0° (entering
angle close to 90°). F
Boring
H
Other information
Machinability
A 57
A Choice of tools – internal turning
Longitudinal turning/facing
B The most commonly used internal turning operation.
• Rhombic shape C-style (80°) insert is frequently used.
Parting and
commonly used.
•D
-style (55°), W-style (80°) and T-style (60°) insert shapes
are also frequently used.
C
Profiling
Threading
frequently used.
E
Longitudinal turning
Boring operations are performed to open up existing holes.
Drilling
Back boring
G
Back boring is a boring operation with reverse feed.
• It is used for turning shoulders less than 90°.
Tool holding
•B
oring bars with –3° lead angles and D-style (55°) inserts are
commonly used.
H
Other information
Machinability
A 58
Choice of tools – internal turning
A
Turning
Insert shape Longitudinal Profiling Facing
turning B
Parting and
+=
grooving
Alternative shape
C Rhombic 80° + ++
C
D Rhombic 55° + ++ +
Threading
R Round + +
S Square + D
T Triangular ++ + +
+ +
Milling
W Trigon 80°
V Rhombic 35° + E
Drilling
Positive inserts generate lower cutting force and tool deflection
• Inserts with clearance angle 7° F
- First choice for small and medium holes
from .236 inch (6 mm) diameter.
• Inserts with clearance angle 11°
Boring
A 59
A Choice of tools – internal turning
D
Cutting edge
Accessibility
strength
F
Rule of thumb!
Choose a nose
radius which is some-
Boring
A 60
Choice of tools – how to apply
A
Turning
Critical stability factors for optimized performance
B
dmm •M
aximum contact between tool and tool
holder (design, dimensional tolerance).
Parting and
•C
lamping length 3 to 4 times bar diam-
grooving
eter (to balance cutting forces).
• Holder strength and stability.
C
3 - 4 x dmm
Threading
D
Milling
Tool requirements for clamping E
Maximum contact between tool and tool holder
Drilling
Best choice
Coromant Capto® coupling F
Acceptable
Boring
G
Not recommended
Tool holding
Not recommended H
Other information
Machinability
A 61
A Choice of tools - how to apply
EasyFix sleeves
Turning
B
Guarantees correct center height
Parting and
grooving
Benefits:
• Cutting edge in right position
C
• Best cutting action gives better surface finish
• Reduced setup time
Threading
D Silicon sealer
Milling
E Groove
Drilling
F
Boring
Spring plunger
H
Other information
Machinability
A 62
Choice of tools - how to apply
A
Turning
Vibration tendencies grow towards the right
B
Parting and
grooving
Lead (entering)
angle C
Threading
Nose radius
Micro and
D
macro geometry
Edge design
Milling
E
Drilling
• Insert wear changes the clearance
(entering angle as close to 90°) as pos-
between the insert and the hole wall.
sible, never more than 15° (less than
This can affect the cutting action and
75° for entering angle). F
lead to vibration.
Nose radius
• Inserts with thin coatings, or uncoated
• Choose a nose radius which is some-
inserts, are to be preferred as they
what smaller than the cutting depth.
normally give lower cutting forces.
Boring
H
Other information
Machinability
A 63
A Choice of tools - how to apply
Chip evacuation
Turning
B •C
entrifugal force presses the chips to
the inside wall of the bore.
Parting and
bore.
F Long chips
• Can cause chip evacuation problems.
•C
auses little vibration tendency, but can
in automated production cause prob-
Boring
G
Tool holding
A 64
Choice of tools - how to apply
A
Turning
Maximum overhang for different types of bars
B
Steel bar
– up to 4 x dmm
Parting and
grooving
Carbide bar
– up to 6 x dmm
Threading
– up to 10 x dmm
Carbide reinforced, damp-
ened bar
– up to 14 x dmm D
Clamping
length:
Overhang: ... x dmm 14 10 7 6 4
4 x dmm
Milling
Eliminate vibrations E
Drilling
Rubber damper • Increase productivity in deep bores
Steel bar
H
Other information
Dampened bar
Machinability
A 65
A Code keys
C
C N M G 4 3 2 - PF
1 2 3 4 5 6 7 8
Threading
1. Insert shape
5. Insert size
D
TOOL HOLDERS
E
External
D C L N R 16 4 D
Drilling
B 1 C 2 D E 5 F
F
C3 -
A
Internal
Boring
G
S 16 T S C L C R 4
H E F B 1 C 2 D 5
Tool holding
Bar diameter
A 66
Code keys
A
Turning
80° 55° 35° 80°
C D R S T V W
B C P N B
4. Insert type 5. Insert size
Parting and
grooving
A G Inscribed circle is indicated in 1/8"
S T W
M T
C
7. Nose radius
Threading
1 rε = 1/64
T-MAX P CoroTurn 107
2 rε = 1/32
3 rε = 3/64 Finishing 2 1
4 rε = 1/16 Medium 2 2
6 rε = 3/32 Roughing 3 2
D
Milling
The manufacturer may add a further two symbols to the code describing the
insert geometry e. g.
E
-PF = ISO P Finishing
-MR = ISO M Roughing
B. Clamping system
Drilling
C D M,W P S F
Top clamping Rigid clamping (RC) Top and hole clamping Hole clamping Screw clamping
Boring
C = 5.000
L D = 6.000
Left-hand style M = 6.000
Bars: M = 4.000
R = 8.000
S =10.000 H
N
Other information
T =12.000
Neutral U =14.000
Machinability
A 67
A Code keys
C
C N M G 09 03 08 - PF
1 2 3 4 5 6 7 8
Threading
1. Insert shape
5. Insert size = cutting edge length
D
TOOL HOLDERS
E
External
D C L N R 16 16 H 09
Drilling
B 1 C 2 D E F G 5
F
C3 -
A
Internal
Boring
G
A 25 T S C L C R 09
H J G B 1 C 2 D 5
Tool holding
Bar diameter
A 68
Code keys
A
Turning
80° 55° 35° 80°
C D R S T V W
B C P N B
4. Insert type 5. Insert size = Cutting edge length
Parting and
grooving
A G
M T l mm: 06–25 07–15 06–32 09–25 06–27 11–16 06–08
C
7. Nose radius
Threading
04 rε = 0.4
T-MAX P CoroTurn 107
08 rε = 0.8
12 rε = 1.2 Finishing 08 04
16 rε = 1.6 Medium 08 08
24 rε = 2.4 Roughing 12 08
D
Milling
The manufacturer may add a further two symbols to the code describing the
insert geometry e. g.
E
-PF = ISO P Finishing
-MR = ISO M Roughing
B. Clamping system
Drilling
D M P S F
Rigid clamping (RC) Top and hole clamping Hole clamping Screw clamping
Boring
Tool length G
R = l1 in mm
Right-hand style
Tool holding
Q = 180 W = 450
Neutral R = 200 Y = 500
Machinability
A 69
A Troubleshooting
Troubleshooting
Turning
Chip control
B Problem Cause Solution
Long unbroken snarls winding • F eed too low for the chosen • Increase the feed.
around the tool or workpieces. geometry.
Parting and
•S
elect an insert geometry
with better chip breaking
grooving
capabilities.
•U
se a tool with high pres-
C sure coolant.
Threading
•D
epth of cut too shallow for • Increase the depth of cut or
the chosen geometry. select a geometry with bet-
ter chip breaking capability.
Very short chips, often sticking • F eed too high for the chosen •C
hoose a geometry
together, caused by too hard geometry designed for higher feeds,
F chip breaking. Hard chip break- preferably a single-sided
ing often causes reduced tool insert.
life or even insert breakages
due to too high chip load on • Reduce the feed.
the cutting edge.
Boring
A 70
Troubleshooting
A
Surface finish
Turning
Problem Cause Solution
Parting and
grooving
•S
elect a positive tool system
with a neutral angle of
inclination.
C
Threading
excessive notch wear on the resistance to oxidation wear,
cutting edge. e.g., a cermet grade.
• Reduce the cutting speed.
D
Milling
with too small nose radius larger nose radius.
generates a rough surface.
• Reduce the feed.
E
Burr formation
Drilling
Burr formation at the end of • The cutting edge is not •U
se inserts with sharp
the cut when the cutting edge sharp enough. edges:
is leaving the workpiece. - PVD coated inserts F
• The feed is too low for the - ground inserts at small
edge roundness. feed rates, < .004 inch/r
(< 0.1 mm/r).
Boring
•E
nd the cut with a chamfer
or a radius when leaving the H
workpiece.
Other information
Machinability
A 71
A Troubleshooting
Vibration
Turning
-E
xcessive flank wear on cut- •S
elect a more wear resistant
D ting edge. grade or reduce speed.
Milling
-C
hip-breaking is too hard •R
educe the feed or select a
giving high cutting forces. geometry for higher feeds.
-V
arying or too low cutting • Increase the depth of cut
forces due to small depth slightly to make the insert
of cut. cut.
Boring
G
- Tool incorrectly positioned. • Check the center height.
Tool holding
H
Other information
Machinability
A 72
A
Turning
Problem Cause Solution
- Instability in the tool due to • Reduce the overhang
long overhang. B
•U
se the largest bar
diameter.
•U
se a Silent Tool or a car-
Parting and
bide bar.
grooving
C
Threading
-U
nstable clamping offers •E
xtend the clamping length D
insufficient rigidity. of the boring bar.
•U
se EasyFix for cylindrical
bars.
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
A 73
B2
Parting & Grooving
• Theory B4
• Selection procedure B7
• System overview B 11
• Troubleshooting B 36
B3
A Theory
Parting off
B
Chip evacuation is essential
Parting and
D •C
hip evacuation is a critical factor in
parting operations.
•C
hip breaking is difficult in the confined
slots created as tools cut deep into the
Milling
workpiece.
• T ypical chips are clock-spring shaped,
E narrower than the groove.
• T he insert geometry shrinks the chip
width.
Drilling
F
Parting off – definition of terms
n
Boring
H
Other information
Machinability
B4
Theory
A
Turning
Feed rate reduction is often advantageous for performance
when machining towards the center to minimize the pressure
on the cutting edge.
B
Parting and
grooving
•C
utting speed declines to zero at the
C
center.
Threading
D
100 – 0% of vc
Milling
Feed reduction towards center E
To reduce pip size, the feed should be reduced by up to
75% when approaching the center, around .079 inch
(2 mm) before the part comes off.
Drilling
F
•R
educe feed by 75% when approaching
Boring
H
.079
Other information
(2mm)
Machinability
B5
A Theory
C
n = spindle speed (rpm)
n vc = cutting speed (ft/min) (m/min)
Threading
E
Face grooving– definition of terms
The feed has a great influence on chip formation, chip
Drilling
H
Other information
Machinability
B6
Selection procedure
A
Turning
Production planning process B
Parting and
grooving
Dimension and quality
of the groove or face
C
1 Component
Workpiece material,
Threading
chip evacuation
Machine parameters
2
Milling
Machine
E
Type of tool:
- Spring-clamp
- Screw-clamp
3
Drilling
Choice of tool
- Insert type
How to apply
G
Tool holding
B7
A Selection procedure
Parameters to be considered
B Component
•A
nalyze the dimensions and quality
demands of the groove or face to be
Parting and
machined.
grooving
Material
P M K
• achinability
M
N S H
Milling
• Clamping
• Chip breaking
E
• Hardness
• Alloy elements
Drilling
F
2. Machine parameters
Condition of the machine
•S tability, power and torque especially for
Boring
larger diameters
• Component clamping
G • Tool changing times/number of tools in
turret
• Chip evacuation
Tool holding
H
Other information
Machinability
B8
Selection procedure
A
3. Choice of tools
Turning
Example of different machining methods
Multiple grooving
B
•M
ultiple grooving is the best method for
rough grooving when the depth is bigger
Parting and
than the width.
grooving
•M
ake a “fork”. This will improve chip flow
and increase tool life.
C
Threading
D
Plunge turning
•P
lunge turning is the best choice when
machining steel and stainless steel and
Milling
when the width of the groove is larger
than the depth.
• Good chip control. E
Drilling
F
Ramping
•R
amping avoids vibration and minimizes
Boring
radial forces.
•R
ound inserts are the strongest inserts G
available.
• Double the number of cuts/passes.
Tool holding
H
Other information
Machinability
B9
A Selection procedure
4. How to apply
Turning
•C
enter height is important, ±.004 inch
B
(±0.1 mm).
•R
educe feed by up to 75% around .079
Parting and
.079
Max ±.004 inch •U
se shortest possible overhang, ar inch
(±0.1 mm) (mm).
C
• L argest height dimension on blade for
bending stiffness.
• Use coolant to improve chip flow.
Threading
ar
Milling
5. Troubleshooting
E Some areas to consider
B 10
System overview
A
System overview
Turning
External parting and grooving
B
1. Parting-off solid bars and tubes 4. Shallow to deep grooving
2. Turning and recessing 5. Face grooving
Parting and
3. Undercutting 6. Profiling
grooving
4 C
Threading
6
D
1
4
Milling
3 4
2
E
Drilling
Internal grooving F
3. Profiling
G
3
Tool holding
1 2
H
1
Other information
Machinability
B 11
A System overview
Different systems
Turning
Insert type
B
Q-Cut Q-Cut U-Lock
Application CoroCut2 CoroCut1 CoroCut3 151.2 151.3 154.0
Parting and
Parting
grooving
(Cut off)
Medium Deep Shallow Deep
C
Grooving
Internal,
Threading
small dia.
Face grooving
D
Turning
Milling
Profiling
E
Undercutting
Drilling
Circlip groov-
F ing
Boring
H
Other information
Machinability
B 12
System overview
A
Turning
Different systems
B
Parting and
grooving
≥.472 ≥.984
≥.165 ≥.394 (≥25) C
(≥12)
(≥4.2) (≥10)
Threading
D
Milling
inch (mm)
Drilling
F
Ø.244 Ø.472 Ø.906 Ø1.339
(Ø6.2) (Ø12) (Ø23) (Ø34) Boring
G
Tool holding
H
Other information
Machinability
B 13
A System overview
Inserts
Turning
Overview
B
Application
Parting and
grooving
Parting
C Machining (Cut off)
Grooving Turning Profiling Profiling
condition
Threading
Finishing CF GF TF
D
Medium CM GM TM RM AM
Milling
Roughing CR
E
Optimizer RO
Drilling
Sharp CS RS
F
ER treated
GE RE
Boring
G
Tool holding
H
Other information
Machinability
B 14
Parting and grooving – how to apply
A
Turning
B
Parting & grooving
and how to apply
Parting and
grooving
• Parting & grooving and how to apply B 16
C
Threading
• General grooving and how to apply B 25
Milling
• Profiling and how to apply B 31
E
• Turning and how to apply B 33
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
B 15
A Parting and grooving – how to apply
Best stability
Threading
•O
verhang (ar) should be as small as
possible.
D
• Largest seat size should be used.
• ar = 8 x la max
Milling
E
Internal machining
Shank type:
Drilling
to 7 x dmm.
G
Tool holding
Inserts:
• Use smallest possible width
• Use light cutting geometries.
H
Other information
Machinability
B 16
Parting and grooving – how to apply
A
Turning
System considerations
B
Deep parting – Ø ≤4.409 inch (≤112 mm)
Parting and
grooving
Medium parting – Ø ≤1.575 inch (≤40 mm)
Threading
D
Milling
clamp blades with single- parting are screw-clamp for economic parting in
edge inserts. holders with 2-edge mass production.
inserts. E
Drilling
Tool block with spring-clamp tool blade for
tool overhang adjustment. F
H
Other information
Machinability
B 17
A Parting and grooving – how to apply
Features/Benefits
• Quicker insert change
B
• Cut off larger diameter
• Adjustability
Parting and
grooving
• Deep grooving
• Double ended
C • Radial feed only
Threading
•E
xtremely small insert widths
G - grooving down to .020 inch (0.5 mm)
- parting down to .039 inch (1 mm).
• Cutting depths up to .236 inch (6 mm).
Tool holding
B 18
Parting and grooving – how to apply
A
Parting-off bars
Turning
Overhang should not exceed 8 x la (width
of insert).
Max ar = 8 x la B
(width of insert) Use as narrow an insert as possible:
- To save material
Parting and
- Minimize cutting force
grooving
- Minimize environmental pollution.
Threading
D
Material savings
Milling
E
Drilling
F
Positioning of the tool
Use maximum deviation of ±.004 inch
Max ±.004 inch (±0.1 mm)
(±0.1 mm) from center line.
Boring
B 19
A Parting and grooving – how to apply
C
Hand of insert
Three types of insert with different entering
Threading
angles:
Hand of insert
- Right hand (R)
- Neutral (N)
D - Left hand (L)
Milling
E
Insert geometry
Neutral entering angle
Drilling
• Increases strength
• Higher feed/productivity
F rε • Better surface finish
laa • Straighter cut
rε ϕr = 0 • Pip stays on part falling off.
Boring
• Smaller PIP
• Better chip control
• Lower feed rate
H Large corner radius
• Increased feed rate
Other information
B 20
Parting and grooving – how to apply
A
Turning
EasyFix sleeves
B
Parting and
accurate machining with less
grooving
vibration and precise height.
Threading
D
Recommended overhang
Milling
dmm
E
Carbide reinforced
dampened bars
Drilling
l <7 x dmm
dmm F
l ≤5 x dmm G
dmm
Tool holding
H
Other information
l ≤3 x dmm
Machinability
B 21
A Parting off – how to apply
Parting off
Pip reduction by using different front angles
Turning
•C
hoose left or right hand front angle to
B control the pip or burr.
• When
the front angle is:
Parting and
D
Milling
Note!
A front-angled insert will give reduced
E chip control due to the direction of the
chip flow. (A neutral insert directs the chip
Example of front angles on
1-, 2- and 3-edge inserts: straight out of the groove).
5°, 10°, 8°, 12°, 15°, 20°
Drilling
H
Other information
Machinability
B 22
Parting off – how to apply
A
Parting-off tubes
Turning
Parting-off tubes
Use insert with the smallest possible B
width (la) to save material, minimize cutting
force and environmental impact.
Parting and
grooving
C
Threading
Make sure that the lowest possible cutting
forces are generated. Use inserts with the
smallest possible width and sharpest cut- D
ting edges.
Milling
Practical hints E
Max ±.004 inch
(±0.1 mm) •C
enter height is impor-
tant, ±.004 inch (±0.1
Drilling
mm).
• If subspindle is used,
pull away the component F
approximately .040 inch
ø .040 inch (1 mm) before center.
(øØ1
0.1 mm)
•R
educe feed by up to
Boring
75%, approximately
.079 inch (2 mm) before
center – also for tube G
parting.
0.25 x fn
Tool holding
H
Other information
.079
Machinability
fn (2mm)
B 23
A Parting off – how to apply
E
Drilling
F
Boring
H
Other information
Machinability
B 24
Grooving – how to apply
A
General grooving
Turning
•S
ingle cut grooving is the most
economic and productive method to B
produce grooves.
• If the depth of the groove is bigger than
Parting and
grooving
the width, multiple grooving is the best
method for rough grooving.
•A
screw-clamp tool holder should be
C
selected for grooving operations.
Threading
D
Milling
E
Single cut grooving
•E
conomic and productive method to
Drilling
produce grooves.
• F inishing geometry has width tolerance
F
of ±.0008 inch (±0.02 mm) and works
well in low feeds.
•W
iper inserts give extremely high quality
surface on the side of the groove.
Boring
G
Tool holding
H
Other information
Machinability
B 25
A Grooving – how to apply
Multiple grooving
Turning
C
Threading
D
Practical hints
When producing high quality grooves, there is often a
need for chamfered corners.
Milling
E
•O
ne way is to use the corners on the in-
A sert, for example, of a finishing grooving
insert, to chamfer; see illustration A.
Drilling
F
Boring
B •A
better way to make grooves with
G chamfer in mass production is to order a
Tailor Made insert with the exact cham-
fer form; see illustration B.
Tool holding
H
Other information
Machinability
B 26
Circlip grooving – how to apply
A
Circlip grooving
Turning
Circlips on shafts and axle components
are very common.
B
•C
irclip grooving can be performed with
three-edge inserts or two-edge grooving
Parting and
inserts.
grooving
• F or internal grooving there is also a wide
choice of inserts and boring bars.
C
Threading
Systems to choose from
D
3-edge inserts 2-edge inserts
• F or best economy, use 3-edge inserts
in widths .039 - .125 inch (1.00 - 3.18
mm).
Milling
•O
r 2-edge inserts in widths
.059 - .236 inch (1.50 - 6.00 mm).
E
internal inserts Carbide rod inserts
• Internal inserts are available for min.
hole diameter .394 inch (10 mm) and
with circlip widths .043 - .163 inch (1.10
Drilling
- 4.15 mm).
•M
in hole diameter for carbide rod inserts F
is .165 inch (4.2 mm) and circlip widths
are .031 - .079 inch (0.78 - 2.00 mm). Boring
B 27
A Face grooving – how to apply
Face grooving
Turning
D
Milling
F
Boring
•C
urved tool for face •C
urved tool for face •E
xchangable cutting
G grooving, shank 0º style. grooving, shank 90º blades make it possible
style. to make a special tool
from standard tools.
Tool holding
H
Other information
Machinability
B 28
Face grooving – how to apply
A
Turning
• T ool is fed axially towards
the end surface of the
part. B
• T ool must be adapted to
the bending radius of the
Parting and
groove.
grooving
•M
achine largest diameter
and work inwards for
best chip control. C
Threading
D
Right hand (R) tool
Milling
Choice of A and B curve, right or left hand tool E
Choose the correct tool – A or B curve, right or left hand
style – depending on machine setup and workpiece rotation.
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
B 29
A Face grooving – how to apply
1
2
C
2 If the insert support rubs workpiece
outside dia:
- maybe the dia. range is wrong
Threading
Roughing Finishing
E
2
1
Drilling
First cut (1) always starts Machine the first cut (1) within the given
on the largest diameter diameter range.
and works inwards. The
Boring
B 30
Profiling – how to apply
A
Profiling
Turning
When machining components with complex
shapes, profiling inserts offer great oppor-
tunities for rationalization. B
•M
odern parting and grooving tool sys-
Parting and
tems can also perform turning.
grooving
•A
screw-clamp tool holder should be
selected for turning and profiling
operations in view of achieving maximum C
stablility.
•A
neutral tool holder is suitable for both
opening up or completing a recess.
Threading
• T he round shape inserts have dedicated
geometries for these operations.
D
Milling
E
Drilling
F
Boring
Ramping
G
Tool holding
•U
se round inserts for outstanding chip control and good
surface finish.
• In unstable setups, use ramping to avoid vibrations.
H
Other information
Machinability
B 31
A Turning – how to apply
Profile turning
Turning
component radius.
grooving
• If you must have the same insert radius as the com-
ponent radius, use micro-stops to make the chip short
C and avoid vibrations.
Threading
fn1 = parallel cuts – max. chip thickness .006 - .016 inch (0.15–0.40 mm).
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
B 32
Turning – how to apply
A
Turning
Turning
The most common applications for wide
grooves or turning between shoulders
are multiple grooving, plunge turning or B
ramping. All three methods are roughing
operations and have to be followed by
Parting and
a separate finishing operation. A rule of
grooving
thumb is that if the width of the groove is
smaller than the depth – multiple grooving
should be used and vice versa for plunge C
turning. However, for slender components,
the ramping method may be used.
Threading
D
•U
se holders with smallest possible over-
hang, screw clamping and insert with rail
Milling
shape if possible.
•U
se a stable, modular tooling system if
possible. E
Drilling
Roughing F
Boring
G
Tool holding
1. Radially infeed to required depth +.008 inch (+0.2 mm) (max 0.75 x insert width).
2. Retract radially .008 inch (0.2 mm).
3. Turn axially to opposite shoulder position.
4. Retract radially .020 inch (0.5 mm).
H
Other information
Machinability
B 33
A Turning – how to apply
Finishing
Turning
C
Threading
Axial turning
E Surface finish
•Y
ou get the best wiper effect when you
Ra max “find” the right combination between
feed (fn) and blade deflection.
F
a value below 20RA (0.5 µm) will be
•R
generated with high bearing.
Boring
G
Tool holding
H
Other information
Machinability
B 34
Undercutting – how to apply
A
Undercutting
Turning
• When a clearance is needed.
• T hese applications require dedicated inserts with round B
cutting edges that are sharp and accurate.
• T he tolerance of these inserts is high: ±.0008 inch
Parting and
(±0.02 mm).
grooving
C
Threading
D
Tools for undercutting
Angled Angled 20° Angled 45°
7° ,45° and 70°
Milling
E
Drilling
F
•H
older for external under- •H
older for internal under- •H
older for external under-
cutting. Insert with two cutting. Insert with two cutting. Insert with one
cutting edges. cutting edges. cutting edge.
Boring
G
Tool holding
H
Other information
Machinability
B 35
A Troubleshooting
Troubleshooting
Turning
Tool wear
B
Problem
Parting and
grooving
More positive
geometry ++
D
Tougher grade ++
Milling
More wear
E resistant grade ++ + +
Increase cutting
+
Drilling
speed
F
Decrease cut-
ting speed + + ++
Boring
Reduce feed
G rate ++ + +
Tool holding
Choose stronger
geometry + ++
H
Other information
B 36
Troubleshooting
A
Problem Solution
Turning
Bad surface
•U se a short and stable •C heck speed/feed guide-
tool. lines. B
• Take away the chips – • Use wiper geometry.
use geometry with good • Check tool setup.
Parting and
chip control.
grooving
C
Bad surface on aluminum
Threading
•S elect the sharpest •S
elect a special soluble
geometry. oil for the material.
• Use geometry with good
chip control. D
Milling
Bad chip breaking
• hange geometry.
C
• Select a higher feed. E
• Use dwelling (pecking).
• Increase coolant.
Drilling
Vibration
F
•U se a stable setup. •C heck tool condition.
• Check speed/feed guide- • Check tool setup.
lines.
• Use shorter overhang.
Boring
• Change geometry.
G
Poor tool life
Tool holding
B 37
F2
Threading
Thread turning is the process of an indexable insert tool
making a number of passes along the section of a work-
piece requiring a screw thread.
By dividing the full cutting depth of the thread into a
series of small cuts, the sensitive thread-profile point of
the cutting edge is not overloaded.
• Theory C4
• Selection procedure C9
• System overview C 13
• How to apply C 19
• Troubleshooting C 25
C3
A Theory
Threading theory
Turning
E
Drilling
F
Metal cutting threading methods
Thread turning Milling Tapping
Boring
G
Tool holding
H
Other information
Machinability
C4
Theory
A
Definitions of terms
Turning
vc = cutting speed (ft/min) (m/min)
n = spindle speed (rpm) B
ap = total depth of thread (inch) (mm)
Parting and
nap = number of passes
grooving
C
Threading
P =p
itch, mm or threads
per inch (t.p.i.) D
β = angle of the thread
d1 = minor diameter external
Milling
D1 = minor diameter internal
d2 = pitch diameter external
E
D2 = pitch diameter internal
d = major diameter external
D = major diameter internal
Drilling
ϕ = helix angle of the thread
F
Boring
G
Tool holding
H
Other information
Machinability
C5
A Theory
Definitions of terms
Turning
1. Root
• The bottom surface joining the two
adjacent flanks of the thread crest.
B
2. Flank
• The side of a thread surface connect-
Parting and
3. Crest
• The top surface joining the two sides,
C or flanks.
Threading
Helix angle
D • The helix angle (ϕ)is dependent on and
related to the diameter and pitch (P) of
the thread.
•B
y changing the shim, the flank clear-
Milling
F
Boring
•A
ggressive cutting data can lead to
movement of insecurely clamped inserts.
H
Other information
Machinability
C6
Theory
A
Turning
Selecting shims for inclination
The inclination angle can be set using shims under the
insert in the tool holder. The choice of which shim to use B
can be made by referring to a chart in the catalog.
As standard, all tool holders are delivered with the shim
Parting and
set at 1°.
grooving
C
Threading
D
Standard shim = 1°
P
tan λ =
π × d2
Milling
E
Pitch, mm Threads/inch
Drilling
F
Boring
G
Tool holding
H
Other information
Workpiece mm
Machinability
diameter inch
C7
A Theory
we can see that the required shim see that the required shim must have
must have an angle of inclination of 3º an angle of inclination of 1º.
(standard shim can be used).
C
Pitch, mm Threads/inch
Threading
D
3
1
Milling
1
Drilling
F
Workpiece mm
diameter inch
Thread profile
Pitch
H
Internal (O)
Other information
External, no marking
Carbide grade
Machinability
C8
Tool selection
A
Turning
Production planning process B
Parting and
grooving
Dimension and
quality of the
thread
C
1 Component
Workpiece mate-
Threading
rial, thread profile
and quantity
Machine parameters
2
Milling
Machine
E
Type of tool:
- Full profile
- V-profile
3
Drilling
Choice of tool
- Multi-point
Cutting data,
in-feed etc.
4
Boring
How to apply
G
Tool holding
Remedies and
5 Troubleshooting
solutions
H
Other information
Machinability
C9
A Tool selection
Component
B •A
nalyze the dimensions and quality
demands of the thread to be machined.
Parting and
P M K
D
N S H
Milling
Material
• Machinability
E
• Chip breaking
• Hardness
• Alloy elements
Drilling
F 2. Machine parameters
• Machine stability
• The spindle speed
G • Coolant supply
• Clamping of the workpiece
• Horizontal or vertical spindle
Tool holding
H
Other information
Machinability
C 10
Tool selection
A
3. Choice of tools
Turning
Different ways to make threads
Full profile inserts B
The thread is cut by the insert with good Advantages
control over the geometrical properties as the
• Better control over the
Parting and
distance between the root and the crest is
thread form.
grooving
controlled.
• Less deburring.
The insert can only cut one pitch.
As the insert is generating both the root and C
the crest, the tool pressure increases, putting Disadvantages
high requirements on setup and overhang. • Each insert can only cut
one pitch.
Threading
D
V-profile inserts
The insert can accommodate a range of Advantages
pitches thus reducing stock. The root and
• Flexibility, one insert
flanks are being formed by the insert.
can be used for several
Milling
The crest is controlled in a prior turning opera-
tion, resulting in high tolerances. pitches.
In setups prone to vibrations, a non-topping
insert can often prove to be a solution due to Disadvantages E
the reduction of cutting pressure. • Can result in burr forma-
tion that needs to be
taken away.
Drilling
F
H
Other information
Machinability
C 11
A Tool selection
4. How to apply
Turning
It influences:
Parting and
- chip control
grooving
- insert wear
- thread quality
C - tool life
E 5. Troubleshooting
Some areas to consider
Insert wear and tool life
Drilling
Insert inclination
G • Ensure there is sufficient and even
clearance (insert – inclination shims).
λ
Tool holding
Insert geometry
• Make sure the right insert geometry is
used (all-purpose, F or C geometries).
H
Other information
Machinability
C 12
System overview
A
System overview
Turning
External threading 1. Small part threading
B
2. Conventional threading
3. Oil pipe threading
Parting and
grooving
C
Threading
3
0.5 – 8 mm
10 – 5 t.p.i 2
32 – 3 t.p.i 1 D
0.2 – 2 mm
Milling
E
Internal threading 10 – 5 t.p.i
Min hole: 2.374
0.5 – 8 mm inch (60.3 mm)
Drilling
32 – 3 t.p.i
Min hole: .472 inch 4
0.5 – 2.5 mm
32 – 10 t.p.i
(12 mm) F
Min hole: .394 inch 3
0.5 – 3 mm
(10 mm)
56 – 16 t.p.i
2
Boring
1. Carbide rods
2. Threading mini-bars
3. Conventional threading H
Other information
C 13
A System overview
C
Threading
Pitch
D 0.2 2.0 5.0 8.0 mm
32 10 3 t.p.i
Milling
Tool holders
Boring
G 2. Shank tools
3. Boring bars
Tool holding
H
Other information
Machinability
C 14
System overview
A
Turning
Choose from an extensive program and several systems
B
Conventional bars Bars for oil pipe
Carbide rods “Old system” threading
Parting and
grooving
Conventional bars
Mini-bars “New system”
C
≥2.362 inch
Threading
≥.472 inch ≥.984 inch (≥60 mm)
≥.157 inch ≥.394 inch (≥25 mm)
(≥4 mm) (≥12 mm)
(≥10 mm)
Milling
.157 .394 .472 .984 2.362
(4) (10) (12) (25) (60)
E
Min. hole diameter, inch (mm)
Drilling
For high precision, internal threading of small components
F
G
Tool holding
H
Other information
Machinability
C 15
A System overview
Thread forms
Turning
B
ISO metric MM
General use
American UN UN
Parting and
grooving
Whitworth, NPT
WH, NT
Pipe thread British Standard (BSPT), NPTF
PT, NF
American National Pipe Threads
C
Food and fire Round DIN405 RN
Threading
MJ MJ
Aerospace
UNJ NJ
D API Rounded RD
Oil and gas API ”V” form 60° V38, 40,
50
Milling
E Trapezoidal TR
Motion
ACME AC
General use
Stub ACME SA
Drilling
C 16
System overview
A
Insert types
Turning
Three different types of threading inserts
B
Full profile inserts
• For high productivity in threading.
Parting and
grooving
C
V-profile inserts - 60º and 55º
• F or threading with minimum tool
Threading
inventory.
D
Multi-point inserts
• F or highly productive, economic threading
Milling
in mass production.
Drilling
All-purpose geometry F-geometry C-geometry
First choice in most Sharp geometry. Chip breaking geometry.
F
operations.
Boring
G
Tool holding
Good chip forming in a Gives clean cuts in sticky Optimized geometry for low
wide range of materials. and work hardening carbon, low alloy and easily
materials. machined stainless steel. H
Other information
Machinability
C 17
A System overview
•U
ltra-rigid threading with fixed position
Parting and
inserts.
grooving
faces).
D
Milling
F
Boring
G
Tool holding
H
Other information
C 18
How to apply
A
How to apply
Turning
Three different types of infeed
The infeed method can have a significant In practice, the machine tool, insert B
impact on the thread machining process. geometry, workpiece material and thread
It influences: pitch influence the choice of infeed
Parting and
- chip control method.
grooving
- insert wear
- thread quality
- tool life. C
Threading
Modified flank infeed
•M
ost newer CNC machines can be programmed for
modified flank.
D
•U
sed with C-geometry as the chip breaker will not
function with radial infeed.
•A
xially directed cutting forces reduce the risk of vibra-
Milling
tions.
• Controlled chip direction.
E
Radial infeed
Drilling
•U
sed by all manual machines and most canned CNC
programs.
• F irst choice for work hardening materials and suitable F
for fine pitches.
Boring
Incremental infeed G
•N
ormally used with very large profiles and pitches, long
Tool holding
C 19
A How to apply
insert.
grooving
Feed direction
Threading
D
Milling
Feed direction
Feed direction
E
Radial infeed
•M ost commonly used method - and only method pos-
Boring
depth of infeed.
• Suitable for fine pitches.
• Vibration possible and poor chip control in coarse
pitches.
H • First choice for work hardening materials.
Other information
Machinability
C 20
How to apply
A
Incremental infeed
Turning
• Recommended for large profiles.
•E
ven insert wear and longest tool life in B
very coarse threads.
•C
hips are directed both ways, making
Parting and
control difficult.
grooving
C
Programming methods
Threading
Ways of improving the machining result
Decreasing depth per pass (Constant chip area)
D
Allows for constant chip • T he deepest pass is the
area. first pass.
This is the most common • Follows recommenda-
Milling
method in CNC programs. tion on infeed tables in
catalog.
• More “balanced” chip E
area.
• Last pass actually
around .0028 inch (0.07
Drilling
mm).
mm or 16 t.p.i.
H
Other information
Machinability
C 21
A How to apply
+.004
0
• T he blank does not need to be turned to the
grooving
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
C 22
How to apply
A
Turning
Max ±.004 inch (± 0.1 mm) Use maximum deviation of ±.004 inch
(±0.1 mm) from centerline.
Too high cutting edge B
• Clearance will decrease.
Parting and
• Cutting edge will rub (break).
grooving
Too low cutting edge
C
• The thread profile can be incorrect.
Threading
Method of threading
Right and left hand threads and inserts D
External Internal
Right hand threads Left hand threads Right hand threads Left hand threads
Milling
E
Drilling
tool/insert tool/insert
F
Right hand Left hand
tool/insert tool/insert
tool/insert tool/insert
G
Left hand Right hand
tool/insert tool/insert
Tool holding
C 23
A Troubleshooting
B •C
heck the workpiece diameter for cor- •O
ptimize infeed method, number and
rect working allowance before thread- size of passes.
turning (add .006 inch (0.14 mm) as
Parting and
•E
nsure the correct cutting speed for the
crest allowance).
grooving
•M
ake sure the correct insert geometry start a minimum distance of 3 times
is used (all-purpose, F or C). the thread pitch before engaging the
workpiece.
• Ensure
there is sufficent and even
D clearance (insert-inclination shims)
to achieve correct flank clearance by
selecting the appropriate shim.
• If threads are rejected, check entire
Milling
E •C
heck the available CNC program for
thread turning.
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
C 24
Troubleshooting
A
Troubleshooting
Turning
Problem Cause Solution
Plastic deformation
B
1. Excessive temperature in 1. R
educe the cutting speed,
cutting zone. increase the number of
Parting and
infeeds.
2. Inadequate supply of
grooving
A B coolant. Reduce the largest infeed
3. Wrong grade. depth, check the diameter
Starts as plastic deformation before threading.
(A). C
2. Improve coolant supply.
which leads to edge chipping
(B). 3. C
hoose a grade with better
resistance to plastic defor-
Threading
mation.
Milling
steel. coated.
A B
- Unsuitable grade.
BUE (A) and edge spalling (B) E
often occur in combination. -C
utting edge temperature
Accumulated BUE is then too low.
ripped away together with
small amounts of insert
Drilling
material, which leads to
spalling.
F
Insert breakage
1. Wrong turned diameter prior 1. T urn to correct diameter
to threading. before threading operation,
Boring
C 25
A Troubleshooting
E
Vibration
1. Incorrect clamping of the 1. Use soft jaws.
Drilling
workpiece.
2. O
ptimize center hole and
2. Incorrect setup of the tool. check pressure of face
F driver.
3. Incorrect cutting data.
4. Incorrect center height. Minimize overhang of tool.
Try F-geometry.
4. Adjust center height.
H
Other information
Machinability
C 26
Troubleshooting
A
Turning
Poor surface finish
1. Cutting speed too low. 1. Increase cutting speed.
B
2. The insert is above the 2. Adjust center height.
center height.
3. U
se C-geometry and modi-
Parting and
3. Uncontrolled chips. fied flank infeed.
grooving
Poor chip control C
1. Incorrect method of infeed. 1. Modified flank infeed 3 - 5°.
2. Incorrect thread geometry. 2. U
se C-geometry with modi-
Threading
fied flank infeed 1°.
Shallow profile D
1. Wrong center height. 1. Adjust center height.
2. Insert breakage. 2. Change cutting edge.
Excessive wear.
Milling
Incorrect thread profile
E
1. Unsuitable thread profile 1. C
orrect tool, shim and
(angle of thread and nose insert combination.
radius) external inserts
used for internal operation 2. Adjust center height.
Drilling
or vice versa. 3. Adjust to 90°.
2. Wrong center height. 4. Correct the machine.
3. Holder not 90° to center F
line.
4. Pitch error in machine.
Boring
C 27
D2
Milling
• Theory D4
• Selection procedure D9
• System overview D 13
• Troubleshooting D 36
D3
A Theory
Milling theory
Turning
Definitions of terms
B Spindle speed, cutting speed and cutter diameter
Parting and
grooving
n =S
pindle speed, rpm
(revolutions per minute)
E
Drilling
H
Other information
Machinability
D4
Theory
A
Turning
Feed, number of teeth and spindle speed
B
fz = F eed per tooth (inch/tooth) (mm/
tooth)
Parting and
vf = Table feed (inch/min) (mm/min)
grooving
zn = Number of cutter teeth (pcs)
zc = E
ffective number of teeth (pcs) C
[in engagement]
fn = F eed per revolution (inch/rev)
Threading
(mm/rev) [fz x zc]
n = Spindle speed (rpm)
D
Milling
vf = fz × zc × n inch/min (mm/min)
Drilling
Feed per tooth, fz inch/tooth (mm/tooth), is a value in
milling for calculating the table feed. The feed per tooth
value is calculated from the recommended maximum chip
F
thickness value.
Feed per minute, vf inch/min (mm/min), also known as
the table feed, machine feed or feed speed is the feed
of the tool in relation to the workpiece in distance per
Boring
Machinability
D5
A Theory
Definitions of terms
Turning
Depth of cut
B ae = R
adial depth of cut (inch) (mm)
[working engagement]
ap = Axial depth of cut (inch) (mm)
Parting and
grooving
C Axial depth of cut, ap inch (mm), is what Radial cutting width, ae inch (mm), is the
the tool removes in metal on the face of width of the component engaged in cut by the
the workpiece. This is the distance the diameter of the cutter. It is the distance across
tool is set below the unmachined surface. the surface being machined or, if the tool diam-
Threading
D
Net power, torque and specific cutting force
[working engagement]
vf = Table feed (inch/min) (mm/min)
E
kc = Specific cutting force (lbs/inch2)
(N/mm2)
Pc = Net power (Hp) (kW)
Drilling
to provide. Pc × 16501
Mc = lbf ft
The specific cutting force value (kc) is π×n
a material constant, expressed in
lbs/inch2 (N/mm2). The values can be Metric
H
found in our main ordering catalog and Pc × 30 × 103
Other information
technical guide. Mc = Nm
π×n
Machinability
D6
Theory
A
Turning
Climb milling – preferred method
Using climb milling (also • In climb milling, the in-
referred to as down mill- sert starts its cut with a
B
ing), the burnishing effect large chip thickness.
is avoided, resulting in less
Parting and
heat and minimal work-
grooving
hardening tendency.
Conventional milling
Threading
The feed direction of the • In conventional milling
workpiece is opposite to (also referred to as up
that of the cutter rotation milling) the chip thick-
at the area of cut. ness starts at zero and D
increases to the end of
the cut.
Milling
Always use climb milling
for best cutting conditions. E
Drilling
The selection of milling cutter diameter is The position of the cutter in relation to the
usually made on the basis of the work- workpiece engagement, and the contact F
piece width with the availability of the ma- which the cutter teeth have, are vital fac-
chine power also being taken into account. tors for a successful operation. Boring
•C
utter diameter should be 20 – 50% larger than the
width of cut. G
•2
/3 rule (i.e., 5.906 inch (150 mm) cutter)
- 2/3 in cut, 3.937 inch (100 mm)
Tool holding
D7
A Theory
C
Dc = Cutter diameter
ae = working engagement
• Not recommended.
G
• T he shock loads at the cutting edge are very high at
entry.
Tool holding
D8
Selection procedure
A
Selection procedure
Turning
Production planning process B
Parting and
grooving
Type of operation and
method
C
1 Component
Workpiece material and
Threading
quantity
Milling
Machine Machine parameters
Drilling
Choice of tool
4
Boring
G
Tool holding
D9
A Selection procedure
Parameters to be considered
B Geometric shape
• Flat surface
Parting and
• Deep cavities
grooving
• Thin walls/bases
• Slots
C
Threading
Material Tolerances
P M K
D N S H • Machinability • Dimensional accuracy
• Chip forming • Surface finish
• Hardness • Part distortion
Milling
2. Machine parameters
Drilling
ration
• Workpiece clamping
H
Other information
Machinability
D 10
Selection procedure
A
3. Choice of tools
Turning
Different ways to optimize milling
Cutters with round inserts
B
Advantages Disadvantages
• Robust milling cutters. •R
ound inserts require
Parting and
more stable machines.
grooving
•V
ery flexible for face mill-
ing and profiling.
•H
igh performance multi- C
purpose cutters.
Threading
45° face mill
D
Advantages Disadvantages
•G
eneral choice for face •M
ax cutting depth
milling. .236-.394 inch
Milling
(6-10 mm).
•B
alanced radial and axial
cutting forces.
E
• Smooth entry into cut.
Drilling
90° square shoulder face mill
Advantages Disadvantages F
H
Other information
Machinability
D 11
A Selection procedure
4. How to apply
Turning
is very important.
• It affects both productiv- Chip formation through cut-
ity and stability. ter positioning
C
Insert geometry •A lways use climb milling.
• Move the cutter off the
•S
elect between a geom-
Threading
center.
etry for Light, Medium or
• Use a cutter with a diam-
Heavy machining.
eter 20–50% larger than
D the cut.
Milling
5. Troubleshooting
Some areas to consider
Drilling
G Vibration
• eak fixture.
W
Tool holding
H
Other information
Machinability
D 12
System overview
A
System overview
Turning
Face milling
B
Cutters for general use
Face and square shoulder
milling cutter for light face
Parting and
milling operations
grooving
Face milling cutter with round inserts
for tough conditions
C
General purpose face milling
cutter with 45° lead (entering)
angle
Threading
D
Milling
E
Dedicated cutters
Drilling
High feed face milling Face milling cutters for cast iron machining
K F
Boring
G
Heavy duty face milling
Face milling cutters for aluminum
Tool holding
machining
H
Other information
Machinability
D 13
A Selection procedure
Shoulder milling
Turning
C
Threading
F
Long edge milling cutter
Solid carbide end mill
Boring
Dedicated cutters
G
Edging with square shoulder milling cutters
Deep shoulder milling
Tool holding
H
Other information
Machinability
D 14
System overview
A
Profiling
Turning
Cutters for general use – roughing
Round insert cutter B
Parting and
grooving
Round insert end mill
Threading
D
Cutters for general use – finishing
End mill with exchange-
able, solid carbide head
Milling
Solid carbide
ball nose end mill E
Drilling
F
Boring
Other methods
Turn milling Blade milling G
Tool holding
H
Other information
Machinability
D 15
A System overview
Slot milling
Turning
C
End mill for internal shallow
grooving and slotting
Threading
D
Cutters for general use
– axial slot milling
Indexable insert end mill
Milling
F
Boring
Thread milling
G Solid carbide end mill
Tool holding
Indexable insert
cutter
Indexable insert
H end mill
Other information
Machinability
D 16
System overview
A
Turning
Modern milling is a very universal machin- Tooling developments have also contribut-
ing method. During the past few years, ed to the new possibilities, along with the
hand-in-hand with machine tool develop- gains in productivity, reliablity and quality B
ments, milling has evolved into a method consistency that have been made in index-
that machines a very broad range of able insert and solid carbide technology.
configurations. The choice of methods
Parting and
grooving
in multi-axis machinery makes milling a
strong contender for producing holes,
cavities, surfaces that used to be turned,
threads, etc. C
Threading
D
Milling
Cutting off Chamfering Profile milling Turn milling
Drilling
Plunge milling Trochoidal milling Circular milling Linear ramping F
Boring
H
Other information
Machinability
D 17
A System overview
Milling methods
Turning
E
Drilling
G
Cutting off Chamfering Plunge milling
Tool holding
H
Other information
Machinability
D 18
System overview
A
Turning
Modern 4/5-axis machining center or multi-task machine
Today, machines are developing in all directions. Turning
centers now have milling capability through driven tools, B
and machining centers have turning capability via turnmill
or mill-turn machines. CAM developments mean that
Parting and
5-axis machines are increasing.
grooving
The results of these trends C
and the development of meth-
ods put new demands and
Threading
opportunities on the tooling,
such as:
• Increased flexibility
• Fewer machines/setups to
D
complete a component
• Reduced stability
• Longer tool lengths
Milling
• Lower depth of cut.
Drilling
Profile milling Turn milling Trochoidal milling Circular milling
F
Boring
G
Linear ramping Circular ramping Thread milling
Tool holding
H
Other information
Machinability
D 19
A System overview
Type of milling
B cutter
Parting and
grooving
C
Considerations Round inserts 10° 45° 90°
Machine/spindle
Threading
D Stability
High High Medium Low
requirement
G
Tool holding
H
Other information
Machinability
D 20
System overview
A
Turning
Type of milling
cutter B
Parting and
grooving
C
90° 90° 90° 90°
Considerations
Threading
Machine/spindle
ISO 40, 50 ISO 30, 40, 50 ISO 40, 50 ISO 30, 40, 50
size
Stability D
High High Medium Low
requirement
Milling
Finishing Acceptable Acceptable Very good Good E
Drilling
Material All All Aluminum Aluminum
F
G
Tool holding
H
Other information
Machinability
D 21
A System overview
Type of milling
B cutter
Parting and
grooving
C
Considerations Round inserts Ball nose Ball nose Ball nose
Machine/spindle
Threading
Stability
D High Medium Medium Low
requirement
G
Tool holding
H
Other information
Machinability
D 22
System overview
A
Turning
Type of milling cutter
B
Parting and
grooving
C
Considerations Side and face Grooving Long edge
Threading
Slot open Open Open Open
Slot closed – – – D
Milling
Versatility Limited Good Good
E
Drilling
F
Machine/spindle size ISO 30, 40, 50 ISO 30, 40, 50 ISO 30, 40, 50
G
Slot open Open Open Open
Tool holding
D 23
A Choice of inserts – how to apply
B
Parting and
grooving
.005 .005
•C
utting edge reinforce- •C
utting edge reinforcement
ment .005 inch (0.13 .005 inch (0.13 mm).
Boring
mm).
• Rake angle 30°.
• Rake angle 30°.
G • Primary land 17°.
• Primary land 11°.
Tool holding
Chip former
Machinability
D 24
Choice of inserts – how to apply
A
Turning
First choice
Low Operation stability High
B
Cutter pitch
L M H
Parting and
grooving
Coarse pitch (-L) Close pitch (-M) Extra close pitch (-H) C
Threading
D
Light (-L) Medium (-M) Heavy (-H)
Machining conditions/
Wear resistant Toughness
Grades
Milling
E
Good conditions Average conditions Difficult conditions
Drilling
Type of application
ap Depth of cut, F
inch (mm) Heavy milling
H • Operation for maximum stock removal and/or severe
conditions.
• Larger depth of cut and feed rate.
Boring
Medium milling G
M • Most applications – general purpose milling.
• Medium operations to light roughing.
Tool holding
Light milling
L • Operations at small depth of cut and low feed rates.
• Operations requiring low cutting forces. H
Other information
fn
Machinability
D 25
A Choice of inserts – how to apply
B
Parting and
grooving
G
bs1 bs2
Tool holding
.002 inch
(0.05 mm)
(8.2)
Machinability
D 26
Choice of inserts – how to apply
A
Turning
Select the geometry and grade according to the application.
Parting and
Good
grooving
Average
C
Difficult
Threading
Good Average Difficult D
Milling
Define machining conditions
E
Drilling
F
•C
utting depth 25% of •C
utting depth 50% of •C
utting depth 50% of
max ap or less. max ap or more. max ap or more. G
•O
verhang under two •O
verhang two to three •O
verhang over three
times cutter diameter. times cutter diameter. times cutter diameter.
Tool holding
D 27
A Choice of inserts and – to apply
mechanisms, e.g.:
grooving
D
Select geometry and grade depending on the type of
workpiece material and type of application.
Milling
E
Drilling
F
Boring
G
ISO GC 4200 ISO GC 2000 ISO GC 3200
P M
Tool holding
H
Other information
Machinability
D 28
Choice of tools – how to apply
A
Turning
B
Parting and
grooving
C
Threading
cutters for small to medium
cutting depths.
D
Milling
First choice
Low Operation stability High E
Cutter pitch
L M H
Drilling
F
Coarse pitch (-L) Close pitch (-M) Extra close pitch (-H)
Boring
Machining conditions/
Wear resistant Toughness
Grades
H
Other information
D 29
A Choice of tools – how to apply
First choice
L M H
Threading
Coarse pitch (-L) Close pitch (-M) Extra close pitch (-H)
•R
educed number of • General purpose •H
igh number of inserts
D inserts. for maximum productivity.
•S
uitable for mixed
• Limited stability. production. • Stable conditions.
• Long overhang. •S
mall to medium • Short chipping materials.
machines
Milling
•S
mall machines/limited • Heat resistant materials.
horsepower. • Usually first choice.
E •D
eep, full slotting
operations.
• Differential pitch.
Drilling
First choice
conditions
Boring
G
Long overhang
K S
Tool holding
D 30
Choice of tools – how to apply
A
Turning
90° entering angle 45° entering angle Round insert cutters
B
Parting and
grooving
C
Threading
D
Milling
E
• Thin-walled components •G
eneral purpose first •S
trongest cutting edge
choice. with multiple indexes.
•W
eak-fixtured compo-
nents. •R
educed vibration on • General purpose cutter.
Drilling
long overhang.
•W
here 90° form is • Increased chip thinning
required. •C
hip thinning effect al- effect for heat resistant
lows increased produc- alloys. F
tivity.
Boring
G
Tool holding
H
Other information
Machinability
D 31
A Choice of tools – how to apply
B • Thin-walled components.
• Axially weak fixtured components.
Parting and
• Square shoulder
grooving
C
Threading
•S
trongest cutting edge with multiple
Boring
indexes.
• General purpose cutter.
G
• Increased chip thinning effect for heat
resistant alloys.
Tool holding
H
Other information
Machinability
D 32
Choice of inserts – how to apply
A
Turning
Max. cutting diameter at a
specific depth (inch). B
Parting and
grooving
Facemilling round insert
(ap<iC/2) (inch). C
hex × iC
fz =
2 × √ ap × iC – ap 2
Threading
Slide milling (ae<Dcap/2) and round insert
(ap<iC/2) (inch). D
hex × iC × Dcap
fz =
4 × √ ap × iC – ap 2 × √Dcap × ae – ae 2
Milling
E
Feed compensation for different entering angles
Drilling
90° = (fz or hex) × 1.0
Boring
Round = depends on ap
H
Other information
Machinability
D 33
A Choice of tools – how to apply
Given: Need:
B
.157 Cutting speed, vc = Spindle speed, n (rpm)
(4 mm) 738 ft/min (225 m/min)
Parting and
Table feed, vf
(inch/min) (mm/min)
grooving
Working engagement, ae =
3.346 inch (85 mm)
Inch Metric
vc × 12 vc × 1000
n= (rpm) n= (rpm)
E π × Dc π × Dc
F
Table feed Given: n = 575 rpm
Inch Metric
vf = n × fz × zn (inch/min) vf = n × fz × zn (mm/min)
Boring
Inch Metric
ap × ae × vf
Q = ap × ae × vf (inch3/min) Q= (cm3/min)
1000
H
4 × 85 × 600
Other information
1000
D 34
Choice of tools – how to apply
A
Turning
Given: Material CMC 02.1
Inch Metric
B
ae × ap × vf × kc ae × ap × vf × kc1
Pc = (Hp) Pc = (kW)
396 × 103 60 × 106
Parting and
grooving
C Cutting
Milling with large engagement Metric
Threading
Specific Hardness
cutting force Brinell CT530
kc 1
Max chip thickness
CMC 0.1 – 0.15 – 0.2
ISO No. Material N/mm2 HB mc Cutting speed vc, m
Steel
P
Unalloyed
01.1
01.2
C = 0.10 – 0.25%
C = 0.25 – 0.55%
1500
1600
125
150
0.25
0.25 D
430–390–50
385–350–15
01.3 C = 0.55 – 0.80% 1700 170 0.25 365–330–00
01.4 1800 210 0.25 315–290–60
01.5 2000 300 0.25 235–210–95
Low alloyed (alloying elements d 5%)
02.1 Non-hardened 1700 175 0.25 300–275–45
02.2 Hardened and tempered 1900 300 0.25 195–180–60
High alloyed (alloying elements > 5%)
Milling
03.11 Annealed 1950 200 0.25 230–205–85
03.13 Hardened tool steel 2150 200 0.25 190–170–55
03.21 2900 300 0.25 165–150–35
03.22 3100 380 0.25 105–95–85
Castings
06.1
06.2
Unalloyed
Low alloyed (alloying elements d 5%)
1400
1600
150
200
0.25
0.25 E
305–280–50
245–220–00
06.3 High alloyed (alloying elements > 5%) 1950 200 0.25 180–160–45
Specific Hardness
cutting force Brinell CT530
kc 1
Max chip thickness
CMC 0.1 – 0.15 – 0.2
ISO No. Material N/mm2 HB mc Cutting speed vc, m
3.346 × .157 × 23.6 × 246500 Stainless steel 85 × 4 × 600 × 1700
Drilling
M
Pc = = 7.7 Hp
Ferritic/martensitic
05.11 Non-hardened Pc = 1800
= 5.8 kW
200 0.21 285 –255 –230
396 × 103 05.12 PH-hardened 60 × 106 2850 330 0.21 205 –185 –165
05.13 Hardened 2350 330 0.21 215 –190 –170
Austenitic
05.21
05.22
Non-hardened
PH-hardened
1950
2850
200
330
0.21
0.21 F
265 –240 –215
200 –175 –160
The calculation above is approximate05.51and valid for an Austenitic-ferritic (Duplex)
Non-weldable t 0.05%C 2000 230 0.21 260 –235 –210
maximum chip thickness (hex) of .0039
05.52 inch (0.1 mm). Weldable < 0.05%C
Stainless steel – Cast
2450 260 0.21 230 –205 –185
( )
15.52 Weldable < 0.05%C 2250 260 0.25 215 –190 –170
γo Specific Hardness G
kc = kc1 × hm-mc × 1 – (lbs/inch2) hm = Average chip thickness cutting force
kc 1
Brinell CB50
Max chip thickness
Material γ
100 CMC 0.1 – 0.15 – 0.2
ISO No.
o = Insert rake angle N/mm HB
2 mc Cutting speed v , m c
Tool holding
( )
Nodular cast
c1
γo 09.1 Ferritic 900 160 0.28 -
Condit
Cutter,
Machinability
D 35
Power capacity
• Check power capability and machine
B rigidity, making sure that the machine
can handle the cutter diameter required.
Parting and
Overhang
grooving
Cutting engagement
• Ensure there is sufficient insert engage-
ment with narrow workpieces or when
Milling
Cutting direction
• Use climb (down) milling whenever pos-
G
sible.
Tool holding
H
Other information
Machinability
D 36
Troubleshooting
A
Turning
Choice of insert geometry
• Use positive geometry indexable inserts
whenever possible for smooth cutting
B
action and lowest power consumption.
Parting and
Dampened milling tools
grooving
• F or longer overhang of more than 4 times
the tool diameter, vibration tendencies
can become more apparent, and damp- C
ened cutters can improve the productivity
radically.
Threading
Entering angle
• Select the most suitable entering angle.
Cutter diameter
• Select the right diameter in relation to
the workpiece width.
Milling
Cutter position E
• Position the milling cutter correctly.
Drilling
Coolant
• Only use coolant if considered neces- F
sary. Milling is generally performed better
without.
Boring
Maintenance
G
• Follow tool maintenance recommenda-
tions and monitor tool wear.
Tool holding
H
Other information
Machinability
D 37
2
Drilling
Drilling covers methods of making cylindrical holes in a
workpiece with metal cutting tools
• Theory E6
• Selection procedure E 15
• System overview E 20
• How to apply E 26
• Troubleshooting E 42
E3
A Theory
•C
hip evacuation is essential; it affects
hole quality, tool life and reliability.
C
Threading
E
Drilling Trepanning
Drilling is classified into
four common methods:
Drilling
- Drilling
F - Trepanning
- Chamfer drilling
- Step drilling
Boring
H
Other information
Machinability
E4
Theory
A
Turning
B
Parting and
grooving
C
Threading
D
1 2 3 4 5 6
Milling
1 Holes with clearance for bolts
2 Holes with a screw thread
E
3 Countersink holes
4 Holes that have a good fit
Drilling
5 Holes that form channels
6 Holes to remove weight for balancing. F
Boring
G
Tool holding
H
Other information
Machinability
E5
A Theory
C
Threading
D
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
E6
Theory
A
Drilling theory
Turning
Cutting speeds for indexable drills
•C
utting speed (vc) for indexable drills B
declines from 100% at the periphery to
zero at the center.
Parting and
• T he central insert operates from cutting
grooving
speed zero to approx. 50% of vc max.
The peripheral insert works from 50% of
vc max up to 100% of vc max. C
0.5 x vc max vc = 0
Threading
vc max
Milling
E
Drilling
center to the periphery.
• Two edges/rev: z = 2. F
Boring
vc = 0 G
vc max
Tool holding
H
Other information
Machinability
E7
A Theory
•C
hisel edge is practically
Parting and
carbide drill.
• T he axial cutting force
C is reduced considerably,
because the chisel edge
140º point angle
is eliminated on solid
Threading
2 2
1 Main cutting edge 1
4 1
Drilling
2 Chisel edge
3 Primary clearance
F 6
6
4 Secondary clearance 8
5 Flute 3 9
7
6 Margin 5
Boring
5
7 First split
•C hisel edge is practically
G eliminated.
8 Negative chamfer
• The main cutting edge
9 Clearance surface
reaches the center point.
Tool holding
E8
Theory
A
Definitions of terms
Turning
Cutting speed
n = spindle speed (rpm)
vc = cutting speed (ft/min) (m/min)
B
fn = feed per revolution (inch/r) (mm/r)
Parting and
vf = penetration rate (inch/min) (mm/
grooving
min)
Dc = drill diameter (inch) (mm)
C
Inch
π × Dc × n
ft/min
Threading
vc =
12
Metric
D
π × Dc × n
vc = m/min
1000
Productivity in drilling is strongly
Milling
related to the penetration rate, vf. vf = fn × n inch/min (mm/min)
Drilling
clines from 100 % at the periphery to zero 2
at the center. vc max
F
The central insert operates from cutting
speed zero to approx. 50% of vc max.
The peripheral insert works from 50%
of vc max up to 100% of vc max.
Boring
G
Cutting speeds for solid and brazed carbide drills vc = 0
Two edges, from the center to the periphery.
Tool holding
vc = max
Two edges/rev: z = 2.
H
Other information
Machinability
E9
A Theory
Effects of cutting speed – vc (ft/min) (m/min)
Turning
•H
igher speed is beneficial for chip formation in long chip-
ping, soft materials, i.e., low carbon steel.
C
Threading
D
Cutting speed (vc) affects:
- tool life
- power consumption.
Milling
G
Tool holding
H
Other information
Machinability
E 10
Theory
A
Feed rate
Turning
Effects of feed rate – fn (inch/r) (mm/r)
•A
ffects the feed force Ff (N), power Pc (Hp) (kW) and
torque Mc (lbf-ft) (Nm). B
• Controls chip formation.
Parting and
• Contributes to hole quality.
grooving
• Primarily influences surface finish.
• Contributes to mechanical and thermal stress.
C
Threading
fn = fz × 2 inch/r (mm/r)
D
Milling
- power consumption
- feed force
E
- mechanical and thermal stress on the drill.
Drilling
- reduced time in cut.
H
Other information
Machinability
E 11
A Theory
(mm/rev)
vf = penetration rate (inch/min)
C (mm/min)
Dc = drill diameter (inch) (mm)
fz = feed per edge (inch) (mm)
Threading
Inch Metric
E fn × vc × Dc × kc1 fn × vc × Dc × kc1
Pc = Hp Pc = kW
132 × 103 240 × 103
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
E 12
Theory
A
Turning
CoroDrill® 880 CoroDrill® Delta-C
B
Parting and
grooving
C
γ0 = 30°
Threading
Inch Metric
D
fn × vc × Dc × kc fn × vc × Dc × kc
Pc = Hp Pc = kW
132 × 103 240 × 103
Milling
γ0
kc = kc1 × (fz × sin κr)-mc × ( 1–
100 ) E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
E 13
A Theory
Dc
Feed force (N) Ff ≈ 0.5 × kc × fn × sin κr (N)
E 2
Inch Metric
Drilling
Pc × 16501 Pc × 30 × 103
Mc = (lbf ft) Mc = (Nm)
F π×n π×n
Boring
G
Tool holding
H
Other information
Machinability
E 14
Tool selection
A
Turning
Production planning process B
Parting and
grooving
Hole dimension
and quality
C
1 Component
Workpiece material, shape
Threading
and quantity
Milling
Machine Machine parameters
3 Type of tool
Drilling
Choice of tool
How to apply
etc.
G
Tool holding
Remedies and
5 Troubleshooting
solutions
H
Other information
Machinability
E 15
A Tool selection
Component:
B - Is the component rotation symmetric
around the hole, i.e., can the hole be
machined with a stationary drill?
Parting and
grooving
-C
lamping, clamping forces and cutting
forces. Is the component sensitive to
vibrations?
C
- Is a tool extension needed to reach the
surface where the hole will be drilled, i.e.,
long tool overhangs?
Threading
D
Material:
- achinability
m
Milling
- chip breaking
- hardness
E - alloy elements.
Drilling
- spindle speed
G - coolant supply
- coolant pressure
- clamping of the workpiece
Tool holding
E 16
Tool selection
A
Turning
Different ways to make a hole
The basic parameters are: The hole type, and the required precision B
affect tool choice.
• diameter
• depth Drilling can be affected by irregular or
Parting and
• quality (tolerance, surface finish, angled entry/exit surfaces and by cross
grooving
straightness). holes.
Threading
Drilling and boring Step drilling Milling, helical
interpolation
Milling
E
Drilling
• Simple standard tools. • Simple Tailor Made tools. • Simple standard tools.
• Relatively flexible. • F astest way to make a • Very flexible.
hole. F
• Low cutting forces.
Disadvantages
Disadvantages
• T wo tools, adapters and Disadvantages
Boring
basic holders. •R
equires more power and
stability. • Longer cycle times.
•R
equires two tool
positions. • Less flexibility. G
Tool holding
H
Other information
Machinability
E 17
A Tool selection
4. How to apply
Turning
•A
lways use shortest possible drill and
grooving
overhang.
• F or best stability and hole quality, use
C modular tools, hydro-mechanical or
hydraulic holding tools.
Threading
D
Tool runout
•M
inimum tool runout is essential for
successful drilling.
Milling
•C
hip formation and evacuation is the
dominant factor in drilling and affects
hole quality.
F
G
Tool holding
H
Other information
Feed
Machinability
E 18
Tool selection
A
5. Troubleshooting
Turning
Some areas to consider
B
Insert wear and tool life
-C
heck the wear pattern and if necessary adjust cutting
Parting and
data accordingly.
grooving
Chip evacuation
C
- Check chip breaking and cutting fluid supply.
Threading
Hole quality and tolerances
ø.984 in.
(ø25mm) -C
heck clamping of drill/workpiece, feed rate, machine
conditions and chip evacuation.
D
Cutting data
-C
orrect cutting speed and feed rate is essential for high
Milling
productivity and tool life.
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
E 19
A System overview
Drilling tools
Turning
Conventional drilling
grooving
C
Irregular surface and
cross-hole drilling
Threading
D
Milling
15xDc
G
10xDc Trepanning drill
Tool holding
5xDc
H Drill
diameter, Dc
Other information
.394 .787 1.181 1.575 1.969 2.362 2.756 3.150 4.331 inch
Machinability
(10) (20) (30) (40) (50) (60) (70) (80) (110) (mm)
E 20
System overview
A
Turning
Step and chamfer drilling
B
Step or step and chamfer
Chamfer drilling drilling
Parting and
grooving
C
Threading
D
Milling
Other methods
E
Drilling
Radial adjusted
drilling Helical interpolation Trepanning
Boring
G
Tool holding
H
Other information
Machinability
E 21
A System overview
diameter holes.
grooving
G
Tool holding
H
Other information
Machinability
E 22
System overview
A
Turning
The basic drill
B
• T he most economical way to
Parting and
produce a hole.
grooving
• For all workpiece materials.
•S
tandard, Tailor Made and special drills
available. C
•A
versatile tool that can do more than
just drilling.
Threading
D
Milling
E
Mounting options
Different mounting options are available, which enables
the user to mount the drill to almost all machine configu-
Drilling
rations. Today, machine tool manufacturers are offering
mounting options integrated to the spindle.
F
G
Tool holding
H
Other information
Machinability
E 23
A System overview
C P M K K N S
N S H
Threading
P M K P
E N S H H
Drilling
F
Short hole drills – ISO material groups
ISO material group
P M K N S H
Boring
H
Indexable
Other information
insert drills
Machinability
E 24
Selection procedure
A
Turning
Large diameter drill
Indexable insert drills are available in diameters B
up to 3.150 inch (80 mm).
Parting and
grooving
C
Threading
Trepanning drill
Trepanning is used for larger hole diameters and where
D
machine power is limited, because it is not as power con-
suming as solid drilling. Trepanning drills are available up
to diameter 4.331 inch (110 mm) as standard.
Milling
E
Drilling
Milling, helical interpolation
F
A milling cutter with helical or circular interpolation can be
used instead of drills or boring tools. The method is less
productive but can be an alternative when chip breaking
is a problem.
Boring
G
Tool holding
H
Other information
Machinability
E 25
A How to apply
How to apply
Turning
taking place.
• Increase or decrease feed rate according to chip
D formation, vibration, hole-surface quality, etc.
Milling
Chip control
Drilling
Not accept-
H able
Other information
Machinability
E 26
How to apply
A
Rotating drill
Turning
Alignment
• If over- or under-sized holes are produced
B
or if the center insert tends to chip, it is
often because the drill is off center.
Parting and
• T urning the drill 180° in its holder may
grooving
solve this problem.
•B
ut it is important to ensure that the
center axis of the drill and the axis of C
rotation are parallel in order to achieve
accurate holes.
Threading
• T he machine spindle and the holder
must be in good condition.
Milling
Radial adjustment E
Adjustable holder
•S
etting is achieved by turning the scale
Drilling
ring surrounding the holder, marked in
increments of .002 inch (0.05 mm),
indicating a diametrical movement of the F
tool.
•R
adial adjustment -.008 /+.028 inch
(-0.2 /+0.7 mm). Note that the adjust-
Boring
E 27
A How to apply
B
Parting and
grooving
C
Rotating drill – eccentric sleeve
Threading
•U
se both screws to clamp the drill in the
fixture and make sure the bolts in the
holder are long enough.
F
Boring
G
Tool holding
H
Other information
Machinability
E 28
How to apply
A
Non-rotating drill
Turning
Alignment
Parting and
grooving
• T he drill should be mounted so that the
top face of the peripheral insert is paral-
lel to the machine’s transverse move-
ment (usually X-axis). C
Threading
D
Milling
Dial indicator and test bar E
•M
isalignment also has the effect of
radial offsetting, which produces either
an over- or under-sized hole.
Drilling
• T esting can be carried out with a dial
indicator together with a test bar.
F
•A
nother way is by making a drill with four
flats equally positioned around the drill
shank. G
1 •M
ake holes with the drill mounted in
each of the four flat positions. Hole
Tool holding
H
4
Other information
3
Machinability
E 29
A How to apply
Deflection of turret
Turning
Problem solving
•D
eflection of the turret on a CNC lathe
B
can be caused by the feed force.
Parting and
grooving
D
B
Milling
A
E
A
G
Tool holding
Feed force
H
Other information
Machinability
E 30
How to apply
A
Radial offset
Turning
•H
oles can be drilled larger than the nominal size of the
drill as well as enlarged and finished with a subsequent B
boring pass.
•N
on-rotating indexable insert drills can also be used to
Parting and
generate tapered holes.
grooving
•A
lso chamfering and reliefs can be machined
with the drill.
C
•A
hole which is to be threaded can be prepared in one
pass along with chamfering.
Threading
D
Milling
Entering non-flat surfaces
When entering non-flat surfaces there is E
A B a risk of drill deflection. To avoid this, the
feed can be reduced when entering.
A. Convex surface
Drilling
• Normally no feed reduction needed.
F
B. Concave surface
• to 1/3 of original feed rate.
C D
Boring
C. Inclined surface
•W
ith entering angle of 2º–89º, reduce G
feed to 1/3 of original feed rate.
Tool holding
D. Curved surface
• Reduce feed 1/3 of original feed rate.
H
Other information
Machinability
E 31
A How to apply
•A
pre-drilled hole should be small rather
grooving
Coolant supply
Milling
•C
an be successful in favorable condi-
tions, but is generally not recommended.
G
Tool holding
H
Other information
Machinability
E 32
How to apply
A
Turning
Coolant supply is essential in drilling and influences:
- chip evacuation B
- hole quality
- tool life.
Parting and
grooving
•The cubic capacity of the coolant tank should be
between 5-10 times larger than the volume of coolant
that the pump supplies per minute.
C
• The volume capacity can be checked using a stopwatch
and a suitably-sized bucket.
Threading
D
Milling
Soluble oil (emulsion)
• 5 to 12% oil (10-25% for stainless steels). E
• EP (extreme pressure) additives.
Neat oil
Drilling
• always with EP additives.
• to be preferred for stainless steels.
• both solid carbide and indexable insert drills work well F
with neat oil.
cutting speeds.
G
Dry drilling, without any coolant
• can be performed in short-chipping materials.
Tool holding
E 33
A How to apply
Tool runout
B Rotating drill Minimum tool runout is one of the main
criteria for successful use of solid carbide
.0008 inch (0.02 mm) drills.
Parting and
grooving
E Tool holding
•A
collet and tool shank in bad condition
will ruin an otherwise perfect setup.
Drilling
•M
ake sure that the TIR (Total Indicator
Readout) is within .0008 inch (0.02
F
mm).
•A
n unacceptable runout can be tempo-
rarily reduced by turning the drill or the
collet 90° or 180° to find lowest TIR.
Boring
G
Tool holding
E 34
How to apply
A
Coolant
Turning
Internal or external
Internal coolant supply
B
• Is always to be preferred to avoid chip jamming.
•S
hould always be used at hole depths above 3 times
Parting and
the diameter.
grooving
•A
horizontal drill should have a flow of coolant coming
out of the drill without any downward drop for at least
12 inches (30 cm). C
Threading
• Can be acceptable in short-chipping materials.
• T o improve chip evacuation at least one coolant nozzle
(two if drill is stationary) should be directed close to the D
tool axis.
•C
an sometimes help to avoid built-up edge formation
due to a higher edge temperature.
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
E 35
A How to apply
Safety precautions
Turning
Safety against •G
uarding against through-hole discs is
B dangerous discs important to avoid damage or injury,
especially when using non-rotating drills.
Parting and
grooving
C
Threading
D
External coolant supply
Rotating stop •A
rotation stop may be necessary for
is an important
rotating drills.
measure
Milling
F
Boring
G
Tool holding
H
Other information
Machinability
E 36
Hole quality and tolerance
A
Turning
Steps to ensure good hole quality in drilling
B
• The
machine tool should be in good
condition.
Parting and
grooving
• T ool holding influences hole quality and
tool life.
•U
se the shortest possible drill for maxi- C
mum stability.
•C
hip breaking and chip evacuation must
Threading
always be satisfactory.
•C
oolant supply and coolant pressure is
important.
D
Milling
E
Drilling
Hole dimensions are characterized by
Dmax three parameters:
Dmin - nominal
value (the theoretical exact
F
value)
- tolerance
width (a number), e.g., IT 7 ac-
cording to ISO
Boring
- position
of the tolerance (designated by
capital letters according to ISO). G
Tool holding
E 37
A Hole quality and tolerance
H10
+.003 inch Nominal value: .591 inch (15.00 mm)
G (0.07 mm)
Position: 0 to plus
(H acc. to ISO)
H
Other information
Machinability
E 38
Hole quality and tolerance
A
Turning
Hole tolerances according to ISO
B
The hole tolerance is often
connected to the tolerance
of an axle, that should fit
Parting and
the hole.
grooving
Axle Hole
Ø .787 inch Ø .787 inch
(20 mm) h7 (20 mm) H7
C
Threading
Hole and axle tolerance according to ISO D
Milling
E
Most common
Drilling
Hole larger Axle larger than F
than axle hole
Boring
E 39
A Hole quality and tolerance
R844 R840
R842
C R850
Tolerance
IT6
Threading
IT7
IT8
D IT9 With pre-setting
IT10
IT11
Milling
IT12
E IT13
E 40
Hole quality and tolerances
A
Turning
Drill tolerance Hole tolerance
• T he diameter tolerance of an indexable • Indexable insert drills give an optimal
insert drill is a combination of the tip cutting force balance and a plus toler- B
seat tolerance in the drill body and the ance (oversized) hole, because most
insert tolerance. holes are with H-tolerance.
Parting and
grooving
C
Threading
Drill depth 2-3 x Dc
Drill diameter, inch (mm) .472 – 1.732 1.732 – 2.086 2.087 – 2.500 D
(12.00 – 43.99) (44.00 – 52.99) (53.00 – 63.50)
Hole tolerance, inch (mm) 0/+.0098 0/+.0110 0/+.0118
(0/+0.25) (0/+0.28) (0/+0.30)
Milling
Tolerance Dc, inch (mm) 0/+.0079 0/+.0098 0/+.0110
(0/+0.20) (0/+0.25) (0/+0.28)
Drilling
(0/+0.40) (0/+0.43) (0/+0.45)
Tolerance Dc, inch (mm) +.0016/+.0094 +.0016/+.0114 +.0016/+.0126
(+0.04/+0.24) (+0.04/+0.29) (+0.04/+0.32) F
E 41
A Troubleshooting
Troubleshooting
Turning
G
Tool holding
H
Other information
Mc lbf-ft (Nm)
Machinability
E 42
Troubleshooting
A
Problem Solution
Turning
Insufficient machine power 1. Reduce speed.
2. Reduce feed.
3. Choose a light cutting geometry to lower the cutting force. B
Parting and
grooving
Pc HP (kW)
Hole not symmetrical Hole widens at bottom (due to chip jam on center insert)
1. Increase coolant flow, clean filter, clear coolant holes in drill.
2. Try a different geometry on peripheral side and adjust feed C
rate within recommended cutting data.
3.Shorten drill overhang.
Threading
Poor tool life 1. Reduce feed. D
2. Choose a light-cutting geometry to lower the cutting force.
Milling
E
Broken insert screws 1. Use torque wrench to fasten the screw together, apply
Molykote.
Drilling
F
E 43
A Troubleshooting
Flank wear
B
a) C utting speed too high. a) R educe cutting speed.
b) Insufficiently wear resistant b) Choose a more wear resistant
grade. grade.
Parting and
grooving
C
Crater wear
Peripheral insert Peripheral insert
Threading
General:
• Choose a more positive geometry.
Milling
E
Plastic deformation (peripheral insert)
a) C utting temperature (cutting a–b) S
elect a more wear resistant
speed) too high, combined with grade with better resistance
high pressure (feed, hardness of to plastic deformation, i.e.,
Drilling
Chipping
Boring
E 44
Troubleshooting
A
Turning
Problem Cause Solution
Parting and
c) Very sticky material, such as c-d) Increase oil mixture and
grooving
certain stainless steels and pure volume/pressure in cutting
aluminum. fluid.
d) Percent of oil mixture in cutting
fluid too low.
C
Threading
D
Milling
1. M
ake sure the right cutting data and
drill geometry are used. E
2. Inspect chip form (compare with picture
on page E 26).
3. C
heck if the cutting fluid flow and pres-
Drilling
sure can be increased.
4. Inspect the cutting edges. Chipping on F
the edge can cause long chips because
the chip is divided.
5. C
heck if the machinability has changed
Boring
H
Other information
Machinability
E 45
A Troubleshooting
E
Tool wear – solid carbide / brazed drills
Cause Solution
Drilling
Built-up edge
1. C utting speed too low and edge 1. Increase cutting speed or use
F temperature too high. external cutting fluid.
2. Negative land too large. 2. Sharper cutting edge.
3. No coating. 3. Coating on the edge.
4. Percentage of oil in the cutting 4. Increase the percentage of oil in
fluid too low. the cutting fluid.
Boring
G
Chipping on the edge corner
1. nstable fixturing.
U 1. heck fixture.
C
Tool holding
E 46
Troubleshooting
A
Turning
Cause Solution
Large wear on the cutting edge
1. utting speed too high.
C 1. ecrease the cutting speed.
D B
2. Feed too low. 2. Increase the feed.
3. Grade too soft. 3. Change to harder grade.
4. Lack of cutting fluid. 4. Check for proper cutting fluid
Parting and
supply.
grooving
Chipping on the cutting edge C
1. U nstable conditions. 1. C heck the setup.
2. Maximum allowed wear 2. Replace drill sooner.
exceeded. 3. Change to softer grade.
Threading
3. Grade too hard.
D
Wear on the circular lands
1. TIR too large. 1. C heck the radial runout.
2. Cutting fluid too weak. 2. Use neat oil or stronger
3.Cutting speed too high. emulsion.
Milling
4. Abrasive material. 3. Decrease cutting speed.
4. Change to harder grade.
E
Wear on the chisel edge
1. Cutting speed too low. 1. Increase cutting speed.
2. Feed too high. 2. Decrease feed.
Drilling
3. Chisel edge too small. 3. Check dimensions.
H
Other information
Machinability
E 47
F2
Boring
Boring operations involving rotating tools are applied to
machine holes that have been made through methods
such as pre-machining, casting, forging, extrusion,
flame-cutting, etc.
• Theory F4
• Selection procedure F9
• System overview F 14
• How to apply F 21
• Troubleshooting F 25
F3
A Theory
Boring theory
Turning
E
Drilling
•H
igh quality hole toler- •H
igh quality demands of
ance and surface (for the machine (for finish-
finishing). ing).
H
Other information
Machinability
F4
Theory
A
Definitions of terms
Turning
Definitions of cutting data terms
Parting and
grooving
fn = feed per revolution (inch/r) (mm/r)
Dc = boring diameter (inch) (mm)
vf = penetration rate (inch/min) (mm/min) C
fz = feed per tooth (inch/rev) (mm/rev)
zc = effective number of teeth that ma-
Threading
chine the final surface
Cutting speed D
Inch
The boring tool rotates at a certain number π × Dc × n
of revolutions (n) per minute generating a vc = (ft/min)
certain diameter (Dc). This gives a specific 12
Milling
cutting speed (vc) measured in ft/min
(m/min) at the cutting edge. Metric
E
π × Dc × n
vc = (m/min)
1000
Drilling
Feed
The axial tool movement is called feed rate vf = fn × n (inch/min) (mm/min) F
(fn) and is measured in inch/revolution
(mm/rev). The feed rate is obtained by mul-
tiplying the feed per tooth, inch/rev (mm/
rev), by the number of effective teeth (zc).
Boring
fn = zc × fz (inch/r) (mm/r)
The feed rate is the key value in determining
the quality of the surface being machined
G
and for ensuring that the chip formation is
within the scope of the insert geometry.
Tool holding
F5
A Theory
B
n = spindle speed (rpm)
vc = cutting speed (ft/min) (m/min)
Parting and
grooving
D
Milling
Torque Inch
E The torque (Mc) is the torque value pro- Pc × 16501
duced by the boring tool during cutting Mc = (lbf ft)
action, which the machine must be able to π×n
provide.
Drilling
Metric
G
into consideration when selecting cutting
data.
Pc =
ap × fn × kc × vc
60 × 103 ( )
1–
ap
Dc
(Hp)
(kW)
Tool holding
in lbs/inch2 (N/mm2).
Machinability
F6
Theory
A
Turning
Rough boring tool with multiple edges
B
•R
ough boring operations are performed to open up the
existing hole to prepare for fine boring.
Parting and
grooving
C
Threading
Single-edge fine boring tool
Milling
Ø.9843 in
(Ø25 mm) H7
E
Ø.9843 in (Ø25 mm)
Ø.9851 in (Ø25.021 mm)
Drilling
Hole tolerance of boring and reaming tools F
IT6
Tool holding
IT7
IT8 H
Other information
IT9
Machinability
F7
A Theory
Single-edge boring
Multi-edge boring
Threading
E Step boring
G Reaming
A light finishing operation performed with a multi-edge
reamer at high feeds.
Tool holding
H
Other information
Machinability
F8
Tool selection
Turning
Production planning process B
Parting and
grooving
Hole dimension
and quality Ø.9843 in
(Ø25 mm) H7
C
1 Component
Workpiece Ø.9843 in (Ø25 mm)
Threading
material, shape Ø.9851 in (Ø25.021 mm)
and quantity
Machine
2 Machine
Milling
parameters
Drilling
Choice of tool Type of tool
Cutting data,
4
Boring
How to apply
coolant, etc.
G
Tool holding
Remedies and
5 Troubleshooting
solutions
H
Other information
Machinability
9
A Tool selection
machine.
grooving
•C
lamping, clamping forces and cutting
forces. Is the component sensitive to
C vibrations?
•S
elect the tool that covers the boring
diameter range and depth for the
Threading
D
Material
• achinability
M
Milling
• Chip breaking
• Hardness
E • Alloy elements
Drilling
F 2. Machine parameters
• Machine stability
G • The spindle speed
• Coolant supply
• Clamping of the workpiece
Tool holding
F 10
Tool selection
A
3. Choice of tools
Turning
Roughing Finishing
B
Parting and
grooving
C
Multi-edge Step boring Single-edge Single-edge Reaming
boring boring boring
Threading
Multi-edge boring Step-boring Single-edge boring
• High metal removal rate. • F or rough boring with • For general fine boring.
large stock removal. D
• Productive boring. • Tolerance capability IT6.
• Improved chip control.
Single-edge boring
Reaming
Milling
• Improved chip control.
•V
ery good surface finish
• L ess machine-power at high penetration rates. E
demanding.
•S
uitable for mass
production.
Drilling
F
Boring
H
Other information
Machinability
F 11
A Tool selection
4. How to apply
Turning
Cutting data
E Cutting speed,
vc ft/min (m/min) •C
orrect cutting speed and feed rate is
essential for high productivity, tool life
and hole quality.
Drilling
F
Boring
Feed, inch/r
(mm/r)
G
Tool holding
H
Other information
Machinability
F 12
Tool selection
A
5. Troubleshooting
Turning
Important application considerations
Insert wear and tool life
B
• C
orrect geometry, grade and cutting data
is essential in boring operations.
Parting and
grooving
Chip evacuation
•C
heck the chip breaking and cutting fluid
C
supply.
Threading
•C
heck clamping of boring tool/work-
piece, feed rate, machine conditions and
Ø.9843 in chip evacuation. D
(Ø25 mm) H7
Cutting data
Ø.9843 in (Ø25 mm) •C
orrect cutting speed, feed rate and
Milling
Ø.9851 in (Ø25.021 mm) cutting depth is essential for high pro-
ductivity, tool life and to avoid vibrations.
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
F 13
A System overview
System overview
Turning
C
Tool with three inserts
Threading
Single-edge tools
Multi-edge reamer
Boring
G
Fine boring head for
fine boring bars
Tool holding
H
Other information
Machinability
F 14
System overview
A
Turning
Rough boring tool with three inserts
Diameter range 1.378 - 12.047 inch (35 - 306 mm)
B
Parting and
Rough boring tool with two inserts
grooving
Diameter range .984 - 10.630 inch (25 - 270 mm)
Threading
D
Diameter
inch 0 1.969 3.937 5.906 7.874 9.843 11.811 13.780 15.748 17.717 19.685 21.654
mm 0 50 100 150 200 250 300 350 400 450 500 550
Milling
Multi-edge reamer
Diameter range .394 - 1.250 inch (10 - 31.75 mm) E
Drilling
Diameter range .118 - 1.654 inch (3 - 42 mm)
G
Single-edge boring tool with modular adapter
Tool holding
Diameter
H
Other information
inch 0 .984 1.969 5.906 7.874 9.843 11.811 19.685 21.654 23.622 35.433 39.370
mm 0 25 50 150 200 250 300 500 550 600 900 1000
Machinability
F 15
A Choice of tool
Choice of tools
Turning
Roughing
Multi-edge boring
B
•H igh metal removal rate.
• Productive boring.
Parting and
grooving
Single-edge boring
• Improved chip control.
C • Less machine-power demanding.
Step-boring
Threading
Finishing
Milling
Single-edge boring
E • F or general fine boring.
• Tolerance capability IT6.
Reaming
Drilling
H
Other information
Machinability
F 16
Choice of tool
A
Turning
Rough boring tool with three inserts
First choice recommendation for medium and high power
machines is a rough boring tool with three cutting edges B
for optimized productivity.
Parting and
grooving
Rough boring tool with two inserts C
A rough boring tool with two cutting edges is first choice
for low to medium power machines, unstable operations
Threading
or large diameters.
Milling
Choose dampened rough boring tools for overhangs
longer than 4 times the coupling diameter.
E
Drilling
Boring tool setup F
All rough boring tools can be set up in three different
ways. Boring
G
Tool holding
H
All rough boring tools can be ordered and assembled, adapted to
Other information
F 17
A Choice of tool
C
Slides with positive inserts
• In rough boring, it is an advantage to use
Threading
E
Lead (entering) angle and insert shape
The lead (entering) angle of boring tools affects the direc-
tion and magnitude of axial and radial forces. A small
lead (large entering) angle produces a large axial force,
while a large lead (small entering) angle results in a large
Drilling
6° 15° 6°
(84°) (75°) (84°)
G 0° - F irst choice for general
(90°) operations, step boring and for
shoulder operations.
Tool holding
0° 0°
(90°) (90°)
–5° - F or high feeds or improved
H (95°) surface finish with Wiper
inserts in stable conditions.
Other information
Machinability
-5° -5°
(95°) (95°)
F 18
Choice of tool
A
Turning
Single-edge fine boring tool
Parting and
grooving
C
Fine boring head with fine boring bars
Threading
For small diameters a fine boring head with fine boring
bars is required.
Milling
Silent Tools for long overhangs
E
Silent Tools (dampened) are the first choice for overhangs
longer than 4 times the coupling diameter.
Drilling
F
Multi-edge reamer
Boring
H
Other information
Machinability
F 19
A Choice of tool
General recommendations
•P
ositive basic-shape inserts with 7°
grooving
Adapters
Milling
G
Tool holding
H
Other information
Machinability
F 20
How to apply
A
How to apply
Turning
Fine boring tools
Adjustable fine boring mechanism B
Parting and
ment possibilities to accurately pre-set the
grooving
cutting edge within microns.
Threading
Tool deflection
•B
oring tools for finishing, with one cut- D
ting edge, will experience some degree
of radial deflection during machining due
to the cutting forces.
Milling
• T he depth of cut and length of overhang
influence the radial deflection of the
boring tool. E
• T he deflection might cause undersized
holes or vibrations.
•A
measuring cut is normally needed,
Drilling
followed by a final adjustment of the tool.
Boring
G
Tool holding
H
Other information
Machinability
F 21
A How to apply
•A
pply cutting fluid for optimized chip
evacuation, cooling and lubrication.
Cutting depth,
Drilling
- feed
- cutting speed
G - material.
H
Other information
Machinability
F 22
How to apply
A
Turning
The cutting data for the insert geometry and grade
chosen can generally be followed with the following
exceptions: B
- Rough boring
Max start value vc = 656 ft/min (200 m/min).
Parting and
grooving
-F ine boring with fine boring adapters:
Max start value vc = 787 ft/min (240 m/min).
- Fine boring with fine boring bars:
Max start value vc = 295 – 394 ft/min C
(90 – 120 m/min).
- Fine boring:
Threading
Max ap = .020 inch (0.5 mm).
If the cutting depth is too small, the insert will tend to
ride on the pre-machined surface, only scratching and
rubbing it, leading to poor results. D
Milling
- chip evacuation
- long overhangs.
E
Drilling
M
Mcc lbf-ft (Nm) When rough boring, make sure the machine can provide
sufficient power and torque.
F
Important parameters are:
- feed
- number of inserts
Boring
- diameter
- depth of cut.
G
Tool holding
H
Other information
Machinability
F 23
A How to apply
•A
lways use a torque wrench and apply the recommend-
ed torque on screws for insert and tool assembly.
B • Check inserts and insert seats regularly.
• Replace worn or exhausted screws and washers.
Parting and
D
Milling
•M
ake sure the reamer is concentric with the pre-ma-
chined hole.
G • Choose the shortest possible tool holder and shank.
•E
mulsion as cutting fluid generates better tool life
Tool holding
than oil.
• Use recommended cutting data.
H
Other information
Machinability
F 24
A
Troubleshooting
Troubleshooting
Turning
Factors that affect vibration tendencies
Vibration tendencies grow towards the right. B
Parting and
grooving
C
Threading
D
inch (mm)
.008 (0.2) .016 (0.4) .031-.047 (0.8-1.2)
Milling
E
Drilling
• Decrease cutting speed. •C
heck that all units in the tool assembly
F
are assembled correctly with the correct
• Apply step boring.
torque.
• Choose a 2-edge rough boring tool.
• Reduce feed or increase feed.
•C
hoose a light-cutting geometry and
Boring
•C
heck machine spindle, wear, clamping,
etc.
• Increase depth of cut (finishing).
• Decrease depth of cut (roughing). H
Other information
F 25
A Troubleshooting
Insert wear
Turning
Chip breaking
Parting and
grooving
Cause Solution
D
Too long • Increase feed
• Decrease cutting speed
• Change geometry to a more
closed chip breaker
Milling
E
Surface
Tool vibration
Drilling
Feed marks
Too high feed • Choose knife edge wiper
insert
• Decrease feed
Machinability
F 26
Troubleshooting
A
Cause Solution
Turning
Insert wear
B
Wrong cutting data •C
hange cutting edge and
investigate reason for wear
pattern – cutting data, insert
Parting and
geometry and insert grade.
grooving
C
Chips scratching surface
Bad chip breaking • Change cutting data
Threading
• Change insert geometry
Surface finish
Milling
Bad surface finish • Increase speed
• Use coolant
E
• Use a cermet grade
Drilling
Machine power limitation
Limited machine power • Decrease cutting data
F
• Apply step boring
Boring
G
Tool holding
H
Other information
Machinability
F 27
Tool holding
The clamping of a cutting tool can influence the produc-
tivity and performance of the cutting tool dramatically.
Therefore it is important to choose the right holding tools.
This chapter will simplify the decision process and give
guidelines how to apply and maintain the holding prod-
ucts.
• Turning centers G 15
• Machining centers G 23
• Multi-task machines G 29
• Chucks G 33
G3
A History and background
machining.
•C
ompared to conventional shank tools,
C a quick change system can increase the
effective cutting time by 25% in turning
centers.
Threading
D
Milling
E
Tool holding systems today
• T ooling has evolved through the neces-
Drilling
H
Other information
Machinability
G4
History and background
A
Turning
• T his style of taper was introduced 40
years ago.
• T he taper was the basis of most B
machine tool spindles, due to the long
taper, giving secure contact and stability.
Parting and
grooving
• It is still popular today, in various sizes,
using taper 7/24, but it is not a modular
tooling solution.
C
Threading
D
Milling
• T here is an ever increasing supply of
quick change and modular tooling sys- E
tems on the market today.
nfortunately, these systems are not
•U
interchangeable with each other, and are
Drilling
very limited in their flexibility between
machining centers and CNC lathes.
F
•M
ost of these systems are not suitable
for multi-task machining operations. Boring
G
Tool holding
H
Other information
Machinability
G5
A History and background
Coromant Capto®
Turning
C
Threading
Basic holders
F
1980 1990
G Standard
ISO 26623
Tool holding
H
Other information
Machinability
G6
Why modular tooling
A
Turning
Machining centers
B
Parting and
grooving
C
Threading
D
Turning centers
Multi-task machines
Milling
Trends E
Machines and machining methods
•M
ulti-task machines requiring one holder system for
both spindle and turrets.
Drilling
•S
everal turrets on multi-task machines and turning
centers.
F
• More multi-function tools for multi-task machines.
• Driven tools in turning centers.
•P
owerful interfaces in the machine control system for
Boring
G7
A Why modular tooling
•M
achine requires frequent setup
B changes.
•M
easuring cuts are necessary to get
correct size.
Parting and
grooving
•M
achining is performed with high cutting
data and relatively short tool life.
C •O
ne operator services more than one
machine.
Threading
D
Milling
-S
ervice and mainte-
Drilling
nance
-M
easuring of the tool
and workpiece
Boring
G8
Why modular tooling
A
Turning
One system! One solution! – For the entire workshop
Coromant Capto is a flexible tooling system, suitable
B
for all types of machining. This makes it possible to
standardize on one system in your entire workshop.
Parting and
grooving
C
Turning centers Vertical lathes
Threading
D
Milling
E
Drilling
F
Machining centers Multi-task machines
Boring
G
Tool holding
H
Other information
Machinability
G9
A Why modular tooling
- two extensions
- 30 different adapters for milling, drilling, tapping, etc.
C - 10 different boring tools.
Threading
Modular Solid
E
Drilling
Number of items with modular tools: Number of items with solid tools:
4 + 2 + 30 + 10 = 46 items 4 x 3 x (30 + 10) = 480 items
Boring
G
Tool holding
G 10
Why modular tooling
A
Turning
The unique Coromant
Taper polygon Gripper groove Capto coupling has some
very specific features: B
- The ground flange contact
face in relation to the
Parting and
ground taper polygon
grooving
gives maximum stability
due to two-face contact
and interference fit. C
- There are four gripper
grooves for the automatic
tool changer.
Threading
- There is one slot for
angular positioning of the
Slot for angular cutting tool. D
positioning
Flange contact
Milling
E
Drilling
- Coolant supply through
Coolant through center center
- Coolant channel in the
F
coupling.
Boring
G
Tool holding
H
Other information
Machinability
G 11
A Why modular tooling
B 1. The radial centering is taken care of by Due to the above features - radial and
the conical part of the polygon. axial contact and self centering ability - the
coupling has extremely good repeatability,
2. The low taper angle makes it possible
Parting and
1 1
E
1.4°
3
Drilling
F 2
3 2
3-way locking
Boring
G
Tool holding
H
Other information
C3– C10
Machinability
G 12
Why modular tooling
A
Turning
• C3 = D 1.260 inch (32 mm)
• C4 = D 1.575 inch (40 mm)
B
• C5 = D 1.969 inch (50 mm)
• C6 = D 2.480 inch (63 mm)
Parting and
grooving
• C8 = D 3.150 inch (80 mm)
• C10 = D 3.937 inch (100 mm)
C
Threading
One coupling offers 3 methods of clamping.
D
Segment clamping Center bolt clamping Front clamping
Milling
E
Clamping method for quick- For modular clamping solu- Machine interface for quick
Drilling
change and automatic tool tions, e.g., when using exten- change in machines.
changing. sions and basic holders.
F
G 13
A Why modular tooling
Transmission of torque
Turning
• Symmetrical loads.
grooving
C
Threading
D
Milling
F
Boring
G 14
Turning centers
A
Turning
Machining centers
B
Parting and
grooving
C
Threading
D
Turning centers
Multi-task machines
Milling
What is a turning center?
E
• T he principle of lathes and turning cent- •W
hen a cutting tool is applied to
ers is to cut a rotating component with a the workpiece, it can be shaped to
stationary cutting tool. produce a component which has
Drilling
rotational symmetry.
• T he cutting tool moves parallel and
perpendicular to the workpiece axis to
provide the desired finished shape. F
Boring
G 15
A Turning centers
B
•S
everal multi-axis machine tool pro-
grams can provide turning results from
Parting and
finishing.
C
Threading
- pre-setting possibilities.
F
The most economical system for:
-s
mall batch production, quicker setup
times
Boring
H
Other information
Machinability
G 16
Turning centers
A
Turning
VDI angled Square shank Automatic unit
Camshaft activated Camshaft activated Hydraulically operated
B
Parting and
grooving
C
Threading
VDI straight Round shank Special applications
Camshaft activated Segment clamping Segment clamping
D
Milling
E
Drilling
Methods of installing quick change F
Directly integrated into the turret
H
Other information
Machinability
G 17
A Turning centers
C
Threading
D
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
G 18
Turning centers
A
Turning
Coromant Disc Interface (CDI)
B
• F lexible and symmetrical interface, 180°
mountable.
Parting and
•S
ame interface for static and driven tool
grooving
holders. Static and driven tool holders can be
used in all positions.
• Higher cutting performance.
C
• Longer cutting tool life.
• Better workpiece quality.
Threading
•M
ore available tool length for radial drilling
operations.
• Increased production.
• Rationalized tooling. D
• Reduction in tooling costs.
Milling
Static clamping unit, E
Driven drill/milling unit,
straight straight
Drilling
F
G
Tool holding
H
Other information
Machinability
G 19
A Turning centers
•N
o risk of losing insert screws in the
grooving
chip conveyer.
• Ergonomic.
C 1. 2.
•E
asy to clean the tip seat outside the
machine.
Threading
E
Drilling
G
Tool holding
H
Other information
Machinability
G 20
Turning centers
A
Turning
Tooling alternatives in conventional turrets
A Hydraulically operated clamping units
B
A
• Manual push-button tool changing
Parting and
• F ully automatic tool changing
grooving
possibilities.
C
B B Shank type clamping units
•S
quare and round shank tools as
Threading
C well as cutting units for external and
internal operations.
Milling
external and internal operations.
E
Drilling
F
Boring
G
Tool holding
H
Other information
Example of installations.
Machinability
G 21
A Turning centers
C •V
arious licensed manufacturers of these
units are available.
•S
pindle dimensions
Threading
E
Drilling
F
Boring
G
Tool holding
H
Other information
Example of installations.
Machinability
G 22
Machining centers
A
Turning
B
Machining centers
Parting and
grooving
C
Threading
D
Turning centers
Milling
Multi-task machines
E
Drilling
•A
machining center is a multi-function •5
-axis machining centers add two more
machine that typically combines boring, axes in addition to the three normal
drilling and milling tasks. axes (X/Y/Z). F
•M
achining centers could be in horizontal
design as well as vertical design.
Boring
G
Tool holding
H
Other information
Machinability
G 23
A Machining centers
C
Threading
E
Drilling
H
Other information
Machinability
G 24
Machining centers
A
Turning
Milling machines, machining centers, multi-task machines
Basic holders
B
Parting and
grooving
Cat V-Flange Cat V-Flange DIN 2080 ISO 7388/1 DIN 96871 MAS BT MAS BT HSK
40 BIG-PLUS/ ISO 40 ISO 30 Form B ISO 30 Form B 50-A/C C
45 90° rotated ISO 50 ISO 40 ISO 40 ISO 40 ISO 40 63-A/C
50 40 ISO 50 ISO 50 ISO 50 ISO 50 100-A/C
60 50 ISO 60 125-A/C
MAS BT 80-F
Threading
Cat V-Flange ISO 7388/1 BIG-PLUS
DIN 69871 BIG-PLUS
Form B ISO 40
ISO 40 ISO 50
40 ISO 50
50 D
Milling
E
Drilling
Modular tooling for machining centers F
Boring
G 25
A Machining centers
D
Milling
E
Directly integrated in the spindle or via basic holder
Drilling
F
Boring
G
Integrated in the spindle Basic holder solution
Tool holding
H
Other information
Machinability
G 26
Machining centers
A
Turning
Extension adapters
Extended tools for machining centers are frequently B
required to be able to reach the surface to be machined.
With Coromant Capto modular system it is possible to
Parting and
build an assembly, so the right length can be achieved.
grooving
• It is important that the minimum length C
is used, particularly when long overhangs
are required.
Threading
•W
ith modular tools it is always possible
to use optimal cutting data for best
productivity!
•M
odular tools are built together D
in minutes!
• Get closer tolerances.
Milling
E
Minimize tool holder inventory in machining centers
Modular tools give access to a very large number of
tooling solutions, with very few items!
Drilling
Modular Solid
F
Boring
G
Tool holding
H
Number of items with modular tools: Number of items solid tools:
Other information
G 27
A Multi-task machines
B Machining centers
Parting and
grooving
C
Threading
Turning centers
Multi-task machines
Milling
•M
ulti-task machines come in a variety of • In a multi-task machine, the workpiece
configurations: can be completed in a single machine
F - horizontal or vertical design setup, e.g., turning, milling, contour-
ing and milling of angled surfaces, and
- two spindles (main and sub) and a
grinding.
B-axis spindle enable milling and turn-
ing operations on both front and back •M
ulti-task machines are a combination
Boring
H
Other information
Machinability
G 28
Multi-task machines
A
Turning
The program language for defining the spindle direction
B
M03 = C
lockwise spindle
direction
Parting and
grooving
M04 = C
ounterclockwise
spindle direction C
Threading
D
Milling
E
Configuration of a multi-task machine
Spindle rotation and definitions of axis
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
G 29
A Multi-task machines
The milling spindle in a multi-task machine Therefore multi-task machine tools needed
B tool should be able to carry both rotating a tooling system with unsurpassed rigidity
and non-rotating tools. Coromant Capto is and repetitive accuracy both radially and
the only tooling system that can fulfill this axially, like Coromant Capto.
Parting and
D
Milling
E
The Coromant Capto tooling
system is directly integrated in
the spindle.
Drilling
F
Boring
G
Turret with Coromant Capto®
tooling system
Tool holding
G 30
Multi-task machines
A
Turning
For taking advantage of versatile multi-task machine tools
and to optimize their efficiency, there is sometimes a B
demand for running them with dedicated tooling. These
tools are only available with Coromant Capto and have been
Parting and
invented for multi-task machine tools, offering:
grooving
- accessibility, stability and higher productivity
- reduced tool changing time
C
- saved tool pocket in tool magazine
- cost reduction - one tool replaces many tools.
Threading
D
Milling
E
Drilling
Multifunctional tools
– one milling and four turn-
Twin tools
ing tools in one F
– two turning tools in one
Boring
G
Tool holding
Mini-turrets
– four turning tools in one H
Other information
Machinability
G 31
A Multi-task machines
component.
D
Milling
- blades
- mini-turrets
F
…to make it possible to use shank tools
also in a multi-task machine with an inte-
grated modular tool system in the spindle.
Boring
G
Tool adapter with blade for Tool adapter for boring bar
parting off
Tool holding
H
Other information
Machinability
G 32
Chucks
A
Chucks
Turning
Chucks are mechanical, hydro-mechanical and hydraulic
chucks respectively, for holding end mills and drills.
B
Parting and
grooving
Choice of chucks and adapters
Hydraulic Hydro- Shrink fit Collet Endmill Drill C
chuck mechanical adapter chuck (Weldon) adapter
chuck adapter
Threading
D
Rank 1 2 3 4 5 6
Milling
Clamping E
area
Clamping
Drilling
force
Ø < .787 in.
(Ø <20 mm) +++ +++ +++ + +++ +++
F
G
Runout +++ +++ +++ + + +
Tool holding
G 33
A Chucks
Hydraulic chucks
Turning
D
Milling
E
Clamping
part
Drilling
F Pressure
screw
Piston
Collet
Boring
G
Tool holding
H
Other information
Machinability
G 34
Chucks
A
Hydro-mechanical chucks
Turning
• igh clamping force.
H
• Large assortment of collets.
• Any shank type can be used. B
• High accuracy, runout max .00024 inch (6 µm) at 3xD.
• Medium tool changing time.
Parting and
• Minimum investment compared to shrink fit.
grooving
• Better reliability than power chucks or shrink fit.
h6 shank
• Any shank type can be used, but recommended to use
solid round-shank cutting tools. C
Threading
Shrink fit adapters
•S mall collapsibility.
D
• High clamping forces for small diameters - low clamping
force for large diameters.
• No collets.
• Tools can be made slender - narrow.
Milling
• High accuracy, low runout.
• Expensive heating systems.
E
h6 shank • Long tool changing time.
• Heavy investment in tools and machinery.
• Low tool lifetime.
• Can only clamp solid round-shank cutting tools.
Drilling
F
•h
6 or h7 tolerance shanks can be used due to large
collapsibility. G
• Low to medium clamping force.
Tool holding
G 35
A Chucks
C
Threading
Tool protru-
sion
H (–50%)
Other information
Machinability
G 36
Chucks
A
Turning
•R
unout should be < .001 inch
(< 0.025 mm).
• F or every .0004 inch (0.01 mm) runout B
- up to 50% decrease in tool life.
Parting and
•M
ore critical as tool diameter gets
grooving
smaller.
Threading
Application - Roughing and semi-finishing
• Main criteria = clamping force.
• High torque capability. D
• F or best performance use cylindrical
shanks.
Milling
• Versatility of collets.
E
Application - Finishing
• Main criteria = runout.
Drilling
Max runout .00024 inch (6 µm) • Influence on tool life and component
- finish and accuracy.
F
Boring
G 37
Machinability
Matching the most suitable cutting tool material (grade)
and insert geometry with the workpiece material to be
machined is important for a trouble-free and productive
machining process.
• Workpiece materials H4
Other information
• Machining economy H 55
H3
A Workpiece materials
Workpiece materials
Turning
the tool.
grooving
E
The largest variety of different types of The aircraft industry and manufactur-
P components is probably in the P-area
N ers of aluminum automotive wheels
as it covers several different sectors in dominate the N-area.
Drilling
the industry.
In the M-area, a big part of the applica- Difficult to machine S-area materials
M tion is in gas and oil, tubes, flanges, S are found in the aerospace, gas turbine
process industry and the pharmaceuti- and power generator industries.
Boring
cal business.
H4
Workpiece materials
A
Turning
Factors that must be identified in order to - T he cutting tool material (grade), e.g.
determine a material’s machinability: coated cemented carbide, ceramic, CBN,
PCD, etc. B
-C lassification, metallurgical/mechanical,
of the workpiece material. The selections will have a great influence
- The cutting edge micro- and macro geom- on the machinability of the material at
Parting and
etry to be used. hand.
grooving
ISO ISO ISO
Steel Stainless steel Cast iron C
P M K
Threading
ISO ISO ISO D
Aluminum
N S Heat resistant and super alloys H Hardened material
Milling
E
Drilling
depend on carbon content. group is generally low.
– Low carbon content = tough sticky Note that there is a big difference between
material. gray cast iron (often near-powder) and
ductile iron, which many times has a chip F
– High carbon content = brittle material.
Cutting force and power needed varies breaking more similar to steel.
very little.
application.
Machinability
H5
A Workpiece materials
C
Workpiece material Application Condition
P Steel
D M Stainless steel
Milling
K Cast iron
Milling
E N Aluminum
Milling
Clamping conditions
F H Hardened steel
H Roughing/
R Heavy
M Medium
M
Boring
L Finishing/
F Light
G
The ISO material groups There are three major types of All components are different
Tool holding
are divided into 6 different application, all requiring differ- in look, need various setups,
types where each type has ent tools, inserts and grades. and require special attention
unique properties regarding These also depend on the and demands from the tool.
machinability. load on the cutting edge, from
finishing to roughing.
H
Other information
Machinability
H6
Workpiece materials
A
Turning
B
Parting and
grooving
C
Component Hardness Cutting environment
Threading
D
Milling
Hardness Brinell Coolant
E
Drilling
F
Depending on the size, type Usually there is a relation be- Carbide performs best when
of material, setup and ma- tween material hardness and machining at high, constant
chining method, a different tool life, as well as machining temperatures. Dry conditions
choice of tooling is required data and type of geometry and should therefore be the first G
(turning, milling, drilling, etc). grade. The higher the hard- choice. Some grades are, how-
ness, the shorter the tool life, ever, developed for wet condi-
Tool holding
with more rapid wear on the tions; for example, grades for
cutting edge. cast iron machining.
H
Other information
Machinability
H7
A Workpiece materials
F
P M K N S H
Boring
* MC = A
new material classification that replaces the CMC
Machinability
H8
Workpiece materials
A
MC code structure
Turning
The structure is set up so that the MC code can represent a variety of workpiece
material properties and characteristics using a combination of letters and numbers. B
Example 1:
Parting and
The code P1.2.Z.AN is interpreted this way:
grooving
P = ISO code for steel
1 = material group: unalloyed steel C
2 = material subgroup: carbon content ?0.25% ≤0.55% C
Z = manufacturing process: forged/rolled/cold drawn
Threading
AN = heat treatment: annealed, supplied with hardness values
Example 2:
Milling
The code N1.3.C.AG is interpreted this way:
N = ISO code for non-ferrous metals
E
1 = material group: aluminum
2 = material subgroup: aluminum with Si content 1-13%
Z = manufacturing process: casting
Drilling
AN = heat treatment: aging
F
By describing not only the material composition, but also the manufacturing process
Boring
and heat treatment, which influences the mechanical properties, a more exact de-
scription is available, which can be used to generate improved cutting data recom-
mendations. G
Tool holding
H
Other information
Machinability
H9
A Workpiece materials
B
Parting and
grooving
C
Machining characteristics: What is steel?
- Long-chipping material -S
teel is the largest group in the metal
Threading
cutting area.
- Relatively easy, smooth chip control
-S
teels can be non-hardened or hardened
- Low carbon steel is sticky and needs
D and tempered with hardness up to
sharp cutting edges
400 HB.
- Specific cutting force kc:
-S
teel is an alloy with the element iron
217,500–449,500 lbs/inch2
( Fe) as the major component. It is pro-
(1500–3100 N/mm2)
Milling
F
Boring
ISO MC Material
G P1 Unalloyed steel
Low-alloyed steel
Tool holding
H 10
Workpiece materials
A
Turning
B
Parting and
grooving
C
Machining characteristics: What is stainless steel?
- Long-chipping material -S
tainless steels are materials alloyed
Threading
with min 11–12% chromium.
-C
hip control is fair in ferritic, to difficult in
austenitic and duplex - T he carbon content is often low (down to
max 0.01%). D
-S
pecific cutting force:
261,000–413,250 lbs/inch2 -A
lloys are mainly Ni (Nickel), Mo
(1800–2850 N/mm2) (Molybdenum), and Ti (Titanium).
-M
achining creates high cutting forces, - T he formed Cr2O3 layer on the steel
Milling
built-up edge, heat and deformation surface makes it non-corrosive.
hardening.
E
Drilling
F
Boring
ISO MC Material
P5 Ferritic/Martensitic stainless G
steel
Tool holding
M
M2 Super-austenitic, Ni≥20%
H 11
A Workpiece materials
B
Parting and
grooving
C
Machining characteristics: What is cast iron?
- Short chipping material - T here are 3 main forms of cast iron:
Threading
phase.
- Moderate cutting forces.
-C
r (Chromium), Mo (Molybdenum), and
E V (Vanadium) form carbides which in-
crease strength and hardness, but lower
machinability.
Drilling
ISO MC Material
F
K1 Malleable cast iron
Boring
G
K K3 Nodular SG iron
Tool holding
K4 CGI
H 12
Workpiece materials
A
Turning
B
Parting and
grooving
C
Machining characteristics: What is Non-ferrous material?
- Long-chipping material - T his group contains non-ferrous, soft
Threading
metals with hardness under 130 HB.
- Relatively easy chip control if alloyed
-A
luminum (Al) alloys with up to 22%
-A
luminum (Al) is sticky and needs sharp
silicon (Si) make up the largest part. D
cutting edges
- Copper, bronze, brass
- Specific cutting force:
50,750–101,500 lbs/inch2 - Plastic
(350–700 N/mm2)
Milling
- Composites (Kevlar)
- Cutting force, and the power needed to
machine ISO N materials, stays within a E
limited range.
Drilling
F
N1 Aluminum-based alloys
G
N2 Magnesium-based alloys
Tool holding
N
N3 Copper-based alloys
H 13
A Workpiece materials
B
Parting and
grooving
C
Machining characteristics: What are Heat Resistant Super Alloys?
- Long-chipping material -- Heat
Resistant Super Alloys (HRSA)
Threading
S2 Nickel-based alloys
G S3 Cobalt-based alloys
S
Tool holding
S4 Titanium-based alloys
S5 Tungsten-based alloys
H See Technical Guide Chapter H
Other information
H 14
Workpiece materials
A
Turning
B
Parting and
grooving
C
Machining characteristics: What is hardened steel?
- Long-chipping material -H
ardened steel is the smallest group
Threading
from a machining point of view.
- Fair chip control
- T his group contains hardened and tem-
- Negative rake angle is required
pered steels with hardness >45–65 HRC. D
-S
pecific cutting force:
- T ypically, however, hard part turned com-
369,750–706,150 lbs/inch2
ponents can be found to be within the
(2550–4870 N/mm2)
range of 55–68 HRC.
Milling
- Cutting forces and power required are
quite high.
E
Drilling
F
Boring
ISO MC Material
H
H3 Stellites
H 15
A Workpiece materials
B
kc1
lbs/in2
(N/mm2)
Parting and
M constant, expressed in
P S lbs (N)
290,000
E (2000)
145,000 K N Fc = kc × ap × fn
Drilling
(1000)
F
Boring
H 16
Workpiece materials
A
Turning
Operations and working conditions
Parting and
01 P10: T urning; copying; threading; milling; high cutting
grooving
speed; small to medium chip area.
P20: T urning; copying; medium cutting speed; facing with
10 small chip area; medium to difficult conditions. C
P30: T urning; milling facing; medium to low cutting speed;
medium to large chip area; includes operations with
Threading
20 tough conditions.
P40: Turning; facing; milling; cutting; grooving; low cutting
speed; large chip area; large possible chip angle; D
30 very tough conditions.
P50: W
hen very high toughness in the tool is needed in
turning, facing, grooving, cutting, low cutting speed,
Milling
large chip area, large possible chip angle, extremely
40 tough conditions.
E
50
Drilling
Toughness
F
The above diagram is related to
the ISO P area. These demands
also apply to all other ISO types
of material, i.e., M, K, N, S, H.
Boring
G
Tool holding
H
Other information
Machinability
H 17
A
Turning The cutting edge
B
The cutting edge
Parting and
grooving
D
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
H 18
The cutting edge
A
Turning
Guess how big the tangential force is on the cutting edge
B
Cemented carbide has a high compressive strength re-
sistance and can also work at high temperatures without
plastic deformation. It can also resist high cutting forces
Parting and
without breaking, as long as the insert is well supported.
grooving
C
ap =a.512 inch (13 mm)
=13 mm Material: Steel
p ap = .319a inch
=8.1(8.1
mm mm)
p
Threading
ap =8.1 mm
fn = .024 in fn = .039 in
fn =0.62 f =1.0
(0.62 mm) (1.0 nmm)
fn =1.0 D
n =0.62
Milling
Fc = 3750 lbf kp
Ft =1700 Ft =1700 kpFc = 3750 lbf
(1700 kp) (1700 kp)
E
Ft =1700 kp Ft =1700 kp
Drilling
F
Boring
H 19
A The cutting edge
B
Parting and
grooving
speed imaging.
D
Cutting zone temperatures
The maximum heat generated during cutting is on the top
Milling
F
• T he rake angle, geometry and feed play
an important role in the chip formation
process.
Boring
•R
emoving heat from the cutting zone
through the chip (80%) is a key factor.
G
• T he rest of the heat is usually evenly
distributed between the workpiece and
Tool holding
the tool.
H
Other information
Machinability
H 20
The cutting edge
A
Turning
B
Parting and
grooving
C
Threading
A steel turning insert for medium turning.
Milling
E
Nose cutting edge design Main cutting edge design
Drilling
.010 in.
(.25 mm)
20°
5° F
Macro geometry with
chip breaker •C
utting edge reinforce-
ment .010 inch (0.25
mm)
Boring
H
Other information
Machinability
H 21
A The cutting edge
•E
R treatment (Edge Roundness) is done
Parting and
Generally the ER
corresponds to the
thickness of a hair,
diameter: ~ .0031 inch
D (80 µm).
Milling
F
Negative
land .0039 in. (0.1 mm)
Boring
G
Chamfer
Tool holding
•A
negative land increases the strength
of the cutting edge, but also creates
H higher cutting forces.
Other information
Machinability
H 22
The cutting edge
A
Turning
The rake angle can be either negative or positive.
Based on that, there are negative and positive inserts,
where the clearance angles are either zero or several B
degrees plus. This determines how the insert can be
tilted in the tool holder, and results in either a negative or
Parting and
positive cutting action.
grooving
C
• T he insert rake angle is
the angle between the
top face of the insert and
Threading
the horizontal axis of the
workpiece.
Milling
E
Positive and negative cutting action
Turning needs a durable edge that can In most drilling applications there is also
Drilling
perform for a long time and often in coolant present, mainly for chip transpor-
continuous cuts at high temperature. This tation reasons which puts the edge under
condition requires an edge with among extra stress from temperature variations. F
other things good chip breaking ability, To be able to transport the chips from the
good resistance against different types of narrow chip flutes and from inside the
wear and against plastic deformation. hole, good chip breaking into short chips
is an important factor.
Boring
the drill.
Machinability
H 23
A The cutting edge
Turning •N
eeds a durable edge that can perform
for a long time, and often in continuous
C cuts at high temperature.
• Good chip breaking ability
•G
ood resistance against different types
Threading
D
M Milling
• T he cutting action is always intermittent
and the edge needs to have good bulk
Milling
S
F
Drilling
H • T he edge must be strong enough to last
at very low cutting speeds; in fact, at
Boring
H 24
The cutting edge
A
Turning
Different characteristics for removing chips
Good chip forming usually results in high cutting forces B
and excess heat, depending on the material. This can
lead to low cutting speeds with adhesive stresses as
Parting and
a result. On the other hand, materials like aluminum,
grooving
unalloyed steels and low-strength cast iron produce less
cutting force.
C
Threading
D
Milling
Steel Stainless steel Cast iron
E
Drilling
F
G
Tool holding
H
Other information
Machinability
H 25
A The cutting edge
General inserts
B • General geometry
• Optimizing with grades
Parting and
• Performance compromised
grooving
C Application area
Dedicated inserts
Threading
•D
edicated geometries
and grades
D •O
ptimized performance
according to workpiece
machinability
Application area
Milling
H 26
The cutting edge
A
Turning
ap Depth of
cut, inch Heavy turning
(mm)
R • Operations for maximum stock removal and/or severe
conditions.
B
• High D.O.C. and feed rate combinations.
• Operations requiring highest edge security.
Parting and
grooving
Medium turning
M • Most applications – general purpose.
• Medium operations to light roughing.
• Wide range of D.O.C. and feed rate combinations. C
Finishing
Threading
F • Operations at light depths of cut (D.O.C.) and low feed rates.
• Operations requiring low cutting forces.
fn
Feed, inch/r (mm/r) D
Milling
dedicated towards specific application areas, giving the
full and optimized usage of the machine and tool capacity,
resulting in improved productivity and lower costs. E
Drilling
ISO/ANSI P STEEL
Finishing Medium Roughing
-WF / GC4215 -WM / GC4205 WR / GC4205
-PF / GC4215 -PM / GC4215 -PR / GC4215
F
-WF / GC4215
Single
sided Dominating application areas
-WM / GC4215 -WR / GC4215
Double
sided
P M K
Single
sided
-PF / GC4215 -PM / GC4225 -PR / GC4225
-WF / GC4225 -WM / GC4225 -WR / GC4225
Boring
Stainless
Material Steel Cast iron
steel
G
Turning F M R F M R F M R
Dedicated
Tool holding
geometries
Milling L M H L M H L M H
H 27
A The cutting edge
ap Depth of
cut, inch Heavy milling
(mm)
B H • Operations at maximum stock removal and/or severe
conditions.
• Larger depth of cut and feed rate.
• Operations requiring highest edge security.
Parting and
grooving
Medium milling
M • Most applications – general purpose milling.
• Medium operations to light roughing.
C • Medium depth of cut and feed rate.
Light milling
Threading
• Extra positive •G
eneral purpose • Reinforced cutting edge
geometry
• Light machining • Heavy machining
G
• Medium feed rates
• Low cutting forces • Highest edge security
•M
edium operations to
• Low feed rates • High feed rates
Tool holding
light roughing
H
Other information
Machinability
H 28
Cutting tool materials
A
Turning
The selection of cutting tool material and grade is an important factor
to consider when planning a successful metal cutting operation.
A basic knowledge of each cutting tool material and its performance is B
therefore important to be able to make the correct selection for each
application. This should take into consideration the workpiece material
Parting and
to be machined, the component type and shape, machining conditions
grooving
and the level of surface quality required for each operation.
Threading
D
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
H 29
A Cutting tool materials
Hardness
B
1
CD
Diamond
Parting and
2
grooving
CB
3
Cubic boron nitride
C 4
5
CC
Threading
Ceramics
D
6
CT
Cermets
1.
2.
Diamond
Cubic boron nitride GC
Milling
3. Ceramics
4. Cermets Coated carbide
5. Coated carbide
6. High Speed Steel
E HSS
High speed steel
Toughness
Drilling
H
Other information
Machinability
H 30
Cutting tool materials
A
Turning
• Uncoated cemented carbide (HW)
• Coated cemented carbide (HC) B
• Cermet (HT, HC)
Parting and
• Ceramic (CA, CN, CC)
grooving
• Cubic boron nitride (BN)
• Polycrystalline diamond (DP, HC) C
Threading
D
Uncoated cemented carbide
Milling
• Used in moderate to difficult applications
related to steel, HRSA, titanium, cast E
iron and aluminum in turning, milling and
drilling.
•G
ood combination of abrasive wear
Drilling
resistance and toughness.
• Gives sharp cutting edges.
F
•G
ood edge security but limited wear
resistance at higher speeds.
•R
epresents a small portion of the total
Boring
grade program.
G
Tool holding
H
Other information
Machinability
H 31
A Cutting tool materials
Cermet
D • Used in finishing and semi-finishing applica-
tions where close tolerance and good surface
finish is required.
• Chemically stable with a hard and wear resist-
ant substrate.
Milling
F
Ceramic
• Depending on type of ceramic, the grades are
mainly used in cast iron and steel, hardened
materials and HRSA.
Boring
H 32
Cutting tool materials
A
Turning
Characteristics, features and benefits
• For finish turning of hardened steel. Roughing
of gray cast iron at high cutting speeds. Rough B
turning of rolls in white/chilled cast iron.
• Applications that require extreme wear resist-
ance and toughness.
Parting and
• CBN consists of Boron nitride with Ceramic or
grooving
Titanium nitride binder.
• Resists high cutting temperatures at high
cutting speeds.
• Special application area with small volume C
inserts. Trend is towards a higher volume of
hard materials to be cut.
Threading
D
Polycrystalline diamond
• Turning of normal aluminum at low tempe-
rature and very abrasive hypereutectic
Milling
aluminum. Used in non-metal and non-ferrous
materials.
• Extremely wear resistant grades. Sensitive to E
chipping.
• Brazed-in corners of polycrystalline diamond
(PCD tip) to an insert or thin diamond coated
film on a substrate.
• Long tool life and extremely good wear resist-
Drilling
ance. Decomposes at high temperatures.
Dissolves easily in iron.
• Fairly low portion of the insert program, with
special limited applications.
F
Boring
G
Tool holding
H
Other information
Machinability
H 33
A Cutting tool materials
At the beginning of the last century, cut- Today with improved geometries and new
ting tool material was only slightly harder coating technique we have reached below
than the material which needed to be cut. 1 minute in cutting time for the 19.685
C Therefore tool life was poor, and cutting inch (500 mm) steel bar.
speed and feed had to be kept very low.
In addition to traditional uncoated and
The introduction of HSS brought major coated carbide, new cutting tool materials
Threading
improvements, which resulted in reduced like cermet, ceramic, cubic boron nitride
cutting time. and diamond, have contributed to opti-
mized and improved productivity.
D 20 years later uncoated cemented carbide
brought down the required time in cut to a
staggering 6 minutes.
The introduction of coated carbide again
Milling
ø3.937
(ø100)
Cemented carbide
Coated carbide
Tool holding
H
Other information
Machinability
H 34
Cutting tool materials
A
Turning
•C
emented carbide is a powder metallur-
gical material consisting of:
B
- hard-particles of WC (tungsten carbide)
Parting and
- a binder metal, cobalt (Co)
grooving
-h
ard-particles of Ti,Ta,Nb
(titanium, tantalum, niobium-carbides).
C
•A
grade represents the hardness or
toughness of the insert, and is deter-
mined by the mixture of ingredients
Threading
which make up the substrate.
Milling
E
Coating of cemented carbide
•C
oating of cemented carbide was
Drilling
developed in the 1960s.
•A
thin Titanium Nitride coating layer was
added, only a few microns thick. This F
improved the performance of carbide
overnight.
•C
oatings offer improved wear resistance
Boring
H
Other information
Machinability
H 35
A Cutting tool materials
Cemented carbide consists of hard The gamma phase has a better hot hard-
particles (carbides) in a binder matrix. ness and is less reactive at elevated
B The binder is more or less in all cases temperatures, so is often seen in grades
cobalt (Co) but could also be Nickel (Ni). where the cutting temperature can get
The hard particles consist mainly of tung- high. WC has a better abrasive wear
sten carbide (WC) with a possible addition resistance.
Parting and
grooving
C
Threading
Elements:
D Alpha-phase
Gamma-phase (TiC) WC (tungsten carbide)
Gamma-phase
Milling
Alpha-phase (WC)
Beta-phase
Drilling
Co (cobalt)
F
Hair diameter
= .0020-.0028 inch (50-70 µm)
Boring
G
Tool holding
H
Other information
Machinability
H 36
Cutting tool materials
A
Fundamental characteristics
Turning
Apart from the grain size of the WC, the An increase in Co content and WC grain
amount of binder phase (cobalt) is an size contributes to an increase in bulk
important factor determining the charac- toughness, but also lowers the hardness. B
teristics of the carbide. The Co content As a result, the substrate has less resist-
in Sandvik Coromant grades is generally ance to plastic deformation, which means
4–15% of the total weight. less wear resistance/lower practical tool
Parting and
grooving
life.
Threading
Amount of binder
Toughness
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
H 37
A Cutting tool materials
Coating design
Turning
- Coating thickness
grooving
- Post treatment
C - Surface morphology.
Threading
D
Milling
E
Example of modern steel turning grades
Structure and build-up of the coating layers
Drilling
ISO P01 – P15 ISO P05 – P30 ISO P10 – P35 ISO P20 – P45
GC4205 GC4215 GC4225 GC4235
H
Thicker coatings mean more wear resistance.
Other information
Machinability
H 38
Cutting tool materials
A
Grade design
Turning
Coatings and substrates vary with the type of application
Parting and
grooving
C
K05 – K15 P05 – P35 M15 M25 M35
Thicker coatings mean more wear resistance.
Threading
Harder substrates mean more deformation resistance.
Milling
E
Al2O3
– Coating for chemical and
thermal wear resistance.
Drilling
TiCN F
– MTCVD coating for mechan-
ical wear resistance. Boring
Functional gradient
– For optimized hardness and G
toughness.
Tool holding
Cemented carbide
– Plastic deformation
resistance.
H
Other information
Machinability
H 39
A Cutting tool materials
TiN
• TiCN provides flank wear resistance.
Al2O3 •A
l2O3 provides temperature protection
C
(plastic deformation resistance).
Ti(C,N) • TiN provides easy wear detection.
Threading
D
TiN = Titanium nitride
Ti(C,N) = Titanium carbonitride
Al2O3 = Aluminum oxide
Milling
(500° C).
H
Other information
Machinability
H 40
Cutting tool materials
A
Turning
Different wear mechanisms on the inserts B
Parting and
grooving
Mechanical stress on
Mechanical the insert edge C
causes breakage.
Threading
Temperature variations
cause cracks and
Thermal heat generates plastic D
deformation (PD) on
the insert edge.
Milling
A chemical reaction
between carbide and E
Chemical working material
causes wear.
Drilling
In cast iron the SiC F
Abrasive inclusions can wear on
the insert edge.
Boring
BUE
BUE
With sticky material, G
Adhesive built-up layers/edges
are formed.
Tool holding
H 41
A Cutting tool materials
grade.
grooving
C
Threading
G
Notch wear (abrasive)
Tool holding
H
Other information
Machinability
H 42
Cutting tool materials
A
Turning
Plastic deformation
(thermal) Cause Remedy B
Cutting temperature too Select a harder grade,
high, combined with a high reduce speed and feed.
Parting and
pressure.
grooving
C
Threading
Chipping (mechanic)
The chips are deflected Change the feed, select an
against the cutting edge. alternative insert geometry.
D
Milling
E
Thermal cracks
Temperature variations Select a tougher grade
caused by: with better resistance to
Drilling
thermal shock.
- intermittent machining
- varying coolant supply Coolant should be applied
copiously, or not at all. F
Boring
Edge chipping/breakage
(mechanic)
G
Overload of mechanical Check the following:
tensile stresses. - chip hammering
Tool holding
- cutting data
- sand inclusions in work-
piece
- built-up edge
- vibration H
Other information
H 43
A
Turning Manufacture of cemented carbide
B
Manufacture of
cemented carbide
Parting and
grooving
application.
D
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
H 44
Manufacture of cemented carbide
Turning
With the development of better carbide substrates, coat-
ings and geometries, productivity and cost savings have B
improved for the end user.
Large improvements in productivity were possible in the
Parting and
60s and 70s when the first coatings were developed.
grooving
After this, the developments continued - with advanced
substrate design, new geometries, edge designs, new ad-
vanced coating techniques and post treatment of coated C
edges.
Threading
D
The effect on end-user productivity
2006
A new insert
Milling
generation
1999
New generation E
coatings
1989
Functional
Drilling
gradients
1980
Thick aluminum
oxide coating F
1969
First coated
1957 insert
Indexable
inserts
Boring
G
Tool holding
H
Other information
Machinability
H 45
A Manufacture of cemented carbide
Powder production
Turning
Niobium
E
(Ta, Nb)C Tantalum
(5%)
(Ti, W)C
Drilling
Co (8%) Titanium
(7%)
WC Tungsten
F Cobalt (80%) carbide
Ready to press
G
Tool holding
H
Other information
Machinability
H 46
Manufacture of cemented carbide
A
Tungsten powder
Turning
The size of the tungsten carbide grains
The main raw material for the manufac-
ture of cemented carbide is tungsten-ore B
concentrate. Tungsten powder is produced
from tungstic oxide derived chemically from
Parting and
the raw material. By varying the conditions
grooving
of reduction, tungsten powder of various
grain size can be manufactured. The car-
bide granules after spray-drying are small C
and vary in size depending on grade.
.0039 inch
(0.10 mm)
Threading
D
Milling
amount of binder phase is an important the wear resistance of the substrate.
factor determining the characteristics
of the carbide. Increasing Co-content,
E
together with increasing WC-grain size,
contributes to increasing toughness but
Drilling
Amount of binder Toughness
Boring
G
Tool holding
H
Other information
Machinability
H 47
A Manufacture of cemented carbide
C
Threading
D
Die and
core pin
Milling
Inspection
E
The pressing operation consists of several pieces
of tooling:
- T op and bottom punches
Drilling
- Core pin
- Cavity.
F
The pressing procedure:
-P owder is poured into the cavity
Boring
H
Other information
Machinability
H 48
Manufacture of cemented carbide
A
Turning
Sintering phase consists of the following phases:
- L oading trays of inserts into a sintering - T he insert will shrink 18% in all directions
furnace. during the sintering phase; this
B
- The temperature is raised to ~2550° F corresponds to about 50% in volume.
(~1400° C).
Parting and
grooving
- This process melts the cobalt and the
cobalt acts as a binder.
Sintering
Threading
Insert trays D
Milling
E
Shrinking
Inspection rate
Drilling
F
Boring
2 3 G
Tool holding
1. Unsintered insert
2. Sintered insert
3. Coated insert
H
1
Other information
Machinability
H 49
A Manufacture of cemented carbide
C
g 00
Bor
Threading
D Neg. land
7 8 9
4 5 6
1 2 3
S3 S4 S5 S6 S7 S8
SI S2
Milling
Chamfer Borg 00
E
Drilling
•E
R-treatment (Edge Roundness) is done
before coating.
Boring
H 50
Manufacture of cemented carbide
A
Turning
Stacks of inserts are placed into a furnace, a series of
gases are introduced to the chamber, lines are purged and
another series of gases introduced. This is repeated until
B
the layers of coating are complete. The process is carried
out at approx. 1650° F (900° C) for 30 hours. Thickness is
approx .00008-.0005 inch (2-12 microns).
Parting and
grooving
C
Threading
D
Milling
E
Drilling
F
H
Other information
Machinability
H 51
A Manufacture of cemented carbide
The inserts are loaded into the coating By using a gas as carrier, the ions can
chamber on trays. Metal source targets are then be transported from the targets to
B placed on the reactor chamber walls. The the inserts. As the inserts are cooler, the
most common source is titanium (Ti). The ions will condensate on the insert surface
targets are heated to a temperature where to form a coating.
Parting and
C
Threading
D
Milling
E
Drilling
F
Boring
G The coating thickness is in the range of • PVD provides good edge line toughness.
.00008-.0002 inch (2-6 microns) depend-
•P
VD coatings can maintain a “sharp”
ing on application area for the insert.
cutting edge.
Tool holding
H 52
Manufacture of cemented carbide
A
Turning
PVD (Physical Vapor Deposition) CVD (Chemical Vapor Deposition)
In a PVD coating process, the coating is In a CVD coating process, the coating is
formed by metal vapor condensating on in- formed by a chemical reaction of different B
sert surfaces. PVD works the same way as gases. Temperature, time, gas flow, gas
when humid air condensates on cold roads atmosphere, etc., are carefully monitored
Parting and
and forms an ice layer on the road. to steer the deposition of the coating lay-
grooving
PVD is formed at a much lower tem- ers. Depending on the type of coating, the
perature than CVD. Normal PVD process temperature in the reactor is about 1470
temperatures are around 930° F (500° C). to 2000 degrees F (800 to 1100 degrees C
The coating thickness is in the range of C). The thicker the coating the longer the
.00008-.0002 inch (2-6 microns) depend- process time. The thinnest CVD coating
ing on application area for the insert. today is below .00016 inch (4 microns)
Threading
and the thickest is above .0008 inch (20
microns).
Milling
~930°F ~1830°F
~1/100000 atm ~1/20 atm E
Drilling
F
Boring
G
Tool holding
H 53
A Manufacture of cemented carbide
C Visual inspection
Marking Packaging
Threading
D
Milling
E
Labelling
Distribution
Drilling
Gimo
F
Boring
G
Tool holding
H
Other information
Machinability
H 54
Machining economy
H 55
Machining economy
F
C
E
A
H
Machinability Tool holding Boring Drilling Milling
D
Turning
G
Other information grooving
A Machining economy
B
Productivity definition
Parting and
grooving
= Output / Input
Threading
D
Milling
135
Boring
130
125 Cost development
G 120
115
110
Tool holding
H 56
Machining economy
A
Maximizing productivity
Turning
The three main machining parameters, cutting speed,
feed, and depth of cut, have an effect on tool life. The
depth of cut has the smallest effect followed by the feed B
rate. Cutting speed has the largest effect by far on insert
tool life.
Parting and
grooving
Depth of cut, inch (mm)
C
Threading
Feed, inch/rev (mm/rev) D
Milling
E
Cutting speed, ft/min (m/min)
Drilling
the productivity
vf
G
Tool holding
H
Other information
Q = vc × ap × fn × 12 Q = ap × ae × vf
Machinability
H 57
A Machining economy
Metal removal rates for a fixed depth of cut of .118 inch (3.0 mm) using:
B Low alloy steel, Insert: CNMG 432-PM 4225 (CNMG 120408-PM 4225)
P MC P2
.118 .118 .118
Hardness, HB 180 ap, inch (mm)
Parting and
Q, inch3/min 12 19 25*
(cm3/min) (191) (310) (412)*
D
* Slowest cutting speed with the highest feed
= highest productivity
Milling
1.969
Insert: Single sided for rough machining.
No of passes / cutting .079 / .295 inch
depth, ap (2 / 7.5 mm)
H
Other information
H 58
Machining economy
A
Turning
Incomplete use of B
additional shifts Machining 20%
Parting and
grooving
Production Tool change 10%
60%
Breakdowns 10%
Threading
Holidays, etc.
Workpiece
change 10%
D
Machining economy
Milling
E
Drilling
F
Boring
G
• Variable costs • Fixed costs
Costs incurred only during production: Costs which exist even when not in
Tool holding
H 59
A Machining economy
D
• Decreased cost:
A 30% decrease in price
Milling
H
Other information
Machinability
H 60
Machining economy
A
Turning
Example:
Shop spends $10,000 B
to make 1000 parts.
Machine cost is $10.00
Parting and
per part.
grooving
C
30% 50% 20%
Threading
Increase
Variable Today Lower price Tool life cutting data
– Tooling $ .30 $ .21 $ .20 $ .45 D
– Material $ 1.70 $ 1.70 $ 1.70 $ 1.70
Milling
Fixed
– Machinery $ 2.70 $ 2.70 $ 2.70 $ 2.16 E
– Labor $ 3.10 $ 3.10 $ 3.10 $ 2.48
– Building $ 2.20 $ 2.20 $ 2.20 $ 1.76
Drilling
Cost per part $ 10.00 $ 9.91 $ 9.90 $ 8.55
G
Tool holding
H
Other information
Machinability
H 61
A Machining economy
Machining ecomomy
Turning
part increases.
grooving
If we add all costs together we will get the curve of total Production cost.
C 1. As speed increases the Parts per hour increase until we reach a point where we are
spending a disproportionate amount of time changing tools and production rate will
start to decrease.
Threading
2. The lowest point on the Production cost curve corresponds to the economic cutting
speed.
3. The highest point on the Production cost curve corresponds to the the maximum
D cutting speed.
The speed between these two points is the High Efficiency Range, which is where we
should be trying to operate.
Milling
Production rate
Production cost
F
Tool cost
Boring
G
Tool holding
Fixed cost
Machine cost
H
Cutting speed
Other information
H 62
Machining economy
A
Turning
Compensation of cutting data for difference in tool life
• Tool life Higher metal removal
B
-A
ll cutting data is based If you want to change the cutting speed to obtain higher metal
removal rates the new cutting speed values can be calculated
on 15 min tool life. from the following table.
Parting and
-1
5 min tool life
grooving
= Factor 1.0
-U
se correction factor for Tool life (min) 10 15 20 25 30 45 60
other values according to Correction
C
factor 1.11 1.0 0.93 0.88 0.84 0.75 0.70
the table.
Example:
Threading
If the recommended cutting speed (vc) = 738 ft/min
(225 m/min.), a tool life of 10 minutes gives you
738 x 1.11 ≈ 819 ft/min (225 x 1.11 ≈ 250 m/min).
D
Milling
Compensation of cutting speed for difference in hardness, HB E
Drilling
ANSI MC1) HB2) -60 -40 -20 0 +20 +40 +60 +80 +100
on the reference materi-
als and the respective P P2 HB2) 180 1.44 1.25 1.11 1.0 0.91 0.84 0.77 0.72 0.67
hardness. M M1 HB2) 180 1.42 1.24 1.11 1.0 0.91 0.84 0.78 0.73 0.68
F
K2 HB2) 220 1.21 1.13 1.06 1.0 0.95 0.90 0.86 0.82 0.79
-E
.g ISO P HB 180 = K
K3 HB2) 250 1.33 1.21 1.09 1.0 0.91 0.84 0.75 0.70 0.65
Factor 1.0.
N N1 HB2) 75 1.05 1.0 0.95
-U
se correction factors for S2 HB2) 350 1.12 1.0 0.89
Boring
S
other values according to H H1 HRC3) 60 1.07 1.0 0.97
the table. 1) MC = material classification code
2) HB = Hardness Brinell G
3) HRC = Hardness Rockwell
Tool holding
H
Other information
Machinability
H 63
A Machining economy
MC P2 MC K2
ISO Stainless steel, HB180 ISO Nodular cast iron, HB250
C M MC M1 K MC K3
Threading
D
Factor for cutting speed
Milling
E
Drilling
G
Tool holding
H
Other information
Machinability
H 64
Machining economy
A
Turning
ISO
Steel Reduced hardness Increased hardness
B
P MC P2 ISO/
ANSI MC1) HB2) -60 -40 -20 0 +20 +40 +60 +80 +100
-R
eference hardness P P2 HB2) 180 1.44 1.25 1.11 1.0 0.91 0.84 0.77 0.72 0.67
Parting and
HB= 180
grooving
M M1 HB2) 180 1.42 1.24 1.11 1.0 0.91 0.84 0.78 0.73 0.68
-1
5 min tool life K
K2 HB2) 220 1.21 1.13 1.06 1.0 0.95 0.90 0.86 0.82 0.79
= Factor 1.0 K3 HB2) 250 1.33 1.21 1.09 1.0 0.91 0.84 0.75 0.70 0.65
N N1 HB2) 75 1.05 1.0 0.95 C
-U
se correction factor for
S S2 HB2) 350 1.12 1.0 0.89
other values according to
the table. H H1 HRC3) 60 1.07 1.0 0.97
Threading
1) MC = material classification code
2) HB = Hardness Brinell
3) HRC = Hardness Rockwell
D
Tensile strength Vickers Brinell Rockwell
• Customer workpiece lbs/inch2) N/mm2) HV HB HRC HRB
material 36,975 255 80 76.0 – –
39,150 270 85 80.7 – 41.0
Milling
- DIN 42CrNiMo4 41,325 285 90 85.5 – 48.0
44,225 305 95 90.2 – 52.0
- T ensile strength
46,400 320 100 95.0 – 56.2
130,500 lbs/inch2 (900 N/mm2) E
50,750 350 110 105 – 62.3
55,825 385 120 114 – 66.7
-1
30,500 lbs/inch2 (900 N/mm2) 60,175 415 130 124 – 71.2
= HB 266 value according to the 65,250 450 140 133 – 75.0
table. 69,600 480 150 143 – 78.7
Drilling
73,950 510 160 152 – 81.7
79,025 545 170 162 – 85.0
83,375 575 180 171 – 87.5
88,450 610 190 181 – 89.5
F
92,800 640 200 190 – 91.5
• Calculating hardness factor 95,700 660 205 195 – 92.5
97,875 675 210 199 – 93.5
- HB 266-180 = +86 100,050 690 215 204 – 94.0
Boring
H 65
A Machining economy
D
Example 2
E
• Example 1
- Increase the feed from, e.g., fn .012 inch/r to .018 inch/r
(0.3 mm/r to 0.45 mm/r)
Drilling
• Example 2
- Increase the cutting speed by +15% e.g from
Boring
H
Other information
Machinability
H 66
Machining economy
A
Turning
Things to consider
B
• Identify the material and hardness HB or
tensile strength lbs/inch2 (N/mm2).
Parting and
• Choose the correct geometry.
grooving
• Choose the correct grade.
•U
se the given cutting data values or C
compensate the cutting data values
according to your needs.
Threading
•C
orrectly applied, our tools can increase
productivity by at least 20%.
Milling
Machining tips for improved tool life
E
•S
peeds and feeds within insert
parameters.
•M
ake use of all available corners on
Drilling
inserts.
•P
roper insert radius in relationship
to D.O.C. F
•C
hoose the right combination of insert
radius and geometry.
Boring
•U
se climb milling over conventional mill-
ing wherever possible.
•W
orn inserts can be used for G
chamfering.
Tool holding
H
Good stability = Successful metal cutting
Other information
Machinability
H 67
F
C
E
A
H
Machinability Tool holding Boring Drilling Milling
D
Threading Parting and
B
Turning
G
Other information grooving
H 68
Maintenance & tool wear
wear
• Tool wear
• Maintenance
Maintenance & tool
H 71
H 69
Maintenance & tool wear
A
Turning
B
Parting and
grooving
C
Threading
D
Milling
E
Drilling
• Damaged inserts
• Damaged shims
F
• Damaged tool holders
• Damaged components
• Damaged machine
Boring
Result:
Tool holding
• Reduced production
• Higher production costs
H
Other information
Machinability
H 69
A Maintenance & tool wear
B •D
amaged shims. Shims should not have
chipped corners in the cutting area.
•S
hims should have no visible wear from
Parting and
the insert.
Chip breakage
C impression
Inspect pockets
Threading
•P
ockets damaged or mushrooming in the
corners.
•O
versized pockets due to wear. The
insert does not sit properly in the pocket
sides. Use a .0008 inch (0.02 mm)
Milling
G
What is the proper way to tighten an insert
Tool holding
screw?
• Important to use the proper wrench.
•A
lways use correct torque. Values are
H marked on tool and shown in product
catalog.
Other information
• Common sense!
Machinability
H 70
Maintenance & tool wear
A
Turning
Torx Plus from Sandvik Coromant
lbs-in (Nm) B
Parting and
grooving
C
Threading
Cross section
Milling
E
Drilling
F
• On
parting and grooving tools an adjust-
able torque wrench is required, as the G
torque is not related to screw size.
Tool holding
H
Other information
Machinability
H 71
A Maintenance & tool wear
• Screw
threads, heads and Torx sockets
should be in good condition.
B
• Use correct keys.
• Ensure correct screw-tightening torque
Parting and
grooving
•A
pply sufficient screw lubrication to
prevent seizure. Lubricant should be
applied to the screw thread as well as
C the screw-head face.
• Replace worn or exhausted screws.
Threading
Important!
Use Molykote for screw heads
Milling
and threads
Tool maintenance
Drilling
•E
nsure correct insert location against
support points.
G
• It is important to ensure that shim cor-
ners have not been knocked off during
Tool holding
machining or handling.
H
Other information
Machinability
H 72
Maintenance & tool wear
A
Tool maintenance
Turning
Contact faces
• Always
check supporting and contact
faces of tool holders, milling cutters and B
drills, making sure there is no damage
or dirt.
Parting and
• In boring operations it is especially
grooving
important to have the best possible
clamping. If the bar is not supported to
the end of the holder, overhang will be C
increased and create vibration.
Threading
D
Production security
• It
is important to select the correct
insert size, insert shape and geometry
Milling
and insert nose radius to achieve good
chip flow.
l -S
elect largest possible point angle on E
the insert for strength and economy.
re -S
elect largest possible nose radius for
insert strength.
Drilling
l = cutting edge length (insert size) -S
elect a smaller nose radius if there is
re = nose radius a tendency for vibration. F
Stability
Boring
H 73
A Maintenance & tool wear
Insert handling
Turning
• Inserts
should never be removed from
the original package until they are ready
B to be installed.
Parting and
grooving
C
Threading
D
Summary of maintenance points
Check tool wear and shims for damage.
Milling
H 74
Formulas and definitions
A
Turning
B
Formulas & defini-
tions, calculator
Parting and
grooving
Turning H 76
C
Milling H 78
Threading
Drilling H 80
Boring H 82 D
Milling
E
Calculator
Drilling
Cutting data calculator H 84
F
Boring
G
Tool holding
H
Other information
Machinability
H 75
A Formulas and definitions
C
Spindle speed, rpm
vc × 12
Threading
n=
π × Dm
D
Designation/
Unit
Milling
lm
Tc =
fn × n
E Dm Machined diameter inch
fn Feed per revolution inch/r
ap Cutting depth inch
vc Cutting speed ft/min
Drilling
F Q = vc × ap × fn × 12 Pc Net power HP
Q Metal removal rate inch3/min
hm Average chip thickness inch
hex Maximum chip thickness inch
Boring
H
Other information
Machinability
H 76
Formulas and definitions
A
Turning
Cutting speed, m/min
B
π × Dm × n
vc =
1000
Parting and
grooving
C
Spindle speed, rpm
vc × 1000
Threading
n=
π × Dm
Designation/ D
Unit
Milling
lm
Tc =
fn × n
Dm Machined diameter mm E
fn Feed per revolution mm/r
ap Cutting depth mm
vc Cutting speed m/min
Drilling
Metal removal rate, cm3/min
n Spindle speed rpm
Q = vc × ap × fn Pc Net power kW F
Q Metal removal rate cm3/min
hm Average chip thickness mm
hex Maximum chip thickness mm
Boring
H
Other information
Machinability
H 77
A Formulas and definitions
C π × Dcap × n
vc =
12
Threading
Designation/
vc × 12
n=
definition
D π × Dcap
Symbol
Unit
Feed per tooth, inch
ae Working engagement inch
Milling
vf
fz = ap Cutting depth inch
n × zc
Dcap C
utting diameter at cutting
E depth ap inch
Feed per revolution, inch/rev Dm Machined diameter
(component diameter) inch
vf
fz =
Drilling
Pc Net power HP
396 × 103
Mc Torque lbf ft
Torque, lbf ft Q Metal removal rate inch3/min
H Pc × 16501 ψr Lead angle degree
Mc =
Other information
π×n
Machinability
H 78
Formulas and definitions
A
Turning
Table feed, mm/min
B
vf = fz × n × zc
Parting and
grooving
Cutting speed, m/min
π × Dcap × n C
vc =
1000
Threading
Spindle speed, r/min
Designation/
vc × 1000
n=
definition
π × Dcap D
Symbol
Unit
Feed per tooth, mm
ae Working engagement mm
Milling
vf
fz = ap Cutting depth mm
n × zc
Dcap C
utting diameter at cutting
depth ap mm
E
Feed per revolution, mm/rev Dm Machined diameter
(component diameter) mm
vf
fz =
Drilling
fz Feed per tooth mm
n
fn Feed per revolution mm/r
n Spindle speed rpm F
Metal removal rate, cm3/min vc Cutting speed m/min
ap × ae × vf vf Table feed mm/min
Q=
1000 zc Number of effective teeth pcs
Boring
Pc Net power kW
60 × 106
Mc Torque Nm
Torque, Nm Q Metal removal rate cm3/min
π×n
Machinability
H 79
A Formulas and definitions
vf = fn × n
Parting and
grooving
Designation/
D Spindle speed, rpm
definition
Symbol
vc × 12
Unit
n=
π × Dc
Milling
Ff Feed force N
Torque, lbf ft
H
Pc × 16501
Mc =
Other information
π×n
Machinability
H 80
Formulas and definitions
A
Turning
Penetration rate, mm/min B
vf = fn × n
Parting and
grooving
Cutting speed, m/min C
π × Dc × n
vc =
1000
Threading
Designation/
Spindle speed, r/min D
definition
Symbol
vc × 1000
Unit
n=
π × Dc
Milling
Dc Drill diameter mm
fn Feed per revolution mm/r
Feed force, N
n Spindle speed rpm E
D
Ff ≈ 0.5×kc × c fn × sin kr vc Cutting speed m/min
2
vf Penetration rate mm/min
Drilling
Ff Feed force N
Torque, Nm
H
Pc × 30 × 103
Mc =
Other information
π×n
Machinability
H 81
A Formulas and definitions
vf = fn × n
Parting and
grooving
Designation/
Spindle speed, rpm
D
definition
vc × 12
Symbol
n=
Unit
π × Dc
Milling
Ff Feed force N
( (
G (zc = 1 for step boring)
vc × ap × fn × kc ap
Pc = 1–
132 × 103 Dc
Tool holding
π×n
Machinability
H 82
Formulas and definitions
A
Turning
Penetration rate, mm/min B
vf = fn × n
Parting and
grooving
Cutting speed, m/min C
π × Dc × n
vc =
1000
Threading
Designation/
Spindle speed, r/min
D
vc × 1000 definition
Symbol
n=
Unit
π × Dc
Milling
Dc Drill diameter mm
Drilling
Ff Feed force N
( (
(zc = 1 for step boring) G
vc × ap × fn × kc ap
Pc = 1–
60 × 103 Dc
Tool holding
π×n
Machinability
H 83
A Calculator
B
The Sandvik Coromant cutting data calcu- The Sandvik Coromant cutting data calcu-
lator is designed to solve most calculation lator also functions as a standard
problems encountered in the metal cutting mathematical calculator. Calculations can
Parting and
• Size 80x125x15 mm
E
Drilling
F
Machining Calculator App
H 84