Cutting Tool Selection

Quick Reference Training Program

 Carbide Tool Bit Overview
• Carbide Tool Bit Benefits
– Very hard
– Will withstand high temperatures
– Replaceable inserts
– Readily available
– Pre-sharpened from factory
• Carbide Tool Bit Drawbacks
– Rubs material rather than cuts material
– Brittle
– Requires more rigidity
– Requires more horsepower
– Usually wrong tool geometry (for portable tools) from tool supply house
– Generally can’t re-sharpen

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 High Speed Steel (HSS)
Tool Bit Overview
• HSS Tool Bit Benefits
– Cuts freely
– Easy to re-sharpen
– Tool geometry easily changed
– Very tough
– Requires little tool pressure
– Readily available
– Pre-sharpened from factory
• HSS Tool Bit Drawbacks
– Must use proper SFPM can’t take the heat
– Viewed as slower
– Operator needs to understand tool geometry

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 Carbide Vs. High Speed Steel Bits

High Speed Steel tool bit Carbide tool bit

geometry geometry

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 Tool Holder Examples

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 Tool Geometry Angle Definitions
• Top Rake: Evacuates chip…roles chip out
• Heel or Clearance Angle: This is the clearance between the cutter and
the surface that has just been cut. Insures that the cutting edge (and not
the back side or heel of the cutter) contacts the work piece first
• Lead Angle: This is formed by the leading edge of the cutter and a
plane perpendicular to the cutter feed motion
• End relief angle: The clearance below the end of the tool
• Side Relief Angle: The clearance below the cutting edge
• Back Rake: This is a shear angle that also evacuates the chip or roles
the chip out
• Nose Radius: The nose radius stretches the cutting edge. It increases
the amount of cutting edge in contact with the work
See Diagram On Next Page
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 Tool Geometry

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 How Tool Geometry Affects The Cut

Negative Lead Angle

Positive Lead Angle

Zero Lead Angle

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 How Tool Geometry Affects The Cut

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 How Tool Geometry Affects The Cut
Top Rake
The Larger top rake dimension equals
A larger entrance angle

The larger radius is used for materials that

resist bending (have a high shear modulus).
Set back must be increased in relation to the
radius to the control entrance angle
Top Rake

A smaller top rake dimension equals a

smaller entrance angle

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 Nose Radius Vs Tool Pressure

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 The Basics Of Chip Formation
Metal is cut by material harder than
itself being forced through it.
The sharper the tool, the easier it is to
force through. Sharpness can be
improved by adding different angles to
the tool (Tool Geometry).

The faster the tool is forced through,

the rougher the surface that is left.

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 Tool Bit Wear

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 Tool Bit Wear

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 Roughing Vs Finishing Bit Overview

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 Finishing Bit Detail

10°

5°

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 Roughing Bit Detail

10°

15°

15°

10° 5°
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 Surface Feet Per Minute Vs. Bar RPM
Bore Diameter (inches)

SFPM vs. Bar RPM; Bore Diameters 2

24 18 12 10 8
300 3
6
250
4
Cutting Speed (sfpm)

200
4
6
150
3 8
100
2 10
50
12
0
0 25 50 75 100 125 150 175 18
14.1cir 8.9 cir 5.9 cir 3.6 cir
17.9 cir

11.3 cir
7.3 cir
24
Bar Speed (rpm)
Note: Motor Sizes show n BB5000 Only
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 Tool Recommendations For Various
Combinations of Cutting Speeds & RPM
Cutting Speed - Surface Feet Per Minute (SFPM)
Bar Speed Bore Diameter (inches)
(rpm) 1 2 3 4 6 8 10 12 18 24 30 36 48 60
5 1 3 4 5 8 10 13 16 24 31 39 47 63 79
10 3 5 8 10 16 21 26 31 47 63 79 94 126 157
20 5 10 16 21 31 42 52 63 94 126 157 188 251 314
30 8 16 24 31 47 63 79 94 141 188 236 283 377 471
40 10 21 31 42 63 84 105 126 188 251 314 377 503 628
50 13 26 39 52 79 105 131 157 236 314 393 471 628 785
60 16 31 47 63 94 126 157 188 283 377 471 565 754 942
70 18 37 55 73 110 147 183 220 330 440 550 660 880 1100
80 21 42 63 84 126 168 209 251 377 503 628 754 1005 1257
90 24 47 71 94 141 188 236 283 424 565 707 848 1131 1414
100 26 52 79 105 157 209 262 314 471 628 785 942 1257 1571
125 33 65 98 131 196 262 327 393 589 785 982 1178 1571 1963
150 39 79 118 157 236 314 393 471 707 942 1178 1414 1885 2356
175 46 92 137 183 275 367 458 550 825 1100 1374 1649 2199 2749
HSS Recommended. Best range for field machining.
HSS/Carbide Recommended. Must have rigid set-up
Carbide Recommended. Must have rigid set-up, no interrupted cuts.
Carbide Recommended. Must have rigid set-up, light finish cuts only.
Not Recommended for field machining

Bore Diameter (inches)

Model 1 2 3 4 6 8 10 12 18 24 30 36 48 60
BB2000 1.4 4
BB3000 1.4 6
BB4000 1.8 10
BB5000 2.5 24
BB6000 6 36
BB7000 8 40
BB8000 16 80
Recommended range for optimum results
Recommended only with very rigid set-up
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 Calculating SFPM & RPM
Formula for calculating SFPM or RPM

SFPM x 12 = Pi x Dia x RPM

Example 1:
50 SPFM (High Speed Steel) x 12 = 3.141 (Pi) x 4 (dia) x ? (RPM)
600 = 12.5 x ? (RPM)
600 ÷ 12.5 = 47 RPM

Example 2:
100 SFPM (Carbide) x 12 = 3.142 (Pi) x 4 (dia) x ? (RPM)
1200 = 12.5 x ? (RPM)
1200 ÷ 12.5 = 96 RPM

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 Calculating Machining Time
Formula for determining Machining Time
(for turning or boring)

Machining Time = Overall Length

RPM x Feed
Example:
4” Dia = Not needed
10” Long = Length of cut
.01” Feed = Inches / Rev
30 RPM = Revolutions/Min
10”
Machining Time = 30 x .01”

10
= .30

Machining Time = 33.33 minutes

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 Chip Characteristics
ƒ Metal chip color is a good
indicator of proper machine speed
(RPM & Feed Rate)
ƒ Objective is to produce straw
colored chips
ƒ Blue color chips indicate excessive
metal heat and boring rate
ƒ Silver chips indicate an
opportunity to increase overall
boring rate

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 Tool Bit Sharpening
When To Sharpen?

ƒ Speed & feed are correct, but still getting blue colored chip
ƒ Tool begins to chatter
ƒ Base metal looking torn Vs. smooth
ƒ Machine is vibrating & working hard

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 Tool Bit Sharpening
Sharpening Techniques

ƒ Match existing angle to wheel relationship

ƒ Cool often (water bucket)
ƒ Check with protractor
ƒ Use stone to take off ragged edges

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 Cutting Lubricants
Overview
ƒ Use of cutting oil will prolong tool life
ƒ If oil is used, insure proper ventilation
ƒ Use extreme care when applying oil…squirt can is
recommended
ƒ Cutting oil is messy…use oil sparingly based on
application
ƒ Apply with squirt can while machine is running
ƒ Use brush to apply prior to machine start up

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 Cutting Fluids
Benefits & Cautions
ƒ Benefits of Using Cutting Fluids
ƒ Lubrication of tools to improve the flow of chips at the cutting face
ƒ Cooling of the tool & work piece for improved dimensional stability
ƒ Reduction in built-up edge
ƒ Improvement in surface finish
ƒ Helps flush away chips….very important during horizontal boring

ƒ Cautions
ƒ Unsteady flow of coolant could cause cracking of carbide tools
ƒ Damaging thermal variation in the cutting tool can be intensified when
utilizing cutting fluid during an interrupted cutting process
ƒ Carbide inserts cannot stand the thermal shock associated with coolant
being turned on and off.
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