Sandvik Metal Cutting Technology Training Handbook

Sandvik Coromant Academy

Metal Cutting Technology

Training Handbook n x D m x π 1000 vc =

Content Turning Theory Selection procedure System overview Choice of inserts Choice of tools - External - Internal Code keys Troubleshooting

Drilling A A A A

4 12 16 22

A A A A

50 56 66 70

Parting & Grooving Theory Selection procedure System overview Parting & grooving - how to apply - Parting off - General grooving - Circlip grooving - Face grooving - Profiling - Turning - Undercutting Troubleshooting

B B B B B B B B B B B B

4 7 11 15 22 25 27 28 31 33 35 36

Threading Theory Selection procedure System overview How to apply Troubleshooting

E E E E E E

6 15 20 26 37 42

F F F F F F

4 9 14 16 21 26

G G G G G G

4 7 15 23 29 33

H H H H

4 18 29 44

H H H H

55 68 75 84

Boring Theory Selection procedure System overview Choice of tools How to apply Troubleshooting

Tool holding History and background Why modular tooling Turning centers Machining centers Multi-task machines Chucks

Machinability C C C C C

4 9 13 19 25

Workpiece materials The cutting edge Cutting tool materials Manufacturing of cemented carbide

Other information

Milling Theory Selection procedure System overview Choice of insert – how to apply Choice of tools – how to apply Troubleshooting

Theory Selection procedure System overview How to apply Hole quality and tolerances Troubleshooting

D D D D D D

4 9 13 24 29 36

Machining economy Maintenance & tool wear Formulas and definitions Cutting data calculator

1

A2

Turning Turning generates cylindrical and rounded forms with a single-point tool. In most cases the tool is stationary with the workpiece rotating.

• Theory

A4

• Selection procedure

A 12

• System overview

A 16

• Choice of inserts – how to apply

A 22

•C hoice of tools – how to apply - External - Internal

A 50 A 56

• Code keys

A 66

• Troubleshooting

A 70

A3

A

Theory

B

Turning is the combination of two movements – rotation of the workpiece and feed movement of the tool.

Parting and grooving

Turning

General turning operations

The feed movement of the tool can be along the axis of the workpiece, which means the diameter of the part will be turned down to a smaller size. Alternatively, the tool can be fed towards the center (facing off), at the end of the part. Often feeds are combinations of these two directions, resulting in tapered or curved surfaces.

Threading

C

D

Milling

Turning and facing as axial and radial tool movements.

Drilling

E

Boring

F

Three common turning operations:

G Tool holding

- Longitudinal turning - Facing - Profiling.

Machinability Other information

H

A4

Theory

A

Turning

Definitions of terms Spindle speed

B

The spindle speed rpm (revolution per minute) is the rotation of the chuck and workpiece.


n (rpm)

Threading

C

vc (ft/min)

(m/min)

The cutting speed is the surface speed, ft/min (m/min), at which the tool moves along the workpiece in feet (meters) per minute.

D

Milling

Cutting speed

Definition of cutting speed

n

C

F

vc = cutting speed, ft/min (m/min)

Boring

The definition of cutting speed as the result of the diameter, pi (π) and spindle speed in revolutions per minute (rpm). The circumference (C) is the distance the cutting edge moves in a revolution.

Drilling

E

Dm = machined diameter, inch (mm)

G Tool holding

n = spindle speed, rpm Circumference, C = π x Dm inch (mm) Metric

vc =

π × Dm × n 12

ft/min

vc =

π × Dm × n 1000

H

m/min

A5


Inch

A

Theory

Turning

Calculation of the circumference •C ircumference = π x diameter (inch) (mm)

B Parting and grooving

• π (pi) = 3.14 Example: Dm2 = 3 .937 inch (100 mm) Circumference = 3.14 x 3.937 = 12.362 inch

C Threading

Circumference = 3.14 x 100 = 314 mm Dm1 = 1 .969 inch (50 mm) Circumference = 3.14 x 1.969 = 6.183 inch

D

Milling

Circumference = 3.14 x 50 = 157 mm

Example of cutting speed fluctuations

E

The cutting speed differs depending on the workpiece diameter. Given:

Drilling

Spindle speed, n = 2000 rpm Diameter, Dm1 = 1.969 inch (50 mm) Diameter, Dm2 = 3.150 inch (80 mm)

Boring

F

Inch

G Tool holding

vc =

vc1 =

H Machinability Other information

Metric

vc2 =

A6

π × Dm × n 12

ft/min

3.14 × 1.969 × 2000 12 3.14 × 3.150 × 2000 12

vc =

= 1030 ft/min

vc1 =

= 1649 ft/min

vc2 =

π × Dm × n 1000

m/min

3.14 × 50 × 2000 1000 3.14 × 80 × 2000 1000

= 314 m/min = 502 m/min

Theory

A

Feed

fn = cutting feed (inch/r) (mm/r) ap = depth of cut (inch) (mm)

κr = entering angle ψr = lead angle

Depth of cut

E

F

Boring

Lead angle = 0° Entering angle = 90°

The cutting depth (ap) in inch (mm) is half of the difference between the un-cut and cut diameter of the workpiece. The cutting depth is always measured at right angles to the feed direction of the tool.

D

Lead (entering) angle The cutting edge approach to the workpiece is expressed through the lead angle (ψr), which is the angle between the cutting edge and the workpiece plane. It can also be expressed as the entering angle (κr), the angle between the cutting edge and the direction of feed. The lead angle is important in the basic selection of the correct turning tool for an operation.

A7

G Tool holding

vc = cutting speed (ft/min) (m/min)

The cutting feed (fn) in inch/r (mm/r) is the movement of the tool in relation to the revolving workpiece. This is a key value in determining the quality of the surface being machined and for ensuring that the chip formation is within the scope of the tool geometry. This value influences, not only how thick the chip is, but also how the chip forms against the insert geometry.

C


n = spindle speed (rpm)


The cutting speed (vc) in ft/min (m/min) at which the periphery of the cut workpiece diameter passes the cutting edge.

Threading

Surface/cutting speed

B

Milling

The workpiece rotates in the lathe, with a certain spindle speed (n), at a certain number of revolutions per minute (rpm).

Drilling

Spindle speed

Turning

Definitions of terms

A

Theory

Turning

Calculating cutting data Example of how to calculate the spindle speed (n) from cutting speed (vc).


B

Cutting speed

Given: Cutting speed, vc = 1312 ft/min (400 m/min)

C Threading

Diameter Dm = 3.937 inch (100 mm)

D

Inch

Metric

Milling

n=

n=

Drilling

E

vc × 12 π × Dm

1312 × 12 3.14 × 3.937

r/min

= 1274 r/min

n=

π × Dm 400 ×1000 3.14 × 100

r/min

= 1274 r/min

Inclination and rake angles Rake angle

F

Boring

λ γ

G

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 and the clearance face is in the form of a radius, chamfer or land and affects tool strength, power consumption, finishing ability of the tool, vibration tendency and chip formation.

Tool holding

Inclination angle

The inclination angle lamda (λ) is the angle the insert is mounted in the tool holder. When mounted in the tool holder, the insert geometry and inclination in the tool holder will determine the resulting cutting angle with which the cutting edge cuts.


vc × 1000

n=

A8

Theory

A

Turning

Cutting depth and chip formation B

ap

κr Parting and grooving

ap

The cutting depth (ap) is the length the edge goes into the workpiece.

Chip formation varies with depth of cut, lead (entering) angle, feed, material and insert geometry.

Threading

C

D

Milling

Feed rate and the effective cutting edge length

Drilling

E

The effective cutting edge length (la) relates to cutting depth and lead (entering) angle.

G Tool holding

Cutting edge length

The feed rate (fn) is the distance the edge moves along the cut per revolution.

H

A9


Feed rate

Boring

F

Turning

A


B

Theory

Insert shape selection, lead (entering) angle and chip thickness The lead angle, ψr (entering angle κr), of the tool and the 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 (smaller entering angle). The direction of chip flow is also changed.

Threading

C

Milling

D

Lead angle ψr: -5°, 15° Entering angle κr: 95°, 75°

Lead angle ψr: -17.5°, -3°, 27.5° Entering angle κr: 107.5°, 93°, 62.5°

TNMG

Lead angle ψr: 45°, 15° Entering angle κr: 45°, 75°

Lead angle ψr: Variable Entering angle κr: Variable

Lead angle ψr: -3°, -1°, 30° Entering angle κr: 93°, 91°, 60°

VNMG Lead angle ψr: -27.5°, -17.5°, 17.5°

Boring

Entering angle κr: 117.5°, 107.5°, 72.5°

Lead angle ψr (Entering angle κr) • Is defined by the holder tip seat in combination with insert shape selected.

Tool holding

G


Lead angle ψr: -5° Entering angle κr: 95°

RCMT

F

H

WNMG

SNMG

Drilling

E

DNMG

CNMG

Maximum chip thickness hex

ψr = 45° hex ≈ fn x 0.71

A 10

hex ≈ fn

•R educes relative to the feed rate as the lead angle increases (entering angle reduces).

Theory

A

Turning

The effect of lead angle (entering angle) on chip thickness Maximum chip thickness hex reduces relative to the feed rate as the lead angle increases (entering angle reduces).


κr

κr

κr

Lead angle ψr Entering angle κr

−5° 95°

15° 75°

30° 60°

45° 45°

0° min 90° max

Chip thickness compared to feed, inch (mm)

.039 (1)

.038 (0.96)

.034 (0.87)

.028 (0.71)

Variable

D .082 (2.08)

.091 (2.3)

.111 (2.82)

Variable Milling

.079 (2)

Calculating power consumption n = spindle speed (rpm)

fn = cutting feed (inch/rev) (mm/rev)

Drilling

vc = cutting speed (ft/min) (m/min) ap = depth of cut (inch) (mm)

F

kc = s pecific cutting force (lbs/in2) (N/mm2) Pc = net power (HP) (kW)

Boring

For information about the kc value, see page H 16.

E

G Pc =

Pc =

vc × ap × fn × kc 33 × 103

vc × ap × fn × kc 60 × 103

HP

Tool holding

The net power (Pc) in HP (kW) required for metal cutting is mainly of interest when roughing, where it is essential to ensure that the machine has sufficient power for the operation. The efficiency factor of the machine is also of great importance.

H

kW

A 11


Contact length la, inch (mm) at ap .079 inch (2 mm)

C Threading

κr

B

Turning

A

Selection procedure Production planning process


B

Selection procedure

Dimension and type of operation

C Component

Threading

1

Workpiece material and quantity

D

Milling

Machine parameters

2

Machine

Drilling

E

3

Choice of tool

Type of turning tool: - External/internal - Longitudinal - Profiling - Facing

Boring

F

4

How to apply

5

Troubleshooting

Cutting data, tool path, etc.

Tool holding

G


H

A 12

Remedies and solutions

Selection procedure

A

Turning

1. Component and the workpiece material Parameters to be considered

C Threading

•A nalyze the dimensions and quality demands of the surface to be machined. • Type of operation (longitudinal, profiling and facing). • External, internal • Roughing, medium or finishing • Tool paths • Number of passes • Tolerances


B

Component

D Material achinability M Cast or pre-machined Chip breaking Hardness Alloy elements

Milling

• • • • •

E

Drilling

2. Machine parameters Condition of the machine

F

Boring

Some important machine considerations: - Stability, power and torque, especially for larger diameters - Component clamping - Tool position - Tool changing times/number of tools in turret - Spindle speed (rpm) limitations, bar feed magazine - Sub spindle, or tail stock available? - Use all possible support - Easy to program - Cutting fluid pressure.

Tool holding

G

H

A 13


P M K N S H

A

Selection procedure

Turning

3. Choice of tools Turning with rhombic inserts


B

Different ways to optimize turning Advantages • Operational versatility. • Small lead angle. • For turning and facing. • Good roughing strength.

Disadvantages • Can cause vibration when turning slender components.

Advantages • Increase feed and gain productivity. • Use normal feed rate and gain surface quality. • Productivity booster.

Disadvantages • In back turning and profiling the wiper edge is not effective.

Threading

C

Turning with wiper inserts

Milling

D

Drilling

E

New ways in profile turning

F

Boring

Advantages • Increase feed and gain productivity. • Use normal feed rate and gain surface quality. • Productivity booster • Tolerance • Setup time

Tool holding

G Rigid insert location with T-rails.


H

A 14

Selection procedure

A

Turning

4. How to apply Important application considerations The tool path has a significant impact on the machining process.


It influences: - Chip control - Insert wear - Surface quality - Tool life.

B

In practice, the tool holder, insert geometry, grade, workpiece material and tool path influences the cycle time and productivity considerably.

Threading

C

D

Milling

5. Troubleshooting Some areas to consider

E Insert style

Positive style

•O ptimize the chip breaking by changing the depth of cut, the feed or the insert geometry.

F

• T he depth of cut should be no less than 2/3 of the nose radius (re). Insert wear

G Tool holding

ake sure that the flank wear does not •M exceed the general recommendation of .012 inch (0.3 mm).

Boring

Nose radius

ap

re

H

A 15


Negative style

Chip breaking

Drilling

•U se positive inserts for lower cutting forces in general and for internal turning.

Turning

A

System overview

External turning, negative inserts 1. Longitudinal turning

B

2. Profiling


3. Facing

C Threading

1

2 3

Milling

D

Drilling

E

Overview of tool holders

Boring

F

Tool holding

G •N egative insert • Rigid clamping system • Modular/shank tools


H

A 16

•N egative insert • Lever clamping system • Modular/shank tools

System overview

Turning

External turning, positive inserts

A

1. Longitudinal turning

B

2. Profiling


3. Facing

C 1 Threading

2 3

Milling

D

E

Drilling


Boring

F

•N egative/positive insert • All clamping systems • Cutting heads • Modular/shank tools

•P ositive insert • Screw clamping system • Modular/shank tools

G Tool holding

• Positive insert • Screw clamping system • T-rail interface • Modular/shank tools

H

A 17


•P ositive insert • Screw clamping system • Modular/shank tools

Turning

A

System overview

Internal turning, negative/positive inserts 1. Longitudinal turning


2. Profiling

3

2

1

3. Longitudinal turning “Mini bars”

Threading

C

Overview of internal tool holders

Milling

D

Drilling

E •N egative insert • Rigid clamping system • Min. hole .984 inch (25 mm) • Modular/boring bars

egative insert •N • Lever clamping system • Min. hole .787 inch (20 mm) • Modular/boring bars

• • • •

• • • •

ositive insert P Screw clamping system Cutting heads Min. hole .236 inch (6 mm) • Modular/boring bars

•D ampened boring bars • Min. hole .512 inch (13 mm) • Boring bars

Boring

F

•N egative/positive inserts • Dampened boring bars • Min. hole 1.575 inch (40 mm) • Boring bars

Tool holding

G


H

egative/positive insert N All clamping systems Cutting heads Min. hole .787 inch (20 mm) • Dampened modular/ boring bars A 18

System overview

Turning

Tools for small part machining 2. External turning (Sliding head machines) 3. Internal turning (Exchangeable inserts)

2

4. Internal turning

C

4

Threading

5. Internal turning (Carbide rods)

5


1. External turning

1

A

3

D


Milling

External tools

•P ositive insert • Screw clamping system • Shank tools

• Quick change tools • Positive insert • Screw clamping system

•P ositive insert • Screw clamping system

Drilling

E

F

Boring

Internal tools

•P ositive insert • Screw clamping system • Min. hole .394 inch (10 mm)

•P ositive insert • Carbide rods • Min. hole .012 inch (0.3 mm) • Machine adapted bars A 19


•P ositive insert • Screw clamping system • Min. hole .236 inch (6 mm)

Tool holding

G

A

System overview

Turning

Overview of insert clamping systems Clamping of negative basic-shape inserts


B

Threading

C

Lever clamping system

Rigid clamping system

Clamping of positive basic-shape inserts

Milling

D

Screw clamping system

Drilling

E

F

Boring

Screw clamping system

Clamping of positive T-rail inserts

Tool holding

G

T-rails


H Screw clamping system

A 20

5°/7°

System overview

A

Turning

Modern insert clamping for turning tools Rigid clamping

B

• Negative inserts


• Excellent clamping • Easy indexing

C

• Negative inserts

Threading

Lever clamping

• Free chip flow

D

Milling

• Easy indexing

E

Screw clamping

Drilling

• Positive inserts •S ecure clamping of the insert

F

Boring

• Free chip flow

Screw clamping system, T-rail

G Tool holding

• Positive inserts • Very secure clamping • High accuracy

A 21


H

Choice of inserts

Choice of inserts

Turning

A


B

Threading

C

Milling

D

Drilling

E

Boring

F

Tool holding

G


H

A 22

• Basic factors

A 23

• Insert geometries

A 32

• Insert grades

A 39

• Insert shape, size, nose radius

A 42

• Cutting data effect on tool life

A 48

Choice of inserts – basic factors

A

Turning

The complex world of metal cutting Getting metal cutting processes right means knowing the workpiece material, then choosing the correct insert geometry and grade to suit the specific application.

• T hese three main basic factors must be carefully considered and adapted for the machining operation in question.

Grade


D

E

Drilling

• T he knowledge and understanding of how to work with and employ these factors is of vital importance.

C Threading

• T he interaction between an optimized insert geometry and grade for a certain workpiece material is the key to successful machining.

Milling

Workpiece material

B

Geometry

F

Boring

The machining starts at the cutting edge

Tool holding

G

A 23


H Typical chip breaking sequences with high speed imaging.

A


Turning

Six material groups


B

In the metal cutting industry there is an incredibly broad range of component designs made from different materials. Each material has its own unique characteristics influenced by the alloying elements, heat treatment, hardness, etc. This strongly influences the selection of cutting tool geometry, grade and cutting data.

Workpiece materials are divided into 6 major groups in accordance with the ISOstandard, where each group has unique properties regarding machinability.

Threading

C

P

Steel

M

Stainless steel

Milling

D

Workpiece material groups

Drilling

E

• ISO P – Steel is the largest material group in the metal cutting area, ranging from unalloyed to high-alloyed material including steel castings and ferritic and martensitic stainless steels. The machinability is normally good, but differs a lot depending on material hardness, carbon content, etc.

Boring

F

Tool holding

G


H

• ISO M – Stainless steels are materials alloyed with a minimum of 12% chromium; other alloys are, e.g., nickel and molybdenum. Different conditions such as ferritic, martensitic, austenitic and austenitic-ferritic (duplex), makes this an extensive material group. Common for all these types are that they expose cutting edges to a great deal of heat, notch wear and built-up edge.

 A 24

K

Cast iron

• ISO K – Cast iron is, contrary to steel, a short-chipping type of material. Gray cast iron (GCI) and malleable cast irons (MCI) are quite easy to machine, while nodular cast iron (NCI), compact cast iron (CGI) and austempered cast iron (ADI) are more difficult. All cast irons contain silicon carbide (SiC) which is very abrasive to the cutting edge.

Turning



A



Aluminum

• ISO N – Non-ferrous metals are softer types of metals such as aluminum, copper, 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 sharp edges.

D

Milling

N

Threading

C

Drilling

E • ISO S – Heat Resistant Super Alloys include a great number of high-alloyed iron, nickel, cobalt and titanium-based 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 shorter tool life for the cutting edges.

F

Boring

S

Heat resistant alloys

• ISO H – This group covers steels with a hardness between 45-65 HRc and also chilled cast iron around 400-600 HB. The hardness makes them all difficult to machine. The materials generate heat during cutting and are very abrasive to the cutting edge.

A 25

G Tool holding

Hardened steel


H

A


Turning

Cutting forces


B

Another expression of the differences in the six material groups is through the force (FT) needed to shear off a specific chip cross-section in certain conditions.

tion of how much power is needed for an operation. kc1 = specific cutting force for average chip thickness .039 inch (1 mm).

This value, the specific cutting force value (kc), is indicated for various types of workpiece materials and used in the calcula-

C

Steel

Threading

P

D

Milling

•P materials have a kc1 variation of: 217,500-449,500 lbs/inch2 (1500-3100 N/mm2).

M

Stainless steel

Drilling

E

Boring

F

K

Cast iron

Tool holding

G

• M materials have a kc1 variation of: 261,000-413,250 lbs/inch2 (1800-2850 N/mm2).

•K materials have a kc1 variation of: 114,550-195,750 lbs/inch2 (790-1350 N/mm2).


H

A 26




A

N

Turning

 Aluminum


B

•N materials have a kc1 variation of: 50,750-195,750 lbs/inch2 (350-1350 N/mm2).

Threading

S

C

Heat resistant super alloys

Hardened material

Boring

F

• H materials have a kc1 variation of: 369,750-706,150 lbs/inch2 (2550 – 4870 N/mm2).

Tool holding

G

H

A 27


H

E

Drilling

• S materials have a kc1 variation of: - 348,000-449,500 lbs/inch2 (2400-3100 N/mm2) for HRSA - 188,500-203,000 lbs/inch2 (1300-1400 N/mm2) for titanium alloys

Milling

D

A


Turning

Chip formation There are three patterns for a chip to break after it has been cut.

B Against the tool

Against the workpiece

Self-breaking, where the material, in combination with how the chip is curved, leads to the chips being parted as they come off the insert.

Chips breaking against the tool, where the chip curves around until it makes contact with the clearance face of the insert or tool holder, and the resulting strain snaps it. Although often accepted, this method can in some cases lead to chip hammering, where the chip damages the insert.

Chips breaking against the workpiece, where the chip snaps when making contact with the surface that has just been machined. This type of chip breaking is usually not suitable in applications where a good surface finish is needed, because of possible damage caused to the component.


Self-breaking

Threading

C

Milling

D

Drilling

E

Boring

F

Tool holding

G


H

 A 28


A

Turning

Chip formation varies with different parameters Chip formation varies with depth of cut, feed, material and tool geometry.

Self-breaking

ap

Against the tool

ap

Against the workpiece


B

C Threading

κr

D

Milling

Insert rake angle The rake angle (γ) can be either negative or positive. Based on this, there are negative and positive inserts, where the clearance angles are either zero or several degrees plus. This determines how the insert can be tilted in the tool holder, giving rise to a negative or positive cutting action.

Drilling

E

F Negative cutting action Boring

Positive cutting action

γ

Tool holding

G

H

 A 29


γ

A


Turning

 Insert rake angle


B

Negative style

Threading

C

There is a distinction in cutting edge geometry between negative and positive insert geometry: - A negative insert has a wedge angle of 90° seen in a cross-section of the basic shape of the cutting edge.

D

-A positive insert has an wedge angle of less than 90°. The negative insert has to be inclined negatively in the tool holder so as to provide a clearance angle tangential to the workpiece while the positive insert has this clearance built in.

• • • • •

ouble/single sided D Edge strength Zero clearance External/internal machining Heavy cutting conditions

• • • • •

ingle sided S Low cutting forces Side clearance Internal/external machining Slender shafts, small bores

Note: The clearance angle is the angle between the front face of the insert and the vertical axis of the workpiece.

Milling

Positive style

Insert geometries

F

Metal cutting is very much the science of removing chips from the workpiece material in the right way. Chips have to be shaped and broken off into lengths that are manageable in the machine.

Boring

Drilling

E

• In milling and drilling a lot of parameters influence the chip formation compared to turning. • Turning is a single-cut operation with a stationary tool and a rotating workpiece. • The insert rake angle, geometry and feed play an important role in the chip formation process. • Removing heat from the cutting zone through the chip (80%) is a key issue.

Tool holding

G


H

A 30

Choice of inserts – geometries

A

Turning

The design of a modern insert Definitions of terms and geometry design

Nose cutting edge design

Main cutting edge design .010 in. (0.25 mm)

20°


B

C

Macro geometry with chip breaker

•C utting edge reinforcement .010 inch (0.25 mm) • Rake angle 20°

Geometry for small cutting depths

Threading

5°

D

• Primary land 5°

Milling

.008 in. (0.2 mm)

E

The reinforcement of the cutting edge Drilling

The ER-treatment (Edge Roundness) gives the cutting edge the final micro-geometry.

G Tool holding

• T he relationship between W/H is what makes inserts suitable for different applications.

F

Boring

•E R-treatment is done before coating, and gives the final shape of the cutting edge (micro-geometry).

A 31


H

Turning

A

The working area of an insert geometry A chip breaking diagram for an insert geometry is defined by acceptable chip breaking for feed and depth of cut.


B


Cutting depth, ap inch (mm)

•C utting depth (ap) and feed (fn) must be 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.

Threading

•C hips which are too long can lead to disturbances in the machining process and bad surface finish.

D

Milling

Feed, fn inch/r (mm/r)

Drilling

E

F

Three main application areas in turning R M F

= Roughing

Roughing

= Medium machining

aximum stock removal and/or severe •M conditions.

= Finishing

• L arge cutting depth and feed rate combinations.


• High cutting forces. Medium machining Boring

• Most applications – general purpose. • Medium operations to light roughing.

G Tool holding

•W ide range of cutting depth and feed rate combinations. Finishing • Small cutting depths and low feed rates. Feed, fn inch/r (mm/r)


H

A 32

• Low cutting forces.


A

Turning

Chip breaking application areas

CNMG 432 (CNMG 120408) .236 (6.0)

Medium – M Medium operations to light roughing. Wide range of depth of cut and feed rate combinations.

.157 (4.0)

.079 .(2.0)

E

Chip breaking area:

P R

ap = 5.0 (1.0 - 7.5 ) fn = 0.5 (0.25 - 0.7)

Drilling

ap = .197 (.039 - .295) inch fn = .020 (.010 - .028) inch/r

CNMM 432-PR (CNMM 120412-PR)


D

Milling

Chip breaking diagram Roughing of low alloy steel

C

mm mm/r

F The area marked in red indicates the area which gives acceptable chip breaking.

.236 (6.0) .118 (3.0)

Boring

(0.1) .004

Finishing – F Operations at light depths of cut and low (0.4) (0.8) feed rates. .016 .031 Feed, fn inch/r (mm/r) Operations requiring low cutting forces.


Roughing – R High depth of cut and feed rate combinations. Operations requiring the highest edge security.


Threading

Turning of low alloy steel

G Tool holding

.059 (1.5) .039 (1.0) .020 (0.5) (0.2) .008

(0.3) .012

(0.4) .016

(0.5) .020

(0.6) .024

(0.7) .028


 A 33


H (0.1) .004

A


Turning

 Medium machining of low alloy steel


B

Chip breaking area:

P M

ap = .118 (.020 - .217) inch fn = .012 (.006 - .020) inch/r ap = 3.0 (0.5 - 5.5) fn = 0.3 (0.15 - 0.5)

CNMG 432-PM (CNMG 120408-PM)


mm mm/r

.236 (6.0)

C Threading

.118 (3.0)

D

.059 (1.5) .039 (1.0) .020 (0.5)

Milling

(0.1) .004

(0.2) .008

(0.3) .012

(0.4) .016

E

Drilling

Finishing of low alloy steel

F



(0.5) .020

Chip breaking area:

P F

ap = .016 (.010 - .059) inch fn = .006 (.003 - .012) inch/r ap = 0.4 (0.25 - 1.5) fn = 0.15 (0.07 - 0.3)

CNMG 434-PF (CNMG 120404-PF)

mm mm/r

Boring

.059 (1.5) .049 (1.25)

G

.039 (1.0)

Tool holding

.030 (0.75) .020 (0.5) .010 (0.25)


H

(0.1) .004

A 34

(0.15) .006

(0.2) .008

(0.25) .010

(0.3) .012

(0.35) .014



A

It is important to select the correct insert size, insert shape, geometry and insert nose radius to achieve good chip control. •S elect the largest possible point angle on the insert for strength and economy. •S elect the largest possible nose radius for insert strength.

l


Considerations when selecting inserts

Turning

Selection of inserts

C

re

Threading

•S elect a smaller nose radius if there is a tendency for vibration.

l = cutting edge length (insert size) re = nose radius

Milling

D

Dedicated inserts for the ISO P, M and K area

E

Finishing

Medium

Roughing

F .008 in. (0.2 mm)

.013 in. (0.32 mm) Boring

.003 in. (0.07 mm)

.004 in. (0.1 mm)

.013 in. (0.32 mm)

G Tool holding

.012 in. (0.29 mm)

.010 in. (0.25 mm)

H

A 35


Workpiece material

Drilling

The different micro and macro-geometries are adapted to the various requirements in the applications.

A


Turning

Geometry description


B

Every insert has a working area with optimized chip control. A geometry description and application information are also available. Geometry working area

Geometry description

Application

-PM

CNMG 432-PM (CNMG 12 04 08-PM) ap = .020 – .217 inch fn = .006 – .020 inch/r

-PM – for medium turning with broad capability for steel. Feed: .004 – .026 inch/r (0.1 – 0.65 mm/r) Depth of cut: .016 – .339 inch (0.4 – 8.6 mm) Operations: turning, facing and profiling. Advantages: all-purpose, reliable, with problemfree machining. Components: axles, shafts, hubs, gears, etc. Limitations: depth of cut and feed, risk of overloading the cutting edge. General recommendations: Combine with a wear resistant grade (GC4225) for best productivity. Possible optimization: geometry WMX.

Threading

C

D

ap = 0.5 – 5.5 fn = 0.15 – 0.5 ap inch (mm) .236 (6.0)

.010 in. (0.25 mm)

.197 (5.0) .157 (4.0)

.008 in. (0.20 mm)

.118 (3.0)

Milling

.079 (2.0) .039 (1.0) (0.1) (0.2) (0.3) (0.4) (0.5) (0.6) (0.7) (0.8) (0.9) .004 .008 .012 .016 .020 .024 .028 .031 .035

mm mm/r

fn inch (mm)

E

Drilling

From universal to optimized turning inserts

F

Universal inserts • Universal geometry. • Optimizing with grades.

Boring

• Performance compromised.

Application area

Optimized inserts

H

•O ptimized performance according to workpiece machinability.


Tool holding

G

•D edicated geometries and grades.

A 36

Application area


A

Dedicated turning inserts Turning

For steel, stainless, cast iron, aluminum, heat resistant super alloys and hardened steel.

Negative basic-shape inserts ISO

Finishing

Medium

Roughing

Positive basic-shape inserts Finishing

Medium

Roughing


B

C Threading

P

D

Milling

M

K

Drilling

E

N

F

Boring

S

G Tool holding

H

A 37


H

A


Turning

Inserts for general turning

Threading

C

•A negative insert has a wedge angle of 90° seen in a cross-section of the basic shape of the cutting edge.

Negative, double/single-sided inserts Plain inserts


B

The choice of different insert concepts

Double sided

Single sided

Without hole

With hole

• A positive insert has a wedge angle less than 90°.

Positive, single-sided inserts

Milling

D

Drilling

E

F

•A vailable as double/singlesided inserts with P-hole or plain.

•A vailable with 7° or 11° clearance angle.

Positive 11°

Positive 7°

Positive T-rail clamping

• The positive T-rail inserts have a clearance angle of 5° or 7°.

Chip forming at high pressure and temperatures The choice of cutting material and grade is critical for success The ideal cutting tool material should:

Boring

e hard to resist flank wear and -b deformation. - be tough to resist bulk breakage.

G Tool holding

-n ot chemically interact with the workpiece material. -b e chemically stable to resist oxidation and diffusion. Temperatures given in Celsius


H

A 38

-h ave good resistance to sudden thermal changes.

Choice of inserts – grades

Turning

The main range of cutting tool materials The most common cutting tool materials are divided into the following main groups:

• HT U ncoated cermet containing primarily titanium carbides (TiC) or titanium nitrides (TiN) or both •HC Cermet as above, but coated

• CC Ceramics as above, but coated. - Cubic boron nitrides (BN)


- Cermets (HT, HC)

itride ceramics containing prima• CN N rily silicon nitride (Si3N4).

C

- Polycrystalline diamonds (DP, HC) • HC P olycrystalline diamonds, but coated.

Threading

- Coated cemented carbides (HC)

B

- Ceramics (CA, CM, CN, CC) • CA O xide ceramics containing primarily aluminum oxide (Al2O3).

D

Milling

• CM M ixed ceramics containing primarily aluminum oxide (Al2O3) but containing components other than oxides.

Drilling

E

Boring

F

Tool holding

G

H

A 39


- Uncoated cemented carbide (HW)

A

A


Turning

How to select insert geometry and grade Select the geometry and grade according to the application.

B

Machining conditions

Build up of a grade chart


Wear resistance Good

C Threading

Average

Difficult

Milling

D

Machining conditions Good conditions • Continuous cuts • High speeds • Pre-machined workpiece • Excellent component clamping • Small overhangs

Drilling

E

Good

F

Boring

Average conditions • Profiling cuts • Moderate speeds • Forged or cast workpiece • Good component clamping

Tool holding

G

Difficult conditions • Interrupted cuts • Low speeds • Heavy cast or forged skin on workpiece • Poor component clamping


H

A 40

Average

Difficult


A

Turning

Dedicated grades for ISO P, M and K Dedicated grades minimize tool wear development


The workpiece material influences the wear during the cutting action in different ways. Therefore dedicated grades have been developed to cope with the basic wear mechanisms, e.g.: - Flank wear, crater wear and plastic deformation in steel - Built-up edge and notch wear in stainless steel

C Threading

- Flank wear and plastic deformation in cast iron.

D

Milling

Select geometry and grade depending on the type of the workpiece material and type of application.

Drilling

E

Boring

F

G GC 4200

ISO

M

GC 2000

ISO

K

GC 3200

Tool holding

P

H

A 41


ISO

A

Choice of inserts – shape

The influence of large and small point angle

B

The insert shape and point angle varies considerably from the smallest, at 35°, to the round insert.


Turning

Selection of the insert shape

-o thers give the best profiling accessibility.

Threading

C

Each shape has unique properties: - some provide the highest roughing strength

Each shape also has unique limitations. For example: - high edge accessibility during machining leads to a weaker cutting edge.

Round

90°

80°

80°

60°

55°

35°

R

S

C

W

T

D

V

Milling

D

Drilling

E Accessibility

Vibration tendency

Power consumption

Large point angle

Small point angle

G

• Stronger cutting edge

• Weaker cutting edge

• Higher feed rates

• Increased accessibility

• Increased cutting forces

• Decreased cutting forces

• Increased vibration

• Decreased vibration

Tool holding

Boring

F

Cutting edge strength


H

A 42


A

Turning

Factors affecting choice of insert shape 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 insert strength and reliability.

B = Most suitable




 = Suitable

C



















Finishing











Longitudinal turning











Profiling

















































Operational versatility





Limited machine power Vibration tendencies Hard material





Intermittent machining





Small lead angle Large lead angle





Milling

E

Drilling

Facing

D

F

Boring

Light roughing/semifinishing

G 















Tool holding





H

A 43


Roughing strength

Threading

Insert shape

A


Turning

Number of cutting edges


B

S

C

W

T

D

V

Number of edges, negative inserts

4/8

2/4

3/6

3/6

2/4

2/4

Number of edges, positive inserts

4

2

3

3

2

2

ISO (first letter)

R

Threading

C

Insert shape

D

Selection of the nose radius

Milling

Effect of small and large nose radius re re

E

Drilling

re

Boring

F

G

Small nose radius

Large nose radius

• Ideal for small cutting depth

• Heavy feed rates

Tool holding

• Reduces vibration • Weak cutting edge


H

A 44

• Large depths of cut

Rule of thumb

• Strong edge security

The depth of cut should be no less than 2/3 of the nose radius rε.

• Increased radial pressures

Choice of inserts – nose radius

A

Turning

A small nose radius should be first choice 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 surface texture and more even pressure on the cutting edge.


B

C DOC

Threading

DOC DOC

D

Milling

• 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 is smaller than the DOC.

E

F

Boring

However with a round insert, radial pressure will never stabilize because the theoretical nose radius is half the insert diameter (iC).

Tool holding

G

H

A 45


The radial force exerted on the workpiece grows linearly until the nose radius of the insert is less than the depth of cut where it stabilizes at the maximum value.

Drilling

Effect of nose radius and DOC

A


Turning

High feed turning with wiper inserts Wiper – General information

B

Why use a wiper • Increase feed and gain productivity.


Wiper insert rWiper

Rmax

se normal feed rate and •U gain surface quality. When to use wipers • Use wipers as a first choice where it’s possible.

Threading

C

Conventional insert

D

Rmax

isually, surfaces can •V look different even though the measured surface is great.

Milling

rISO

Limitations • General limitation is vibration.

E

Wiper – Technical solution Drilling

•O ne wiper cutting edge is based on 3-9 radii. •C ontact surface between insert and component is longer with wipers.

F

• L onger contact surface makes a better surface finish. Boring

• L onger contact surface increases cutting forces which makes a wiper insert more sensitive to vibration when machining unstable components.

Tool holding

G


H A conventional nose radius compared with a wiper nose radius.

A 46


A

Turning

Wiper – Surface finish Traditional insert

B

• T wo times feed with a wiper will generate as good surface as conventional geometries with normal feed.

C

• T he same feed with a wiper will generate twice as good surface compared with conventional geometries.

Threading

Wiper insert Twice the feed, same Ra


Rule of thumb

Rt = Maximum value peak-to-valley height Ra = A rithmetic average height of the profile

Milling

D Wiper insert Same feed, half Ra

Drilling

E

Achieved surface – traditional ISO inserts and wipers

F

Ra

157 (4.00)

Standard -PM

118 (3.00)

Wiper -WM

79 (2.00) Wiper -WMX

0 (0.00) (0.20) .008

(0.35) .014

(0.50) .020

H

(0.65) Feed, fn inch/r (mm/r) .026

A 47


39 (1.00)

G Tool holding

Insert geometry

197 (5.00)

Boring

(µm) 236 (6.00)

A

Choice of inserts – speed and tool life

Turning

Cutting data parameters affect tool life B Parting and grooving

Use the potential of: - ap – to reduce number of cuts - fn – for shorter cutting time - vc – for best tool life

Threading

C

Cutting speed

Tool life

D

vc – large effect on tool life.

Milling

Adjust vc for best economy.

Boring

F

Cutting speed vc

Feed

Tool life

Drilling

E

fn – less effect on tool life than vc.

Feed fn

Cutting depth

Tool life

Tool holding

G

ap – little effect on tool life.


H Cutting depth ap

A 48

Choice of inserts – speeds and tool life

A

Turning

Effects of cutting speed The single largest factor determining tool life Too low

• Rapid flank wear

• Built-up edge

• Poor finish

• Uneconomical


Too high

• Rapid cratering • Plastic deformation

Threading

C

Effects of feed rate

D

Too high

Too low

• Loss of chip control

• Stringers

• Poor surface finish

• Uneconomical

Milling

The single largest factor determining productivity

E

ratering, plastic defor•C mation

• Chip hammering

F

Boring

• Chip welding

Drilling

• High power consumption

Effects of depth of cut • High power consumption

• Loss of chip control

• Insert breakage

• Vibrations

• Increased cutting forces

• Excessive heat

G Tool holding

Too small

• Uneconomical

H

A 49


Too deep

Turning

A

Choice of tools – external turning

External turning Tool selection and how to apply


General guidelines •S ecure insert and tool holder clamping is an essential factor for stability in turning. • T ool holder types are defined by the lead (entering) angle, the shape and size of the insert used.

C Threading

• T he selection of tool holder system is mainly based on the type of operation. •A nother important selection is the use of negative versus positive inserts.

D

Milling

•W henever possible choose modular tools.

E

Drilling

Definitions of key figures

Boring

F

22° Max in copy angle

Lead angle ψr –3° (Entering angle κr = 93°)

Feed directions

Tool holding

G


H Insert point angle

A 50

60°

Insert shape


A

Turning

Four main application areas Longitudinal turning/facing • Rhombic shape C-style (80°) insert is frequently used. • Holders with lead angles of –5° and –3° (entering angles of 95° and 93°) are commonly used.

C Threading

• Alternatives to the C-style insert are D-style (55°), W-style (80°) and T-style (60°).


B

The most common turning operation.

Profiling Versatility and accessibility is the determining factor. • The effective lead angle (ψr ) (entering angle (kr)) should be considered for satisfactory machining.

D

•M ost commonly used lead angle is –3° (entering angle = 93°) because it allows an in-copying angle between 22°-27°. Milling

• T he most frequently used insert shapes are D-style (55°), V-style (35°) and T-style (60°) inserts.

E Facing •P ay attention to the cutting speed which will change progressively when feeding towards the centre.

Drilling

The tool is fed in towards the center.

• L ead angles of 15° and –5°/–1° (entering angles of 75° and 95°/91°) are commonly used.

F

Boring

• C-style (80°), S-style (90°), and T-style (60°) inserts are frequently used.

Plunging •R ound inserts are very suitable for plunge turning as they can be used for both radial and axial feeds. • Neutral 90° holders for round inserts are commonly used.

Tool holding

G

A method to produce or widen shallow grooves.

A 51


H

A


Turning

Small lead angle Features / Benefits • Cutting forces directed towards chuck.

B

• Can turn against a shoulder.


• Higher cutting forces at entrance and exit of cut.

–5°

• Tendency to notch in HRSA and hard materials.

Threading

C

D

Large lead angle

Milling

Features / Benefits • Produces a thinner chip - Increased productivity.

E

• Reduced notch wear. • Cannot turn against a shoulder.

Drilling

45°

Boring

F

Tool holding

G


H

A 52


A

Turning

The lead angle Important consideration in profile turning Longitudinal turning

B

Out-copying


In-copying

ψr ψr

ψr

β

• T he maximum in-copying angle beta (β) is recommended for each tool type and is specified in the catalogs.

D

Milling

β

• T he effective lead angle (ψr) should also be considered for satisfactory machining when the operation involves profiling.

Threading

C

E

Axial and radial cutting forces Large lead angle

Drilling

Small lead angle

F Ff = axial Fp = radial

Boring

Fp = radial

Ff = axial

• Higher cutting forces especially at entrance and exit of cut.

• Reduced load on the cutting edge. • F orces are directed both axially and radially. - Vibration tendencies.

H

A 53


• Forces are directed both axially and radially.

Tool holding

G • Forces directed toward the chuck. Less tendency for vibration.

A


++

++

++

+

+

+

Wedge clamp design

+

+

+

Screw clamp design

+

++

+

+

++

++

++

++

+

+

+

=R ecommended tool holder system = Alternative system

Plunging

++ +

Facing

Tooling system

Profiling


B


Turning

Define the suitable clamping system

Milling

D

Rigid clamp design

Negative inserts

Threading

C

Boring

F

Positive inserts

Drilling

E

Lever design

Screw clamp design

T-rail

+

++


H

Ceramic and CBN inserts

Tool holding

G

A 54

Rigid clamp design

Top clamp design

++


A

Alternative shape

Rhombic 80°

++

D

Rhombic 55°

+

++

+

R

Round

+

+

+

S

Square

+

T

Triangular

+

W

Trigon 80°

+

V

Rhombic 35°

K

Rhombic 55°

C

+

++

Threading

C


Plunging

Recommended insert shape

Facing

D

++ +

+

+

E

+

Drilling

+

Milling

++ = +=

Profiling

Insert shape


Turning

Insert recommendation depending on operation

+ +

+

F

Screw clamping

Screw clamping, T-rail

G Tool holding

“P lever style”

H

A 55


Rigid clamping

Boring

Modern insert clamping for turning tools

Turning

A

Choice of tools - internal turning

Internal turning Tool selection and how to apply


General guidelines • In internal turning (boring operations) the choice of tool is very much restricted by the component’s hole diameter and length.

C

hip evacuation is a critical factor for -C successful boring.

D

- T he clamping method has a decisive effect on the performance and result.

Milling

Threading

-C hoose the largest possible bar diameter and the smallest possible overhang.

Drilling

E

Boring

F

Tool holding

G

Selection factors Tool and insert geometry

Chip evacuation

Tool requirements

• Lead (entering) angle

• Chip size

• Reduced length

• Insert shape, negative/ positive

• Chip control

• Increased diameters

• Techniques

• Optimized shape

• Insert geometry • Nose radius


H

A 56

• Different tool materials • Clamping

Choice of tools – internal turning

A

Turning

Effect of cutting forces on internal turning Radial and tangential cutting forces deflect the boring bar

B

Tangential cutting force, Ft


• F orces the tool down, away from the center line. • Gives a reduced clearance angle.

• Alters cutting depth and chip thickness. ives out of tolerance dimension and •G risk of vibration.

Fr

• Directed along the feed of the tool. Milling

Ft

D

Feed force, Fa

Fa

Threading

C

Radial cutting force, Fr

F

E

• If possible, do not choose a lead angle more than 15° (entering angle less than 75°), since this leads to a dramatic increase of the radial cutting force Fr. - L ess force in radial direction = less deflection.

F

Boring

•S elect a lead angle close to 0° (entering angle close to 90°).

G Tool holding

Lead angle and cutting forces

Drilling

Selecting lead (entering) angles

A 57


H

A


Turning

Four main application areas Longitudinal turning/facing

B

The most commonly used internal turning operation.


• Rhombic shape C-style (80°) insert is frequently used. • Boring bars with lead angles of –5° and –3° are commonly used. •D -style (55°), W-style (80°) and T-style (60°) insert shapes are also frequently used.

Threading

C

Profiling Versatility and accessibility is the determining factor. • The effective lead angle (ψr) should be considered.

D

• Bars with lead angle of –3°, allowing an in-copying angle between 22–27°, are commonly used. Milling

-style (55°), V-style (35°) and T-style (60°) inserts are •D frequently used.

E

Longitudinal turning • A lead angle of close to 0° is recommended.

F

•C -style (80°), S-style (90°) and T-style (60°) inserts are frequently used.

Boring

Drilling

Boring operations are performed to open up existing holes.

Back boring Back boring is a boring operation with reverse feed. • It is used for turning shoulders less than 90°.

Tool holding

G

• Use smallest possible overhang.

•B oring bars with –3° lead angles and D-style (55°) inserts are commonly used.


H

A 58


A


Insert shape

Facing


Recommended insert shape Alternative shape

Rhombic 80°

+

D

Rhombic 55°

+

R

Round

+

S

Square

+

T

Triangular

++

W

Trigon 80°

+

V

Rhombic 35°

++ ++

C

+ Threading

C

+

D

+

+ +

Milling

++ = +=

Profiling

Turning

Insert recommendation depending on operation

+

E

Drilling

Selecting the insert basic shape

• Inserts with clearance angle 11° - First choice when small cutting forces and long overhangs are required. • F or best economy - Use negative inserts in stable conditions and with short overhang. 7°, positive, single sided inserts

Negative, double sided inserts

G

H

A 59


11°, positive, single sided inserts

F

Boring

• Inserts with clearance angle 7° - First choice for small and medium holes from .236 inch (6 mm) diameter.

Tool holding

Positive inserts generate lower cutting force and tool deflection

A


Turning

Insert point angle


B

Small point angle: Use the smallest angle giving acceptable strength and economy

- Increases accessibility - Decreases vibration - Decreases cutting forces. Round

90°

80°

80°

60°

55°

35°

R

S

C

W

T

D

V

Threading

C

D

Milling

Cutting edge strength

Accessibility

Vibration tendency

Power consumption

E

Drilling

Chip area and nose radius Cutting forces and cutting tool deflection

F

Boring

Rule of thumb!

Tool holding

G


H

•B oth small and large chip areas can cause vibration: - Large due too high cutting forces - Small due too high friction between the tool and the workpiece.

A 60

• The relationship between rε (nose radius) and ap (depth of cut) affects vibration tendencies. • L ess force in radial direction = less deflection.

Choose a nose radius which is somewhat less than the cutting depth.

Choice of tools – how to apply

A

Turning

Clamping the boring bar

•M aximum contact between tool and tool holder (design, dimensional tolerance).

dmm

lamping length 3 to 4 times bar diam•C eter (to balance cutting forces). • Holder strength and stability.


Critical stability factors for optimized performance

C Threading

3 - 4 x dmm

Milling

D

Tool requirements for clamping

E

Drilling

Maximum contact between tool and tool holder

Best choice

F

Coromant Capto® coupling

Boring

Acceptable

G Tool holding

Not recommended

Not recommended

A 61


H

A

Choice of tools - how to apply

Turning

EasyFix sleeves For correct clamping of cylindrical bars


Guarantees correct center height

C

Benefits: • Cutting edge in right position • Best cutting action gives better surface finish

Threading

• Reduced setup time • Even insert wear. Silicon sealer

Milling

D

E

Drilling

Groove

Boring

F

G

A spring plunger mounted in the sleeve clicks into a groove in the bar and guarantees correct center height.

Tool holding

Spring plunger

The slot in the cylindrical sleeve is filled with a silicon sealer which allows the existing coolant supply system to be used.


H

A 62


A

Turning

Factors that affect vibration tendencies Vibration tendencies grow towards the right


B

Lead (entering) angle

Threading

C

Nose radius Micro and macro geometry

D

Milling

Edge design

E

• Inserts with thin coatings, or uncoated inserts, are to be preferred as they normally give lower cutting forces.

Micro and macro geometry • Use a positive basic-shape insert, as these give lower cutting forces compared to negative inserts.

Drilling

• Insert wear changes the clearance between the insert and the hole wall. This can affect the cutting action and lead to vibration.

F

Boring

Nose radius • Choose a nose radius which is somewhat smaller than the cutting depth.

Edge design

Tool holding

G

H

A 63


Lead (entering) angle • Choose a lead angle as close to 0° (entering angle as close to 90°) as possible, never more than 15° (less than 75° for entering angle).

A


Turning

Chip evacuation Chip evacuation is a critical factor for successful boring


•C entrifugal force presses the chips to the inside wall of the bore. • T he chips can damage the inside of the bore. - Internal coolant can help with chip evacuation.

C Threading

-B oring upside down helps to keep chips away from the cutting edge.

D

Chip evacuation and chip control Milling

Hard breaking of chips, short chips • Power demanding and can increase the vibration.

E

Drilling

•C an cause excessive crater wear and result in poor tool life and chip jamming.

F

Long chips • Can cause chip evacuation problems.

Boring

• Causes little vibration tendency, but can in automated production cause problems due to chip evacuation difficulties.

Tool holding

G Short and spiral chips • To be preferred. Easy to transport and do not cause a lot of stress on the cutting edge during chip breaking.


H

A 64


A

Turning

Recommended tool overhang Maximum overhang for different types of bars


Steel bar – up to 4 x dmm Carbide bar – up to 6 x dmm Short, dampened bar – up to 7 x dmm

C Threading

Long, dampened bar – up to 10 x dmm Carbide reinforced, dampened bar – up to 14 x dmm 14

10

7

6

4

Clamping length: 4 x dmm

Milling

Overhang: ... x dmm

D

E

Eliminate vibrations • Increase productivity in deep bores • Minimize vibration

Coolant tube

•M achining performance can be maintained or improved

Oil

•D ampened boring bars are available in diameters from .394 inch (10 mm) High density mass

- F or max overhang 14 x dmm (carbide reinforced)

F

Boring

Rubber damper

Drilling

Internal machining with dampened boring bars

G Tool holding

Cutting head

Steel bar

Dampened bar

A 65


H

Turning

A

Code key for inserts and toolholders - INCH Extract from ISO 1832—1991

INSERT

Tolerances

Insert thickness Nose radius


B

Code keys

C N M G

C Threading

1

2

3

4

4 3 2 - PF 5

1. Insert shape

6

7

8

5. Insert size

D

Milling

2. Insert clearance angle

TOOL HOLDERS External

D C L N R 16 4 D

Drilling

E

F

E B 1 C 2 D

Boring

Internal

S 16 T S C L C R

G

H

Tool holding Machinability Other information

F

C3 A

H

5

E

F

B

1

C

2

D

4 5

Bar diameter

Coromant Capto® coupling size A 66

S = Solid steel bar A = Steel bar with coolant supply E = Carbide shank bar F = Dampened, carbide shank bar

Holder lead angle

Code keys

C

55°

S

R

D

4. Insert type

35°

T

V

80°

W

B

C

P

N

5. Insert size

A

G

Inscribed circle is indicated in 1/8"

M

T

S

W

T


80°

Turning


1. Insert shape

A

C 7. Nose radius rε rε rε rε rε rε

= = = = = =

.008 1/64 1/32 3/64 1/16 3/32

First choice nose radius recommendations: Finishing Medium Roughing

T-MAX P

CoroTurn 107

2 2 3

1 2 2

Threading

0 1 2 3 4 6

D

Milling

8. Geometry — manufacturer’s option 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

Drilling

B. Clamping system

D

Right-hand style L Left-hand style

Bars:

Boring

E. Shank or bar size Shanks: height and width

R

Neutral

F

S

Rigid clamping (RC) Top and hole clamping Hole clamping Screw clamping

D. Hand of tool

N

P

G. Tool length External, l1 in inch

Internal, l1 in inch

A = 4.000 B = 4.500 C = 5.000 D = 6.000 M = 4.000

M = 6.000 R = 8.000 S = 10.000 T = 12.000 U = 14.000

A 67

G Tool holding

Top clamping

M,W


C

Turning

A

Code key for inserts and toolholders - METRIC Extract from ISO 1832—1991

INSERT

Tolerances

Insert thickness Nose radius


B

Code keys

C N M G 09 03 08 - PF

C Threading

1

2

3

1. Insert shape

4

5

6

7

8

5. Insert size = cutting edge length

D

Milling


TOOL HOLDERS External

D C L N R 16 16 H 09

Drilling

E

F

E B 1 C 2 D

5

Boring

Internal

A 25 T S C L C R 09

G

H

Tool holding Machinability Other information

G

C3 A

H

F

J

G

B

1

C

2

D

Bar diameter

Coromant Capto® coupling size A 68

S = Solid steel bar A = Steel bar with coolant supply E = Carbide shank bar F = Dampened, carbide shank bar

Holder style

5

Code keys

C

55°

S

R

D

4. Insert type

T

35°

V

80°

W

B

C

P

N

5. Insert size = Cutting edge length

A

G

M

T

l mm: 06–25

07–15

06–32

09–25

06–27

11–16

06–08


80°

Turning


1. Insert shape

A

C 7. Nose radius = = = = = =

First choice nose radius recommendations:

0.2 0.4 0.8 1.2 1.6 2.4

Finishing Medium Roughing

T-MAX P

CoroTurn 107

08 08 12

04 08 08

Threading

02 rε 04 rε 08 rε 12 rε 16 rε 24 rε

D

Milling

8. Geometry — manufacturer’s option 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

M

Rigid clamping (RC)

D. Hand of tool

Top and hole clamping

E. Shank height

R

P

F

S

Hole clamping

Screw clamping

G. Tool length

Boring

D

Drilling

B. Clamping system

Tool length

G

F. Shank width

L Left-hand style N Neutral

H = 100 K = 125 M = 150 P = 170 Q = 180 R = 200

S = 250 T = 300 U = 350 V = 400 W = 450 Y = 500

A 69


Right-hand style

Tool holding

= l1 in mm

Turning

A


B

Troubleshooting

Troubleshooting Chip control Problem Long unbroken snarls winding around the tool or workpieces.

Cause • F eed too low for the chosen geometry.

Solution • Increase the feed. elect an insert geometry •S with better chip breaking capabilities. se a tool with high pres•U sure coolant.

Threading

C

•D epth of cut too shallow for the chosen geometry.

• Increase the depth of cut or select a geometry with better chip breaking capability.

• Nose radius too large.

•S elect a smaller nose radius.

• Unsuitable lead angle

•S elect a holder with as small a lead angle as possible (ψr =0° [κr =90°]).

• Feed too high for the chosen geometry

•C hoose a geometry designed for higher feeds, preferably a single-sided insert.

Milling

D

Drilling

E

Boring

F

Very short chips, often sticking together, caused by too hard chip breaking. Hard chip breaking often causes reduced tool life or even insert breakages due to too high chip load on the cutting edge.

• Unsuitable lead angle.

• Select a holder with as small a lead angle as possible (ψr =45°–15° [κr=45°–75°]).

• Nose radius too small.

• Select a larger nose radius.

Tool holding

G

• Reduce the feed.


H

A 70

Troubleshooting

A

The surface looks and feels “hairy” and does not meet the tolerance requirements

Cause • The chips are breaking against the component and marking the finished surface.

Solution • Select a geometry which guides the chips away.

B

• Change lead angle. • Reduce the depth of cut. •S elect a positive tool system with a neutral angle of inclination.


Problem

Turning

Surface finish

• Reduce the cutting speed.

• Too high feed in combination with too small nose radius generates a rough surface.

• Select a wiper insert or a larger nose radius. • Reduce the feed.

E

Burr formation • The cutting edge is not sharp enough.

F

Boring

• The feed is too low for the edge roundness.

•U se inserts with sharp edges: - PVD coated inserts - ground inserts at small feed rates, < .004 inch/r (< 0.1 mm/r).

•U se a holder with a large lead angle.

•E nd the cut with a chamfer or a radius when leaving the workpiece.

A 71

G Tool holding

• Notch wear at depth of cut, or chipping.


Burr formation at the end of the cut when the cutting edge is leaving the workpiece.

D

Milling

• Select a grade with better resistance to oxidation wear, e.g., a cermet grade.

Drilling

• Hairy surface caused by excessive notch wear on the cutting edge.

Threading

C

A

Troubleshooting

Turning

Vibration


B

High radial cutting forces due to:

Cause - Unsuitable lead angle.

Nose radius too large. Vibrations or chatter marks which are caused by the tooling or the tool mounting. Typical for internal machining with boring bars.

•S elect as small lead angle as possible (ψr = 0°)

elect a smaller nose •S radius.

elect a grade with a thin •S coating, or an uncoated grade.

xcessive flank wear on cut-E ting edge.

elect a more wear resistant •S grade or reduce speed.

- Insert geometry creating high cutting forces.

•S elect a positive insert geometry.

hip-breaking is too hard -C giving high cutting forces.

educe the feed or select a •R geometry for higher feeds.

-V arying or too low cutting forces due to small depth of cut.

• Increase the depth of cut slightly to make the insert cut.

- Tool incorrectly positioned.

• Check the center height.

Milling

D

Solution

nsuitable edge rounding, or -U negative chamfer.

Threading

C

Problem

High tangential cutting forces due to:

Drilling

E

Boring

F

Tool holding

G


H

 A 72

A

- Instability in the tool due to long overhang.

Solution • Reduce the overhang

B

se the largest bar •U diameter. • Use a Silent Tool or a carbide bar.


Cause

Threading

C

•E xtend the clamping length of the boring bar.

D

Milling

•U se EasyFix for cylindrical bars.

Drilling

E

Boring

F

G Tool holding

nstable clamping offers -U insufficient rigidity.

H

A 73


Problem

Turning



B2

Parting & Grooving Parting and grooving is a category of turning. It has a wide range of machining applications requiring dedicated tools. These tools can be used, to some extent, for general turning.

• Theory

B4


B7

• System overview

B 11

• Parting & grooving – how to apply

B 15

• Troubleshooting

B 36

B3

Turning

A


B

Parting & grooving theory Parting off Chip evacuation is essential Chip evacuation is a critical factor in parting operations. There is little opportunity to break chips in the confined space as the tool moves deeper. The cutting edge is designed largely to form the chip so it can be evacuated smoothly. Consequences of poor chip evacuation are chip obstruction, which leads to poor surface quality, and chip jamming, leading to tool breakdown.

Threading

C

Theory

•C hip evacuation is a critical factor in parting operations.

D

Milling

•C hip breaking is difficult in the confined slots created as tools cut deep into the workpiece. • T ypical chips are clock-spring shaped, narrower than the groove.

E

Drilling

• T he insert geometry shrinks the chip width.

F

Parting off – definition of terms Boring

n n = spindle speed (rpm)

G


Tool holding

fnx = radial cutting feed (inch/r) (mm/r) ar = depth of groove (inch) (mm) (outer dia. to center or bottom of groove)


H

B4

Theory

A

Turning

Cutting speed value Feed rate reduction is often advantageous for performance when machining towards the center to minimize the pressure on the cutting edge.


B

•C utting speed declines to zero at the center.

Threading

C

D

Milling

100 – 0% of vc

E

Feed reduction towards center

Drilling

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.

educe feed by 75% when approaching •R the center, around .079 inch (2 mm) before the part comes off.

Boring

F

G

• Feed reduction reduces pip size.

Tool holding

• F eed reduction reduces vibration and increases tool life.

B5


H

.079 (2mm)

A

Theory

Turning

Grooving– definition of terms


B

The tool movement in directions X and Z is called feed rate (fn), or fnx/fnz, inch/r (mm/r). When feeding towards center (fnx), the rpm will increase until it reaches the rpm limit of the machine spindle. When this limitation is passed, the cutting speed (vc) will decrease until it reaches 0 ft/min (m/min) at the component center.

C


n Threading

vc = cutting speed (ft/min) (m/min) fnz = axial cutting feed (inch/r) (mm/r) fnx = radial cutting feed (inch/r) (mm/r) ar = depth of groove (inch) (mm) (outer dia. to center or bottom of groove)

D

Milling

ap = depth of cut in turning

E

Drilling

Face grooving– definition of terms

Boring

F

The feed has a great influence on chip formation, chip breaking, and thickness, and also influences how chips form in the insert geometry. In sideways turning or profiling (fnz), the depth of the cut (ap) will also influence chip formation.


G


Tool holding

n

fnx = radial cutting feed (inch/r) (mm/r) ar = depth of groove (inch) (mm)


fnz = axial cutting feed (inch/r) (mm/r)

B6

Selection procedure

Turning

Tool selection procedure

A

Production planning process <.0004 (.01 mm)

Dimension and quality of the groove or face


B

C Component

Workpiece material, chip evacuation

Threading

1

D

2

Milling

Machine parameters Machine

E

Choice of tool

Drilling

3

Type of tool: - Spring-clamp - Screw-clamp - Insert type

F

How to apply

Boring

4

Cutting data, method, cutting fluid, etc

Troubleshooting


H

B7


5

Tool holding

G

A

Selection procedure

Turning


B

Component


•A nalyze the dimensions and quality demands of the groove or face to be machined. • • • •

Threading

C

T ype of operation: parting, grooving Cutting depth Cutting width Corner radius

D

Milling

P M K N S H

• • • • •

achinability M Clamping Chip breaking Hardness Alloy elements

Drilling

E

Material

F


Boring

tability, power and torque especially for •S larger diameters • Component clamping • Tool changing times/number of tools in turret • Chip evacuation • Cutting fluid and coolant

Tool holding

G


H

B8

Selection procedure

A

Turning

3. Choice of tools Multiple grooving •M ultiple grooving is the best method for rough grooving when the depth is bigger than the width. •M ake a “fork”. This will improve chip flow and increase tool life.


Example of different machining methods

C Threading

D

• Good chip control.

E

Drilling

•P lunge turning is the best choice when machining steel and stainless steel and when the width of the groove is larger than the depth.

Milling

Plunge turning

F

•R amping avoids vibration and minimizes radial forces.

Boring

•R ound inserts are the strongest inserts available.

G

• Double the number of cuts/passes.

Tool holding

Ramping

• F irst choice in heat resistant super alloys (HRSA). Reduces notch wear.

B9


H

A

Selection procedure

Turning

4. How to apply Important application considerations •C enter height is important, ±.004 inch (±0.1 mm).


educe feed by up to 75% around .079 •R inch (2 mm) before center. .079

Max ±.004 inch (±0.1 mm)

C

se shortest possible overhang, ar inch •U (mm). • L argest height dimension on blade for bending stiffness.

Threading

• Use coolant to improve chip flow.

D

Milling

ar

Some areas to consider Insert wear and tool life • Check the wear pattern and if necessary adjust cutting data accordingly.

Drilling

E

5. Troubleshooting

To improve chip formation & tool wear • Use recommended chip former. • Use neutral front angle. • Check center height. • Use cutting fluid.

Boring

F

General recommendation – parting off • Neutral inserts (insert without front angle). • To save material, use smallest possible insert width. • Largest possible tool holder. • Shortest possible overhang, ar.

Tool holding

G


H

B 10

System overview

Turning

System overview

A

External parting and grooving 4. Shallow to deep grooving

2. Turning and recessing

5. Face grooving

3. Undercutting

6. Profiling


1. Parting-off solid bars and tubes

4

C Threading

5

6

D

1

2

3

Milling

4

4

E

Drilling

1

Internal grooving

F

1. Grooving and pre-parting Boring

2. Face grooving 3. Profiling

G

2

1

B 11


1

Tool holding

3

A

System overview

Turning

Different systems Insert type


Application

Threading

C

CoroCut2

CoroCut1

CoroCut3

Q-Cut 151.2

Medium

Deep

Shallow

Deep

Q-Cut 151.3

U-Lock 154.0

Parting (Cut off)

Grooving Internal, small dia. Face grooving

D

Milling

Turning

Profiling

E

Drilling

Undercutting

Circlip grooving

Boring

F

G

First choice

Tool holding

Medium parting – Ø ≤1.575 inch (40 mm) Second choice


Deep parting – Ø ≤4.409 inch (112 mm)

B 12

Shallow parting – Ø ≤.472 inch (12 mm)

System overview

Turning

Internal parting and grooving

A

Different systems

B

≥.472 (≥12)

≥.394 (≥10)

≥.984 (≥25)

C Threading

≥.165 (≥4.2)


Internal grooving – min hole diameter

.165 .394 (4.2) (10)

.472 .984 (12) (25)

Min. hole diameter, inch (mm)

Milling

D

E

Drilling

Face grooving – min/max first cut diameter

F Ø.472 (Ø12)

Ø.906 (Ø23)

Boring

Ø.244 (Ø6.2)

Ø1.339 (Ø34)

.472 – 1.181 (12 – 30)

.906 – 2.756 (23 – 70)

1.339 – ∞ (34 – ∞)

First cut diameter, inch (mm)

H

B 13


.244 – .709 (6.2 – 18)

Tool holding

G

Turning

A

System overview

Inserts Overview


Application

Threading

C

Milling

D

Machining condition

Parting (Cut off)

Grooving

Turning

Finishing

CF

GF

TF

Medium

CM

GM

TM

Roughing

CR

Profiling

RM

E

RO

Drilling

Optimizer

Sharp

F

Boring

ER treated

Tool holding

G


H

B 14

RS

CS GE

RE

Profiling

AM

A

Turning

Parting and grooving – how to apply

B

• Parting & grooving and how to apply

B 16

• Parting off and how to apply

B 22

• General grooving and how to apply

B 25

Threading


Parting & grooving and how to apply

• Circlip grooving and how to apply

B 27

D

• Face grooving and how to apply

B 28

• Profiling and how to apply

B 31

• Turning and how to apply

B 33

• Undercutting and how to apply

B 35

Milling

C

Drilling

E

Boring

F

Tool holding

G

B 15


H

A


Turning

Tool overhang & workpiece deflection


B

The tool overhang should always be minimized for improved stability. In parting and grooving operations consideration must be given to the depth of cut and the width of the groove, which means that stability must often be compromised to meet the demands of accessibility.

Threading

C Best stability •O verhang (ar) should be as small as possible.

D

• Largest seat size should be used.

Milling

• ar = 8 x la max

E

Drilling

Internal machining Shank type:

F

• Dampened steel bars ≤5 x dmm

• Steel bars ≤3 x dmm • Carbide bars ≤5 x dmm

Boring

•C arbide reinforced dampened bars, up to 7 x dmm.

Tool holding

G Inserts: • Use smallest possible width • Use light cutting geometries.


H

B 16


A

Turning

Tool holder selection parameters System considerations

Medium parting – Ø ≤1.575 inch (≤40 mm)

C Threading

Shallow parting – Ø ≤.472 inch (12 mm)


B

Deep parting – Ø ≤4.409 inch (≤112 mm)

Deep parting

Medium parting

Shallow parting

• F irst choice are springclamp blades with singleedge inserts.

• First choice for medium parting are screw-clamp holders with 2-edge inserts.

•U se the 3-edge insert for economic parting in mass production.

Milling

D

E

Drilling

General tool holder considerations Tool block with spring-clamp tool blade for tool overhang adjustment.

F

Boring

• Shortest possible overhang, ar inch (mm) • Maximum tool holder shank • Largest height dimension

Tool holding

H

B 17


ar

G

• Maximum blade width

A


Turning

Spring-clamp design blades Features/Benefits • Quicker insert change

B

• Cut off larger diameter Parting and grooving

• Adjustability • Deep grooving • Double ended

Threading

C

• Radial feed only

Screw-clamp design holders

D

Features/Benefits

Milling

• Smaller diameters • Shallow grooving

E

• Increased rigidity

• Radial & axial feed

Drilling

• Single ended

F

Screw-clamp design holders Boring

Features/Benefits •E xtremely small insert widths - grooving down to .020 inch (0.5 mm) - parting down to .039 inch (1 mm).

G Tool holding

• Cutting depths up to .236 inch (6 mm). • One holder for all insert widths. • Very tight insert indexing tolerance.


H

• The productivity choice, 3 cutting edges.

B 18


A

Overhang should not exceed 8 x la (width of insert).

B

Use as narrow an insert as possible: - To save material - Minimize cutting force - Minimize environmental pollution.


Max ar = 8 x la (width of insert)

Turning

Parting-off bars

Threading

C

D

Milling

Material savings

Drilling

E

F

Positioning of the tool

Boring

Use maximum deviation of ±.004 inch (±0.1 mm) from center line. Too high cutting edge • Clearance will decrease. • Cutting edge will rub (break).

Tool holding

G

Too low cutting edge • Tool will leave material in center (PIP).

H

 B 19


Max ±.004 inch (±0.1 mm)

A


Turning

 Positioning of the tool 90º mounting of tool holder •P erpendicular surface • Reduce vibrations


B

Hand of insert

Threading

C

Hand of insert

Milling

D

E

Three types of insert with different entering angles: - Right hand (R) - Neutral (N) - Left hand (L)

Right hand (R)

Insert geometry

Drilling

Neutral entering angle

F

rε

laa ϕr = 0

Increases strength Higher feed/productivity Better surface finish Straighter cut Pip stays on part falling off.

Boring

rε

• • • • •

Tool holding

G

Small/large corner radius rε


H

B 20

Small corner radius • Smaller PIP • Better chip control • Lower feed rate Large corner radius • Increased feed rate • Longer tool life


A

Turning

Recommendations for boring bar solutions EasyFix sleeves


Use EasyFix clamping sleeves for accurate machining with less vibration and precise height.

Threading

C

D

Milling

Recommended overhang dmm

E

Drilling

Carbide reinforced dampened bars

l <7 x dmm

F

dmm Dampened steel bars

Boring

Carbide bars

l ≤5 x dmm

G Tool holding

dmm Solid steel bars

l ≤3 x dmm B 21


H

A

Parting off – how to apply

Pip reduction by using different front angles

B

•C hoose left or right hand front angle to control the pip or burr.


Turning

Parting off

• When the front angle is: - increased, the pip/burr is decreased - decreased, the chip control and tool life are improved.

C

•C entrifugal force will always push away the parted off component - Tool will leave material in center (PIP).

Threading

R L

Milling

D

E

Drilling

Example of front angles on 1-, 2- and 3-edge inserts: 5°, 10°, 8°, 12°, 15°, 20°

Note! A front-angled insert will give reduced chip control due to the direction of the chip flow. (A neutral insert directs the chip straight out of the groove).

Tool selection - Review

Boring

F

Tool holding

G


H

B 22

General recommendations:

Consider:

-N eutral inserts - Smallest possible insert width - Largest possible tool holder.

-

utting depth C Insert width Front angle Corner radius.


A

Turning

Parting-off tubes

Use insert with the smallest possible width (la) to save material, minimize cutting force and environmental impact.


Parting-off tubes

Parting-off thin walled tubes

D

Milling

Make sure that the lowest possible cutting forces are generated. Use inserts with the smallest possible width and sharpest cutting edges.

Threading

C

•C enter height is important, ±.004 inch (±0.1 mm). • If subspindle is used, pull away the component approximately .040 inch (1 mm) before center.

ø .040 inch (øØ1 0.1 mm)

•R educe feed by up to 75%, approximately .079 inch (2 mm) before center – also for tube parting.

G Tool holding

0.25 x fn

F

Boring

Max ±.004 inch (±0.1 mm)

Drilling

E

Practical hints

fn

.079 (2mm)

B 23


H

A


Turning

Use cutting fluid


B

Cutting fluid has an important function since the space often is restricted and obstructed by the chips. It is therefore important that coolant always is used in large amounts and directed at the cutting edge throughout the whole operation.

• Use large amounts.

C

• Direct at the cutting edge. Threading

• Use coolant adapter. • Has positive effect on chip formation. • Prevents chip jamming.

Milling

D

Drilling

E

Boring

F

Example of external coolant supply in addition to internal coolant channels.

Tool holding

G


H

B 24

Grooving – how to apply

A

Turning

General grooving •S ingle cut grooving is the most economic and productive method to produce grooves.

•A screw-clamp tool holder should be selected for grooving operations.

C Threading

• If the depth of the groove is bigger than the width, multiple grooving is the best method for rough grooving.


B

Milling

D

E

Single cut grooving

Drilling

•E conomic and productive method to produce grooves.

•W iper inserts give extremely high quality surface on the side of the groove.

F

Boring

• F inishing geometry has width tolerance of ±.0008 inch (±0.02 mm) and works well in low feeds.

Tool holding

G

B 25


H

A

Grooving – how to apply

Turning

Multiple grooving • T he best method for rough grooving when depth is bigger than width.


•U se the insert width to produce full grooves and then remove the rings.

Threading

C

Milling

D

Practical hints When producing high quality grooves, there is often a need for chamfered corners.

E • One way is to use the corners on the insert, for example, of a finishing grooving insert, to chamfer; see illustration A.

B

• A better way to make grooves with chamfer in mass production is to order a Tailor Made insert with the exact chamfer form; see illustration B.

Drilling

A

Boring

F

Tool holding

G


H

B 26

Circlip grooving – how to apply

A

•C irclip grooving can be performed with three-edge inserts or two-edge grooving inserts. • F or internal grooving there is also a wide choice of inserts and boring bars.


Circlips on shafts and axle components are very common.

Turning

Circlip grooving

Threading

C

Systems to choose from

r 2-edge inserts in widths •O .059 - .236 inch (1.50 - 6.00 mm).

E

• Internal inserts are available for min. hole diameter .394 inch (10 mm) and with circlip widths .043 - .163 inch (1.10 - 4.15 mm). in hole diameter for carbide rod inserts •M is .165 inch (4.2 mm) and circlip widths are .031 - .079 inch (0.78 - 2.00 mm).

internal

Internal/external

Milling is an alternative for non-rotating components • T he circlip widths for diameters .382 - 1.366 inch (9.7 – 34.7 mm) cutters are .028 - .203 inch (0.70 - 5.15 mm).

Cutter diameter .382 - 1.366 inch (9.7 – 34.7 mm)

Cutter diameter 1.535 - 2.480 inch (39 – 80 mm)

• T he circlip widths for diameters 1.535 - 2.480 inch (39 – 80 mm) cutters are .043 - .203 inch (1.10 - 5.15 mm).

B 27

Drilling

Carbide rod inserts

F

Boring

internal inserts

Milling

D • F or best economy, use 3-edge inserts in widths .039 - .125 inch (1.00 - 3.18 mm).

G Tool holding

2-edge inserts


3-edge inserts

A

Face grooving – how to apply

Turning

Face grooving Making grooves axially on the faces on a component requires tools dedicated to the application.


• T he correct curve on the tool is dependent on the radius of the workpiece. • T he inner and outer diameters of the groove need to be taken into account in order to select the tool.

Threading

C

Milling

D

Tools for face grooving

Drilling

E

Boring

F

•C urved tool for face grooving, shank 0º style.

Tool holding

G


H

B 28

urved tool for face •C grooving, shank 90º style.

•E xchangable cutting blades make it possible to make a special tool from standard tools.


A

• T ool must be adapted to the bending radius of the groove. achine largest diameter •M and work inwards for best chip control.


• T ool is fed axially towards the end surface of the part.

Turning

Choice of R and L tools depending on rotation

C Threading

Left hand (L) tool

D

Milling

Right hand (R) tool

Choice of A and B curve, right or left hand tool

E

Drilling

Choose the correct tool – A or B curve, right or left hand style – depending on machine setup and workpiece rotation.

Boring

F

Tool holding

G

B 29


H

A


Turning

First cut consederation 1 If the insert support rubs workpiece inside dia: - maybe the dia. range is wrong - tool is not parallel to axis - check center height - lower the tool below center line.


B

1 2

C

2 If the insert support rubs workpiece

Threading

outside dia: - maybe the dia. range is wrong - tool is not parallel to axis - check center height - lift the tool above center line.

Milling

D

Roughing

Finishing

1

Drilling

E

Roughing and finishing

2 3

Boring

F

Tool holding

G


H

First cut (1) always starts on the largest diameter and works inwards. The first cut offers chip control but less chip breaking. Cuts two (2) and three (3) should be 0.5–0.8 x width of the insert. Chip breaking will now be acceptable and the feed can be increased slightly.

B 30

Machine the first cut (1) within the given diameter range. Cut two (2) finishes the diameter. Always start outside and turn inwards. Finally, cut three (3) finishes the inner diameter to the correct dimensions.

Profiling – how to apply

A

Turning

Profiling When machining components with complex shapes, profiling inserts offer great opportunities for rationalization.


•M odern parting and grooving tool systems can also perform turning. •A screw-clamp tool holder should be selected for turning and profiling operations in view of achieving maximum stablility.

C Threading

•A neutral tool holder is suitable for both opening up or completing a recess. • T he round shape inserts have dedicated geometries for these operations.

Milling

D

Drilling

E

Boring

F

Ramping

•U se round inserts for outstanding chip control and good surface finish. • In unstable setups, use ramping to avoid vibrations.

Tool holding

G

B 31


H

A

Turning – how to apply

Turning

Profile turning Insert radius < component radius

B

Recommended

• L arge area of insert creates high cutting pressure so feed should be reduced.


• If possible, use an insert radius that is smaller than the component radius. • If you must have the same insert radius as the component radius, use micro-stops to make the chip short and avoid vibrations.

Threading

C

Insert radius ≥ component radius is not recommended

Milling

D

E

Drilling

fn1 = parallel cuts – max. chip thickness .006 - .016 inch (0.15–0.40 mm). fn2 = radius plunging – 50% max. chip thickness.

Boring

F

Tool holding

G


H

B 32


A

Turning

Turning The most common applications for wide grooves or turning between shoulders are multiple grooving, plunge turning or ramping. All three methods are roughing operations and have to be followed by a separate finishing operation. A rule of thumb is that if the width of the groove is smaller than the depth – multiple grooving should be used and vice versa for plunge turning. However, for slender components, the ramping method may be used.


B

Threading

C

•U se holders with smallest possible overhang, screw clamping and insert with rail shape if possible. •U se a stable, modular tooling system if possible.

Milling

D

E

Drilling

• Reinforced blade will increase stability.

Roughing

Boring

F

Tool holding

G 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.

B 33


H

4. Retract radially .020 inch (0.5 mm).

A


Turning

Finishing


B

As the insert contours around the radius, most of the movement is in the Z direction. This produces an extremely thin chip along the front cutting edge which can result in rubbing and hence vibration.

Threading

C

• T he axial and radial cutting depth should be .020–.039 inch (0.5–1.0 mm).

Milling

D

E

Axial turning Surface finish

Drilling

• T his wiper effect generates high quality surface finish.

Ra max

F

Boring

•R a value below 20RA (0.5 µm) will be generated with high bearing.

Tool holding

G


•Y ou get the best wiper effect when you “find” the right combination between feed (fn) and blade deflection.

B 34

Undercutting – how to apply

A

Turning

Undercutting • T hese applications require dedicated inserts with round cutting edges that are sharp and accurate. • T he tolerance of these inserts is high: ±.0008 inch (±0.02 mm).


• When a clearance is needed.

Threading

C

D

Tools for undercutting Angled 20°

Angled 45° Milling

Angled 7° ,45° and 70°

Drilling

E

F

Boring

•H older for external undercutting. Insert with one cutting edge.

G Tool holding

•H older for internal undercutting. Insert with two cutting edges.

H

B 35


•H older for external undercutting. Insert with two cutting edges.

Turning

A

B

Troubleshooting

Troubleshooting Tool wear


Problem

Flank wear

C

Plastic deformation

Crater wear

Chipping

Fracture

Built-up edge

Threading

Solution More positive geometry

++

D

++

Milling

Tougher grade

Drilling

E

More wear resistant grade

++

+

+

Increase cutting speed

+

F

Boring

Decrease cutting speed

Tool holding

G

+

Reduce feed rate

Choose stronger geometry

+ ++

++ +

+

+

++


H + + = Best possible remedy B 36

+ = Possible remedy

Troubleshooting

Bad surface •U se a short and stable tool. • Take away the chips – use geometry with good chip control.

•C heck speed/feed guidelines. • Use wiper geometry. • Check tool setup.

Turning

Solution


Problem

A

C

•S elect a special soluble oil for the material.

D

Milling

• Select the sharpest geometry. • Use geometry with good chip control.

Bad chip breaking hange geometry. C Select a higher feed. Use dwelling (pecking). Increase coolant.

E

Drilling

• • • •

Threading

Bad surface on aluminum

Vibration •C heck tool condition. • Check tool setup.

F

Boring

•U se a stable setup. • Check speed/feed guidelines. • Use shorter overhang. • Change geometry.

•C heck center height. • Check angle between tool and component.

•C heck condition of blade. If blade is old, the insert could be unstable in the tip seat.

B 37


Poor tool life

Tool holding

G

F2

Threading Thread turning is the process of an indexable insert tool making a number of passes along the section of a workpiece 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


C9

• System overview

C 13

• How to apply

C 19

• Troubleshooting

C 25

C3

Turning

A


B

Threading

C

D

Theory

Threading theory The threading methods The prime functions of a thread are: - to form a mechanical coupling - to transmit motion by converting rotational movement into linear and vice-versa - to obtain a mechanical advantage; using a small force to create a larger one.

Different ways of making threads Grinding

Rolling

Milling

Molding

Drilling

E

F

Metal cutting threading methods

Boring

Thread turning

Tool holding

G


H

C4

Milling

Tapping

Theory

A

Turning

Definitions of terms vc = cutting speed (ft/min) (m/min)

B

= spindle speed (rpm)

ap = total depth of thread (inch) (mm) nap = number of passes


n

Threading

C

itch, mm or threads P = p per inch (t.p.i.)

β

D

= angle of the thread Milling

d1 = minor diameter external D1 = minor diameter internal d2 = pitch diameter external

E

D2 = pitch diameter internal d = major diameter external

Drilling

D = major diameter internal

ϕ = helix angle of the thread

Boring

F

Tool holding

G

 C5


H

A

Theory

Turning

Definitions of terms 1. Root • The bottom surface joining the two adjacent flanks of the thread crest.


2. Flank • The side of a thread surface connecting the crest and the root. 3. Crest • The top surface joining the two sides, or flanks.

C Threading

Helix angle • The helix angle (ϕ)is dependent on and related to the diameter and pitch (P) of the thread.

D

Milling

•B y changing the shim, the flank clearance of the insert is adjusted. • T he angle of inclination is lambda (λ). The most common angle of inclination is 1° which is the standard shim in the tool holder.

Drilling

E

Boring

F

Cutting forces in and out of the thread • The highest axial cutting force in the threading operation occurs during the entrance and exit of the cutting tool.

Tool holding

G

•A ggressive cutting data can lead to movement of insecurely clamped inserts.


H

C6

Theory

A

Turning

Inclining the insert for clearance 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 can be made by referring to a chart in the catalog. As standard, all tool holders are delivered with the shim set at 1°.


B

Threading

C

D tan λ =

P

π × d2

Milling

Standard shim = 1°

E Threads/inch

Drilling

Pitch, mm

Boring

F

Tool holding

G

Workpiece diameter

mm inch

C7


H

A

Theory

Turning

Selecting shims for inclination


B

Threading

C

The diameter and pitch influence the inclination angles. Example of how to use the diagram. 1. The workpiece diameter is 40 mm (1.575 inch) with a thread with a pitch of 6 mm (.236 inch). From the diagram we can see that the required shim must have an angle of inclination of 3º (standard shim can be used).

2. T he workpiece diameter is 4 inches (102 mm) with a thread with a pitch of 5 threads. From the diagram we can see that the required shim must have an angle of inclination of 1º.

Pitch, mm

Threads/inch

D 3 Milling

1

E

Drilling

1

F

Boring

Workpiece diameter

mm inch

Marking of threading inserts and shims How to read and understand markings.

Tool holding

G


H

Angle of shim inclination

Thread profile Pitch Internal (O) External, no marking

C8

Carbide grade

Tool selection

Turning

Tool selection procedure Production planning process


B

Dimension and quality of the thread Component

C

Workpiece material, thread profile and quantity

Threading

1

A

D

2

Milling

Machine parameters Machine

E

Choice of tool

Drilling

3

Type of tool: - Full profile - V-profile - Multi-point

F

How to apply

Boring

4

Cutting data, in-feed etc.

Troubleshooting


H

C9


5

Tool holding

G

A

Tool selection

Turning

1. Component and the workpiece material B

•A nalyze the dimensions and quality demands of the thread to be machined.


Component

• Type of operation (external or internal) • Right- or left-hand thread • Type of profile (metric, UN, etc.)

C

• Pitch size

Threading

• Number of thread starts • Tolerance (profile, position)

P M K N S H

Milling

D

Material • Machinability

E

• Chip breaking

Drilling

• Hardness

F

• Alloy elements


Boring

• • • • • • • •

Tool holding

G


H

C 10

pindle interface S Machine stability The spindle speed Coolant supply Clamping of the workpiece Horizontal or vertical spindle Power and torque Tool magazine

Tool selection

A

Turning

3. Choice of tools Different ways to make threads Full profile inserts

The insert can only cut one pitch.

Disadvantages • Each insert can only cut one pitch.

C Threading

As the insert is generating both the root and the crest, the tool pressure increases, putting high requirements on setup and overhang.

B Advantages • Better control over the thread form. • Less deburring.


The thread is cut by the insert with good control over the geometrical properties as the distance between the root and the crest is controlled.

In setups prone to vibrations, a non-topping insert can often prove to be a solution due to the reduction of cutting pressure.

Advantages • Flexibility, one insert can be used for several pitches. Disadvantages • Can result in burr formation that needs to be taken away.

E

Drilling

The insert can accommodate a range of pitches thus reducing stock. The root and flanks are being formed by the insert. The crest is controlled in a prior turning operation, resulting in high tolerances.

Milling

D

V-profile inserts

The tool pressure increases exponentially, requiring stable setups and shortened overhangs. Sufficient room behind the last thread is also needed.

Advantages • Reduced number of infeeds. • Very high productivity. Disadvantages • Requires stable setups. • Needs sufficient room behind the last thread.

G Tool holding

A full profile (topping) insert with several teeth reduces the number of required in-feeds and generates high productivity, e.g. a multi-point insert with two teeth reduces the number of in-feeds to half.

H

C 11


Multi-point inserts

Boring

F

A

Tool selection

Turning

4. How to apply Important application considerations The infeed method can have a significant impact on the thread machining process.


It influences: - chip control - insert wear - thread quality - tool life

C Threading

In practice, the machine tool, insert geometry, workpiece material and thread pitch influence the choice of infeed method.

Milling

D

E

5. Troubleshooting Some areas to consider

Drilling

Insert wear and tool life • Check the wear pattern and if necessary adjust the cutting data accordingly.

F

Boring

Infeed type • Optimize infeed method, number and size of pass.

G Tool holding

λ

Insert geometry • Make sure the right insert geometry is used (all-purpose, F or C geometries).


Insert inclination • Ensure there is sufficient and even clearance (insert – inclination shims).

C 12

System overview

External threading

Turning

System overview

A

1. Small part threading

B

2. Conventional threading


3. Oil pipe threading

Threading

C

3 0.5 – 8 mm 32 – 3 t.p.i

10 – 5 t.p.i

2

1

D

Milling

0.2 – 2 mm

E

Internal threading

10 – 5 t.p.i

Min hole: .157 inch (4 mm)


4

F

3

2

Boring

0.5 – 3 mm 56 – 16 t.p.i


1

2. Threading mini-bars

Tool holding

G

3. Conventional threading

H

1. Carbide rods

4. Oil pipe threading

C 13


0.5 – 2.5 mm 32 – 10 t.p.i

Min hole: 2.374 inch (60.3 mm)

Drilling

0.5 – 8 mm 32 – 3 t.p.i

A

System overview

Turning

External threading assortment

Inserts


B

Choose from an extensive program

Threading

C

Milling

D

Drilling

E

Pitch 0.2 32

2.0 10

5.0

mm t.p.i

8.0 3

• Three standard geometries • F our insert sizes: 1/4, 3/8, 1/2 and 5/8 inch (11, 16, 22 and 27 mm)

1/4 (11)

3/8 (16)

1/2 (22)

5/8 (27)

F

Boring

Tool holders 1. Coromant Capto® cutting units

G

2. Shank tools

Tool holding

3. Boring bars 4. Exchangable cutting heads 5. Cartridges


H

C 14

System overview

A

Turning

Internal threading assortment Choose from an extensive program and several systems

Conventional bars “New system”

Mini-bars

≥.157 inch (≥4 mm)

Bars for oil pipe threading

≥.394 inch (≥10 mm)

≥.984 inch (≥25 mm)

≥.472 inch (≥12 mm)

C ≥2.362 inch (≥60 mm)

Threading

Conventional bars “Old system”

Carbide rods


B

.394 (10)

.472 (12)

.984 (25)

2.362 (60) Min. hole diameter, inch (mm)

E

Drilling

.157 (4)

Milling

D

For high precision, internal threading of small components

F

Boring

Inserts for mini-bars

Tool holding

G

H

C 15


Carbide rods

A

System overview

Turning

Thread forms Thread type

Code

General use

ISO metric American UN

MM UN

Pipe thread

Whitworth, NPT British Standard (BSPT), NPTF American National Pipe Threads

WH, NT PT, NF

Food and fire

Round DIN405

RN

Aerospace

MJ UNJ

MJ NJ

Oil and gas

API Rounded API ”V” form 60°

RD V38, 40, 50

Oil and gas

Buttress, VAM

BU

Motion General use

Trapezoidal ACME Stub ACME

TR AC SA

Application

Insert/thread form


B

Threading

C

Milling

D

Drilling

E

F

General usage • Good balance between load bearing capacity and volume of material.

Boring

Pipe Threads • Ability to bear loads.

Tool holding

G


H

•A ble to form leak-proof connections (threads are often conical). Food & Fire • Same as for pipe threads but round, for easy cleaning for food. • Easily repeated connecting/disconnecting for fire. Aerospace • High precision and minimized risk for stress concentration and breakage.

C 16

Oil & Gas • Extreme load bearing and leak proof requirements, with limitations of thin wall thickness of pipe. Motion • Symmetrical form. • Large contact surface. • Sturdy form.

System overview

A

Turning

Insert types Three different types of threading inserts

B Full profile inserts Parting and grooving

• For high productivity in threading.

C V-profile inserts - 60º and 55º Threading

• F or threading with minimum tool inventory.

D

• F or highly productive, economic threading in mass production.

Milling

Multi-point inserts

E

Drilling

Three different geometries F-geometry

C-geometry

First choice in most operations.

Sharp geometry.

Chip breaking geometry.

F

Boring

All-purpose geometry

Gives clean cuts in sticky and work hardening materials.

Optimized geometry for low carbon, low alloy and easily machined stainless steel.

C 17


Good chip forming in a wide range of materials.

Tool holding

G

A

System overview

Turning

A new, modern threading solution Ultra-rigid threading tool


•U ltra-rigid threading with fixed position inserts. • T he insert locates in the correct position with guidance of the rail.

C Threading

• T he screw forces the insert on the rail back to a radial stop at one contact face in the insert seat. (The red contact faces).

Milling

D

Quick change coupling

Boring bar

Coromant Capto® coupling

Drop head

Drilling

E

A variety of tool holder solutions

Boring

F

Tool holding

G


H CoromantCapto® coupling C 18

Shank tool

Exchangable cutting head

How to apply

Turning

How to apply In practice, the machine tool, insert geometry, workpiece material and thread pitch influence the choice of infeed method.


Three different types of infeed

Threading

C

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. • Axially directed cutting forces reduce the risk of vibrations. • Controlled chip direction.

Milling

The infeed method can have a significant impact on the thread machining process. It influences: - chip control - insert wear - thread quality - tool life.

A

E

• Used by all manual machines and most canned CNC programs.

F

Boring

• F irst choice for work hardening materials and suitable for fine pitches.

Drilling

Radial infeed

ormally used with very large profiles and pitches, long •N work threading cycles where tool life needs to match the length of the thread. • Requires special programming.

Tool holding

G

Incremental infeed

C 19


H

A

How to apply

Turning

Modified flank infeed •M ost CNC machines have a programmed cycle using this infeed. • Chip is similar to that in conventional turning - easier to form and guide. • Chip is thicker, but has contact with only one side of the insert. • Less heat is transferred to the insert. • First choice for most threading operations.


B

Threading

C Feed direction Chip flow

Chip flow

Milling

D

Feed direction Feed direction

E

Drilling

C-geometry insert

•B etter chip control. • Better surfaces. • For C-geometry insert, modified flank infeed is the only suitable infeed.

F

Radial infeed Boring

•M ost commonly used method - and only method possible on older non-CNC lathes. • Makes a stiff “V” chip. • Even insert wear. • Insert tip exposed to high temperatures, which restricts depth of infeed. • Suitable for fine pitches. • Vibration possible and poor chip control in coarse pitches. • First choice for work hardening materials.

Tool holding

G


H

C 20

How to apply

A

Turning

Incremental infeed •E ven insert wear and longest tool life in very coarse threads.

B

•C hips are directed both ways, making control difficult.


• Recommended for large profiles.

C Threading

Programming methods Ways of improving the machining result Decreasing depth per pass (Constant chip area)

Milling

• T he deepest pass is the first pass. • Follows recommendation on infeed tables in catalog. • More “balanced” chip area. • Last pass actually around .0028 inch (0.07 mm).

E

Drilling

Allows for constant chip area. This is the most common method in CNC programs.

D

F

G Tool holding

•M uch more demanding on the insert. • Offers best chip control. • Should not be used for pitches larger than 1.5 mm or 16 t.p.i.

H

C 21


Each pass is of an equal depth, regardless of the number of passes.

Boring

Constant depth per pass

A

How to apply

Use extra stock/material for topping the thread

B

For topping inserts, .001 – .003 inch (0.03 -– 0.07 mm) material should be left from prior turning operations to allow for proper forming of the crest.


Turning

Threading with full profile inserts

Threading

C

~.005

Infeed values recommendations ISO inch, external

Drilling

E

Boring

F

Tool holding

G


•A dd extra stock/material on the workpiece diameter, .002 – .006 inch (0.06 -– 0.14 mm) for topping the finish diameter of the thread.

Number of infeeds and total depth of thread.

Milling

D

• T he blank does not need to be turned to the exact diameter prior to the threading.

+.004 0

C 22

How to apply

A

Use maximum deviation of ±.004 inch (±0.1 mm) from centerline.

Max ±.004 inch (± 0.1 mm)

Turning

Positioning of the tool B

Too high cutting edge


• Clearance will decrease. • Cutting edge will rub (break). Too low cutting edge

C

Method of threading

Threading

• The thread profile can be incorrect.

Right and left hand threads and inserts

D

Internal

Right hand threads

Left hand threads

Right hand threads

Left hand threads

Milling

External

E

Left hand tool/insert

Right hand tool/insert


Drilling


F






Boring


G Tool holding



H

A negative shim must be used.

C 23




A

Troubleshooting

Turning

Thread turning application hints


B

Threading

C

Milling

D

•C heck the workpiece diameter for correct working allowance before threadturning (add .006 inch (0.14 mm) as crest allowance). osition the tool accurately in the •P machine. heck the setting of the cutting edge in •C relation to pitch diameter. •M ake sure the correct insert geometry is used (all-purpose, F or C). • Ensure there is sufficent and even clearance (insert-inclination shims) to achieve correct flank clearance by selecting the appropriate shim.

ptimize infeed method, number and •O size of passes. nsure the correct cutting speed for the •E demands of the application. • In case of pitch error on component thread, check to see if machine pitch is correct. • It is recommended that the tool should start a minimum distance of 3 times the thread pitch before engaging the workpiece.

• If threads are rejected, check entire setup, including machine tool. heck the available CNC program for •C thread turning.

Drilling

E

Some vital factors to consider to achieve success

Boring

F

Tool holding

G


H

 C 24

Troubleshooting Problem

Cause

Solution

1. Excessive temperature in cutting zone.

educe the cutting speed, 1. R increase the number of infeeds.

Plastic deformation

Starts as plastic deformation (A).

2. Inadequate supply of coolant. 3. Wrong grade.

Reduce the largest infeed depth, check the diameter before threading. 2. Improve coolant supply.

which leads to edge chipping (B).

3. C hoose a grade with better resistance to plastic deformation.

D

Built-up edge (BUE) ften occurs in stainless -O material.

B

BUE (A) and edge spalling (B) often occur in combination. Accumulated BUE is then ripped away together with small amounts of insert material, which leads to spalling.

ften occurs in low carbon -O steel.

- Increase cutting speed. -C hoose an insert with good toughness, preferably PVD coated.

- Unsuitable grade.

E

-C utting edge temperature too low.

Drilling

A

C Threading

B


B

Milling

A

A

Turning

Troubleshooting

F

3. Wrong grade. 4. Poor chip control. 5. Center height incorrect.

2. Increase number of infeeds. Reduce size of the largest infeeds. 3. Choose a tougher grade. 4. C hange to C-geometry and use modified flank infeed. 5. Correct center height.

 C 25

G Tool holding

2. Infeed series too tough.

1. Turn to correct diameter before threading operation, .001 – .003 inch (0.03 – 0.07 mm) radially larger than max. diameter for thread.


1. Wrong turned diameter prior to threading.

Boring

Insert breakage

A

Troubleshooting

Turning

Problem

Cause

Solution

1. Highly abrasive material.

1. W rong grade. Choose a more wear resistant grade.

Rapid flank wear

B

2. Cutting speed too high.


3. Infeed depths too shallow. 4. Insert is above center line.

2. Reduce cutting speed. 3. Reduce number of infeeds. 4. Correct center height.

Threading

C Abnormal flank wear 1. Incorrect method for flank infeed. 2. Insert inclination angle does not agree with the lead angle of the thread.

D

hange shim to obtain 2. C correct angle of inclination.

Milling

Poor surface on one flank of thread.

1. C hange method of flank infeed for F-geometry and standard geometry; 3 - 5° from flank, for C-geometry; 1° from flank.

E Vibration Drilling

1. Incorrect clamping of the workpiece. 2. Incorrect setup of the tool.

F

3. Incorrect cutting data. 4. Incorrect center height.

1. Use soft jaws. 2. O ptimize center hole and check pressure of face driver. Minimize overhang of tool.

Boring

Check that the clamping sleeve for bars is not worn. Use 570-3 anti-vibration bars.

G Tool holding

3. Increase cutting speed; if this does not help, lower the speed dramatically. Try F-geometry. 4. Adjust center height.


H

 C 26

Solution

1. Cutting speed too low.

1. Increase cutting speed.

2. The insert is above the center height.

2. Adjust center height.

Poor surface finish

3. Uncontrolled chips.

3. U se C-geometry and modified flank infeed.

1. Incorrect method of infeed.

1. Modified flank infeed 3 - 5°.

2. Incorrect thread geometry.

2. U se C-geometry with modified flank infeed 1°.

1. Wrong center height.


2. Insert breakage. Excessive wear.

2. Change cutting edge.

1. Unsuitable thread profile (angle of thread and nose radius) external inserts used for internal operation or vice versa.

1. C orrect tool, shim and insert combination.

3. Adjust to 90°.

2. Wrong center height.

4. Correct the machine.

Poor chip control

Turning

Cause

B

C

Shallow profile

Threading

Problem

A


Troubleshooting

Milling

D

Incorrect thread profile

E

Drilling


F

3. Holder not 90° to center line.

Boring

4. Pitch error in machine.

1. R educe the number of infeeds.

2. Excessive pressure on cutting edge.

2. Change to a tougher grade.

3. Profile with too small thread profile angle.

Change to F-geometry.

3. Use modified flank infeed.

C 27


1. Work hardening material in combination with infeed depths which are too shallow.

Tool holding

G

Excessive edge pressure

D2

Milling Milling is performed with a rotating, multi-edge cutting tool which performs programmed feed movements against a workpiece in almost any direction. Milling is mostly applied to generate flat faces, but with the development of machines and software there are increasing demands to produce other forms and surfaces.

• Theory

D4


D9

• System overview

D 13

• Choice of inserts – how to apply

D 24

• Choice of tools – how to apply

D 29

• Troubleshooting

D 36

D3

Turning

A

Milling theory Definitions of terms Spindle speed, cutting speed and cutter diameter


B

Theory

n = S pindle speed, rpm (revolutions per minute)

C

vc = Cutting speed (ft/min) (m/min)

Threading

ve = E ffective cutting speed (ft/min) (m/min) Dc = Cutter diameter (inch) (mm) De = Dcap = C utting diameter (inch) (mm) [at cutting depth]

Milling

D

Drilling

E

Boring

F

Cutting speed (vc) in ft/min (m/min) indicates the surface speed at which the cutting edge machines the workpiece. Specified cutter diameter (Dc), having an effective cutting diameter (De), which is the basis for the cutting speed vc or ve.

Tool holding

G

Spindle speed (n) in rpm is the number of revolutions the milling tool on the spindle makes per minute.


H

 D4

Theory

A

Turning

 Feed, number of teeth and spindle speed


fz = F eed per tooth (inch/tooth) (mm/ tooth) vf = Table feed (inch/min) (mm/min) zn = Number of cutter teeth (pcs)

C

zc = E ffective number of teeth (pcs) [in engagement]

Threading

fn = F eed per revolution (inch/rev) (mm/rev) [fz x zc] n = Spindle speed (rpm)

vf = fz × zc × n

Milling

D

inch/min (mm/min)

Drilling

E

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 thickness value.

F

Boring

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 time-unit related to feed per tooth and number of teeth in the cutter.

G Tool holding

The number of available cutter teeth in the tool (zn) varies considerably and is used to determine the table feed while the effective number of teeth (zc) is the number of effective teeth in cut. Feed per revolution (fn) in inch/rev (mm/rev) is a value used specifically for feed calculations and often to determine the finishing capability of a cutter.

 D5


H

A

Theory

Turning

Definitions of terms Depth of cut ae = R adial depth of cut (inch) (mm) [working engagement]


ap = Axial depth of cut (inch) (mm)

Threading

C

D

Axial depth of cut, ap inch (mm), is what the tool removes in metal on the face of the workpiece. This is the distance the tool is set below the unmachined surface.

Radial cutting width, ae inch (mm), is the width of the component engaged in cut by the diameter of the cutter. It is the distance across the surface being machined or, if the tool diameter is smaller, that is covered by the tool.

Net power, torque and specific cutting force ap = Axial depth of cut (inch) (mm)

Milling

ae = Radial depth of cut (inch) (mm) [working engagement] vf = Table feed (inch/min) (mm/min)

E

kc = Specific cutting force (lbs/inch2) (N/mm2)

Drilling

Pc = Net power (Hp) (kW)

Boring

F

Tool holding

G


H

Mc = Torque (lbf ft) (Nm)

The net power (Pc) is the power the machine must be able to provide to the cutting edges in order to drive the cutting action. The efficiency of the machine must be taken into consideration when selecting cutting data. The torque (Mc) is the torque value produced by the tool during cutting action, which the machine must be able to provide.

The specific cutting force value (kc) is a material constant, expressed in lbs/inch2 (N/mm2). The values can be found in our main ordering catalog and technical guide. D6

Inch Pc =

ap × ae × vf × kc 396 × 103

Hp

Metric Pc =

ap × ae × vf × kc 60 × 106

kW

Inch Mc =

Pc × 16501 π×n

lbf ft

Metric Mc =

Pc × 30 × 103 π×n

Nm

Theory

A

Turning

Climb or conventional milling Climb milling – preferred method • In climb milling, the insert starts its cut with a large chip thickness.


Using climb milling (also referred to as down milling), the burnishing effect is avoided, resulting in less heat and minimal workhardening tendency.

C

Always use climb milling for best cutting conditions.

F

Boring

The position of the cutter in relation to the workpiece engagement, and the contact which the cutter teeth have, are vital factors for a successful operation.

Drilling

E

Cutter diameter and position

•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) - 1/3 out of cut, 1.969 inch (50 mm). y moving the milling cutter off the center, a more •B constant and favorable direction of cutting forces will be obtained.

D7

Tool holding

The selection of milling cutter diameter is usually made on the basis of the workpiece width with the availability of the machine power also being taken into account.

D

Milling

• In conventional milling (also referred to as up milling) the chip thickness starts at zero and increases to the end of the cut.


The feed direction of the workpiece is opposite to that of the cutter rotation at the area of cut.

Threading

Conventional milling

A

Theory

Turning

Chip formation through cutter position


B

The cutting edge in a radial direction engages with the workpiece in three different phases: 1. Entrance into cut 2. Arc of engagement in cut 3. Exit from cut

C

Dc = Cutter diameter ae = working engagement

Threading

The centerline of the cutter is well inside the workpiece width, ae >75% of Dc. • M ost favorable cutting conditions and optimized use of the cutter diameter.

D

Milling

• T he initial impact at the entry of cut is taken up further along the cutting edge, away from the sensitive tip. • The insert leaves the cut gradually.

E

T he centerline of the cutter is well outside the workpiece width, ae <25% of Dc. • The angle of entry is positive

Drilling

• T he impact at the entry is taken up by the outermost tip of the insert and the load is gradually taken up by the the tool.

F

Boring

The centerline of the cutter is in line with the workpiece edge, ae = 50% of Dc. • Not recommended.

G Tool holding

• T he shock loads at the cutting edge are very high at entry.

= Recommended cutter position.


H

= Alternative cutter position. = Not recommended cutter position.

D8

Selection procedure

Turning

Selection procedure

A

Production planning process


B

Type of operation and method

C

1

Component Threading

Workpiece material and quantity

2

Machine

Milling

D

Machine parameters

E

Choice of tool

Select type of cutter

Drilling

3

4

How to apply

Boring

F

Cutting data, method etc.

Troubleshooting


H

D9


5

Tool holding

G

A

Selection procedure

Turning


B

Geometric shape


• Flat surface • Deep cavities • Thin walls/bases • Slots

Threading

C

P M K N S H

Milling

D

Material

Tolerances

• Machinability

• Dimensional accuracy

• Chip forming

• Surface finish

• Hardness

• Part distortion

• Alloy elements

• Surface integrity

Drilling

E

Condition of the machine

Boring

F

2. Machine parameters

G

Tool holding

• Available power

• Long overhang

• Age/condition – stability

• Poor holding

• Horizontal/vertical

• Axial/radial runout

• Spindle type and size

Tool holding

•N umber of axes/configuration • Workpiece clamping


Material

D 10

Selection procedure

A

Turning

3. Choice of tools Different ways to optimize milling Cutters with round inserts Disadvantages

• Robust milling cutters.

•R ound inserts require more stable machines.

•V ery flexible for face milling and profiling.


B Advantages

C Threading

•H igh performance multipurpose cutters.

45° face mill Disadvantages

•G eneral choice for face milling.

• Max cutting depth .236-.394 inch (6-10 mm).

E

Drilling

• Smooth entry into cut.

90° square shoulder face mill

F

Disadvantages

• Great versatility.

• F eed per tooth is relatively low while fz = hex.

• Large depth of cut.

Boring

Advantages

• L ow axial cutting forces (thin workpieces).

G Tool holding

• Light-cutting inserts with true four edges.

H

D 11


•B alanced radial and axial cutting forces.

D

Milling

Advantages

A

Selection procedure

Important application considerations

B

Number of cutting edges/pitch


Turning

4. How to apply

•S electing the right number of edges or pitch is very important. • It affects both productivity and stability.

C

Insert geometry Threading

•S elect between a geometry for Light, Medium or Heavy machining.

•C hoose largest possible spindle size or outer diameter. Chip formation through cutter positioning •A lways use climb milling. • Move the cutter off the center. • Use a cutter with a diameter 20–50% larger than the cut.

Milling

D

Stability

E

Drilling

5. Troubleshooting Some areas to consider Insert wear and tool life

Boring

•C heck the wear pattern and if necessary adjust the cutting data accordingly.

G

Vibration

Tool holding

F

• • • •


H

D 12

eak fixture. W Long tool overhang. Weak workpiece. Size of spindle taper.

Unsatisfactory surface finish •C heck spindle runout. • Use wiper inserts. • Decrease feed per tooth.

System overview

Turning

System overview

A

Face milling

B

Cutters for general use


Face milling cutter with round inserts for tough conditions

Face and square shoulder milling cutter for light face milling operations

C Threading

General purpose face milling cutter with 45° lead (entering) angle

Milling

D

E

High feed face milling

Drilling

Dedicated cutters Face milling cutters for cast iron machining

K

Boring

F

G

Heavy duty face milling

Tool holding

Face milling cutters for aluminum machining

N

 D 13


H

A

Selection procedure

Turning

Shoulder milling Cutters for general use Face and shoulder milling for light shoulder milling operations


Face and shoulder milling cutter for heavy machining

Threading

C

Side and face milling cutter used for shoulder milling operation

D

Milling

End mills and long edge cutters

Indexable insert end mill

Drilling

E

End mill with exchangeable, solid carbide head

F Long edge milling cutter

Boring

Solid carbide end mill

G

Dedicated cutters Edging with square shoulder milling cutters

Tool holding

Deep shoulder milling


H

 D 14

System overview

A

Turning

 Profiling Cutters for general use – roughing Round insert cutter


B

Round insert end mill

Threading

C

D

Cutters for general use – finishing Milling

End mill with exchangeable, solid carbide head Solid carbide ball nose end mill

Drilling

E

Boring

F

Other methods

G Tool holding

Blade milling

H

 D 15


Turn milling

A

System overview

Turning

Slot milling Side and face mill for slot milling


B

Cutters for general use – radial slot milling

Slitting cutter for grooving and parting off

Threading

C

Cutter for external, shallow grooving and slotting

Cutters for general use – axial slot milling

Milling

D

End mill for internal shallow grooving and slotting

End mill with exchangeable, solid carbide head

E


Long edge milling cutter

Drilling


Boring

F

Thread milling

G Tool holding


Indexable insert cutter Indexable insert end mill


H

D 16

System overview

A

Face milling

High-feed milling


Tooling developments have also contributed to the new possibilities, along with the gains in productivity, reliablity and quality consistency that have been made in indexable insert and solid carbide technology.

C Shoulder milling

Slot milling

Threading

Modern milling is a very universal machining method. During the past few years, hand-in-hand with machine tool developments, milling has evolved into a method that machines a very broad range of configurations. The choice of methods in multi-axis machinery makes milling a strong contender for producing holes, cavities, surfaces that used to be turned, threads, etc.

Turning

Overview of milling operations

Cutting off

Chamfering

Profile milling

Milling

D

Turn milling

Drilling

E

Trochoidal milling

Circular milling

Linear ramping

F

Boring

Plunge milling

G Tool holding

Thread milling

H

D 17


Circular ramping

A

System overview

B

Milling machines may be manually operated, mechanically automated, or digitally automated via computer numerical control (CNC).


Turning

Milling methods

Conventional milling methods Vertical milling machines In conventional 3-axis machines, milling most frequently entails the generation of flat faces, shoulders and slots.

Threading

C

Surfaces and forms, other than those described below, are increasing steadily as the number of five-axis machining centers and multi-task machines grows.

Milling

D

Drilling

E

Face milling

High-feed milling

Shoulder milling

Cutting off

Chamfering

Plunge milling

Boring

F

Tool holding

G


H

D 18

Slot milling

System overview

A

Turning

Advanced milling methods 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, and machining centers have turning capability via turnmill or mill-turn machines. CAM developments mean that 5-axis machines are increasing.


B

Threading

• Increased flexibility • Fewer machines/setups to complete a component • Reduced stability • Longer tool lengths • Lower depth of cut.

C

D

Milling

The results of these trends and the development of methods put new demands and opportunities on the tooling, such as:

Turn milling

Trochoidal milling

Circular milling

F

Boring

Profile milling

Drilling

E

G Thread milling Tool holding

Circular ramping

H

D 19


Linear ramping

A

System overview

Turning

Positioning of cutters for face milling Type of milling cutter


B

Threading

C

Milling

D

E

Considerations

Round inserts

10°

45°

90°

ISO 40, 50

ISO 40, 50

ISO 40, 50

ISO 30, 40, 50

High

High

Medium

Low

Roughing

Very good

Good

Very good

Acceptable

Finishing

Acceptable

Acceptable

Very good

Good

Medium

Small

Medium

High

Versatility

Very good

Good

Good

Very good

Productivity

Very good

Very good

Very good

Good

Machine/spindle size Stability requirement

Drilling

Cutting depth ap

Boring

F

Tool holding

G


H

D 20

System overview

A

Turning

Positioning of cutters for shoulder milling Type of milling cutter


B

90°

90°

ISO 40, 50

ISO 30, 40, 50

ISO 40, 50

ISO 30, 40, 50

High

High

Medium

Low

D

Roughing

Very good

Good

Acceptable

Good

Finishing

Acceptable

Acceptable

Very good

Good

Large

Medium

Small

Large

All

All

Aluminum

Aluminum

Very good

Very good

Acceptable

Good

Machine/spindle size Stability requirement

E

Drilling

Cutting depth ap

Milling

90°

Threading

C

90°

Considerations

Boring

G Tool holding

Versatility

F

H

D 21


Material

A

System overview

Turning

Positioning of cutters for profile milling Type of milling cutter


B

Threading

C

Milling

D

E

Round inserts

Ball nose

Ball nose

Ball nose

ISO 40, 50

ISO 40, 50

ISO 30, 40

ISO 30, 40

High

Medium

Medium

Low

Roughing

Very good

Good

Acceptable

Acceptable

Finishing

Acceptable

Acceptable

Very good

Very good

Medium

Medium

Small

Small

Versatility

Very good

Very good

Very good

Very good

Productivity

Very good

Good

Good

Good

Considerations Machine/spindle size Stability requirement

Drilling

Cutting depth ap

Boring

F

Tool holding

G


H

D 22

System overview

A

Turning

Positioning of cutters for slots and grooves Type of milling cutter


B

Slot open Slot closed Cutting width Cutting depth ap inch (mm) Versatility

Grooving

Long edge

ISO 50

ISO 40, 50

ISO 40, 50

Open

Open

Open

Threading

Machine/spindle size

C

Side and face

–

–

–

D

Small

Small

Very good

≤4.508 (≤114.5)

≤.256 (≤6.5)

Good

Limited

Good

Good

Milling

Considerations

E

Drilling

Type of milling cutter


Exchangablehead end mill


Machine/spindle size

ISO 30, 40, 50

ISO 30, 40, 50

ISO 30, 40, 50

Open

Open

Open

Closed

Closed

Closed

Good

Small

Small

Cutting depth ap

Very good

Small

Large

H

Versatility

Very good

Very good

Very good

Slot closed Cutting width

D 23

G


Slot open

Boring

Considerations

Tool holding

F

Turning

A

Choice of inserts – how to apply

Choice of inserts and how to apply


B

Modern milling inserts for face milling operations.

Threading

C

D

Milling

The design of a modern milling insert E

Definitions of terms and geometry design

Drilling

Corner design

Main cutting edge design

.005

.005

Boring

F

Tool holding

G

•C utting edge reinforcement .005 inch (0.13 mm). • Rake angle 30°.

Corner reinforcement


• Rake angle 30°. • Primary land 17°.

• Primary land 11°.

Chip former

D 24

•C utting edge reinforcement .005 inch (0.13 mm).



A

Turning

Making the tool choice in milling First choice High

B

Cutter pitch

H

M

L Close pitch (-M)

Extra close pitch (-H)

Light (-L)

Medium (-M)

Heavy (-H)

C Threading

Coarse pitch (-L)


Operation stability

Low

D

Toughness

Milling

Machining conditions/ Grades

Wear resistant

E Good conditions

Difficult conditions Drilling

Average conditions

Type of application

L

Tool holding

M

G

Medium milling • Most applications – general purpose milling. • Medium operations to light roughing. • Medium depth of cut and feed rate.

Light milling • Operations at small depth of cut and low feed rates. • Operations requiring low cutting forces.

H fn

Feed, inch/tooth (mm/tooth)

D 25


H

Heavy milling • Operation for maximum stock removal and/or severe conditions. • Larger depth of cut and feed rate. • Operations requiring highest edge security.

Boring

F

ap Depth of cut, inch (mm)

A


Turning

Selecting the insert geometry


B

C

Light (-L) • Extra positive.

Threading

• Light machining. • Low cutting forces. • Low feed rates.

Medium (-M) •G eneral purpose geometry. • Medium feed rates. •M edium operations to light roughing.

Heavy (-H) • Reinforced cutting edge. • Heavy machining. • Highest edge security. • High feed rates.

Milling

D

E

Achieving good surface finish in milling

Drilling

Surface roughness Standard insert

•U se wiper inserts for higher productivity and improved surface finish.

One wiper insert

• L imit the feed to 60% of the parallel land.

F

Boring

•M ount the wiper inserts correctly. fn1 = ≤.031 x bs1 (fn1 = ≤0.8 x bs1)

G


 

H

fn Feed, inch/tooth (mm/tooth)

bs2

Tool holding

bs1

fn1 = ≤.024 x bs2 (fn1 = ≤0.6 x bs2)

bs, inch .079 (mm) (2.0)

D 26

.323 (8.2)

.002 inch (0.05 mm)

•S et the wiper inserts below other inserts.


A

Turning

How to select insert grade Select the geometry and grade according to the application.

B

Machining conditions


Build-up of a grade chart Good

Average

C Threading

Difficult

Average

Difficult

D

Milling

Good

Define machining conditions

Drilling

E

F

•C utting depth 25% of max ap or less.

•C utting depth 50% of max ap or more.

•C utting depth 50% of max ap or more.

• Overhang under two times cutter diameter.

•O verhang two to three times cutter diameter.

•O verhang over three times cutter diameter.

• Continuous cuts.

• Interrupted cuts.

• Interrupted cuts.

• Wet or dry machining.



Boring

Difficult conditions

G Tool holding

Average conditions

H

 D 27


Good conditions

A

Choice of inserts and – to apply

Turning

Dedicated grades for ISO P, M and K


B

C

Dedicated grades minimize tool wear development The workpiece material influences the wear during the cutting action in different ways. Therefore dedicated grades have been developed to cope with the basic wear mechanisms, e.g.: - Flank wear, crater wear and plastic deformation in steel - Built-up edge and notch wear in stainless steel

Threading

- Flank wear and plastic deformation in cast iron.

D

Milling

Select geometry and grade depending on the type of workpiece material and type of application.

Drilling

E

Boring

F

G ISO

Tool holding

P


H

D 28

GC 4200

ISO

M

GC 2000

ISO

K

GC 3200


Turning

Choice of cutter and how to apply

A


B

High performace face milling cutters for small to medium cutting depths.

Threading

C

D

Milling

Making the tool choice in milling First choice Operation stability

Low

E

High

Close pitch (-M)


F

Boring

Coarse pitch (-L)

H

M

L

Drilling

Cutter pitch

G

Wear resistant

Medium (-M) Machining conditions/ Grades

Heavy (-H)

Tool holding

Light (-L)

Toughness

Good conditions

Average conditions

Difficult conditions D 29


H

A


Turning

Selecting cutter pitches First choice Operation stability

Low

B

High


Cutter pitch

Threading

C

D

Coarse pitch (-L) •R educed number of inserts. • Limited stability.

Milling

• Long overhang.

E

H

M

L

•S mall machines/limited horsepower.


Close pitch (-M) • General purpose •S uitable for mixed production. •S mall to medium machines

•H igh number of inserts for maximum productivity. • Stable conditions. • Short chipping materials. • Heat resistant materials.

• Usually first choice.

•D eep, full slotting operations.

Drilling

• Differential pitch.

F

Limited stability

Stable conditions



Boring

First choice

G Tool holding

Long overhang

Limited horsepower


H

D 30

K

S

Cast iron (CMC 08)

Heat resistant alloys (CMC 20)


A

Turning

Cutting forces and entering angle 45° entering angle

Round insert cutters


90° entering angle

Threading

C

Milling

D

• General purpose cutter.

•C hip thinning effect allows increased productivity.

• Increased chip thinning effect for heat resistant alloys.

Drilling

educed vibration on •R long overhang.

E

F

Boring

here 90° form is •W required.

•S trongest cutting edge with multiple indexes.

G Tool holding

eak-fixtured compo•W nents.

•G eneral purpose first choice.

H

D 31


• Thin-walled components

A


Turning

Axial and radial cutting forces Effect of entering angle (90º)

B

• Thin-walled components.


• Axially weak fixtured components. • Square shoulder • hex = fz (In case ae > 50% x Dc)

Threading

C

Effect of entering angle (45º) • General purpose 1st choice.

D

• Reduced vibration on long tool overhang.

Milling

•C hip thinning effect allows increased productivity. • fz = 1.41 x hex (Compensating for entering angle).

Drilling

E

Effect of entering angle (90º) On round inserts, the chip load and entering angle vary with the depth of cut.

•S trongest cutting edge with multiple indexes.

Boring

F

• General purpose cutter.

G Tool holding

• Increased chip thinning effect for heat resistant alloys. • hex = depends on ap.


H

D 32


A

Turning

Formulas for cutters with round inserts Max. cutting diameter at a specific depth (inch). iC2 – (iC – 2 × ap)2


√

Facemilling round insert (ap
hex × iC 2 × √ ap × iC – ap 2

Threading

fz =

C

Slide milling (ae
hex × iC × Dcap 4 × √ ap × iC – ap 2 × √Dcap × ae – ae 2

E

Drilling

Feed compensation for different entering angles 90° = (fz or hex) × 1.0

Boring

F

45° = (fz or hex) × 1.41

Tool holding

G

Round = depends on ap

H

D 33


fz =

D

Milling

Dcap = Dc +

B

A


Turning

Calculating cutting data


B

Example in face milling Need:

Given:

Spindle speed, n (rpm)

Cutting speed, vc = 738 ft/min (225 m/min)

.157 (4 mm)

Table feed, vf (inch/min) (mm/min)

Feed per tooth, fz = .0082 inch (0.21 mm)

Metal removal rate, Q (inch3/min) (cm3/min)

Number of cutter teeth, zn = 5

C

Power consumption (Hp) (kW)

Cutter diameter, Dc = 4.921 inch (125 mm)

3.346 (85 mm)

Threading

Cutting depth, ap = .157 inch (4 mm) Working engagement, ae = 3.346 inch (85 mm)

D

Milling

Spindle speed Inch

n= Drilling

Metric n=

E

F

Given: vc = 738 ft/min (225 m/min)

vc × 12 π × Dc

738 × 12 3.14 × 4.921

Table feed

(rpm)

= 575 rpm

n=

n=

Boring Tool holding

3.14 × 125

= 575 rpm

vf = n × fz × zn (mm/min)

vf = 575 × .0082 × 5 = 23.6 inch/min

Metal removal rate

Given vf = 23.6 inch/min (600 mm/min)

Inch Q = ap × ae × vf

vf = 575 × 0.21 × 5 = 600 mm/min

Metric (inch3/min)

Q=


225 × 1000

(rpm)

Metric vf = n × fz × zn (inch/min)

Q = .157 × 3.346 × 23.6 = 12.4 inch3/min D 34

π × Dc

Given: n = 575 rpm

Inch

G

vc × 1000

Q=

ap × ae × vf 1000 4 × 85 × 600 1000

(cm3/min)

= 204 cm3/min


A

Turning

Net power consumption Given: Material CMC 02.1 Metric

Pc =

ae × ap × vf × kc 396 × 103

(Hp)

Pc =

B ae × ap × vf × kc1

(kW)

60 × 106


Inch

C Cutting

Specific cutting force kc 1

02.1 02.2 03.11 03.13 03.21 03.22 06.1 06.2 06.3

Low alloyed (alloying elements d 5%) Non-hardened Hardened and tempered High alloyed (alloying elements > 5%) Annealed Hardened tool steel

Castings Unalloyed Low alloyed (alloying elements d 5%) High alloyed (alloying elements > 5%)

N/mm2

HB

mc

1500 1600 1700 1800 2000

125 150 170 210 300

0.25 0.25 0.25 0.25 0.25

430–390–50 385–350–15 365–330–00 315–290–60 235–210–95

1700 1900

175 300

0.25 0.25

300–275–45 195–180–60

1950 2150 2900 3100

200 200 300 380

0.25 0.25 0.25 0.25

230–205–85 190–170–55 165–150–35 105–95–85

1400 1600 1950

150 200 200

0.25 0.25 0.25

305–280–50 245–220–00 180–160–45

mc

CT530 Max chip thickness 0.1 – 0.15 – 0.2 Cutting speed vc, m

Specific cutting force kc 1 CMC ISO No.

Material Stainless steel

Ferritic/martensitic Hp = 7.7 Pc = 05.11 Non-hardened

396 × 103

05.12 05.13 05.21 05.22

PH-hardened Hardened Austenitic Non-hardened PH-hardened Austenitic-ferritic (Duplex) Non-weldable t 0.05%C Weldable < 0.05%C Stainless steel – Cast Ferritic/martensitic Non-hardened PH-hardened Hardened Austenitic PH-hardened Austenitic-ferritic (Duplex) Non-weldable t 0.05%C Weldable < 0.05%C

The calculation above is approximate05.51and valid for an 05.52 inch (0.1 mm). maximum chip thickness (hex) of .0039 For a more accurate value of power consumption (Pc) the 15.11 15.12 kc value should be calculated accordingly. 15.13 15.21 15.22

Inch kc = kc1 × hm-mc × 1 – 100 Metric

( )

γo kc = kc1 × hm-mc × 1 – 100

15.51 15.52

60 × 106

HB

= 5.8 kW 200 0.21

1800 2850 2350

330 330

0.21 0.21

285 –255 –230 205 –185 –165 215 –190 –170

1950 2850

200 330

0.21 0.21

265 –240 –215 200 –175 –160

2000 2450

230 260

0.21 0.21

260 –235 –210 230 –205 –185

1700 2450 2150 1800 2450

200 330 330 200 330

0.25 0.25 0.25 0.25 0.25

255 –230 –205 180 –160 –145 195 –175 –155 255 –225 –205 180 –160 –145

230 260

0.25 0.25

245 –220 –195 215 –190 –170

1800 2250 Specific cutting force kc 1

Hardness Brinell

F

G

CB50 hm = Average chip thickness Max chip thickness 0.1 – 0.15 – 0.2 CMC ISO No. Material γ mc N/mm HB Cutting speed v , m o = Insert rake angle Malleable cast iron K 07.1 Ferritic (short chipping) 790 130 0.28 = C hip thickness compensation factor m c 07.2 Pearlitic (long chipping) 900 230 0.28 Grey cast iron 08.1 Low tensile k strength 180 0.28 850 –720 –620 c = Specific cutting force 890 08.2 High tensile strength 1100 245 0.28 910 –780 –670 Nodular cast iron = S pecific cutting force for average chip k c1 09.1 Ferritic 900 160 0.28 09.2 0.28 495 –420 –360 thickness .039 inch1350 (1 mm)250 2) Pearlitic (N/mm H 45-60q entering angle. Positive cutting geometry and coolant should be used.

(lbs/inch2)

2

c

Tool holding

( ) γo

N/mm2

85 × 4 × 600 × 1700

E

1)

100 mm

125 mm

D 35 MILLING Cutting data


Pc =

3.346 × .157 × 23.6 × 246500 M

Hardness Brinell

D

Milling

01.1 01.2 01.3 01.4 01.5

Material Steel Unalloyed C = 0.10 – 0.25% C = 0.25 – 0.55% C = 0.55 – 0.80%

Drilling

P

CT530 Max chip thickness 0.1 – 0.15 – 0.2 Cutting speed vc, m

Boring

CMC ISO No.

Hardness Brinell

Threading

Milling with large engagement Metric

Condit Cutter, over the engage

A

Troubleshooting

Turning

Application hints for milling Power capacity • Check power capability and machine rigidity, making sure that the machine can handle the cutter diameter required.


B

Overhang • Machine with the shortest possible tool overhang on the spindle.

C Threading

Select correct cutter pitch • Use the correct cutter pitch for the operation to ensure that there are not too many inserts engaged in cut, as this may cause vibration.

D

Milling

Cutting engagement • Ensure there is sufficient insert engagement with narrow workpieces or when milling over voids.

E

Drilling

Up to .020 inch (0.50 mm) Use correct feed • Ensure that the right feed per insert is used to achieve the right cutting action by use of the recommended maximum chip thickness.

Boring

F

Cutting direction • Use climb (down) milling whenever possible.

Tool holding

G


H

 D 36

Choice of insert geometry • Use positive geometry indexable inserts whenever possible for smooth cutting action and lowest power consumption.

Turning

Dampened milling tools

Entering angle • Select the most suitable entering angle.

C Threading

• For longer overhang of more than 4 times the tool diameter, vibration tendencies can become more apparent, and dampened cutters can improve the productivity radically.

B

Cutter diameter • Select the right diameter in relation to the workpiece width. Cutter position • Position the milling cutter correctly.

Milling

D

F

Boring

Coolant • Only use coolant if considered necessary. Milling is generally performed better without.

Drilling

E

G Tool holding

Maintenance • Follow tool maintenance recommendations and monitor tool wear.

H

D 37




A


Troubleshooting

2

Drilling Drilling covers methods of making cylindrical holes in a workpiece with metal cutting tools

• Theory

E6


E 15

• System overview

E 20

• How to apply

E 26

• Hole quality and tolerances

E 37

• Troubleshooting

E 42

E3

Turning

A

Theory

The drilling process • T he drill is always engulfed in the workpiece, leaving no view of the operation.


• Chips must be controlled. hip evacuation is essential; it affects •C hole quality, tool life and reliability.

Threading

C

Milling

D

Four common drilling methods

E Drilling

Trepanning

Drilling

Drilling is classified into four common methods: - Drilling

F

- Trepanning - Chamfer drilling

Boring

- Step drilling

Chamfer drilling

Tool holding

G


H

E4

Step drilling

Theory

A

Turning

The most common holes


B

Threading

C

1 2 3 4 5

6

Milling

The most common holes are:

D

1 Holes with clearance for bolts

E

2 Holes with a screw thread 3 Countersink holes

6 Holes to remove weight for balancing.

F

Boring

5 Holes that form channels

Drilling

4 Holes that have a good fit

Tool holding

G

E5


H

A

Theory

Turning

Maximum hole depth


Chip evacuation

Maximum hole depth is a function of hole diameter Dc and hole depth (l4). Example: max hole depth l4 = 3 x Dc.

Threading

C

Milling

D

Drilling

E

Boring

F

Tool holding

G


Hole depth (l4) determines the choice of tool.

E6

Theory

Turning

Drilling theory •C utting speed (vc) for indexable drills declines from 100% at the periphery to zero at the center. • T he 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.

C Threading

vc = 0


Cutting speeds for indexable drills

0.5 x vc max

A

vc max

Milling

D

E

Cutting speeds for solid and brazed carbide drills Drilling

• T wo effective cutting edges, from the center to the periphery. • Two edges/rev: z = 2.

Boring

F

G Tool holding

vc max

H

E7


vc = 0

A

Theory

Turning

Solid carbide drill (SCD) vs. high speed drills (HSS)

Solid carbide drill •C hisel edge is practically eliminated with the solid carbide drill.


B

Point angle and chisel edge

C Threading

140º point angle Chisel edge

HSS drill

• T his results in better centering features and cuts chips close to the center of the drill point. This eliminates the need for a center drill.

D

Milling

• T he axial cutting force is reduced considerably, because the chisel edge is eliminated on solid carbide drills.

118º point angle

Drilling

E

F

1

4

2 Chisel edge 3 Primary clearance

2

2

1 Main cutting edge

6

4 Secondary clearance

Boring

5 Flute

Tool holding

G

6 Margin 7 First split 8 Negative chamfer 9 Clearance surface


H

E8

8

1

6 9

3

7 5

•C hisel edge is practically eliminated. • The main cutting edge reaches the center point. • Gives longer life and productivity. • Lower thrust and torque. • Better tolerances.

5

Theory

A

Cutting speed

Turning

Definitions of terms n = spindle speed (rpm)

B



fn = feed per revolution (inch/r) (mm/r) vf = penetration rate (inch/min) (mm/ min) Dc = drill diameter (inch) (mm)

C Inch

π × Dc × n 12

ft/min

Threading

vc = Metric

Productivity in drilling is strongly related to the penetration rate, vf.

π × Dc × n 1000

D m/min

Milling

vc =

vf = fn × n inch/min (mm/min)

E Cutting speeds for indexable drills vc = 0

vc max 2

Drilling

Cutting speed (vc) for indexable drills declines from 100 % at the periphery to zero at the center.

vc max

F

Boring

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.

G vc = 0 Tool holding

Two edges, from the center to the periphery.

vc = max

Two edges/rev: z = 2.

H

 E9


Cutting speeds for solid and brazed carbide drills

A

Theory

Turning




B

Effects of cutting speed – vc (ft/min) (m/min) • Affects the power Pc (Hp) (kW) and torque Mc (lbf-ft) (Nm). • The largest factor determining tool life. igher speed generates higher temperature and in•H creased flank wear, especially on the peripheral corner. •H igher speed is beneficial for chip formation in long chipping, soft materials, i.e., low carbon steel.

Threading

C

Milling

D

Drilling

E

Too high cutting speed causes: - rapid flank wear - plastic deformation - poor hole quality - bad hole tolerance. Too low cutting speed causes: - built-up edge - bad chip evacuation - longer time in cut.

Boring

F

Cutting speed (vc) affects: - tool life - power consumption.

Tool holding

G


H

E 10

Theory

A

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).

Turning

Feed rate


• Controls chip formation. • Contributes to hole quality. • Primarily influences surface finish. • Contributes to mechanical and thermal stress.

Threading

C

fn = fz × 2 inch/r (mm/r)

D

Milling

Feed rate (fn) affects: - chip formation - power consumption - feed force - mechanical and thermal stress on the drill.

E

Drilling

High feed rate: - harder chip breaking - reduced time in cut.

F

Boring

Low cutting speed: - higher risk of drill breakage - reduced hole quality. Low feed rate: - longer, thinner chips - quality improvement - accelerated tool wear - longer time in cut.

Tool holding

G

E 11


H

A

Theory

Turning

Approximate calculation of power consumption CoroDrill® 880

CoroDrill® Delta-C n = spindle speed (rpm) vc = c utting speed (ft/min) (m/min) fn = feed per revolution (inch/rev) (mm/rev) vf = penetration rate (inch/min) (mm/min) Dc = drill diameter (inch) (mm) fz = feed per edge (inch) (mm) kc1 = specific cutting force (lbf ft/ inch2) (N/mm2) Pc = power consumption (Hp) (kW) Ff = feed force (N) Mc = torque (lbf ft) (Nm)


B

Threading

C

Milling

D

Inch

E

fn × vc × Dc × kc1 132 × 103

Hp

Drilling

Pc =

Metric

Boring

F

Tool holding

G

For information about the kc value, see page H16.


H

E 12

Pc =

fn × vc × Dc × kc1 240 × 103

kW

Theory

A

CoroDrill® Delta-C


CoroDrill® 880

Turning

Accurate calculation of power consumption

Pc =

Metric

fn × vc × Dc × kc 132 × 103

Pc =

Hp

D

fn × vc × Dc × kc

kW

240 × 103

κr)-mc ×

(

1–

γ0

100

)

E

Drilling

kc = kc1 × (fz × sin

Milling

Inch

C Threading

γ0 = 30°

Boring

F

Tool holding

G

For information about the kc value, see page H16.

E 13


H

A

Theory

Turning

Calculation of torque and feed force


B

C

n = Spindle speed (rpm) fn = F eed per revolution (inch/rev) (mm/rev) Dc = Drill diameter (inch) (mm)

Power consumption (Hp) (kW)

kc1 = S pecific cutting force (lbf ft/inch2) (N/mm2) Ff = Feed force (N)

Threading

Mc = Torque (lbf ft) (Nm)

Torque (lbf ft) (Nm)

Milling

D

Feed force (N)

Drilling

E

Mc =

Boring

F

Inch

Tool holding

G


H

E 14

Ff ≈ 0.5 × kc ×

Dc 2

fn × sin κr (N)

Metric

Pc × 16501 π×n

(lbf ft)

Mc =

Pc × 30 × 103 π×n

(Nm)

Tool selection

Turning

Tool selection procedure

A

Production planning process


B

Hole dimension and quality

C Component

Workpiece material, shape and quantity

Threading

1

2

Machine

Milling

D

Machine parameters

E

Choice of tool

Type of tool

Drilling

3

F

How to apply

Cutting data, coolant, etc.

Boring

4

Troubleshooting


H

E 15


5

Tool holding

G

A

Tool selection

Turning

1. Component and the workpiece material Component:


- Is the component rotation symmetric around the hole, i.e., can the hole be machined with a stationary drill? -C lamping, clamping forces and cutting forces. Is the component sensitive to vibrations?

C Threading

- Is a tool extension needed to reach the surface where the hole will be drilled, i.e., long tool overhangs?

D Material: Milling

-

Drilling

E

achinability m chip breaking hardness alloy elements.

F

2. Important machine considerations Condition of the machine:

Boring

-

Tool holding

G


H

E 16

achine stability m spindle speed coolant supply coolant pressure clamping of the workpiece horizontal or vertical spindle power and torque tool magazine.

Tool selection

A

Turning

3. Choice of drilling tools The basic parameters are: • diameter • depth • quality (tolerance, surface finish, straightness).

The hole type, and the required precision affect tool choice. Drilling can be affected by irregular or angled entry/exit surfaces and by cross holes.


Different ways to make a hole

Drilling and boring

Step drilling

Threading

C

Milling, helical interpolation

Milling

D

Advantages

Advantages

Advantages

• Simple standard tools.

• Simple Tailor Made tools.

• Simple standard tools.

• Relatively flexible.

• F astest way to make a hole.

• Very flexible.

Drilling

E

F

• Low cutting forces.

Disadvantages Disadvantages

Boring

• Requires more power and stability.

• Longer cycle times.

G

• Less flexibility.

Tool holding

•R equires two tool positions.

Disadvantages

H

E 17


• T wo tools, adapters and basic holders.

Turning

A

Tool selection

4. How to apply Important application considerations


Tool holding lways use shortest possible drill and •A overhang. • F or best stability and hole quality, use modular tools, hydro-mechanical or hydraulic holding tools.

Threading

C

D Tool runout

Milling

•M inimum tool runout is essential for successful drilling.

E

Drilling

Chip evacuation and cutting fluid hip formation and evacuation is the •C dominant factor in drilling and affects hole quality.

Boring

F

Cutting speed

Thicker and stiffer chips

Tool holding

G More open due to less friction


H Feed

E 18

Tool selection

Turning

5. Troubleshooting

A

Some areas to consider

B -C heck the wear pattern and if necessary adjust cutting data accordingly. Chip evacuation


Insert wear and tool life

C

Hole quality and tolerances -C heck clamping of drill/workpiece, feed rate, machine conditions and chip evacuation.

D

-C orrect cutting speed and feed rate is essential for high productivity and tool life.

Milling

Cutting data

Drilling

E

Boring

F

Tool holding

G

H

E 19


ø.984 in. (ø25mm)

Threading

- Check chip breaking and cutting fluid supply.

Turning

A


B

System overview

Drilling tools Drilling tools covering diameters from .0118 inch up to 4.331 inch (0.30 mm – 110 mm) and even larger as engineered products. Conventional drilling

C Threading

Irregular surface and cross-hole drilling

Milling

D

E

Drilling

F

Deep hole drill

Solid carbide drill Brazed carbide drill

Short hole drill

L/Dc

Boring

Large diameter drill 15xDc

G

Trepanning drill

Tool holding

10xDc

5xDc


H

E 20

.394 (10)

.787 (20)

1.181 (30)

1.575 (40)

1.969 (50)

2.362 2.756 3.150 (60) (70) (80)

4.331 (110)

Drill diameter, Dc inch (mm)

System overview

A

Turning

Choice of drilling tools Step and chamfer drilling


Chamfer drilling

B

Step or step and chamfer drilling

Threading

C

Milling

D

Other methods

E

Drilling

Trepanning

F

Boring

Helical interpolation

G Tool holding

Radial adjusted drilling

Plunge drilling

H

E 21


Solid drilling

A

System overview

Positioning of short hole drills

B

Indexable insert drills


Turning

Diameter and hole depth

Always to be considered as the first choice due to lower cost per hole. They are also very versatile tools.

•M edium and large diameter holes. • Medium tolerance demands. • Blind holes requiring a “flat” bottom. • Plunge drilling or boring operations.

First choice for smaller diameters and when closer hole tolerance is required.

•S mall diameter. • Close or precision tolerance holes. • Short to relatively deep holes.

An alternative choice to a solid carbide drill for larger diameters and when stability is bad (due to the less sensitive steel body).

Complement to solid carbide for larger diameters or when process stability is poor – the steel part of the drill provides toughness.

Threading

C

Application areas

Solid carbide drills

Milling

D

E

Drilling

Brazed carbide drills

Boring

F

Tool holding

G


H

E 22

System overview

A

Turning

Indexable insert drills The basic drill

• For all workpiece materials. •S tandard, Tailor Made and special drills available. •A versatile tool that can do more than just drilling.

C Threading

• T he most economical way to produce a hole.


B

Milling

D

E

Mounting options

Drilling

Different mounting options are available, which enables the user to mount the drill to almost all machine configurations. Today, machine tool manufacturers are offering mounting options integrated to the spindle.

F Coromant Capto® coupling

Cylindrical with flat

Boring

Cylindrical shank

Whistle Notch

Other modular systems

H

E 23


P-shank

Tool holding

G

A

System overview

Turning

Solid carbide drills The basic choice

Material-optimized drills


B

Threading

C

Milling

D

K

N

S

Special tools

Application-optimized drills Precision drill for hard steel

Chamfer drill

P M K N S H

P H

Drilling

E

P M K N S H

F

Short hole drills – ISO material groups ISO material group

M

K

N

S














Brazed carbide drills


























Boring

P

Tool holding

G


H

E 24

H

Selection procedure

A

Turning

Large hole diameters Large diameter drill


Indexable insert drills are available in diameters up to 3.150 inch (80 mm).

Threading

C

Trepanning drill

D

Milling

Trepanning is used for larger hole diameters and where machine power is limited, because it is not as power consuming as solid drilling. Trepanning drills are available up to diameter 4.331 inch (110 mm) as standard.

Drilling

E

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.

F

Boring


Tool holding

G

E 25


H

Turning

A

How to apply Indexable insert drills Setup routine • Use the shortest possible drill.


B

How to apply

• Check programming length. •S tart drilling with a mid-range recommended feed rate to a depth of .125 inch (3.2 mm).

C

• Check chip formation and measure hole size. Threading

• Inspect the drill to make sure no drill-to-hole rubbing is taking place. • Increase or decrease feed rate according to chip formation, vibration, hole-surface quality, etc.

Milling

D

E

Drilling

Chip control • Improved chip evacuation is initially achieved by improving chip formation.

F

• Long chips may cause chip jamming in the drill flutes. Excellent

Boring

• Rectification involves selecting the correct insert geometry and adjusting cutting data.

G Tool holding

Acceptable

Not acceptable


•A lso the surface finish may be affected and the insert or tool may be at risk.

E 26

• CoroDrill 880 has three insert geometries to suit different materials and cutting conditions.

How to apply

A

Turning

Rotating drill • If over- or under-sized holes are produced or if the center insert tends to chip, it is often because the drill is off center. • T urning the drill 180° in its holder may solve this problem.

C Threading

•B ut it is important to ensure that the center axis of the drill and the axis of rotation are parallel in order to achieve accurate holes.


Alignment

• T he machine spindle and the holder must be in good condition.

Milling

D

Radial adjustment

E

• It may be necessary to reduce the feed/rev (fn) due to longer tool overhang and less balanced cutting forces created by the offsetting. leeves are used to adapt various ISO •S shank sizes for one holder.

E 27

Boring

G Tool holding

•R adial adjustment -.008 /+.028 inch (-0.2 /+0.7 mm). Note that the adjustment range for the drill should not be exceeded. (Maximum adjustment can be seen on the ordering pages in the catalog).

F


•S etting is achieved by turning the scale ring surrounding the holder, marked in increments of .002 inch (0.05 mm), indicating a diametrical movement of the tool.

Drilling

Adjustable holder

A

How to apply

Turning

Adjustable sleeve for drills with ISO 9766 shanks


B

C Threading

Rotating drill – eccentric sleeve Drill diameter can be adjusted for closer hole tolerance. The adjustment range is approx. ±.012 (±0.3 mm), but adjustment in the negative direction should be made only if the drill produces an oversized hole (not in order to achieve undersized holes).

D

Milling

•O ne dot increases/decreases the diameter by .004 inch (0.10 mm). • Increase the diameter by turning the sleeve clockwise.

E

Drilling

•D ecrease the diameter by turning the sleeve counterclockwise. •U se both screws to clamp the drill in the fixture and make sure the bolts in the holder are long enough.

Boring

F

Tool holding

G


H

E 28

How to apply

A

Turning

Non-rotating drill

.001 inch

• T he total runout between the center line of the machine and the workpiece must not exceed .001 inch (0.03 mm).

C Threading

• T he drill should be mounted so that the top face of the peripheral insert is parallel to the machine’s transverse movement (usually X-axis).


Alignment

Milling

D

• Misalignment also has the effect of radial offsetting, which produces either an over- or under-sized hole. • T esting can be carried out with a dial indicator together with a test bar.

Drilling

E

Dial indicator and test bar

F

1

2

•M ake holes with the drill mounted in each of the four flat positions. Hole measurement will indicate the state of machine alignment.

G Tool holding

• Another way is by making a drill with four flats equally positioned around the drill shank.

Boring

Drill with four flats

3 E 29


H

4

A

How to apply

Turning

Deflection of turret Problem solving •D eflection of the turret on a CNC lathe can be caused by the feed force.


B

Feed force

Threading

C

• F irst, check if you can minimize torque by mounting the tool differently. Position B is preferable to position A.

D

Milling

B A

A

E

Drilling

• T o avoid wear on the drill body and retraction marks in the hole, mount the drill with the peripheral insert as shown in the picture.

F

Boring

Peripheral insert

Tool holding

G

Feed force


H

E 30

• F inally, a reduction of the feed/revolution (fn) can be made to minimize the feed force.

How to apply

A

•N on-rotating indexable insert drills can also be used to generate tapered holes. •A lso chamfering and reliefs can be machined with the drill.

C Threading

hole which is to be threaded can be prepared in one •A pass along with chamfering.


•H oles can be drilled larger than the nominal size of the drill as well as enlarged and finished with a subsequent boring pass.

Turning

Radial offset

Milling

D

Entering non-flat surfaces A

B

When entering non-flat surfaces there is a risk of drill deflection. To avoid this, the feed can be reduced when entering.

Drilling

A. Convex surface

E

• Normally no feed reduction needed.

F B. Concave surface Boring

• to 1/3 of original feed rate. C. Inclined surface

G

•W ith entering angle of 2º–89º, reduce feed to 1/3 of original feed rate.

Tool holding

D

D. Curved surface • Reduce feed 1/3 of original feed rate.

H

 E 31


C

A

How to apply

Turning

 Irregular surfaces and pre-drilled holes When entering or exiting an irregular surface there is a risk of the inserts chipping.


• T he feed rate should therefore be reduced. pre-drilled hole should be small rather •A than large - not more than 25% of the drill diameter - to avoid drill deflection.

C Threading

•H owever, reduced feed does allow broad machining of pre-drilled holes.

Milling

D

Coolant supply Internal coolant supply

E

Drilling

•A lways to be preferred especially in longchipping materials and when drilling deeper holes (4-5 x Dc). External coolant supply •C an be used when chip formation is good and when the hole depth is shallow.

F

Boring

Compressed air, minimal lubrication or dry drilling •C an be successful in favorable conditions, but is generally not recommended.

Tool holding

G


H

 E 32

How to apply

A

Turning

 Coolant – Important for successful performance Coolant supply is essential in drilling and influences: - chip evacuation - hole quality - tool life.

C Threading

•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. • The volume capacity can be checked using a stopwatch and a suitably-sized bucket.


B

D

Milling

The cutting fluid Soluble oil (emulsion) • 5 to 12% oil (10-25% for stainless steels). • EP (extreme pressure) additives.

Mist cutting fluid or minimal lubrication • can be used with good performance especially at high cutting speeds.

F

Boring

Neat oil • always with EP additives. • to be preferred for stainless steels. • both solid carbide and indexable insert drills work well with neat oil.

Drilling

E

G Tool holding

Dry drilling, without any coolant • can be performed in short-chipping materials. • hole depths up to 3 times the diameter. • preferably in horizontal applications. • tool life will be influenced negatively.

E 33


H

A

How to apply

Turning

Brazed and solid carbide drills

Rotating drill .0008 inch (0.02 mm)


B

Tool runout Minimum tool runout is one of the main criteria for successful use of solid carbide drills. The runout should not exceed .0008 inch (0.02 mm) in order to achieve: - close hole tolerance

C Threading

- good surface finish - long and consistent tool life.

Stationary drill .0008 inch (0.02 mm)

Milling

D

Tool holding collet and tool shank in bad condition •A will ruin an otherwise perfect setup.

Drilling

E

•M ake sure that the TIR (Total Indicator Readout) is within .0008 inch (0.02 mm).

F

Boring

•A n unacceptable runout can be temporarily reduced by turning the drill or the collet 90° or 180° to find lowest TIR.

Tool holding

G

For best performance use hydro-mechanical, hydraulic or shrink fit chuck.


H

E 34

How to apply

A

Turning

Coolant Internal or external Internal coolant supply

•S hould always be used at hole depths above 3 times the diameter. •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

External coolant supply


B

• Is always to be preferred to avoid chip jamming.

• T o improve chip evacuation at least one coolant nozzle (two if drill is stationary) should be directed close to the tool axis. •C an sometimes help to avoid built-up edge formation due to a higher edge temperature.

D

Milling

• Can be acceptable in short-chipping materials.

Drilling

E

Boring

F

Tool holding

G

E 35


H

A

How to apply

Turning

Safety precautions Internal coolant supply Safety against dangerous discs

uarding against through-hole discs is •G important to avoid damage or injury, especially when using non-rotating drills.

Rotating stop is an important measure

•A rotation stop may be necessary for rotating drills.


B

Threading

C

External coolant supply

Milling

D

• If the coolant contains chip particles, the slit seatings may seize and as a result the housing will rotate.

E

Drilling

• If the rotating connector has not been used for a long time, check that the holder rotates in the housing before the machine spindle is started.

Boring

F

Tool holding

G


H

E 36

Hole quality and tolerance

Turning


A

Steps to ensure good hole quality in drilling

• T ool holding influences hole quality and tool life. se the shortest possible drill for maxi•U mum stability. •C hip breaking and chip evacuation must always be satisfactory.

D

Milling

•C oolant supply and coolant pressure is important.

C Threading

• The machine tool should be in good condition.


B

E

F

- nominal value (the theoretical exact value) - tolerance width (a number), e.g., IT 7 according to ISO

G Tool holding

- position of the tolerance (designated by capital letters according to ISO).

Boring

Dmin

Hole dimensions are characterized by three parameters:

Dmax minus Dmin is the tolerance width, also called, e.g., IT 7.

H

E 37


Dmax

Drilling

Hole and hole tolerance

A


Turning

Hole tolerance according to ISO

Diameter range, inch/mm


B

Threading

C

Milling

D

E

Tolerance

Drilling Boring

.709– 1.181 18–30

1.181– 1.969 30–50

1.969– 3.150 50–80

3.150– 4.724 80–120

IT7

.0005 .0006 .0007 .0008 .0010 .0012 .0014 0.012 0.015 0.018 0.021 0.025 0.030 0.035

IT8

.0007 .0009 .0011 .0013 .0015 .0018 .0021 0.018 0.022 0.027 0.033 0.039 0.046 0.054

IT9

.0012 .0014 .0017 .0020 .0002 .0029 .0034 0.030 0.036 0.043 0.052 0.062 0.074 0.087

IT10

.0019 .0022 .0028 .0033 .0039 .0047 .0055 0.048 0.058 0.070 0.084 0.100 0.120 0.140

IT11

.0030 .0035 .0043 .0051 .0062 .0074 .0089 0.075 0.090 0.110 0.130 0.160 0.190 0.220

IT12

.0047 .0059 .0071 .0083 .0098 .0118 .0138 0.120 0.150 0.180 0.210 0.250 0.300 0.350

IT13

.0071 .0087 .0106 .0130 .0154 .0181 .0213 0.180 0.220 0.270 0.330 0.390 0.460 0.540

Examples

  Bearings   1)  Holes for  threading  Normal tap  holes 

Holes for threading with fluteless taps (rolled threads)

• The lower the IT-number, the closer the tolerance. • The tolerance for one IT-class grows with larger diameters.

+.003 inch (0.07 mm) +0.00

Example:

Ø .591 inch (15.00 mm) H10

Nominal value:

.591 inch (15.00 mm)

Tolerance width: .003 inch (0.07 mm) (IT 10 acc. to ISO) Position:


.394– .709 10–18

.0003 .0004 .0004 .0005 .0006 .0007 .0009 0.008 0.009 0.011 0.013 0.016 0.019 0.022

Tool holding

G

.236– .394 6–10

IT6

1)

F

.118– .236 3–6

E 38

0 to plus (H acc. to ISO)

A

Turning


Hole Ø .787 inch (20 mm) H7

Axle Ø .787 inch (20 mm) h7

The hole tolerance is often connected to the tolerance of an axle, that should fit the hole.


Hole tolerances according to ISO

Threading

C

D

Hole and axle tolerance according to ISO

Milling

Axle tolerance position is denominated by lower case letters corresponding to the hole tolerance. The figure below gives a complete picture.

E

Drilling

Most common

Axle larger than hole

F

Boring

Hole larger than axle

G Drive fit

Interface

Tool holding

Play (bearings)

Slide fit

Grip = negative play (fix joints)

H

E 39


Running fit

A


Turning

Hole and tool tolerance Obtainable hole tolerance with different tools



Threading

C

D

R844 Tolerance

Brazed carbide drill

Indexable insert drill

R840 R842 R850

IT6 IT7 IT8 IT9

With pre-setting

Milling

IT10

E

IT11 IT12 IT13

Drilling

Solid carbide and brazed drills Drill diameter Dc tolerance

F

Boring

• T he drill is ground to a certain diameter tolerance, designated by lower case letters according to ISO. Dc tolerance for a solid carbide drill and a brazed carbide drill


The hole tolerance • F or modern solid carbide or brazed carbide drills like CoroDrill Delta-C and Coromant Delta, the hole tolerance is very close to the drill tolerance.

Tool holding

G

Drill tolerance

E 40

Hole quality and tolerances

A

Hole tolerance

• T he diameter tolerance of an indexable insert drill is a combination of the tip seat tolerance in the drill body and the insert tolerance.

• Indexable insert drills give an optimal cutting force balance and a plus tolerance (oversized) hole, because most holes are with H-tolerance.


Drill tolerance

Turning


Threading

C

Drill depth 2-3 x Dc

Hole tolerance, inch (mm)

.472 – 1.732 (12.00 – 43.99) 0/+.0098 (0/+0.25)

1.732 – 2.086 (44.00 – 52.99) 0/+.0110 (0/+0.28)

2.087 – 2.500 (53.00 – 63.50) 0/+.0118 (0/+0.30)

0/+.0079 (0/+0.20)

0/+.0098 (0/+0.25)

0/+.0110 (0/+0.28)

Tolerance Dc, inch (mm)

D

Milling

Drill diameter, inch (mm)

2.087 – 2.500 (53.00 – 63.50) 0/+.0177 (0/+0.45)

+.0016/+.0094 (+0.04/+0.24)

+.0016/+.0114 (+0.04/+0.29)

+.0016/+.0126 (+0.04/+0.32)

How to improve the hole tolerance

Ø.9876 in (Ø25.084 mm) Ø.9843 in (Ø25 mm)

One way of eliminating the manufacturing tolerance of the drill body and inserts is to preset the drill. This can be done in a lathe or with an adjustable holder/sleeve, see page E27.

Ø.9843 inch (Ø25 mm) H10

A tolerance width (IT) inside .004 inch (0.10 mm) can then be obtained.

F

Boring

Tolerance Dc, inch (mm)

1.732 – 2.086 (44.00 – 52.99) 0/+.0169 (0/+0.43)

G Tool holding

Hole tolerance, inch (mm)

.472 – 1.732 (12.00 – 43.99) 0/+.0157 (0/+0.40)

H

E 41


Drill diameter, inch (mm)

Drilling

E

Drill depth 4-5 x Dc

Turning

A


B

Troubleshooting

Troubleshooting Indexable insert drill Problem

Solution

Oversized holes

Rotating drill 1. Increase coolant flow, clean filter, clear coolant holes in drill. 2. Try a tougher geometry on peripheral side (keep center insert).

Non-rotating drill 1. Check alignment on lathe. 2. Rotate drill 180°. 3. Try a tougher geometry on peripheral side (keep center insert).

Undersized holes

Rotating drill 1. Increase coolant flow, clean filter, clear coolant holes in drill. 2. Try a tougher geometry on center side and a light cutting geometry on peripheral side.

Non-rotating drill 1. Stationary: Check alignment on lathe. 2. Stationary: Rotate drill 180°. 3. Try a tougher geometry on peripheral side (keep center).

Pin in hole

Rotating drill 1. Increase coolant flow, clean filter, clear coolant holes in drill. 2. Try a different geometry on peripheral side and adjust feed rate within recommended cutting data. 3. Shorten drill overhang.

Non-rotating drill 1. Check alignment on lathe. 2. Increase coolant flow, clean filter, clear coolant holes in drill. 3. Shorten drill overhang. 4. Try a different geometry on peripheral side and adjust feed rate within recommended cutting data.

Vibrations

1. Shorten drill overhang, Improve the workpiece stability. 2. Reduce cutting speed. 3. Try a different geometry on peripheral side and adjust feed rate within recommended cutting data.

Insufficient machine torque

1. Reduce feed. 2. Choose a light cutting geometry to lower the cutting force.

Threading

C

Milling

D

Drilling

E

Boring

F

Tool holding

G


H Mc lbf-ft (Nm) E 42



Troubleshooting

A

Solution

Insufficient machine power

1. Reduce speed. 2. Reduce feed. 3. Choose a light cutting geometry to lower the cutting force.

Pc HP (kW) 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 rate within recommended cutting data. 3.Shorten drill overhang.

C Threading

Hole not symmetrical


Problem

Turning



1. Reduce feed. 2. Choose a light-cutting geometry to lower the cutting force.

Broken insert screws

1. Use torque wrench to fasten the screw together, apply Molykote.

D

Milling

Poor tool life

Drilling

E

Bad surface finish

1. Important to have good chip control. 2. Reduce feed (if it is important to keep vf, increase speed as well). 3. Increase coolant flow, clean filter, clear coolant holes in drill. 4. Shorten drill overhang, improve the workpiece stability.

Boring

F

Caused by long chips 1. Check geometry and cutting data recommendations. 2. Increase coolant flow, clean filter, clear coolant holes in drill. 3. Reduce feed within recommended cutting data. 4. Increase cutting speed within recommended cutting data.

H

E 43


Chip jamming in the drill flutes

Tool holding

G

A

Troubleshooting

Turning

Tool wear – Indexable insert drill Cause

Solution

a) C utting speed too high. b) Insufficiently wear resistant grade.

a) R educe cutting speed. b) Choose a more wear resistant grade.

Peripheral insert • Diffusion wear caused by temperature too high on rake face.

Peripheral insert • Select GC4024 or GC4014 with Al2O3 coating against oxidation. • Reduce speed.

Flank wear


B

Problem

C Threading

Crater wear

Central insert: • Abrasive wear caused by built-up edge and smearing.

D

Milling

General: • Choose a more positive geometry.

Plastic deformation (peripheral insert)

Drilling

E

Boring

F

utting temperature (cutting a) C speed) too high, combined with high pressure (feed, hardness of workpiece). b) As a final result of excessive flank wear and/or crater wear.

a–b) S elect a more wear resistant grade with better resistance to plastic deformation, i.e., GC4014 or GC4024. a–b) Reduce cutting speed. a) Reduce feed.

a) Insufficent toughness of grade. b) Insert geometry too weak. c) Built-up edge (BUE). d) Irregular surface. e) Bad stability. f) Sand inclusions (cast iron).

a) S elect a tougher grade, i.e., GC4044. b) Select a stronger geometry, i.e., -GT. c) Increase cutting speed or select a more positive geometry. d) Reduce feed at entrance. Choose geometry -GT. e) Improve stability. f) Choose a stronger geometry, i.e., -GR or -GT. Reduce feed.

Chipping

Tool holding

G


Central insert: • Choose GC1044, if H13A is used. • Reduce feed.

 E 44

Troubleshooting

A

Cause

Solution

a) L ow cutting speed (temperature too low at the cutting edge). b) Cutting geometry too negative. c) Very sticky material, such as certain stainless steels and pure aluminum. d) Percent of oil mixture in cutting fluid too low.

a) Increase cutting speed or change to a coated grade. b) Select a more positive geometry. c-d) Increase oil mixture and volume/pressure in cutting fluid.

Built-up edge (BUE)


Problem

Turning



Threading

C

D

Checkpoints and remedies 1. M ake sure the right cutting data and drill geometry are used.

Milling

Chip evacuation - general recommendations

E

4. Inspect the cutting edges. Chipping on the edge can cause long chips because the chip is divided.

F

6. A djust feed and speed. See diagram on page E 18.

G Tool holding

5. C heck if the machinability has changed due to a new batch of workpiece material. Cutting data may need to be adjusted.

Boring

heck if the cutting fluid flow and pres3. C sure can be increased.

Drilling

2. Inspect chip form (compare with picture on page E 26).

E 45


H

A

Troubleshooting

Turning

Peck drilling – solid carbide / brazed drills


B

Peck drilling can be used if no other solution can be found. There are two different ways to perform a peck drilling cycle: 1 2 3 4 5 6 7 8

Do not retract the drill more than approx. .012 inch (0.3 mm) from the hole bottom. Alternatively, make a periodical stop, while the drill is still rotating, before continuing to drill.

C Threading

- Method 1 for best productivity

1 2 3 4 5 6 7 8

D

- Method 2 for best chip evacuation

Milling

After each drilling cycle, retract the drill out from the hole to ensure that no chips are stuck onto the drill.

Drilling

E

Tool wear – solid carbide / brazed drills

1. C utting speed too low and edge temperature too high. 2. Negative land too large. 3. No coating. 4. Percentage of oil in the cutting fluid too low.

1. Increase cutting speed or use external cutting fluid. 2. Sharper cutting edge. 3. Coating on the edge. 4. Increase the percentage of oil in the cutting fluid.

Boring

Chipping on the edge corner

Tool holding

1. Unstable fixturing. 2. TIR too large. 3. Intermittent cutting. 4. Insufficient cutting fluid (thermal cracking). 5. Unstable tool holding.


Solution

Built-up edge

F

G

Cause

1. 2. 3. 4. 5.

heck fixture. C Check radial runout. Decrease the feed. Check cutting fluid supply. Check the tool holder.

 E 46

Troubleshooting

A

Solution 1. 2. 3. 4.

B

Large wear on the cutting edge 1. Cutting speed too high. 2. Feed too low. 3. Grade too soft. 4. Lack of cutting fluid.

ecrease the cutting speed. D Increase the feed. Change to harder grade. Check for proper cutting fluid supply.

Chipping on the cutting edge

C

1. C heck the setup. 2. Replace drill sooner. 3. Change to softer grade.

Threading

1. Unstable conditions. 2. Maximum allowed wear exceeded. 3. Grade too hard.

D

Wear on the circular lands 1. C heck the radial runout. 2. Use neat oil or stronger emulsion. 3. Decrease cutting speed. 4. Change to harder grade.

Milling

1. TIR too large. 2. Cutting fluid too weak. 3.Cutting speed too high. 4. Abrasive material.


Cause

Turning



E Wear on the chisel edge 1. Increase cutting speed. 2. Decrease feed. 3. Check dimensions.

Drilling

1. Cutting speed too low. 2. Feed too high. 3. Chisel edge too small.

F

Thermal cracks (notches) 1. Inconsistent cutting fluid

G Tool holding

1. D ecrease the cutting speed and/or feed. 2. Increase cutting fluid pressure. 3. Use a harder grade.

1. Check cutting fluid supply 2. Fill cutting fluid tank

H

E 47


1. C utting speed and/or feed too high. 2. Not enough cutting fluid supply. 3. Unsuitable drill/grade.

Boring

Wear due to plastic deformation

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


F9

• System overview

F 14

• How to apply

F 21

• Troubleshooting

F 25

F3

Turning

A


B

Boring theory The boring process • T ypically, boring operations are performed in machining centers and horizontal boring machines. • T he rotating tool is fed axially through the hole. •M ost holes are through-holes, often in prismatic components such as housings and casings.

Threading

C

Theory

Three different basic boring methods Boring with a stationary tool

Milling

D

Boring with a rotating tool


Drilling

E

Boring

F

Tool holding

G

• F or unsymmetrical components machined in a machining center.

•P rofiling can be carried out with standard boring bars.

• F lexible tool solutions with adjustable diameters.

ery flexible tool solu•V tions with interchangeable cutting heads.

•V ery productive in roughing operations.

•G ood solution when chip breaking is a problem.

•H igh quality hole tolerance and surface (for finishing).

•H igh quality demands of the machine (for finishing).


•V ery flexible solution where one milling cutter can be used for different diameters.

• T o be used only for symmetrical components in a turning lathe.

F4

•S aves space in the tool magazine.

Theory

A

Turning

Definitions of terms Definitions of cutting data terms

B

n = spindle speed (rpm) ap = radial depth of cut (inch) (mm)


vc = cutting speed (ft/min) (m/min) fn = feed per revolution (inch/r) (mm/r) Dc = boring diameter (inch) (mm)

C

vf = penetration rate (inch/min) (mm/min) fz = feed per tooth (inch/rev) (mm/rev)

π × Dc × n 12

(ft/min) Milling

vc = Metric

1000

E (m/min) Drilling

vc =

π × Dc × n

Feed

F

vf = fn × n (inch/min) (mm/min)

Boring

The axial tool movement is called feed rate (fn) and is measured in inch/revolution (mm/rev). The feed rate is obtained by multiplying the feed per tooth, inch/rev (mm/ rev), by the number of effective teeth (zc). The feed rate is the key value in determining the quality of the surface being machined and for ensuring that the chip formation is within the scope of the insert geometry.

fn = zc × fz (inch/r) (mm/r)

G

Penetration rate

Cutting depth

The penetration rate (vf) is the speed of the axial movement and is strongly related to productivity.

The cutting depth (ap) is the difference between the uncut and the cut hole radius.

F5

Tool holding

The boring tool rotates at a certain number of revolutions (n) per minute generating a certain diameter (Dc). This gives a specific cutting speed (vc) measured in ft/min (m/min) at the cutting edge.

D

Inch


Cutting speed

Threading

zc = effective number of teeth that machine the final surface

A

Theory

Turning

Calculating power consumption and torque B Parting and grooving

n = spindle speed (rpm) vc = cutting speed (ft/min) (m/min)

Pc Hp (Nm)

Dc = boring diameter (inch) (mm)

C Threading

fn = feed per revolution (inch/r) (mm/r) kc = specific cutting force (lbs/inch2) (N/mm2)

Mc lbf ft (Nm)

Pc = power consumption (Hp) (kW) Mc = torque (lbf ft) (Nm)

Milling

D

Drilling

E

Boring

F

Tool holding

G


H

Torque The torque (Mc) is the torque value produced by the boring tool during cutting action, which the machine must be able to provide.

Net power The net power (Pc) is the power the machine must be able to provide to the cutting edges in order to drive the cutting action. The mechanical and electrical efficiency of the machine must be taken into consideration when selecting cutting data.

Specific cutting force Cutting force/area for a given chip thickness in tangential direction. The kc value indicates the machinability of a certain material and is expressed in lbs/inch2 (N/mm2). F6

Inch

Mc =

Pc × 16501

(lbf ft)

π×n

Metric

Mc =

Pc =

Pc × 30 × 103

π×n

ap × fn × kc × vc 60 × 103

(Nm)

( ) 1 –

ap

Dc

(Hp) (kW)

Theory

A

Turning

Tools for roughing and finishing

•R ough boring operations are performed to open up the existing hole to prepare for fine boring.


Rough boring tool with multiple edges

Single-edge fine boring tool • F ine boring operations are performed to make the hole within final hole tolerance, position and surface finish limits.

D

Milling

• T he diameter of a fine boring tool can be adjusted within microns.

Threading

C

Ø.9843 in (Ø25 mm) H7

E

Drilling

Ø.9843 in (Ø25 mm) Ø.9851 in (Ø25.021 mm)

Hole tolerance of boring and reaming tools Single-edge fine boring tool

Multi-edge reamer for high feed finishing

Boring

Rough boring tool with multiple edges

F

G Tool holding

IT6 IT7 IT8 IT9

F7


H

A

Theory

Turning

Hole making methods Single-edge boring Usually applied for finishing operations and for roughing in materials where chip control is demanding, or when machine tool power is limited.


B

Threading

C Multi-edge boring Involves two or three cutting edges and is employed for roughing operations where metal removal rate is the first priority.

Milling

D

Step boring Performed in roughing by a boring tool having the inserts set at different axial heights and diameters. Employed where large stock removal is required or to get improved chip control. Good choice for off-center holes.

Drilling

E

Boring

F

Reaming A light finishing operation performed with a multi-edge reamer at high feeds.

Tool holding

G


H

F8

Tool selection

Turning

Tool selection procedure Production planning process

1

Component

Workpiece material, shape and quantity


Ø.9843 in (Ø25 mm) H7

C

Ø.9843 in (Ø25 mm) Ø.9851 in (Ø25.021 mm)

Threading

Hole dimension and quality

B

D

Machine

Machine parameters

Milling

2

3

Choice of tool

Drilling

E

Type of tool

F

How to apply

Cutting data, coolant, etc.

Boring

4

Troubleshooting


H

9


5

Tool holding

G

A

Tool selection

Turning


B

Component


• Identify the type of operation and note characteristics regarding the hole to be machined, limitations, material and machine. •C lamping, clamping forces and cutting forces. Is the component sensitive to vibrations?

C Threading

•S elect the tool that covers the boring diameter range and depth for the operation, surface finish and tolerance.

D

Milling

Material

Drilling

E

F

• • • •

achinability M Chip breaking Hardness Alloy elements

• • • • • • • •

pindle interface S Machine stability The spindle speed Coolant supply Clamping of the workpiece Horizontal or vertical spindle Power and torque Tool magazine

2. Machine parameters

Boring

Condition of the machine

Tool holding

G


H

F 10

Tool selection

A

Turning

3. Choice of tools Finishing

Roughing


B

C Single-edge boring

Single-edge boring

Reaming Threading

Step boring

Multi-edge boring

Step-boring

Single-edge boring

• High metal removal rate.

• F or rough boring with large stock removal.

• For general fine boring.

• Productive boring.

• Improved chip control.

Single-edge boring

• Tolerance capability IT6.

Reaming

• Improved chip control.

•V ery good surface finish at high penetration rates.

• L ess machine-power demanding.

D

Milling

Multi-edge boring

E

Drilling

uitable for mass •S production.

Boring

F

Special boring operations

G

Engineered tools

Tool holding

• Many operations in one tool. • T he operations can be completed during one feed motion.

F 11


H

A

Tool selection

Turning

4. How to apply Important application considerations Tool holding


lways use the strongest coupling and •A aim for the shortest tool overhang. • F or best stability and hole quality use Coromant Capto®, dampened tools and tapered shanks.

C Threading

Tool considerations onsider lead (entering) angle, insert •C geometry and grade.

D

Chip evacuation and cutting fluid

Milling

hip formation and evacuation are im•C portant factors in boring and affect hole quality and hole tolerance. Cutting data Cutting speed, vc ft/min (m/min)

orrect cutting speed and feed rate is •C essential for high productivity, tool life and hole quality.

Drilling

E

Boring

F

Feed, inch/r (mm/r)

Tool holding

G


H

F 12

Tool selection

A

Turning

5. Troubleshooting Important application considerations Insert wear and tool life

•C heck the chip breaking and cutting fluid supply. Hole quality and tolerances

Ø.9843 in (Ø25 mm) H7

heck clamping of boring tool/work•C piece, feed rate, machine conditions and chip evacuation.

C Threading

Chip evacuation


B

• C orrect geometry, grade and cutting data is essential in boring operations.

D

E

Drilling

orrect cutting speed, feed rate and •C cutting depth is essential for high productivity, tool life and to avoid vibrations.

Boring

F

Tool holding

G

H

F 13


Ø.9843 in (Ø25 mm) Ø.9851 in (Ø25.021 mm)

Milling

Cutting data

Turning

A


B

System overview

System overview Rough boring tools Rough boring operations are performed to open up an existing hole to prepare for finishing. Heavy duty tool with two inserts

Tool with two inserts

C

Tool with one insert

Threading

Tool with three inserts

D

Milling

Tool with dampened adapter

E

Fine boring tools

Drilling

Fine boring operations are performed to finalize hole within tolerance and surface finish limits.

F

Single-edge tool with dampened adapter

Single-edge tool with modular adapter Single-edge tools

Boring

Multi-edge reamer

G Tool holding

Fine boring head for fine boring bars


H

F 14

A

Turning

System overview

Rough boring tool with three inserts Diameter range 1.378 - 12.047 inch (35 - 306 mm)


B

Rough boring tool with two inserts Diameter range .984 - 10.630 inch (25 - 270 mm)

C Diameter range 5.906 - 21.654 inch (150 - 550 mm)

D

Milling

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

Threading

Heavy duty rough boring tool with two inserts

Multi-edge reamer Diameter range .394 - 1.250 inch (10 - 31.75 mm)

E

Drilling

Fine boring head Diameter range .118 - 1.654 inch (3 - 42 mm)

F Single-edge boring tool with integrated adapter Boring

Diameter range .906 - 6.953 (23 - 176.6 mm)

G Diameter range 5.906 - 38.646 inch (150 - 981.6 mm)

Diameter

Tool holding

Single-edge boring tool with modular adapter

F 15


H

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

Turning

A

Choice of tool

Choice of tools Roughing Multi-edge boring


•H igh metal removal rate. • Productive boring. Single-edge boring • Improved chip control. • Less machine-power demanding.

C Threading

Step-boring • F or rough boring with large stock removal. • Improved chip control.

Milling

D

Finishing Single-edge boring

E

• F or general fine boring. • Tolerance capability IT6.

Drilling

Reaming •V ery good surface finish at high penetration rates. • Suitable for mass production.

Boring

F

G

Special boring operations

Tool holding

Engineered tools •M any operations in one tool. • The operations can be completed during one feed motion.


H

F 16

Choice of tool

A

Rough boring tool with three inserts


First choice recommendation for medium and high power machines is a rough boring tool with three cutting edges for optimized productivity.

Turning

Rough boring tools

Rough boring tool with two inserts A rough boring tool with two cutting edges is first choice for low to medium power machines, unstable operations or large diameters.

Threading

C

D

Milling

Dampened rough boring tool for long overhangs Choose dampened rough boring tools for overhangs longer than 4 times the coupling diameter.

Drilling

E

Boring tool setup

F

Single-edge boring

Multi-edge boring

Boring

All rough boring tools can be set up in three different ways. Step boring

Tool holding

G

F 17


H

All rough boring tools can be ordered and assembled, adapted to the chosen type of rough boring method.

A

Choice of tool

Turning

Slides for rough boring tools Slides with negative inserts • F or stable conditions, choose negative shape inserts for better insert economy.


se negative inserts in tough applica•U tions that require strong inserts and improved process security.

Slides with positive inserts • In rough boring, it is an advantage to use positive basic-shape inserts as they give lower cutting forces compared to negative inserts.

Threading

C

Milling

D

Lead (entering) angle and insert shape

Drilling

E

• A small nose angle and small nose radius also contribute to keeping the cutting forces down.

The lead (entering) angle of boring tools affects the direction 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 radial cutting force.

F

Positive inserts

Negative inserts

Boring

- For interrupted cuts, sand 15°/6° (75°/84°) inclusions, stack boring etc. Through holes only. 6° (84°)

G Tool holding

0° (90°)

- F irst choice for general operations, step boring and for shoulder operations. 0° (90°)

0° (90°)

–5° (95°)


6° (84°)

15° (75°)

-5° (95°)

F 18

- F or high feeds or improved surface finish with Wiper inserts in stable conditions. -5° (95°)

Choice of tool

A

Turning

Fine boring tools Single-edge fine boring tool


A single-edge fine boring tool is the first choice for fine boring operations.

C

For small diameters a fine boring head with fine boring bars is required.

Threading

Fine boring head with fine boring bars

Milling

D

Silent Tools for long overhangs

E

Drilling

Silent Tools (dampened) are the first choice for overhangs longer than 4 times the coupling diameter.

F

G Tool holding

Multi-edge reamers are suitable for high feeds in mass production.

Boring

Multi-edge reamer

F 19


H

A

Choice of tool

Turning

Cartridges for fine boring tools General recommendations • In fine boring, positive basic-shape inserts are used, as they give lower cutting forces compared to negative inserts.


B

Positive inserts 7° clearance angle

C

•P ositive basic-shape inserts with 7° clearance angle are the first choice • L ight-cutting insert geometries, thin coatings and a small nose radius (maximum .016 inch (0.4 mm)) also contribute to keep the cutting forces down.

Threading

Positive inserts 11° clearance angle

Milling

D

Adapters • Choose the shortest possible adapter length.

E

• Choose the largest possible diameter/size of adapter.

• If possible, use a tapered adapter to increase the static stiffness and to reduce the deflection.

F

• F or long overhangs, ensure rigid clamping with flange contact to spindle if possible.

Boring

Drilling

• F or long overhangs (larger than 4 x coupling diameter) use dampened adapters.

Tool holding

G


H

F 20

How to apply

Adjustable fine boring mechanism

B Single-edge fine boring tools have adjustment possibilities to accurately pre-set the cutting edge within microns.


Fine boring tools

Turning

How to apply

A

Threading

C

•B oring tools for finishing, with one cutting edge, will experience some degree of radial deflection during machining due to the cutting forces.

D

• T he depth of cut and length of overhang influence the radial deflection of the boring tool.

Milling

Tool deflection

E

•A measuring cut is normally needed, followed by a final adjustment of the tool.

Drilling

• T he deflection might cause undersized holes or vibrations.

Boring

F

Tool holding

G

F 21


H

A

How to apply

Turning

Boring tools – general Chip evacuation, cooling and lubrication between the tool and the workpiece material are primary functions of cutting fluid.


B

Cutting fluid supply

•A pply cutting fluid for optimized chip evacuation, cooling and lubrication. • Affects hole quality and tool life.

C Threading

• Internal cutting fluid is recommended in order to direct the fluid to the cutting zone.

D

Milling

Chip control and chip evacuation

Drilling

E

Chip formation and chip evacuation are critical issues in boring operations, especially in blind holes. Ideally, chips should be in the form of defined commas or spirals.


Factors that have an influence on chip breaking are: - the insert micro and macro geometry - nose radius - lead (entering) angle - cutting depth - feed - cutting speed - material.

Boring

F

G Tool holding

Feed, inch/r (mm/r)


H

F 22

How to apply

A

Turning

Cutting data recommendations The cutting data for the insert geometry and grade chosen can generally be followed with the following exceptions:


- Rough boring Max start value vc = 656 ft/min (200 m/min). - Fine 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 (90 – 120 m/min). - Fine boring: 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.

When rough boring, make sure the machine can provide sufficient power and torque.

F

Boring

Important parameters are: - feed - number of inserts - diameter - depth of cut.

Drilling

E

Power and torque consumption

Tool holding

G

H

F 23


M Mcc lbf-ft (Nm)

D

Milling

Cutting speed is mainly limited by: - vibration tendencies - chip evacuation - long overhangs.

Threading

C

A

How to apply

Turning

Tool maintenance and use of torque wrench •A lways use a torque wrench and apply the recommended torque on screws for insert and tool assembly.

B

• Check inserts and insert seats regularly.


• Replace worn or exhausted screws and washers. • Clean all assembly items before assembly. • L ubricate all assembly items with oil at least once a year.

C Threading

• L ubricate the fine adjustment mechanism for fine boring regularly.

Milling

D

How to apply reaming tools • T he reamer should not be expected to correct any positional or straightness errors in the pre-machined hole.

Drilling

E

• T he straightness of the pre-machined hole should be less than .0020 inch (0.05 mm).

F

• A small runout is very important for reaming operations. Boring

• Maximum recommended runout is 5 microns. •M ake sure the reamer is concentric with the pre-machined hole.

G

• Choose the shortest possible tool holder and shank.

Tool holding

•E mulsion as cutting fluid generates better tool life than oil. • Use recommended cutting data.


H

F 24

Troubleshooting

Turning

Troubleshooting

A

Factors that affect vibration tendencies Vibration tendencies grow towards the right.


B

Threading

C

D .008 (0.2)

.016 (0.4)

.031-.047 (0.8-1.2) Milling

inch (mm)

Drilling

E

• Apply step boring. • Choose a 2-edge rough boring tool. •C hoose a light-cutting geometry and grade. • Use a smaller nose radius.

•C heck that all units in the tool assembly are assembled correctly with the correct torque.

F

• Reduce feed or increase feed. • Use the largest tool diameter possible. • Use the shortest tool overhang possible.

Boring

• Decrease cutting speed.

G Tool holding

• Check workpiece clamping. •C heck machine spindle, wear, clamping, etc. • Increase depth of cut (finishing).

• Use dampened tools if long overhang. F 25


H

• Decrease depth of cut (roughing).

A

Troubleshooting

Turning

Insert wear Insert wear patterns and remedies in boring are generally very similar to turning.


B

Chip breaking Cause Too short, hard

C

Solution • Increase cutting speed • Decrease feed

Threading

•C hange geometry to a more open chip breaker

D

Too long

• Increase feed • Decrease cutting speed

Milling

•C hange geometry to a more closed chip breaker

E

Surface Drilling

Tool vibration

Boring

F

Too high feed

• Decrease feed

Too high speed

• Decrease speed

Too large cutting depth

• Apply step boring

Too high cutting forces

• Decrease depth of cut • Use positive inserts • Use smaller nose radius

Tool holding

G Feed marks

•C hoose knife edge wiper insert

H

• Use larger nose radius


Too high feed

• Decrease feed

 F 26

Troubleshooting

A

 Turning

Solution

Wrong cutting data

•C hange cutting edge and investigate reason for wear pattern – cutting data, insert geometry and insert grade.

C

Chips scratching surface Bad chip breaking


Insert wear

• Change cutting data • Change insert geometry

Threading

Cause

D

• Increase speed • Use coolant

E

Drilling

• Use a cermet grade

Machine power limitation • Decrease cutting data

F

Boring

• Apply step boring

G Tool holding

Limited machine power

H

F 27


Bad surface finish

Milling

Surface finish

Tool holding The clamping of a cutting tool can influence the productivity 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 products.

• History and background

G4

• Why modular tooling

G7

• Turning centers

G 15

• Machining centers

G 23

• Multi-task machines

G 29

• Chucks

G 33

G3

Turning

A


B

Tool holding systems • T he tool holding interface with the machine plays a very important part in the cutting process. •S tability, time for tool changing, accuracy, flexibility, modularity, handling and storing is of vital importance for successful machining. •C ompared to conventional shank tools, a quick change system can increase the effective cutting time by 25% in turning centers.

Threading

C

History and background

Milling

D

Tool holding systems today • T ooling has evolved through the necessity to produce new types of machine manufacturing standards.

Drilling

E

F

• These tools have generally followed the spindle interface design of MTMs, without any standardization controls.

Boring

• There are over 35 types of spindle interface on machines today, with as many tooling options to support, hence exchangeability and assortment availability decreases dramatically.

Tool holding

G


H

G4


A

Turning

History of machine tapers

• T he taper was the basis of most machine tool spindles, due to the long taper, giving secure contact and stability.

C Threading

• It is still popular today, in various sizes, using taper 7/24, but it is not a modular tooling solution.


• T his style of taper was introduced 40 years ago.

D

Milling

Quick change systems

•U nfortunately, these systems are not interchangeable with each other, and are very limited in their flexibility between machining centers and CNC lathes.

F

Boring

•M ost of these systems are not suitable for multi-task machining operations.

E

Drilling

• T here is an ever increasing supply of quick change and modular tooling systems on the market today.

Tool holding

G

G5


H

A


Turning

Coromant Capto® A multi-purpose, quick-change modular tooling system


B

Threading

C

Capto is Latin and means “to grab”.

D

Milling

The history of the Coromant Capto® system • Machining center / Rotating tools

Drilling

E

Solid holders

Boring

F

Varilock

1980

Coromant Capto®/ Basic holders 1990

• Turning center / Turning tools

Standard

G Tool holding

ISO 26623 Shank holders


H

G6

Block Tool System

Coromant Capto®/ Clamping units

Why modular tooling

A

Turning

A dramatic development of the machines Machining centers


B

Threading

C

D

Turning centers

Milling

Multi-task machines

Trends

E

Machines and machining methods Drilling

ulti-task machines requiring one holder system for •M both spindle and turrets. everal turrets on multi-task machines and turning •S centers.

F

• More multi-function tools for multi-task machines.

owerful interfaces in the machine control system for •P higher degrees of automation.

Boring

-D models of tools and holders to virtually check the •3 machine process.

G

• Integration of various manufacturing technologies into fewer machine types.

Tool holding

• Driven tools in turning centers.

• High pressure coolant.

G7


H

A

Why modular tooling

Turning

When to use quick change tooling •M achine requires frequent setup changes.


•M easuring cuts are necessary to get correct size. •M achining is performed with high cutting data and relatively short tool life. •O ne operator services more than one machine.

Threading

C

Milling

D

Reduce downtime in your turning centers

E Only 36% of the machine time is used for metal cutting Drilling

-S ervice and maintenance - Insert change and tool change

F

Boring

-M easuring of the tool and workpiece

25%

Tool holding

G Conventional shank tools

Coromant Capto® quick- change system

- Effective cutting time

Quick change tooling offers a productivity increase of 25%


- Change of workpiece

G8

Why modular tooling

A

Turning

A true modular tooling system One system! One solution! – For the entire workshop Coromant Capto is a flexible tooling system, suitable for all types of machining. This makes it possible to standardize on one system in your entire workshop.


B

C

Vertical lathes

Threading

Turning centers

Milling

D

Drilling

E

F

Boring

Multi-task machines

Tool holding

G

H

G9


Machining centers

A

Why modular tooling

Turning

Minimize tool holder inventory


B

Threading

C

By combining basic holders, adapters and (when needed) extensions or reductions, many different assemblies for different machines can be built. The below examples represent a customer that has four different spindles resulting in: - taper 40, taper 50, HSK 63 and HSK 100, - two extensions - 30 different adapters for milling, drilling, tapping, etc. - 10 different boring tools.

ISO 40

ISO 50

HSK 100

HSK 63

Milling

D

Solid

Modular

Drilling

E

Boring

F Number of items with modular tools: 4 + 2 + 30 + 10 = 46 items

Number of items with solid tools: 4 x 3 x (30 + 10) = 480 items

Tool holding

G

Modular tools give access to a very large number of tooling solutions, with very few items!


H

G 10

Why modular tooling

A

- T he ground flange contact face in relation to the ground taper polygon gives maximum stability due to two-face contact and interference fit. - T here are four gripper grooves for the automatic tool changer.

C

D

Milling

Flange contact

E

-C oolant supply through center -C oolant channel in the coupling.

Drilling

Coolant through center

There are two options for coolant supply:

F

Boring

Coolant channel in coupling

G Tool holding

Slot for angular positioning

- T here is one slot for angular positioning of the cutting tool.


The unique Coromant Capto coupling has some very specific features:

Threading

Gripper groove

H

G 11


Taper polygon

Turning

The Coromant Capto® coupling

A

Why modular tooling

B

1. The radial centering is taken care of by the conical part of the polygon.


The main feature of the coupling is the positive 3-way locking

2. T he low taper angle makes it possible to transmit the full force into the flange contact. The strength of the polygon coupling makes it possible to clamp with higher force than other systems. This is very important for the bending stiffness.

Threading

C

3. A polygon shape is self centering and takes care of the orientation without the need for a driving slot, therefore there is no play in the coupling. The polygon shape is also unique due to its capability to transmit high torque due to three contact areas.

Milling

D

Due to the above features - radial and axial contact and self centering ability - the coupling has extremely good repeatability, within .00008 inch (2 microns).

1

1

E

1.4°



Turning

Coupling features and benefits



Drilling

3 2 3

2

3-way locking

Boring

F

Tool holding

G


H C3– C10

G 12

Why modular tooling

A

Turning

Six different coupling sizes • 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) • C8 = D 3.150 inch (80 mm) • C10 = D 3.937 inch (100 mm) 

C



Threading

Three different methods of clamping One coupling offers 3 methods of clamping.

Center bolt clamping

D

Front clamping

Milling

Segment clamping

Clamping method for quickchange and automatic tool changing.

For modular clamping solutions, e.g., when using extensions and basic holders.

Machine interface for quick change in machines.

Drilling

E

F

Boring

Excellent repetitive accuracy and guaranteed center height

B C

• F ew or no measuring cuts needed if pre-measuring is used (first component right).

G 13

G Tool holding

A


• T he repeatable accuracy is ±.00008 inch (±2 microns [µm]) of the center height, length and the radial measurement (A),(B),(C).

A

Why modular tooling

Turning

Transmission of torque The polygon shape transmits torque without any loose parts such as pins or keys.

B

• No pins, keys, etc.


• No play in the coupling. • Symmetrical loads. • Two face contact/high clamping force.

Threading

C

Milling

D

In internal machining the Coromant Capto coupling is an outstanding solution to clamp the boring bar, with a firm secure grip around the entire polygon.

Drilling

E

Less vibration with stable coupling

Boring

F

G Tool holding

The boring bar is very often clamped with 2-3 screws. This causes problems with vibration, bad surface finish, inserts worn out quickly and production disturbances, with downtime spent on adjusting cutting data and measuring the component.


H

G 14

Turning centers

Turning

Quick change tooling for turning centers

A

Machining centers


B

Threading

C

D

Turning centers

Milling

Multi-task machines

What is a turning center?

F

Boring

• T he cutting tool moves parallel and perpendicular to the workpiece axis to provide the desired finished shape.

hen a cutting tool is applied to •W the workpiece, it can be shaped to produce a component which has rotational symmetry.

Drilling

• T he principle of lathes and turning centers is to cut a rotating component with a stationary cutting tool.

E

The turning center has a choice of configurations

G Tool holding

• Horizontal and vertical design. • Sub-spindle for two-sided machining. • Driven tools. • Y-axis for eccentric boring and milling.

G 15


H

A

Turning centers

Turning

Configuration of a turning center Spindle rotation and definitions of axis


•S everal multi-axis machine tool programs can provide turning results from roughing and grooving to threading and finishing.

Threading

C

D

Milling

Quick change tooling for turning centers A quick-change system offers:

E

- faster and efficient tool changing

Drilling

- inserts which can be changed outside the machine - pre-setting possibilities.

F

The most economical system for:

Boring

-s mall batch production, quicker setup times - operations with frequent insert changes.

G Tool holding

Less than 180° for clamp and unclamp


H

G 16

Turning centers

A

Square shank Camshaft activated

Automatic unit Hydraulically operated


VDI angled Camshaft activated

Turning

Typical clamping units for turning centers

VDI straight Camshaft activated

Round shank Segment clamping

Special applications Segment clamping

Threading

C

Milling

D

Drilling

E

Methods of installing quick change

G Tool holding

Coromant Capto directly integrated in turrets is the best solution to get maximum performance out of the Coromant Capto coupling.

Boring

F

Directly integrated into the turret

G 17


H

A

Turning centers

Turning

Conversion of a turret by using standard clamping units Turning lathes can easily be converted to Coromant Capto quick-change tools using standard clamping units. No modification to the turret, and no special adapters required.


B

Threading

C

Milling

D

Drilling

E

Boring

F

Tool holding

G


H

G 18

Turning centers

A

Turning

Machine adapted clamping units Coromant Disc Interface (CDI)

• Same interface for static and driven tool holders. Static and driven tool holders can be used in all positions. • Higher cutting performance.


B

• F lexible and symmetrical interface, 180° mountable.

C

• Longer cutting tool life.

•M ore available tool length for radial drilling operations. • Increased production.

Threading

• Better workpiece quality.

D

• Rationalized tooling.

Milling

• Reduction in tooling costs.

Driven drill/milling unit, straight

E

Drilling

Static clamping unit, straight

Driven drill/milling unit, right angle

Tool holding

G

H

G 19


Static clamping unit, right angle

Boring

F

A

Turning centers

Turning

A quick change system Insert change by using sister tools • Less downtime.


• F ew or no measuring cuts. Improved profitability. •N o risk of losing insert screws in the chip conveyer.

1.

2.

• Ergonomic. •E asy to clean the tip seat outside the machine.

Threading

C

0.5 min

1.5 min

Milling

D

Drilling

E

F

Boring

Changing to a sister tool with a quick change system is faster than changing the insert inside the machine.

Tool holding

G


H

G 20

Turning centers

A

Turning

Different ways how to install quick change

A

A Hydraulically operated clamping units • Manual push-button tool changing • F ully automatic tool changing possibilities.


Tooling alternatives in conventional turrets

C

C

B Shank type clamping units quare and round shank tools as •S well as cutting units for external and internal operations.

Threading

B

D

•A ngled and straight clamping units for external and internal operations.

Milling

C Clamping units for VDI turrets

Drilling

E

Boring

F

Tool holding

G

Example of installations.

G 21


H

A

Turning centers

Turning

Coromant Capto® driven tool holders


B

Driven tool holders provide the key to dramatic improvements in machining economy by allowing milling, turning and drilling operations to be carried out in a single setup.

•V arious licensed manufacturers of these units are available.

C Threading

•S pindle dimensions - Machine type and model - Maximum turret swing diameter - Maximum tool length.

Milling

D

Drilling

E

Boring

F

Tool holding

G


H Example of installations.

G 22

Machining centers

Turning

Modular tooling for machining centers

A


Machining centers

Threading

C

D

Milling

Turning centers Multi-task machines

E

•A machining center is a multi-function machine that typically combines boring, drilling and milling tasks.

•5 -axis machining centers add two more axes in addition to the three normal axes (X/Y/Z).

Drilling

What is a machining center? F

Boring

• Machining centers could be in horizontal design as well as vertical design.

Tool holding

G

G 23


H

A

Machining centers

Turning

Spindle rotation and definitions of axis Configuration of a vertical machining center


B

Threading

C

Configuration of a horizontal machining center

Milling

D

Drilling

E

What is a basic holder? • A basic holder is an adapter which connects the modular tools to the machine interface.

F

Boring

• Basic holders with front clamp solution offer quick change in machines that do not have automatic tool changing.

Tool holding

G

Front clamping


H

G 24

Center bolt clamping

Machining centers

A

Turning

Commonly used tool holding range Milling machines, machining centers, multi-task machines

Basic holders

Cat V-Flange DIN 69871 Form B 40 50

ISO 7388/1 DIN 96871 Form B ISO 30 ISO 40 ISO 40 ISO 50 ISO 50 ISO 60 ISO 7388/1 BIG-PLUS ISO 40 ISO 50

MAS BT ISO 30 ISO 40 ISO 50

MAS BT Form B ISO 40 ISO 50

MAS BT BIG-PLUS ISO 40 ISO 50

HSK 50-A/C 63-A/C 100-A/C 125-A/C 80-F


DIN 2080 ISO 40 ISO 50

C Threading

Cat V-Flange Cat V-Flange BIG-PLUS/ 40 90° rotated 45 50 40 60 50

B

D

Milling

Chucks and adapters

Drilling

E

Modular tooling for machining centers

- one single system in the machine

G

-m aximum power of the machine can be utilized thanks to the rigidity of the coupling -e asier handling as modular tools are relatively small in size and weight.

Tool holding

A modular tooling system integrated into machining centers gives many advantages:

Boring

F

G 25


H

A

Machining centers

Turning

Spindle integration in machining centers Integration of the female coupling in the spindles An integrated clamping mechanism could be used in most of the machines on the market today and gives many advantages:


B

- standardization in the workshop - better torque transmission and stability

C

- shorter tools due to integration tools

Threading

- more space in the machine - no need for basic holders.

Milling

D

E

Drilling

Directly integrated in the spindle or via basic holder

Boring

F

G Tool holding

Integrated in the spindle


H

G 26

Basic holder solution

Machining centers

A

Turning

Right combination for best possible rigidity Extension adapters

B

• It is important that the minimum length is used, particularly when long overhangs are required.

C

•W ith modular tools it is always possible to use optimal cutting data for best productivity!

Threading


Extended tools for machining centers are frequently required to be able to reach the surface to be machined. With Coromant Capto modular system it is possible to build an assembly, so the right length can be achieved.

odular tools are built together •M in minutes!

D

Milling

• Get closer tolerances.

E

Minimize tool holder inventory in machining centers

Solid

F

Boring

Modular

Drilling

Modular tools give access to a very large number of tooling solutions, with very few items!

Tool holding

G

H

Number of items solid tools: 4 x 3 x (30 + 10) = 480 items. G 27


Number of items with modular tools: 4 + 2 + 30 + 10 = 46 items.

Turning

A

Multi-task machines

Modular tooling for multi-task machines


Machining centers

Threading

C

D Turning centers Milling

Multi-task machines

E

Drilling

What is a multi-task machine?

Boring

F

Tool holding

G

•M ulti-task machines come in a variety of configurations: - horizontal or vertical design - two spindles (main and sub) and a B-axis spindle enable milling and turning operations on both front and back face of the workpiece - each spindle acts as a workpiece holder allowing multi-axis machining on either front or back face of the workpiece.


H

G 28

• In a multi-task machine, the workpiece can be completed in a single machine setup, e.g., turning, milling, contouring and milling of angled surfaces, and grinding. •M ulti-task machines are a combination of a turning center and a machining center.

Multi-task machines

A

Turning

Definitions of the spindle directions The program language for defining the spindle direction lockwise spindle M03 = C direction

C Threading

ounterclockwise M04 = C spindle direction


B

Milling

D

E

Configuration of a multi-task machine Drilling

Spindle rotation and definitions of axis

Boring

F

Tool holding

G

G 29


H

A

Multi-task machines

Turning

Definitions of the spindle directions


B

Therefore multi-task machine tools needed a tooling system with unsurpassed rigidity and repetitive accuracy both radially and axially, like Coromant Capto.

Multi-task machine tools are often used in “done-in-one” applications in which operations run from roughing to finishing in one machine tool setup.

Threading

C

The milling spindle in a multi-task machine tool should be able to carry both rotating and non-rotating tools. Coromant Capto is the only tooling system that can fulfill this demand without compromise.

Milling

D

E

Drilling

The Coromant Capto tooling system is directly integrated in the spindle.

Boring

F

Tool holding

G


H

Turret with Coromant Capto® tooling system Multi-task machine tool with Coromant Capto integrated tool spindle and lower turning turret with Coromant Capto clamping units.

G 30

Multi-task machines

A

Turning

New multifunctional tools for multi-task machines For taking advantage of versatile multi-task machine tools and to optimize their efficiency, there is sometimes a demand for running them with dedicated tooling. These tools are only available with Coromant Capto and have been invented for multi-task machine tools, offering:


B

- accessibility, stability and higher productivity - reduced tool changing time

C

- saved tool pocket in tool magazine

Threading

- cost reduction - one tool replaces many tools.

Milling

D

Twin tools – two turning tools in one

Boring

F

Tool holding

G

Mini-turrets – four turning tools in one

G 31


Multifunctional tools – one milling and four turning tools in one

Drilling

E

A

Multi-task machines

Turning

Build your own mini-turret Four cutting heads applied to one tool holder


Radial

Pick and choose from a large number of exchangeable cutting heads for turning, threading, parting and grooving operations for building an optimized tool for the component. educe tool changing time •R • Save tool pockets in tool magazine • For both external and internal use

C Threading

Axial

Milling

D

Tool adapters for shank tools Turning tool adapters for - shanks - bars - blades - mini-turrets …to make it possible to use shank tools also in a multi-task machine with an integrated modular tool system in the spindle.

Drilling

E

Use of shank tools in a multi-task machine

Boring

F

Tool holding

G Tool adapter with blade for parting off


H

G 32

Tool adapter for boring bar

Chucks

Turning

Chucks

A

Chucks are mechanical, hydro-mechanical and hydraulic chucks respectively, for holding end mills and drills.


B

Choice of chucks and adapters Hydromechanical chuck

Shrink fit adapter

Collet chuck

Endmill (Weldon) adapter

Drill adapter

C Threading

Hydraulic chuck

D 1

2

3

4

5

6 Milling

Rank

Clamping area

+++

+++

Ø < .787 in. (Ø <20 mm)

+++

+++

Runout

+++

Balance

Balanced by rotational testing

+++

+

+++

+++

++

+

+++

+++

+++

+++

+

+

+

Balanced by rotational testing

Balanced by design (C4-C5)



No

F

Tool holding

G

G 33


Ø < .787 in. (Ø <20 mm)

Boring

Clamping force

Drilling

E

A

Chucks

Turning

Hydraulic chucks • • • • • • • •

igh clamping forces. H Large assortment of collets. High accuracy, runout max .00024 inch (6 µm) at 3xD. Large assortment of tools. For drilling, reaming and milling. Fast tool changing time. Can damage hydraulic membrane if not used properly. Any shank type can be used, but recommended to use solid round-shank cutting tools. • High speed capability


B

Threading

C

Milling

D

E

Drilling

Clamping part

F

Pressure screw

Boring

Collet

Tool holding

G


H

G 34

Piston

Chucks

A


C

•S mall collapsibility. • High clamping forces for small diameters - low clamping force for large diameters. • No collets. • Tools can be made slender - narrow. • High accuracy, low runout. • Expensive heating systems. • Long tool changing time. • Heavy investment in tools and machinery. • Low tool lifetime. • Can only clamp solid round-shank cutting tools.

D

Milling

Shrink fit adapters

h6 shank

B

Threading

igh clamping force. H Large assortment of collets. Any shank type can be used. High accuracy, runout max .00024 inch (6 µm) at 3xD. Medium tool changing time. Minimum investment compared to shrink fit. Better reliability than power chucks or shrink fit. Any shank type can be used, but recommended to use solid round-shank cutting tools.

E

Drilling

h6 shank

• • • • • • • •

Turning

Hydro-mechanical chucks

F

• Large collapsing range. •h 6 or h7 tolerance shanks can be used due to large collapsibility.

Boring

Collet chuck adapter – ER type G Tool holding

• Low to medium clamping force. • General purpose clamping system. • Large assortment of collets. • Industry standard.

H

G 35


h6/h7 shank

A

Chucks

Turning

Drill adapter for drills, screw type • Screw type adapter for drills. • Good general purpose tool.

B

• Limited clamping area, typically less than 10%.


•R unout typically is around .0016 inch (40 μm) at the surface of the chuck. • Can cause vibration problems.

Threading

C

Endmill (Weldon) holders • Screw type holders.

D

• Good general-purpose tool. • Limited clamping area, typically less than 10%.

Milling

unout typically is around .0016 inch (40 μm) at the •R surface of the chuck. • Can cause vibration problems.

E

Drilling

• Low-cost solution for holding tools.

Try to minimize the gauge length • It is important to maintain as short a gauge length as possible to increase stability and reduce deflection.

Boring

F

Overhang

G Tool holding

(–20%)


H

Tool protrusion (–50%)

G 36

• L ength reduction as little as 20% can have a significant reduction in deflection (-50%).

Chucks

A

Turning

Influence of runout on tool life

• F or every .0004 inch (0.01 mm) runout - up to 50% decrease in tool life.

B

•M ore critical as tool diameter gets smaller.


•R unout should be < .001 inch (< 0.025 mm).

C Threading

Tool holding requirements Application - Roughing and semi-finishing • Main criteria = clamping force.

D

• High torque capability.

Milling

• F or best performance use cylindrical shanks. • Versatility of collets.

E

• Main criteria = runout.

F

Boring

• Influence on tool life and component - finish and accuracy.

Unbalance in tool holders

G Tool holding

Unbalance in tool holders causes: - poor surface finish - poor part tolerances - reduction in tool life

H

- premature machine-spindle wear.

G 37


Max runout .00024 inch (6 µm)

Drilling

Application - Finishing

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

• The cutting edge

H 18

• Cutting tool materials

H 29

• Manufacturing of cemented carbide

H 44

Other information • Machining economy

H 55

• Maintenance and tool wear

H 68

• Formulas and definitions

H 75

H3

Turning

A


B

Workpiece materials Six main groups The ISO standard material groups are divided into six different types. Each type has unique properties regarding machinability and setups that make different demands on the tool.

ISO

P

Steel

ISO

Stainless steel

M

ISO

K

Cast iron

Threading

C

Workpiece materials

D

ISO

Aluminum

ISO

S

Heat Resistant Super Alloys

ISO

H

Hardened material

Milling

N

E The largest variety of different types of components is probably in the P-area as it covers several different sectors in the industry.

N

The aircraft industry and manufacturers of aluminum automotive wheels dominate the N-area.

M

In the M-area, a big part of the application is in gas and oil, tubes, flanges, process industry and the pharmaceutical business.

S

Difficult to machine S-area materials are found in the aerospace, gas turbine and power generator industries.

K

The K-area is dominated by automotive components, the machine builders and the iron works production.

H

Hardened materials in the H-area are seen in a variety of industries such as automotive and their subcontractors, as well as in machine builders and the die and mold business.

Drilling

P

Boring

F

Tool holding

G


H

H4

Workpiece materials

A

-C lassification, metallurgical/mechanical, of the workpiece material. - The cutting edge micro- and macro geometry to be used. ISO

Steel

ISO

M

The selections will have a great influence on the machinability of the material at hand.

Stainless steel

ISO

K

Cast iron

B

C Threading

P

- T he cutting tool material (grade), e.g. coated cemented carbide, ceramic, CBN, PCD, etc.


Factors that must be identified in order to determine a material’s machinability:

Turning

Characteristics for chip formation and removal

ISO

Aluminum

ISO

ISO

S Heat resistant and super alloys H

Hardened material

D

Milling

N

N M

ISO-M forms a lamellar, irregular chip formation where the cutting forces are higher compared to normal steel. There are many different types of stainless steels. Chip breaking varies depending on the alloying properties and the heat treatment, from easy to almost impossible-to-break chips.

Chip formation for ISO-K materials varies from near-powderlike chips to a long chip. The power needed to machine this material group is generally low. Note that there is a big difference between gray cast iron (often near-powder) and ductile iron, which many times has a chip breaking more similar to steel. Low power needed per inch3 (mm3), but due to the high metal removal rate, it is still a good idea to calculate the maximum power required.

S

The range is wide, but in general high cutting forces are present.

H

Often a continuous, red-glowing chip. This high temperature helps to lower the kc1 value and is important to help out with the application.

H5

F

Boring

K

G Tool holding

ISO-P materials are generally long chipping and have a continuous, relatively even flow of chip formation. Variations usually depend on carbon content. – Low carbon content = tough sticky material. – High carbon content = brittle material. Cutting force and power needed varies very little.


P

Drilling

E

A

Workpiece materials

Turning

The complex world of metal cutting Many parameters influence the cutting process


B

C

Steel

D

M

Stainless steel

K

Cast iron

N

Aluminum

Milling

Threading

Turning

P

E

Application

Workpiece material

Condition Cutting conditions

Milling

Milling

Drilling

Clamping conditions

F

S


H

Hardened steel R

Boring

M F

Tool holding

G The ISO material groups are divided into 6 different types where each type has unique properties regarding machinability.


H

L

M

H

Roughing/ Heavy Medium

Finishing/ Light

There are three major types of application, all requiring different tools, inserts and grades. These also depend on the load on the cutting edge, from finishing to roughing.

All components are different in look, need various setups, and require special attention and demands from the tool.

 H6

Workpiece materials

Turning



A


B

Hardness

Cutting environment

C Threading

Component

Hardness Brinell

Milling

D

Coolant

Drilling

E

F

Carbide performs best when machining at high, constant temperatures. Dry conditions should therefore be the first choice. Some grades are, however, developed for wet conditions; for example, grades for cast iron machining.

G Tool holding

Usually there is a relation between material hardness and tool life, as well as machining data and type of geometry and grade. The higher the hardness, the shorter the tool life, with more rapid wear on the cutting edge.

H

H7


Depending on the size, type of material, setup and machining method, a different choice of tooling is required (turning, milling, drilling, etc).

Boring

Dry machining

Turning

A

Workpiece materials

The interaction between workpiece material, geometry and grade Workpiece material

• T he interaction between an optimized geometry and grade for a certain workpiece material is the key for a successful machining process.


B

• T hese three basic factors must be considered carefully and adapted for each machining operation.

C Threading

• T he knowledge and understanding of how to work with and adjust these factors is of vital importance.

Insert grade

Insert geometry

Milling

D

Workpiece materials, main groups

E

Materials are classified using MC codes

Drilling

Steel

F

Boring

P

Heat resistant super alloys and titanium

Cast iron

M

Stainless steel

K

N

Aluminum

Tool holding

G

Within each material group there are subgroups depending on the hardness of the material, kc1 value, and metallurgical and mechanical properties.


H * MC = A new material classification that replaces the CMC (Coromant Material Classification) codes. H8

S

H

Hardened material

Workpiece materials

A

Turning

MC code structure 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

P = ISO code for steel


Example 1:

1 = material group: unalloyed steel

C

The code P1.2.Z.AN is interpreted this way:

2 = material subgroup: carbon content ?0.25% ≤0.55% C Threading

Z = manufacturing process: forged/rolled/cold drawn AN = heat treatment: annealed, supplied with hardness values

D

Milling

Example 2: 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%

Drilling

Z = manufacturing process: casting AN = heat treatment: aging

F

Boring

By describing not only the material composition, but also the manufacturing process and heat treatment, which influences the mechanical properties, a more exact description is available, which can be used to generate improved cutting data recommendations.

Tool holding

G

H9


H

A

Workpiece materials

Turning

Steel ISO P – main characteristics


B

Threading

C

Milling

D

What is steel?

- Long-chipping material

-S teel is the largest group in the metal cutting area.

- Relatively easy, smooth chip control - Low carbon steel is sticky and needs sharp cutting edges - Specific cutting force kc: 217,500–449,500 lbs/inch2 (1500–3100 N/mm2) - Cutting force, and the power needed to machine ISO P materials, stays within a limited range.

-S teels can be non-hardened or hardened and tempered with hardness up to 400 HB. teel is an alloy with the element iron -S ( Fe) as the major component. It is produced through a melting process. -U nalloyed steels have a carbon content lower than 0,8 %, and only Fe, with no other alloying elements. -A lloyed steels have a carbon content which is lower than 1,7 % and alloying elements like Ni, Cr, Mo, V, W.

Drilling

E

Machining characteristics:

Boring

F

ISO

Tool holding

G

Material

P1

Unalloyed steel

P2

Low-alloyed steel (≤5% alloying elements)

P3

High-alloyed steel (>5% alloying elements)

P4

Sintered steels

P


MC

See Technical Guide Chapter H for detailed MC code listing

H 10

Workpiece materials

A

Turning

Stainless steel ISO M – main characteristics


B


What is stainless steel?


tainless steels are materials alloyed -S with min 11–12% chromium.

-C hip control is fair in ferritic, to difficult in - T he carbon content is often low (down to austenitic and duplex max 0.01%). - Specific cutting force: - Alloys are mainly Ni (Nickel), Mo 261,000–413,250 lbs/inch2 (Molybdenum), and Ti (Titanium). (1800–2850 N/mm2)

Milling

- T he formed Cr2O3 layer on the steel surface makes it non-corrosive.

D

E

Drilling

achining creates high cutting forces, -M built-up edge, heat and deformation hardening.

Threading

C

Material

P5

Ferritic/Martensitic stainless steel

G

M1

Austenitic stainless steels

M2

Super-austenitic, Ni≥20%

Tool holding

MC

M See Technical Guide Chapter H for detailed MC code listing

H M3

Duplex (austenitic/ferritic)

H 11


ISO

Boring

F

A

Workpiece materials

Turning

Cast iron ISO K – main characteristics


B

Threading

C

Milling

D


What is cast iron?

- Short chipping material

- T here are 3 main forms of cast iron: gray (GCI), nodular (NCI) and compacted graphite (CGI).

- Good chip control in all conditions -S pecific cutting force: 114,550–195,750 lbs/inch2 (790–1350 N/mm2)

-C ast iron is an Fe-C composition with relatively high content of Si (1–3%).

- Machining at higher speeds creates abrasive wear

-C arbon content is over 2% which is the max solubility of C in the Austenitic phase.

- Moderate cutting forces.

Drilling

E

-C r (Chromium), Mo (Molybdenum), and V (Vanadium) form carbides which increase strength and hardness, but lower machinability.

ISO

MC

Material

K1

Malleable cast iron

K2

Gray cast iron

K3

Nodular SG iron

K4

CGI

K5

ADI

Boring

F

G Tool holding

K


H


H 12

Workpiece materials

A

Turning

Non-ferrous materials ISO N – main characteristics


B


What is Non-ferrous material?


- T his group contains non-ferrous, soft metals with hardness under 130 HB.

-A luminum (Al) is sticky and needs sharp cutting edges - Specific cutting force: 50,750–101,500 lbs/inch2 (350–700 N/mm2)

-A luminum (Al) alloys with up to 22% silicon (Si) make up the largest part.

D

- Copper, bronze, brass - Plastic Milling

- Relatively easy chip control if alloyed

Threading

C

- Composites (Kevlar)

- Cutting force, and the power needed to machine ISO N materials, stays within a limited range.

Drilling

E

ISO

MC

Material

N1

Aluminum-based alloys

Boring

F

N2

Magnesium-based alloys

N3

Copper-based alloys

N4

Zinc-based alloys

Tool holding

G

N

H

H 13



Turning

A

Workpiece materials

Heat resistant super alloys and titanium ISO S – main characteristics


B

Threading

C

Milling

D

Drilling

E


What are Heat Resistant Super Alloys?


Resistant Super Alloys (HRSA) -- Heat include a great number of high alloyed iron, nickel, cobalt or titanium based materials.

- Difficult chip control (segmented chips) -N egative rake angle is required with ceramics, a positive rake angle with carbide - Specific cutting force: For HRSA: 348,000–449,500 lbs/inch2 (2400–3100 N/mm2) For titanium: 188,500–203,000 lbs/inch2 (1300–1400 N/mm2) - Cutting forces, and power required are quite high.

Condition: Annealed, Solution heat treated, Aged rolled, Forged, cast. Properties: - Increased alloy content (Co more than Ni), results in better resistance against heat, increased tensile strength and higher corrosive resistance.

ISO

Boring

F

Groups: Fe-based, Ni-based, Co-based

G

Material

S1

Iron-based alloys

S2

Nickel-based alloys

S3

Cobalt-based alloys

S4

Titanium-based alloys

S5

Tungsten-based alloys

S6

Molybdenum-based alloys

Tool holding

S


MC


H 14

Workpiece materials

A

Turning

Hardened steel ISO H – main characteristics


B

What is hardened steel?


ardened steel is the smallest group -H from a machining point of view.

- Fair chip control - Negative rake angle is required pecific cutting force: -S 369,750–706,150 lbs/inch2 (2550–4870 N/mm2)

- T his group contains hardened and tempered steels with hardness >45–65 HRC. - T ypically, however, hard part turned components can be found to be within the range of 55–68 HRC.

- Cutting forces and power required are quite high.

D

Milling


Threading

C

Drilling

E

Material

H1

Steels (extra hard)

G

H2

Chilled cast iron

H3

Stellites

Tool holding

MC

H See Technical Guide Chapter H for detailed MC code listing

H H4

Ferro-TiC

H 15


ISO

Boring

F

A

Workpiece materials

Turning

The specific cutting force


B

kc1 – the material constant varies for each material kc1 lbs/in2 (N/mm2)

• T he cutting force (Fc) is the force needed to shear off a specific chip cross-section in certain conditions

870,000 (6000)

C Threading

725,000 (5000)

D

Fc 580,000 (4000)

H

Milling

435,000 (3000)

Drilling

E

P

M

S

290,000 (2000)

145,000 (1000)

K

N

Boring

F

G

kc1 values in lbs/inch2 (N/mm2)

P 217,500 – 449,500

N 50,750 – 195,750

M 261,000 – 413,250

S 188,500 – 449,500

K 114,550 – 195,750

H 369,750 – 706,150

Tool holding

(1500 – 3100)


H

(1800 – 2850) (790 – 1350)

H 16

(350 – 1350)

(1300 – 3100) (2550 – 4870)

• T his value (Fc) is used in the calculation of the power consumption needed for an operation

• T he specific cutting force value (Fc) is a material constant, expressed in lbs (N)

Fc = kc × ap × fn

Workpiece materials

A

Turning

The ISO nomenclature in the ISO-P area

01

P10: T urning; copying; threading; milling; high cutting speed; small to medium chip area.

10

P20: T urning; copying; medium cutting speed; facing with small chip area; medium to difficult conditions.

20

P30: T urning; milling facing; medium to low cutting speed; medium to large chip area; includes operations with tough conditions.

30 40

P40: Turning; facing; milling; cutting; grooving; low cutting speed; large chip area; large possible chip angle; very tough conditions. P50: W hen very high toughness in the tool is needed in turning, facing, grooving, cutting, low cutting speed, large chip area, large possible chip angle, extremely tough conditions.


P

P01: Internal and external finishing turning; high cutting speed; small chip area; good surface finish; narrow tolerances; no vibrations.

C Threading

Wear resistance

D

Milling

Operations and working conditions

E

Drilling

50 Toughness

F

Boring

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.

Tool holding

G

H 17


H

The cutting edge

Turning

A


The cutting edge The design of the cutting edge and insert geometry is of vital importance for the chip formation process and tool life in metal cutting.

Threading

C

Milling

D

Drilling

E

Boring

F

Tool holding

G


H

H 18

The cutting edge

A

Turning

The high cutting force on a cutting edge Guess how big the tangential force is on the cutting edge


Cemented carbide has a high compressive strength resistance and can also work at high temperatures without plastic deformation. It can also resist high cutting forces without breaking, as long as the insert is well supported.

C p

Material: Steel

ap = .319a inch =8.1(8.1 mm mm) p

CMC 02.1 180 HB

ap =13 mm fn = .024 in fn =0.62 (0.62 mm)

fn = .039 in f =1.0 (1.0 nmm)

Threading

ap =a.512 inch (13 mm) =13 mm

ap =8.1 mm

D

Fc = 3750 lbf kp Ft =1700 (1700 kp)

Milling

fn =1.0

n =0.62

Ft =1700 kpFc = 3750 lbf

(1700 kp)

E Ft =1700 kp Drilling

Ft =1700 kp

Boring

F

G Tool holding

Fc = kc x ap x fn Fc = 304563 x .512 x .024 = 3742 = 1700 kp Fc = 2100 x 13 x 0.62 = 16926 N (Newton) = 1700 kp

The tangential cutting force in these two cases (approx. 3750 lbf, 16671 N, or 1700 kp) is equivalent to the weight of a passenger car.

H

H 19


Calculation of Fc Material: MC P2 (low alloyed steel) 180 HB kc = 304,563 lbs/in2 (2100N/mm2)

A

The cutting edge

Turning

The machining starts at the cutting edge


B

C Threading

Typical chip breaking sequences with high speed imaging.

D

Milling

Cutting zone temperatures

Drilling

E

The maximum heat generated during cutting is on the top part of the insert, in the chip breaker, and close to the cutting edge. This is where the maximum pressure from the material is, and, with the friction between chip and carbide, causes these high temperatures.

F

Boring

• T he rake angle, geometry and feed play an important role in the chip formation process. •R emoving heat from the cutting zone through the chip (80%) is a key factor.

G Tool holding

• T he rest of the heat is usually evenly distributed between the workpiece and the tool.


H

H 20

The cutting edge

A

Turning

The design of a modern insert


B

Threading

C

A steel turning insert for medium turning.

D

Milling

Definitions of terms and geometry design

E

.010 in. (.25 mm)

Geometry for small cutting depths

F

5° •C utting edge reinforcement .010 inch (0.25 mm)

Boring

Macro geometry with chip breaker

20°

Drilling


• Rake angle 20° • Primary land 5°

G Tool holding

.008 in. (0.2 mm)

H

H 21


Nose cutting edge design

A

The cutting edge

Turning

The reinforcement of the cutting edge

•E R treatment (Edge Roundness) is done before coating, and gives the final shape of the cutting edge (micro-geometry).

C

• T he relation between W/H depends on the application.

Threading


B

The ER treatment gives the cutting edge the final micro-geometry

Milling

D

Generally the ER corresponds to the thickness of a hair, diameter: ~ .0031 inch (80 µm).

Drilling

E

A negative land increases the strength of the cutting edge Milling inserts often have a negative land and reinforced insert corners, making them stronger and more secure in the intermittent cutting action.

F .0039 in. (0.1 mm)

Boring

Negative land

G Tool holding

Chamfer

negative land increases the strength •A of the cutting edge, but also creates higher cutting forces.


H

H 22

The cutting edge

A

Turning

Insert rake angle 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 degrees plus. This determines how the insert can be tilted in the tool holder, and results in either a negative or positive cutting action.


B

C Threading

• T he insert rake angle is the angle between the top face of the insert and the horizontal axis of the workpiece.

Milling

D

E

Boring

F

G Tool holding

In milling, which always has an intermittent cutting action, the edge needs to have good bulk strength to resist breakage. A large variation in cutting edge temperature due to interrupted cuts also makes resistance to thermal cracks of vital importance.

In most drilling applications there is also coolant present, mainly for chip transportation reasons which puts the edge under extra stress from temperature variations. To be able to transport the chips from the narrow chip flutes and from inside the hole, good chip breaking into short chips is an important factor.

In drilling, the edge must be strong enough to last at very low cutting speeds, and even at zero speed in the center of the drill.

H

H 23


Turning needs a durable edge that can perform for a long time and often in continuous cuts at high temperature. This condition requires an edge with among other things good chip breaking ability, good resistance against different types of wear and against plastic deformation.

Drilling

Positive and negative cutting action

A

The cutting edge

Turning

Peak performance in machining There are major differences in insert geometry and grade requirements between applications in turning, milling and drilling.


B

Dedicated inserts for different applications

Turning

C

•N eeds a durable edge that can perform for a long time, and often in continuous cuts at high temperature.

Threading

• Good chip breaking ability

Milling

D

ood resistance against different types •G of wear and against plastic deformation.

P M

Milling

K

•V ariations in cutting edge temperature due to the interrupted cuts also mean that the resistance to thermal cracks is of vital importance.

E

Drilling

N F

S

Boring

H

Drilling

• T he edge must be strong enough to last at very low cutting speeds; in fact, at zero speed in the center of the drill. •C oolant is present, mainly for chip transportation reasons, which puts the edge under extra stress from temperature variations.

Tool holding

G

• T o transport the chips from the narrow chip flutes and from inside the hole, good chip breaking is important.


• T he cutting action is always intermittent and the edge needs to have good bulk strength to resist breaking.

H 24

The cutting edge

A

Turning

Six main groups of workpiece materials Different characteristics for removing chips


Good chip forming usually results in high cutting forces and excess heat, depending on the material. This can lead to low cutting speeds with adhesive stresses as a result. On the other hand, materials like aluminum, unalloyed steels and low-strength cast iron produce less cutting force.

Threading

C

Steel

Stainless steel

Milling

D

Cast iron

Drilling

E

F

Boring

Hardened steel

G Tool holding


H

H 25


Aluminum

A

The cutting edge

Turning

From universal to optimized turning inserts General inserts

B

• General geometry


• Optimizing with grades • Performance compromised

Threading

C Dedicated inserts edicated geometries •D and grades •O ptimized performance according to workpiece machinability

Application area

Milling

D

Application area

E

Dedicated inserts for the ISO P, M and K areas

Drilling

The different micro- and macro-geometries are adapted to the various requirements in the applications. Workpiece material

F

Finishing

Roughing

.008 in. (0.2 mm)

.013 in. (0.32 mm)

.011 in. (0.29 mm)

.013 in. (0.32 mm)

Boring

.028 in. (0.7 mm)

Medium

Tool holding

G

.004 in. (0.1 mm)


H

H 26

.010 in. (0.25 mm)

The cutting edge

A

Medium turning • Most applications – general purpose. • Medium operations to light roughing. • Wide range of D.O.C. and feed rate combinations.

M

C

Finishing • Operations at light depths of cut (D.O.C.) and low feed rates. • Operations requiring low cutting forces.

F


R

Heavy turning • Operations for maximum stock removal and/or severe conditions. • High D.O.C. and feed rate combinations. • Operations requiring highest edge security.

fn Feed, inch/r (mm/r)

Threading


Turning

Type of application - Turning

D

Dedicated geometries and grades

E

Drilling

ISO/ANSI

Milling

Today’s insert/grade/geometry options are much more dedicated towards specific application areas, giving the full and optimized usage of the machine and tool capacity, resulting in improved productivity and lower costs.

P STEEL

Finishing

Medium

Roughing

-WF / GC4215 -PF / GC4215

-WM / GC4205 -PM / GC4215

WR / GC4205 -PR / GC4215

Dominating application areas

Single sided

-WF / GC4215

-WM / GC4215

-WR / GC4215

-PF / GC4215

-PM / GC4225

-PR / GC4225

F

P

Single sided

-WR / GC4225 -PR/ GC4235

Material Dedicated geometries

Steel

M

K

Stainless steel

Cast iron

G

Turning

F M R

F M R

F M R

Milling

L M H

L M H

L M H

Grades

GC4200

GC2000

GC3200

H 27

Tool holding

-WM / GC4225 -PM / GC4235


-WF / GC4225 -PF / GC4225

Boring

Double sided

A

The cutting edge

Turning

Type of application - Milling

H


B


M

Threading

C

L

Heavy milling • Operations at maximum stock removal and/or severe conditions. • Larger depth of cut and feed rate. • Operations requiring highest edge security.

Medium milling • Most applications – general purpose milling. • Medium operations to light roughing. • Medium depth of cut and feed rate.

Light milling • Operations at small depth of cut and low feed rates. • Operations requiring low cutting forces.

Milling

D

Selecting the insert geometry in milling

Drilling

E

Feed fz, inch/tooth (mm/tooth)

F

Boring

Light (-L)

G

• Extra positive • Light machining

Tool holding

• Low cutting forces • Low feed rates


H

H 28

Medium (-M) •G eneral purpose geometry • Medium feed rates •M edium operations to light roughing

Heavy (-H) • Reinforced cutting edge • Heavy machining • Highest edge security • High feed rates

Cutting tool materials

Turning


A

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 therefore important to be able to make the correct selection for each application. This should take into consideration the workpiece material to be machined, the component type and shape, machining conditions and the level of surface quality required for each operation.

Threading

C

Milling

D

Drilling

E

Boring

F

Tool holding

G

H 29


H

Turning

A


Different types of cutting tool materials Hardness

 

B

CD


1

Diamond

2 3

C

CB

Cubic boron nitride

4

Threading

5

    CC

Ceramics

CT

6

D

Cermets

Milling

1. Diamond 2. Cubic boron nitride 3. Ceramics 4. Cermets 5. Coated carbide 6. High Speed Steel

E

GC

Coated carbide

HSS

Drilling

High speed steel

F

Toughness

The ideal cutting tool material should: - be hard, to resist flank wear and deformation

Boring

- be tough, to resist bulk breakage

- be chemically stable to resist oxidation and diffusion - have good resistance to sudden thermal changes.

Tool holding

G

- not chemically interact with the workpiece material


H

H 30


A

Turning

The main range of cutting tool materials • Uncoated cemented carbide (HW)

B

• Coated cemented carbide (HC)

• Cubic boron nitride (BN)


• Cermet (HT, HC)

• Polycrystalline diamond (DP, HC)

C Threading

• Ceramic (CA, CN, CC)

D

Characteristics, features and benefits • Used in moderate to difficult applications related to steel, HRSA, titanium, cast iron and aluminum in turning, milling and drilling.

E

Drilling

•G ood combination of abrasive wear resistance and toughness.

Milling

Uncoated cemented carbide

• Gives sharp cutting edges.

•R epresents a small portion of the total grade program.

Boring

F

•G ood edge security but limited wear resistance at higher speeds.

Tool holding

G

 H 31


H

A


Turning

Coated cemented carbide Characteristics, features and benefits • General use in all kinds of components and materials for turning, milling and drilling applications. • Extremely good combination of wear resistance and toughness in a variety of jobs. • Consists of a large variety of grades with hard to tough substrates, usually with gradient sintering, and various coatings of CVD and PVD-type. • Shows very good wear characteristics with long tool life. • Dominates the insert program, with increasing share.


B

Threading

C

Cermet

D

Milling

• Used in finishing and semi-finishing applications where close tolerance and good surface finish is required. • Chemically stable with a hard and wear resistant substrate. • Consists of Titanium based (TiC, TiCN) cemented carbide with cobalt as a binder. • PVD-coating adds wear resistance and tool life. “Self sharpening ” properties. Limited toughness behavior. • Quite low share of total insert program.

Drilling

E

Ceramic • Depending on type of ceramic, the grades are mainly used in cast iron and steel, hardened materials and HRSA. • Ceramic grades are generally wear resistant and with good hot-hardness. Wide application area in different types of material and component. • Ceramics are considered brittle and need stable conditions. With additions in the mix and whisker reinforced ceramic, toughness is improved. • Fairly low share of total insert usage, but increased usage in the aerospace and hardened steel-cast iron areas.

Boring

F

Tool holding

G


H

 H 32


A

B

C Threading

• For finish turning of hardened steel. Roughing of gray cast iron at high cutting speeds. Rough turning of rolls in white/chilled cast iron. • Applications that require extreme wear resistance and toughness. • CBN consists of Boron nitride with Ceramic or Titanium nitride binder. • Resists high cutting temperatures at high cutting speeds. • Special application area with small volume inserts. Trend is towards a higher volume of hard materials to be cut.


Characteristics, features and benefits

Turning

Cubic boron nitride

D

Drilling

E

F

Boring

• Turning of normal aluminum at low temperature and very abrasive hypereutectic aluminum. Used in non-metal and non-ferrous materials. • Extremely wear resistant grades. Sensitive to 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 resistance. Decomposes at high temperatures. Dissolves easily in iron. • Fairly low portion of the insert program, with special limited applications.

Milling

Polycrystalline diamond

Tool holding

G

H 33


H

A


Turning

The development of cutting tool material


B

Threading

C

Milling

D

The development of cutting tool material through the years can be seen in the reduced time taken to machine a component 19.685 inch long, with 3.937 inch diameter (500 mm long, with 100 mm diameter) from 1900 to today. At the beginning of the last century, cutting tool material was only slightly harder than the material which needed to be cut. Therefore tool life was poor, and cutting speed and feed had to be kept very low. The introduction of HSS brought major improvements, which resulted in reduced cutting time. 20 years later uncoated cemented carbide brought down the required time in cut to a staggering 6 minutes.

Today with improved geometries and new coating technique we have reached below 1 minute in cutting time for the 19.685 inch (500 mm) steel bar. In addition to traditional uncoated and coated carbide, new cutting tool materials like cermet, ceramic, cubic boron nitride and diamond, have contributed to optimized and improved productivity.

The introduction of coated carbide again lowered the cutting time to 1.5 minutes.

E Carbon steel

Drilling

Min (log)

ø3.937 (ø100)

F

Boring

High speed steel (HSS)

19.685 (500)

Cemented carbide

G Tool holding

Coated carbide Insert geometries, new coatings New cutting tool materials


H

H 34


A

•C emented carbide is a powder metallurgical material consisting of:

Turning

What is cemented carbide and a grade? B

- a binder metal, cobalt (Co) -h ard-particles of Ti,Ta,Nb (titanium, tantalum, niobium-carbides).


- hard-particles of WC (tungsten carbide)

Threading

C •A grade represents the hardness or toughness of the insert, and is determined by the mixture of ingredients which make up the substrate.

Milling

D

E

•A thin Titanium Nitride coating layer was added, only a few microns thick. This improved the performance of carbide overnight. • Coatings offer improved wear resistance giving longer tool life and possibility to use higher cutting data.

G Tool holding

•Today modern grades are coated with different carbide, nitride and oxide layers.

F

Boring

•C oating of cemented carbide was developed in the 1960s.

Drilling

Coating of cemented carbide

H 35


H

A


Turning

Microstructure of cemented carbide


B

Cemented carbide consists of hard particles (carbides) in a binder matrix. The binder is more or less in all cases cobalt (Co) but could also be Nickel (Ni). The hard particles consist mainly of tungsten carbide (WC) with a possible addition of gamma phase (Ti-, Ta- Nb-carbides and nitrides).

The gamma phase has a better hot hardness and is less reactive at elevated temperatures, so is often seen in grades where the cutting temperature can get high. WC has a better abrasive wear resistance.

Threading

C

Elements:

D

Milling

Gamma-phase (TiC)

Beta-phase (Co)

E

Drilling

Alpha-phase (WC)

Alpha-phase WC (tungsten carbide)

Gamma-phase (Ti,Ta,Nb)C (titanium, tantalum, niobium-carbides)

Beta-phase Co (cobalt)

F

Boring

Hair diameter = .0020-.0028 inch (50-70 µm)

Tool holding

G


H

H 36


A

An increase in Co content and WC grain size contributes to an increase in bulk toughness, but also lowers the hardness. As a result, the substrate has less resistance to plastic deformation, which means less wear resistance/lower practical tool life.


Apart from the grain size of the WC, the amount of binder phase (cobalt) is an important factor determining the characteristics of the carbide. The Co content in Sandvik Coromant grades is generally 4–15% of the total weight.

Turning

Fundamental characteristics

Amount of binder

Toughness

Threading

C

Milling

D

Drilling

E

WC grain size

Tool holding

G

H

H 37


Wear resistant

Boring

F

A


Turning

Coating design Many factors influence the behavior of the insert:

B

- Coating process


- Coating material - Coating thickness - Post treatment

C Threading

- Surface morphology.

Milling

D

E

Example of modern steel turning grades

Drilling

Structure and build-up of the coating layers

P

Wear resistance

Toughness

Boring

F

Gradient substrate for optimized hardness and toughness

Tool holding

G

ISO P01 – P15

ISO P05 – P30

ISO P10 – P35

ISO P20 – P45

GC4205

GC4215

GC4225

GC4235


H Thicker coatings mean more wear resistance. Harder substrates mean more deformation resistance. H 38


A

Turning

Grade design Coatings and substrates vary with the type of application


B

C K05 – K15

P05 – P35

M15

M25

M35 Threading

Thicker coatings mean more wear resistance. Harder substrates mean more deformation resistance.

D

The coating of a modern turning grade Milling

The grade plays a very important part of the performance

E

Drilling

Al2O3 – Coating for chemical and thermal wear resistance.

G Tool holding

Functional gradient – For optimized hardness and toughness.

F

Boring

TiCN – MTCVD coating for mechanical wear resistance.

Cemented carbide – Plastic deformation resistance.

H 39


H

A


Turning

Properties of different coating materials CVD coating of inserts Chemical Vapor Deposition


B

TiN

• TiCN provides flank wear resistance.

Al2O3

•A l2O3 provides temperature protection (plastic deformation resistance).

Ti(C,N)

• TiN provides easy wear detection.

Threading

C

• T he most common CVD layers today are TiN, Ti(C,N) and Al2O3.

D

Milling

TiN = Titanium nitride Ti(C,N) = Titanium carbonitride Al2O3 = Aluminum oxide

Drilling

E

PVD coating of inserts Physical Vapor Deposition

F

•P VD coatings are generally tougher than CVD coatings.

Boring

•P VD coatings are often used in combination with fine-grained substrates to coat “sharp” cutting edges. • T otal thickness of the PVD layers is often between .0001 – .0002 inch (3 – 6 μm).

G Tool holding

• T he coating is applied at approx. 932° F (500° C).


H

H 40


A

Turning

The tough environment in metal cutting Different wear mechanisms on the inserts Wear picture

Cause

Mechanical stress on the insert edge causes breakage.

Thermal

Temperature variations cause cracks and heat generates plastic deformation (PD) on the insert edge.

Chemical

A chemical reaction between carbide and working material causes wear.

Abrasive

In cast iron the SiC inclusions can wear on the insert edge.

C

D

Milling

Mechanical


Symbol

Threading

Type of load

B

Drilling

E

Boring

F

BUE = Built-Up Edge

G Tool holding

Adhesive

With sticky material, built-up layers/edges are formed.

H

PD = Plastic Deformation

H 41


BUE BUE

A


Some of the most common wear patterns

B

Flank wear (abrasive)


Turning

Wear pictures, cause and remedy

Cause Cutting speed too high, insufficient wear resistance.

Remedy Reduce cutting speed, select a more wear resistant grade.

Cutting temperature too high.

Reduce cutting speed, select a more wear resistant grade (Al2O3 coated grade).

Cutting speed too low Unsuitable grade.

Increase cutting speed, choose a tougher grade, preferably PVD coated.

Cutting speed too high or insufficient wear resistance.

Select a more wear resistant grade or reduce cutting speed.

Threading

C

Crater wear (chemical)

Milling

D

E

Drilling

Built-up edge (abrasive)

Boring

F

G Tool holding

Notch wear (abrasive)


H

H 42

Cause Cutting temperature too high, combined with a high pressure.

Remedy Select a harder grade, reduce speed and feed.


Plastic deformation (thermal)

A

Turning


Chipping (mechanic) Change the feed, select an alternative insert geometry.

D

Milling

The chips are deflected against the cutting edge.

Threading

C

Temperature variations caused by:

Coolant should be applied copiously, or not at all.

F

Boring

- intermittent machining - varying coolant supply

Select a tougher grade with better resistance to thermal shock.

Drilling

E

Thermal cracks

Check the following: - chip hammering - cutting data - sand inclusions in workpiece - built-up edge - vibration - excessive wear on insert. H 43

G Tool holding

Overload of mechanical tensile stresses.


Edge chipping/breakage (mechanic)

Manufacture of cemented carbide

Turning

A


Manufacture of cemented carbide The manufacture of cemented carbide inserts is a carefully designed process, where geometry and grade are balanced to give a product perfectly matched to the application.

Threading

C

Milling

D

Drilling

E

Boring

F

Tool holding

G


H

H 44


Turning

The development of cutting tool material With the development of better carbide substrates, coatings and geometries, productivity and cost savings have improved for the end user.


Large improvements in productivity were possible in the 60s and 70s when the first coatings were developed. After this, the developments continued - with advanced substrate design, new geometries, edge designs, new advanced coating techniques and post treatment of coated edges.

Threading

C

D

The effect on end-user productivity 2006

Milling

A new insert generation

1999 New generation coatings

E

1989 1980

Drilling

Functional gradients Thick aluminum oxide coating

F

1969

Boring

G Tool holding

Indexable inserts

First coated insert

H

H 45


1957

A


Turning

Powder production


B

Threading

C

There are two main elements of a cemented carbide insert: - WC = Tungsten Carbide - Co = Cobalt Other commonly used elements are Titanium, Tantalum and Niobium Carbides. Designing different types of powder and different percentages of the elements is what makes up the different grades. The powder is milled and sprayed-dried, sifted and poured into containers.

D

Milling

Raw material Niobium

Drilling

E

F

Milling

(Ta, Nb)C Tantalum (5%)

Co (7%) Cobalt

(Ti, W)C (8%)

Boring

Cemented carbide powder Ready to press

Tool holding

G


H

H 46

Titanium

WC Tungsten (80%) carbide

Spray drying


A

The main raw material for the manufacture of cemented carbide is tungsten-ore concentrate. Tungsten powder is produced from tungstic oxide derived chemically from the raw material. By varying the conditions of reduction, tungsten powder of various grain size can be manufactured. The carbide granules after spray-drying are small and vary in size depending on grade.

C Threading

.0039 inch (0.10 mm)


The size of the tungsten carbide grains

Turning

Tungsten powder

D

Amount of binder

also to a lower hardness which reduces the wear resistance of the substrate.

E

Drilling

Apart from the grain size for the WC, the amount of binder phase is an important factor determining the characteristics of the carbide. Increasing Co-content, together with increasing WC-grain size, contributes to increasing toughness but

Milling

Basic properties of cemented carbide

Toughness

Boring

F

Tool holding

G

Wear resistant

WC grain size H 47


H

A


Turning

Pressing powder compacts Top and bottom punches


Press force 20 - 50 tons

Threading

C

Die and core pin

Milling

D

Drilling

E

Inspection The pressing operation consists of several pieces of tooling: - T op and bottom punches - Core pin - Cavity.

F

Boring

The pressing procedure:

Tool holding

G

owder is poured into the cavity -P - Top and bottom punches come together (20-50 tons) - The insert is picked and placed via robot onto a graphite tray. - Random SPC is performed, to check for weight. The insert is 50% porous at this stage.


H

H 48


A

Turning

Sintering the pressed inserts Sintering phase consists of the following phases: - T he insert will shrink 18% in all directions during the sintering phase; this corresponds to about 50% in volume.


- L oading trays of inserts into a sintering furnace. - The temperature is raised to ~2550° F (~1400° C). - This process melts the cobalt and the cobalt acts as a binder.

C Threading

Sintering

D

Milling

Insert trays

E Shrinking rate Drilling

Inspection

Boring

F

G Tool holding

3 1. Unsintered insert 2. Sintered insert 3. Coated insert

H

1

H 49


2

A


Turning

Different types of grinding operations B

Free profiling

Profiling


Top and bottom

C Threading

g 00 Bor

Chamfer – negative land

D

Neg. land

Periphery

7

8 9

4 5 1

Milling

SI

Chamfer

S2

S3

S4

S5

S6

6

2 3

S7 S8

Borg 00

Drilling

E

The reinforcement of the cutting edge The ER-treatment gives the cutting edge the final micro-geometry. •E R-treatment (Edge Roundness) is done before coating.

Boring

F

• T he relation between W/H depends on the application.

Tool holding

G

Generally the ER corresponds to the thickness of a hair, diameter: ~.0031 inch (~80 µm).


H

H 50


A

Turning

CVD – Chemical Vapor Deposition 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 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).


B

Threading

C

Milling

D

Drilling

E

F

• The ability to making thick coatings.

•V ery good adherence to the carbide substrate.

G

• Very good wear resistance.

Tool holding

• Ability to make even coating thickness.

Boring

The advantages of CVD coatings

• Possibility to make oxide coatings.

H 51


H

A


Turning

PVD – Physical Vapor Deposition


B

The inserts are loaded into the coating chamber on trays. Metal source targets are placed on the reactor chamber walls. The most common source is titanium (Ti). The targets are heated to a temperature where the solid metal ionizes.

By using a gas as carrier, the ions can then be transported from the targets to the inserts. As the inserts are cooler, the ions will condensate on the insert surface to form a coating.

The coating thickness is in the range of .00008-.0002 inch (2-6 microns) depending on application area for the insert.

• PVD provides good edge line toughness.

Threading

C

Milling

D

Drilling

E

Boring

F

Tool holding

G

The most common PVD layers today are TiN, Ti(C,N), (Ti,Al)N, (Ti,Al,Cr)N and now also aluminum oxides.


H

H 52

•P VD coatings can maintain a “sharp” cutting edge. • PVD can be used on brazed tips. • PVD can be used on solid carbide tools.


A

In a PVD coating process, the coating is formed by metal vapor condensating on insert surfaces. PVD works the same way as when humid air condensates on cold roads and forms an ice layer on the road. PVD is formed at a much lower temperature than CVD. Normal PVD process temperatures are around 930° F (500° C). The coating thickness is in the range of .00008-.0002 inch (2-6 microns) depending on application area for the insert.

In a CVD coating process, the coating is formed by a chemical reaction of different gases. Temperature, time, gas flow, gas atmosphere, etc., are carefully monitored to steer the deposition of the coating layers. Depending on the type of coating, the temperature in the reactor is about 1470 to 2000 degrees F (800 to 1100 degrees C). The thicker the coating the longer the process time. The thinnest CVD coating today is below .00016 inch (4 microns) and the thickest is above .0008 inch (20 microns).


CVD (Chemical Vapor Deposition)

C Threading

PVD (Physical Vapor Deposition)

Turning

PVD vs. CVD coating process

Milling

D

~1830°F ~1/20 atm

E

Drilling

~930°F ~1/100000 atm

Boring

F

• Thicker coating

• Sharper edges

• More wear resistant

• Tougher

• Thermal resistant

H

H 53


• Thinner coating

Tool holding

G

A


Turning

Vision control, marking and packaging


B

After inspection of dimensions, coating and grade, the insert is marked with a grade designation and placed in a 10-piece box, labeled and packed and ready for distribution to the customer or into stock in the warehouse.

C

Visual inspection Packaging

Threading

Marking

Milling

D

E

Labelling

Drilling

Distribution

Gimo

Boring

F

Tool holding

G


H

H 54

Tool holding

Boring

Drilling

Milling

Threading


Machining economy

How to improve machining economy

H 55


Turning

Machining economy

A

B

C

D

E

F

G

H

A

Machining economy

Turning

Doing more machining in the same production time B Parting and grooving

Productivity definition

The value of output produced divided by the value of input or resources.

C Threading

= Output / Input

Milling

D

Drilling

E

F

Attack the productivity gap In all industrial operations, the cost of running the operation, e.g. for labor, raw material, equipment, etc., is increasing at a faster rate than the price of the goods that are sold. In order to bridge that gap, one needs to continuously increase efficiency, resulting in higher productivity. Bridging this gap is the only way to stay competitive and ultimately to stay in business.

Boring

135 130

G

120

125

Cost development

Tool holding

115


H

110 105 100 95

Productivity gap Price development

Source: Mechanical Industry in OECD.

H 56

Machining economy

A

Turning

Maximizing productivity 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 rate. Cutting speed has the largest effect by far on insert tool life.


B

Depth of cut, inch (mm)

Threading

C

D

Milling

Feed, inch/rev (mm/rev)

Optimizing the feed rate is the best way to maximize the productivity

Drilling

E

Cutting speed, ft/min (m/min)

F

Boring

Productivity “Q” is measured as the amount of material removed in a fixed time period, inch3/min (cm3/min).

G Tool holding

vf

Q = vc × ap × fn × 12

Q = ap × ae × vf H 57


H

A

Machining economy

Turning

Maximizing productivity – examples


B

Metal removal rates for a fixed depth of cut of .118 inch (3.0 mm) using:

P

Low alloy steel, MC P2

Hardness, HB 180

C Threading Milling

.118 (3.0)

.118 (3.0)

.118 3.0

.006 f , inch/r (mm/r) n (0.15)

.012 (0.3)

.020 (0.5)

*

Slowest cutting speed with the highest feed = highest productivity

Using a trigon W-style insert, versus a C-style double-sided or single-sided insert Low alloy steel, MC P2

Hardness, HB 180

F

Boring

.591

Trigon shape Insert: double-sided for medium machining. .118 / .157 inch (3 / 4 mm) No of passes / cutting depth, ap .039 / .118 inch (1 / 3 mm) 22 seconds Machining time, Tc

Rhombic shape Insert: double sided for medium machining. No of passes / cutting depth, ap

G Tool holding

Machining time, Tc 1.969

Machining time, Tc H 58

.118 / .197 inch (3 / 5 mm) 16 seconds

Insert: Single sided for rough machining. No of passes / cutting depth, ap


25* (412)*

Q, inch3/min 12 19 3/min) (cm (191) (310)

P Drilling

a , inch (mm) p

1394 1132 902 v , ft/min (m/min) c (425) (345) (275)

D

E

Insert: CNMG 432-PM 4225 (CNMG 120408-PM 4225)

.079 / .295 inch (2 / 7.5 mm) 8 seconds

Machining economy

A

Turning

Machine tool utilization Incomplete use of additional shifts

B

Production 60%

Tool change 10%


Machining 20%

Set & gauge 10%

C Threading

Breakdowns 10% Holidays, etc.

Workpiece change 10%

D

Milling

Machining economy

Drilling

E

Boring

F

G Tool holding

• Fixed costs Costs which exist even when not in production: - machine and tool holders (27%) - labor (31%) - buildings, administration, etc. (22%).

H

H 59


• Variable costs Costs incurred only during production: - cutting tools, consumables (3%) - workpiece materials 17%.

A

Machining economy

Turning

Machine tool utilization


B

The cost of the tooling, an easily measured value, is always under price or discount pressure, but even when the price is reduced by 30% it only influences the component cost by 1%. We have a similar result of a 1% cost saving when tool life is increased by 50%. Increasing the cutting data by only 20% will dramatically reduce component costs and lead to a 10% component saving.

Threading

C

Cost, tool life or productivity

D

Milling

• Decreased cost: A 30% decrease in price only reduces total cost per component by 1%.

Drilling

E

A 50% increase in tool life only reduces total cost per component by 1%.

Boring

F

• Increased tool life:

Tool holding

G

• Increased cutting data: A 20% increase in cutting data reduces total cost per component by more than 10%.


H

H 60

Machining economy

A

Turning

Machine tool utilization Example:

B

Shop spends $10,000 to make 1000 parts.


Machine cost is $10.00 per part.

20%

Increase cutting data

Today

Lower price

Tool life

– Tooling

$ .30

$ .21

$ .20

$ .45

– Material

$ 1.70

$ 1.70

$ 1.70

$ 1.70

– Machinery

$ 2.70

$ 2.70

$ 2.70

$ 2.16

– Labor

$ 3.10

$ 3.10

$ 3.10

$ 2.48

– Building

$ 2.20

$ 2.20

$ 2.20

$ 1.76

Cost per part

$ 10.00

$ 9.91

$ 9.90

$ 8.55

D

Milling

Variable

C Threading

30% 50%

Fixed

Drilling

E

F

15% Boring

1%

G Tool holding

1%

H

H 61


Savings

A

Machining economy

Turning

Machining ecomomy


B

Threading

C

• Cutting speed has no effect on fixed costs. • As cutting speed increases more parts are produced per hour and therefore cost per part is reduced. • As cutting speed increases more tools are used and therefore cost per part increases. If we add all costs together we will get the curve of total Production cost. 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. 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 cutting speed. The speed between these two points is the High Efficiency Range, which is where we should be trying to operate.

Milling

D

Cutting data and cost

E

F

Cost per part

Drilling

Parts per hour Production rate Production cost

Boring

Tool cost

Tool holding

G

Fixed cost Machine cost


H Economic High Efficiency Speed for maximum speed Range production H 62

Cutting speed

Machining economy

A

Turning

Base for cutting data recommendations • Tool life

Higher metal removal

-A ll cutting data is based on 15 min tool life.

If you want to change the cutting speed to obtain higher metal removal rates the new cutting speed values can be calculated from the following table.

5 min tool life -1 = Factor 1.0 -U se correction factor for other values according to the table.

Tool life (min)

10

15

20

25

Correction factor

1.11

1.0

0.93

0.88 0.84

30

45

60


Compensation of cutting data for difference in tool life

C

0.75 0.70 Threading

Example: 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).

Milling

D

E

Compensation of cutting speed for difference in hardness, HB

-U se correction factors for other values according to the table.

-60 -40 -20 0 +20 +40 +60 +80 +100

P

P2 HB2) 180 1.44 1.25 1.11

1.0 0.91 0.84 0.77 0.72 0.67

M

M1 HB2) 180 1.42 1.24 1.11

1.0 0.91 0.84 0.78 0.73 0.68

K2 HB2) 220 1.21 1.13 1.06

1.0 0.95 0.90 0.86 0.82 0.79

K

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

S

S2 HB2) 350

1.12

1.0 0.89

H

H1 HRC3) 60

1.07

1.0 0.97

Drilling

Increased hardness

F

Boring

-E .g ISO P HB 180 = Factor 1.0.

Reduced hardness ISO/ ANSI MC1) HB2)

1) MC = material classification code 2) HB = Hardness Brinell 3) HRC = Hardness Rockwell

G Tool holding

-A ll cutting data is based on the reference materials and the respective hardness.

H

H 63


• Hardness

Turning

A

Use the table or diagram to compensate the cutting speed for different hardnesses Diagram form for P, M and K


B

Machining economy

ISO

P

ISO

M

ISO

Gray cast iron, HB220 MC K2

Stainless steel, HB180 MC M1

ISO

Nodular cast iron, HB250 MC K3

Threading

C

Steel, HB180 MC P2

Drilling

E

Specific cutting force / hardness

Boring

F

Factor for cutting speed

Milling

D

Tool holding

G


H

H 64

K K

Example of calculating hardness factor and cutting speed compensation Steel MC P2

-R eference hardness HB= 180 -1 5 min tool life = Factor 1.0 -U se correction factor for other values according to the table.

Reduced hardness ISO/ ANSI MC1) HB2)

Increased hardness

B

-60 -40 -20 0 +20 +40 +60 +80 +100

P

P2 HB2) 180 1.44 1.25 1.11

1.0 0.91 0.84 0.77 0.72 0.67

M

M1 HB2) 180 1.42 1.24 1.11

1.0 0.91 0.84 0.78 0.73 0.68

K2 HB2) 220 1.21 1.13 1.06

1.0 0.95 0.90 0.86 0.82 0.79

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

S

S2 HB2) 350

1.12

1.0 0.89

H

H1 HRC3) 60

1.07

1.0 0.97

K


P

C Threading

ISO

A

Turning

Machining economy

1) MC = material classification code 2) HB = Hardness Brinell 3) HRC = Hardness Rockwell

• Calculating hardness factor - HB 266-180 = +86 - Cutting speed factor vc = 0.70. -R educe the cutting speed to 70%.

HV 80 85 90 95 100 110 120 130 140 150 160 170 180 190 200 205 210 215 220 225 230 240 250 255 260 265 270 280 290 295 300 310

HB 76.0 80.7 85.5 90.2 95.0 105 114 124 133 143 152 162 171 181 190 195 199 204 209 214 219 228 238 242 247 252 257 266 276 280 285 295

HRC – – – – – – – – – – – – – – – – – – – – – 20.3 22.2 23.1 24.0 24.8 25.6 27.1 28.5 29.2 29.8 31.0

N/mm2) 255 270 285 305 320 350 385 415 450 480 510 545 575 610 640 660 675 690 705 720 740 770 800 820 835 850 865 900 930 950 965 995

HRB – 41.0 48.0 52.0 56.2 62.3 66.7 71.2 75.0 78.7 81.7 85.0 87.5 89.5 91.5 92.5 93.5 94.0 95.0 96.0 96.7 98.1 99.5 – (101) – (102) – (105) – – –

H 65

E

Drilling

-1 30,500 lbs/inch2 (900 N/mm2) = HB 266 value according to the table.

lbs/inch2) 36,975 39,150 41,325 44,225 46,400 50,750 55,825 60,175 65,250 69,600 73,950 79,025 83,375 88,450 92,800 95,700 97,875 100,050 102,225 104,400 107,300 111,650 116,000 118,900 121,075 123,250 125,425 130,500 134,850 137,750 139,925 144,275

F

Boring

- T ensile strength 130,500 lbs/inch2 (900 N/mm2)

Rockwell

G Tool holding

- DIN 42CrNiMo4

Brinell


• Customer workpiece material

Vickers

Milling

D Tensile strength

A

Machining economy

Threading

C

D

• How to calculate cutting data compensation - The cutting data is based on 15 min tool life. Increased feed fn, inch/r (mm/r) Example 1

Starting value

Example 2

Milling

Decreased feed fn, inch/r (mm/r)

E

Drilling

• Example 1

F

- Increase the feed from, e.g., fn .012 inch/r to .018 inch/r (0.3 mm/r to 0.45 mm/r) = +.006 inch/r (+0.15 mm/r) -D ecrease the cutting speed by 12% from the given cutting speed value.

Boring

• Example 2

- Decrease the feed by .007 inch/r (0.18 mm/r) from the given feed value.

Tool holding

G

- Increase the cutting speed by +15% e.g from 1132 ft/min to 1312 ft/min (345 m/min to 400 m/min)


H

H 66

Increased cutting speed, %


B

Decreased cutting speed, %

Turning

Cutting speed and feed data compensation for turning

Machining economy

A

Turning

How can you improve your productivity?

• Identify the material and hardness HB or tensile strength lbs/inch2 (N/mm2). • Choose the correct geometry.

se the given cutting data values or •U compensate the cutting data values according to your needs.

C

•C orrectly applied, our tools can increase productivity by at least 20%.

Threading

• Choose the correct grade.


Things to consider

Milling

D

Machining tips for improved tool life

•M ake use of all available corners on inserts. •P roper insert radius in relationship to D.O.C.

Drilling

E

•S peeds and feeds within insert parameters.

F

•W orn inserts can be used for chamfering.

G Tool holding

•U se climb milling over conventional milling wherever possible.

Boring

•C hoose the right combination of insert radius and geometry.

H 67


H

Good stability = Successful metal cutting


Tool holding

Boring

Drilling

Milling

Threading


Turning

A Maintenance & tool wear

B

Maintenance & tool wear

C

D

E

F

G

H

H 68 • Tool wear H 69

• Maintenance H 71


A

Turning

Consequences of excessive tool wear


B

Threading

C

Milling

D

Drilling

E

• Damaged inserts

• Damaged shims

F

• Damaged tool holders

• Damaged components Boring

• Damaged machine

G Tool holding

Result: • Reduced production • Higher production costs

H 69


H

A


Visually inspect shims & shim seats

B

•D amaged shims. Shims should not have chipped corners in the cutting area.


Turning

Inspection of tool wear

Damage

•S hims should have no visible wear from chip breaking and/or impressions from the insert.

Chip breakage impression

C Threading

Inspect pockets •P ockets damaged or mushrooming in the corners.

D

Milling

•O versized pockets due to wear. The insert does not sit properly in the pocket sides. Use a .0008 inch (0.02 mm) shim to check the gap.

Drilling

E

F

mall gaps in the corners, between the •S shim and the bottom of the pocket.

The importance of using the correct wrench Why use the proper wrenches? • Extends life of screw and wrench.

Boring

• Reduces risk of stripping screw.

G Tool holding

What is the proper way to tighten an insert screw? • Important to use the proper wrench. lways use correct torque. Values are •A marked on tool and shown in product catalog.


H

• Common sense! H 70


A

Torx Plus from Sandvik Coromant


lbs-in (Nm)

Turning

Torx Plus® wrenches

C Threading

Torx Plus® vs. Torx Cross section Torx Plus®

Torx

D

Milling

Torx Plus®

E Standard Torx screw Drilling

Torx Plus is a registered trademark of Camcar-Textron (USA)

parting and grooving tools an adjust• On able torque wrench is required, as the torque is not related to screw size. • It should of course be used on all products with a clamp screw.

G Tool holding

Torx Plus® wrenches with adjustable torque

Boring

F

H 71


H

A


Turning

Insert screws / clamping screws • Screw threads, heads and Torx sockets should be in good condition.

B

• Use correct keys.


• Ensure correct screw-tightening torque pply sufficient screw lubrication to •A prevent seizure. Lubricant should be applied to the screw thread as well as the screw-head face.

C Threading

• Replace worn or exhausted screws.

D Important! Milling

Use Molykote for screw heads and threads

Drilling

E

Tool maintenance Shim and insert seat • Check shim damage.

F

•C lean insert seat and damaged location and support for cutting edge. Boring

• If necessary index or replace shim. •E nsure correct insert location against support points.

G Tool holding

• It is important to ensure that shim corners have not been knocked off during machining or handling.


H

H 72


A

check supporting and contact • Always faces of tool holders, milling cutters and drills, making sure there is no damage or dirt.

C Threading

• In boring operations it is especially important to have the best possible clamping. If the bar is not supported to the end of the holder, overhang will be increased and create vibration.


Contact faces

Turning

Tool maintenance

l = cutting edge length (insert size) re = nose radius

-S elect largest possible nose radius for insert strength. -S elect a smaller nose radius if there is a tendency for vibration.

Stability • Stability is the key factor for successful metal cutting, affecting machining costs and productivity. •M ake sure that any unnecessary play, overhang, weakness, etc., has been eliminated and that correct types and sizes of tools are employed for the job.

Drilling

re

E

F

Boring

-S elect largest possible point angle on the insert for strength and economy.

G

H

H 73


l

Tool holding

• It is important to select the correct insert size, insert shape and geometry and insert nose radius to achieve good chip flow.

Milling

D

Production security

A


Turning

Insert handling • Inserts should never be removed from the original package until they are ready to be installed.


B

Threading

C

D

Summary of maintenance points

Milling

 Check tool wear and shims for damage.  Make sure insert seat is clean.

E

 Make sure of correct insert location.

Drilling

 Make sure correct keys and drivers are used.  Insert screws should be correctly

F

 Lubricate screws before tool assembly.

tightened.

 Make sure contact faces are clean and undamaged on Boring

tools, holding tools and machine spindles.

Tool holding

G


H

 Make sure boring bars are clamped well and that holder is undamaged at the end.

 A well organized, maintained and documented tool inventory is a production cost saver.

 Stability is always a critical factor in any metal cutting operation.

H 74

A

Turning

Formulas and definitions


Formulas & definitions, calculator

Milling

H 78

Drilling

H 80

Boring

H 82

C Threading

H 76

D

Milling

Turning

E

H 84

Boring

F

Tool holding

G

H

H 75


Cutting data calculator

Drilling

Calculator

A


Turning

Formulas and definitions for turning - INCH B

Cutting speed, ft/min

π × Dm × n 12


vc =

Spindle speed, rpm

Threading

C

n=

vc × 12

π × Dm

Drilling

E

Metal removal rate, inch3/min Q = vc × ap × fn × 12

Boring

F

Net power, HP v × ap × fn × kc Pc = c 33 × 103

Tool holding

G


lm fn × n

H 76

Unit

Tc =

Designation/ definition

Milling

Machining time, min

Symbol

D

Dm

Machined diameter

inch

fn

Feed per revolution

inch/r

ap

Cutting depth

inch

vc

Cutting speed

ft/min

n

Spindle speed

rpm

Pc

Net power

HP

Q

Metal removal rate

inch3/min

hm

Average chip thickness

inch

hex

Maximum chip thickness

inch

Tc

Period of engagement

min

lm

Machined length

mm

kc

Specific cutting force

lbs/inch2

Lead angle

degree

ψr


A

Turning

Formulas and definitions for turning - METRIC Cutting speed, m/min 1000


vc =

B

π × Dm × n

C

Spindle speed, rpm vc × 1000

Threading

n=

π × Dm

Milling

v × ap × fn × kc Pc = c 60 × 103

E

mm/r

ap

Cutting depth

mm

vc

Cutting speed

m/min

n

Spindle speed

rpm

Drilling

Net power, kW

mm

Feed per revolution

Pc

Net power

kW

F

Q

Metal removal rate

cm3/min

hm


mm

hex


mm

Tc

Period of engagement

min

Boring

Q = vc × ap × fn

Machined diameter

fn

lm

Machined length

mm

G


N/mm2

Entering angle

degree

kc

kr

Tool holding

Metal removal rate, cm3/min

Dm

H

H 77


lm fn × n

Unit

Tc =


Machining time, min

Symbol

D

A


Turning

Formulas and definitions for milling - INCH Table feed, inch/min

B

Cutting speed, ft/min vc =

π × Dcap × n 12

Spindle speed, rpm

D

Milling

Feed per tooth, inch vf fz = n × zc

E

Feed per revolution, inch/rev Drilling

fz =

Metal removal rate, inch3/min Q = ap × ae × vf

G

Net power, HP

Tool holding

Boring

F

Pc =

ae × ap × vf × kc 396 × 103

Torque, lbf ft


vf n

Mc =

H 78

Pc × 16501 π×n

ae

Working engagement

inch

ap

Cutting depth

inch

Dcap C utting diameter at cutting depth ap

Unit

vc × 12 π × Dcap

n=


Threading

C

Symbol


vf = fz × n × zc

inch

Dm

Machined diameter (component diameter)

inch

fz

Feed per tooth

inch

fn

Feed per revolution

inch

n

Spindle speed

rpm

vc

Cutting speed

ft/min

vf

Table feed

inch/min

zc

Number of effective teeth

pcs

hex


inch

hm


inch

kc


lbs/inch2

Pc

Net power

HP

Mc

Torque

lbf ft

Q

Metal removal rate

inch3/min

ψr

Lead angle

degree


A

Turning

Formulas and definitions for milling - METRIC Table feed, mm/min


vf = fz × n × zc Cutting speed, m/min

π × Dcap × n

C Threading

1000

fz =

vf n

Metal removal rate, cm3/min Q=

ap × ae × vf 1000

Net power, kW Pc =

ae × ap × vf × kc 60 × 106

Torque, Nm Mc =

Pc × 30 × 103

Working engagement

mm

ap

Cutting depth

mm

Dcap C utting diameter at cutting depth ap

Milling

E

mm

Dm

Machined diameter (component diameter)

mm

fz

Feed per tooth

mm

fn

Feed per revolution

mm/r

Drilling

Feed per revolution, mm/rev

ae

n

Spindle speed

rpm

F

vc

Cutting speed

m/min

vf

Table feed

mm/min

zc

Number of effective teeth

pcs

hex


mm

hm


mm

kc


N/mm2

Pc

Net power

kW

Mc

Torque

Nm

Q

Metal removal rate

cm3/min

kr

Entering angle

degree

Boring

vf fz = n × zc

G

π×n H 79

Tool holding

Feed per tooth, mm

D Unit

vc × 1000 π × Dcap


n=

Symbol

Spindle speed, r/min


vc =

A


Turning

Formulas and definitions for drilling - INCH Penetration rate, inch/min vf = fn × n



π × Dc × n

D

Milling Drilling

F

vc × 12

π × Dc

Feed force, N D Ff ≈ 0.5×kc × c × fn × sin kr 2

Metal removal rate, inch3/min

Boring

Q = vc × Dc × fn × 3

G

Net power, HP

Tool holding

Pc =

vc × Dc × fn × kc 132 × 103

Torque, lbf ft


Dc

Drill diameter

inch

fn

Feed per revolution

inch/r

n

Spindle speed

rpm

vc

Cutting speed

ft/min

vf

Penetration rate

inch/min

Ff

Feed force

N

kc


lbs/inch2

Mc

Torque

lbf ft

Pc

Net power

HP

Q

Metal removal rate

inch3/min

ψr

Lead angle

degree

Spindle speed, rpm n=

E

Unit

12

Threading

vc =


C

Symbol

B

Mc = H 80

Pc × 16501

π×n


A

Turning

Formulas and definitions for drilling - METRIC B

Penetration rate, mm/min


vf = fn × n

Cutting speed, m/min

π × Dc × n


Unit

Dc

Drill diameter

mm

fn

Feed per revolution

mm/r

n

Spindle speed

rpm

vc

Cutting speed

m/min

vf

Penetration rate

mm/min

Ff

Feed force

N

kc


N/mm2

Mc

Torque

Nm

Pc

Net power

kW

Q

Metal removal rate

cm3/min

kr

Entering angle

degree

D Ff ≈ 0.5×kc × c fn × sin kr 2

Metal removal rate, cm3/min v × Dc × fn Q= c 4

E

F

Net power, kW

G Tool holding

v × Dc × fn × kc Pc = c 240 × 103

Torque, Nm Mc =

Milling

Feed force, N

Drilling

π × Dc

Boring

vc × 1000

D

H

Pc × 30 × 103

π×n H 81


Spindle speed, r/min n=

Threading

1000

Symbol

vc =

C

A


Turning

Formulas and definitions for boring - INCH Penetration rate, inch/min vf = fn × n



π × Dc × n

vc =

D

vc × 12

Milling

π × Dc

Feed per revolution, inch/rev

Drilling

fn = zc × fz

F

Metal removal rate, inch3/min

Boring

Q = vc × Dc × fn × 3

G

Net power, HP

Tool holding

Pc =

vc × ap × fn × kc 132 ×

103

(

1–

Torque, lbf ft


Dc

Drill diameter

inch

fn

Feed per revolution

inch/r

n

Spindle speed

rpm

vc

Cutting speed

ft/min

vf

Table speed

inch/min

Ff

Feed force

N

kc


lbs/inch2

Mc

Torque

lbf ft

Pc

Net power

HP

Q

Metal removal rate

inch3/min

ψr

Lead angle

degree

Number of effective teeth (zc = 1 for step boring)

pcs

Spindle speed, rpm n=

E

Unit

Threading

12 Designation/ definition

C

Symbol

B

Mc =

H 82

ap Dc

(

zc

Feed force, N Pc × 16501

π×n

Ff ≈ 0.5 × kc × ap × fn × sin κr


A

Turning

Formulas and definitions for boring - METRIC B

Penetration rate, mm/min


vf = fn × n

Cutting speed, m/min

C

π × Dc × n

Symbol


Unit

Dc

Drill diameter

mm

fn

Feed per revolution

mm/r

n

Spindle speed

rpm

vc

Cutting speed

m/min

vf

Table speed

mm/min

Ff

Feed force

N

kc


N/mm2

Mc

Torque

Nm

Pc

Net power

kW

Q

Metal removal rate

cm3/min

kr

Entering angle

degree

Number of effective teeth (zc = 1 for step boring)

pcs

fn = zc × fz

Metal removal rate, cm3/min Q=

vc × Dc × fn 4

Net power, kW Pc =

vc × ap × fn × kc 60 × 103

(

1–

Torque, Nm Mc =

ap Dc

(

zc

E

F

G

Feed force, N Pc × 30 × 103

π×n

Milling

Feed per revolution, mm/r

Drilling

π × Dc

Boring

n=

D

Tool holding

Spindle speed, r/min vc × 1000

Threading

1000

H

Ff ≈ 0.5 × kc × ap × fn × sin κr

H 83


vc =

A

Calculator

Turning

Cutting data calculator


B

Threading

C

The Sandvik Coromant cutting data calculator is designed to solve most calculation problems encountered in the metal cutting area.

The Sandvik Coromant cutting data calculator also functions as a standard mathematical calculator. Calculations can be done in metric or inch.

The calculator is self-explanatory and very easy to use. Users include programmers, operators, machinists, supervisors, foremen, designers and more. As a user, you simply decide what parameter you want to calculate, choose the appropriate formula from the menu in the display and enter the input as prompted by the calculator. This means that the user does not need to memorize any metal cutting formulas. • Calculator metric/inch

Milling

D

Self-explanatory and very easy to use

• Size 80x125x15 mm

Drilling

E

Machining Calculator App The Machining Calculator app from Sandvik Coromant is designed to help engineers and machinists optimize the performance of their turning, milling and drilling applications by calculating optimal cut settings based on job parameters.

Boring

F

The app is free and can be downloaded at the Sandvik Coromant website.

H

*Available on select smartphones. See website for details.


Tool holding

G

H 84

Sandvik Metal Cutting Technology Training Handbook

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