Professional Documents
Culture Documents
Training Handbook
n
x
D
m
x
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
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
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
A 22
C
hoice of tools how to apply
- External
- Internal
A 50
A 56
Code keys
A 66
Troubleshooting
A 70
A3
Theory
Parting and
grooving
Turning
Threading
Milling
Drilling
Boring
G
Tool holding
- Longitudinal turning
- Facing
- Profiling.
Machinability
Other information
A4
Theory
Turning
Definitions of terms
Spindle speed
Parting and
grooving
n (rpm)
Threading
vc (ft/min)
(m/min)
Milling
Cutting speed
Boring
Drilling
G
Tool holding
vc =
Dm n
12
ft/min
vc =
Dm n
1000
m/min
A5
Machinability
Other information
Inch
Theory
Turning
B
Parting and
grooving
(pi) = 3.14
Example:
Dm2 = 3
.937 inch (100 mm)
Circumference = 3.14 x 3.937
= 12.362 inch
C
Threading
Milling
Circumference = 3.14 x 50
= 157 mm
Drilling
Boring
Inch
G
Tool holding
vc =
vc1 =
H
Machinability
Other information
Metric
vc2 =
A6
Dm n
12
ft/min
vc =
= 1030
ft/min
vc1 =
= 1649
ft/min
vc2 =
Dm n
1000
m/min
3.14 50 2000
1000
3.14 80 2000
1000
= 314
m/min
= 502
m/min
Theory
Feed
r = entering angle
r = lead angle
Depth of cut
Boring
Lead angle = 0
Entering angle = 90
A7
G
Tool holding
H
Machinability
Other information
Parting and
grooving
Threading
Surface/cutting speed
Milling
Drilling
Spindle speed
Turning
Definitions of terms
Theory
Turning
Parting and
grooving
Cutting speed
Given:
Cutting speed, vc = 1312 ft/min (400 m/min)
C
Threading
Inch
Metric
Milling
n=
n=
Drilling
vc 12
Dm
1312 12
3.14 3.937
r/min
= 1274 r/min
n=
Dm
400 1000
3.14 100
r/min
= 1274 r/min
Boring
Tool holding
Inclination angle
The inclination angle lamda () 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.
H
Machinability
Other information
vc 1000
n=
A8
Theory
Turning
ap
r
Parting and
grooving
ap
Threading
Milling
Drilling
G
Tool holding
A9
Machinability
Other information
Feed rate
Boring
Turning
Parting and
grooving
Theory
Threading
Milling
Lead angle r:
-5, 15
Entering angle r:
95, 75
Lead angle r:
-17.5, -3, 27.5
Entering angle r:
107.5, 93, 62.5
TNMG
Lead angle r:
45, 15
Entering angle r:
45, 75
Lead angle r:
Variable
Entering angle r:
Variable
Lead angle r:
-3, -1, 30
Entering angle r:
93, 91, 60
VNMG
Lead angle r:
-27.5, -17.5, 17.5
Boring
Entering angle r:
117.5, 107.5, 72.5
Tool holding
Machinability
Other information
Lead angle r:
-5
Entering angle r:
95
RCMT
WNMG
SNMG
Drilling
DNMG
CNMG
r = 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
Turning
Parting and
grooving
Lead angle r
Entering angle r
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)
Drilling
kc = s
pecific cutting force (lbs/in2)
(N/mm2)
Pc = net power (HP) (kW)
Boring
G
Pc =
Pc =
vc ap fn kc
33 103
vc ap fn kc
60 103
HP
Tool holding
kW
A 11
Machinability
Other information
C
Threading
Turning
Selection procedure
Production planning process
Parting and
grooving
Selection procedure
C
Component
Threading
Milling
Machine parameters
Machine
Drilling
Choice of tool
Boring
How to apply
Troubleshooting
Tool holding
Machinability
Other information
A 12
Selection procedure
Turning
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
Parting and
grooving
Component
D
Material
achinability
M
Cast or pre-machined
Chip breaking
Hardness
Alloy elements
Milling
Drilling
2. Machine parameters
Condition of the machine
Boring
Tool holding
A 13
Machinability
Other information
P M K
N S H
Selection procedure
Turning
3. Choice of tools
Turning with rhombic inserts
Parting and
grooving
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
Milling
Drilling
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.
Machinability
Other information
A 14
Selection procedure
Turning
4. How to apply
Important application considerations
The tool path has a significant impact on
the machining process.
Parting and
grooving
It influences:
- Chip control
- Insert wear
- Surface quality
- Tool life.
Threading
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.
G
Tool holding
Boring
Nose radius
ap
re
A 15
Machinability
Other information
Negative style
Chip breaking
Drilling
U
se positive inserts for lower cutting forces in
general and for internal turning.
Turning
System overview
2. Profiling
Parting and
grooving
3. Facing
C
Threading
2
3
Milling
Drilling
Boring
Tool holding
G
N
egative insert
Rigid clamping system
Modular/shank tools
Machinability
Other information
A 16
N
egative insert
Lever clamping system
Modular/shank tools
System overview
Turning
1. Longitudinal turning
2. Profiling
Parting and
grooving
3. Facing
C
1
Threading
2
3
Milling
Drilling
Boring
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
A 17
Machinability
Other information
P
ositive insert
Screw clamping
system
Modular/shank
tools
Turning
System overview
B
Parting and
grooving
2. Profiling
3. Longitudinal turning
Mini bars
Threading
Milling
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
N
egative/positive inserts
Dampened boring bars
Min. hole 1.575 inch
(40 mm)
Boring bars
Tool holding
Machinability
Other information
egative/positive insert
N
All clamping systems
Cutting heads
Min. hole .787 inch
(20 mm)
Dampened modular/
boring bars
A 18
System overview
Turning
4. Internal turning
Threading
5. Internal turning
(Carbide rods)
B
Parting and
grooving
1. External turning
Milling
External tools
P
ositive insert
Screw clamping system
Shank tools
P
ositive insert
Screw clamping system
Drilling
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
H
Machinability
Other information
P
ositive insert
Screw clamping system
Min. hole .236 inch
(6 mm)
Tool holding
System overview
Turning
Parting and
grooving
Threading
Milling
Drilling
Boring
Tool holding
T-rails
Machinability
Other information
H
Screw clamping system
A 20
5/7
System overview
Turning
Negative inserts
Parting and
grooving
Excellent clamping
Easy indexing
Negative inserts
Threading
Lever clamping
Milling
Easy indexing
Screw clamping
Drilling
Positive inserts
S
ecure clamping of
the insert
Boring
G
Tool holding
Positive inserts
Very secure clamping
High accuracy
A 21
Machinability
Other information
Choice of inserts
Choice of inserts
Turning
Parting and
grooving
Threading
Milling
Drilling
Boring
Tool holding
Machinability
Other information
A 22
Basic factors
A 23
Insert geometries
A 32
Insert grades
A 39
A 42
A 48
Turning
Grade
Parting and
grooving
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
Geometry
Boring
Tool holding
A 23
Machinability
Other information
H
Typical chip breaking
sequences with high speed
imaging.
Turning
Parting and
grooving
Threading
Steel
Stainless
steel
Milling
Drilling
Boring
Tool holding
Machinability
Other information
A 24
Cast iron
Turning
B
Parting and
grooving
Aluminum
Milling
Threading
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.
Boring
Heat resistant
alloys
A 25
G
Tool holding
Hardened
steel
H
Machinability
Other information
Turning
Cutting forces
Parting and
grooving
Steel
Threading
Milling
P
materials have a kc1 variation of:
217,500-449,500 lbs/inch2
(1500-3100 N/mm2).
Stainless steel
Drilling
Boring
Cast iron
Tool holding
K
materials have a kc1 variation of:
114,550-195,750 lbs/inch2
(790-1350 N/mm2).
Machinability
Other information
A 26
Turning
Aluminum
Parting and
grooving
N
materials have a kc1 variation of:
50,750-195,750 lbs/inch2
(350-1350 N/mm2).
Threading
Hardened material
Boring
Tool holding
A 27
Machinability
Other information
Drilling
Milling
Turning
Chip formation
There are three patterns for a chip to break
after it has been cut.
B
Against the tool
Parting and
grooving
Self-breaking
Threading
Milling
Drilling
Boring
Tool holding
Machinability
Other information
A 28
Turning
Self-breaking
ap
ap
Parting and
grooving
C
Threading
Milling
Drilling
F
Negative cutting action
Boring
Tool holding
A 29
Machinability
Other information
Turning
Parting and
grooving
Negative style
Threading
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.
-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
Milling
Positive style
Insert geometries
Boring
Drilling
Tool holding
Machinability
Other information
A 30
Turning
20
Parting and
grooving
C
utting edge reinforcement .010 inch
(0.25 mm)
Rake angle 20
Threading
Primary land 5
Milling
G
Tool holding
Boring
E
R-treatment is done before coating, and
gives the final shape of the cutting edge
(micro-geometry).
A 31
Machinability
Other information
Turning
Parting and
grooving
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
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.
Milling
Drilling
= Roughing
Roughing
= Medium machining
= Finishing
Cutting depth,
ap inch (mm)
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)
Machinability
Other information
A 32
Turning
Medium M
Medium operations to light roughing.
Wide range of depth of cut and feed rate
combinations.
.157 (4.0)
.079 .(2.0)
P R
Drilling
CNMM 432-PR
(CNMM 120412-PR)
Cutting depth,
ap inch (mm)
Milling
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.
B
Parting and
grooving
Roughing R
High depth of cut and feed rate combinations. Operations requiring the highest
edge security.
Cutting depth,
ap inch (mm)
Threading
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
Machinability
Other information
H
(0.1)
.004
Turning
Medium machining of
low alloy steel
Parting and
grooving
P M
CNMG 432-PM
(CNMG 120408-PM)
Cutting depth,
ap inch (mm)
mm
mm/r
.236 (6.0)
C
Threading
.118 (3.0)
.059 (1.5)
.039 (1.0)
.020 (0.5)
Milling
(0.1)
.004
(0.2)
.008
(0.3)
.012
(0.4)
.016
Drilling
Cutting depth,
ap inch (mm)
(0.5)
.020
P F
CNMG 434-PF
(CNMG 120404-PF)
mm
mm/r
Boring
.059 (1.5)
.049 (1.25)
.039 (1.0)
Tool holding
.030 (0.75)
.020 (0.5)
.010 (0.25)
Machinability
Other information
(0.1)
.004
A 34
(0.15)
.006
(0.2)
.008
(0.25)
.010
(0.3)
.012
(0.35)
.014
B
Parting and
grooving
Turning
Selection of inserts
re
Threading
S
elect a smaller nose radius if there is a
tendency for vibration.
Milling
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)
A 35
Machinability
Other information
Workpiece
material
Drilling
Turning
Geometry description
Parting and
grooving
Geometry
description
Application
-PM
CNMG 432-PM
(CNMG 12 04 08-PM)
ap = .020 .217 inch
fn = .006 .020 inch/r
Threading
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)
Drilling
Universal inserts
Universal geometry.
Optimizing with grades.
Boring
Performance compromised.
Application area
Optimized inserts
O
ptimized performance
according to workpiece
machinability.
Machinability
Other information
Tool holding
D
edicated geometries
and grades.
A 36
Application area
Finishing
Medium
Roughing
Medium
Roughing
Parting and
grooving
C
Threading
Milling
Drilling
Boring
G
Tool holding
A 37
Machinability
Other information
Turning
Threading
A
negative insert has a
wedge angle of 90 seen in
a cross-section of the basic
shape of the cutting edge.
Parting and
grooving
Double
sided
Single
sided
Without
hole
With hole
Milling
Drilling
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.
Boring
G
Tool holding
-n
ot chemically interact with the workpiece
material.
-b
e chemically stable to resist oxidation
and diffusion.
Temperatures given
in Celsius
Machinability
Other information
A 38
-h
ave good resistance to sudden thermal
changes.
Turning
HT U
ncoated cermet containing
primarily titanium carbides (TiC)
or titanium nitrides (TiN) or both
HC Cermet as above, but coated
Parting and
grooving
Threading
Milling
CM M
ixed ceramics containing
primarily aluminum oxide (Al2O3)
but containing components other
than oxides.
Drilling
Boring
Tool holding
A 39
Machinability
Other information
Turning
Machining conditions
Parting and
grooving
Wear resistance
Good
C
Threading
Average
Difficult
Milling
Machining conditions
Good conditions
Continuous cuts
High speeds
Pre-machined workpiece
Excellent component clamping
Small overhangs
Drilling
Good
Boring
Average conditions
Profiling cuts
Moderate speeds
Forged or cast workpiece
Good component clamping
Tool holding
Difficult conditions
Interrupted cuts
Low speeds
Heavy cast or forged skin on workpiece
Poor component clamping
Machinability
Other information
A 40
Average
Difficult
Turning
B
Parting and
grooving
C
Threading
Milling
Drilling
Boring
G
GC 4200
ISO
GC 2000
ISO
GC 3200
Tool holding
A 41
Machinability
Other information
ISO
Parting and
grooving
Turning
-o
thers give the best profiling
accessibility.
Threading
Round
90
80
80
60
55
35
Milling
Drilling
E
Accessibility
Vibration
tendency
Power
consumption
Increased accessibility
Increased vibration
Decreased vibration
Tool holding
Boring
Cutting edge
strength
Machinability
Other information
A 42
Turning
B
= Most suitable
Parting and
grooving
= Suitable
Finishing
Longitudinal turning
Profiling
Operational versatility
Intermittent machining
Milling
Drilling
Facing
Boring
Light roughing/semifinishing
Tool holding
A 43
Machinability
Other information
Roughing strength
Threading
Insert shape
Turning
Parting and
grooving
Number of edges,
negative inserts
4/8
2/4
3/6
3/6
2/4
2/4
Number of edges,
positive inserts
Threading
Insert shape
Milling
Drilling
re
Boring
Tool holding
Reduces vibration
Weak cutting edge
Machinability
Other information
A 44
Rule of thumb
Increased radial
pressures
Turning
Parting and
grooving
C
DOC
Threading
DOC
DOC
Milling
Boring
However with a round insert, radial pressure will never stabilize because the
theoretical nose radius is half the insert
diameter (iC).
Tool holding
A 45
Machinability
Other information
Drilling
Turning
Parting and
grooving
Wiper insert
rWiper
Rmax
Threading
Conventional insert
Rmax
Milling
rISO
Limitations
General limitation is
vibration.
O
ne wiper cutting edge is based on
3-9 radii.
C
ontact surface between insert and
component is longer with wipers.
Tool holding
Machinability
Other information
H
A conventional nose radius compared
with a wiper nose radius.
A 46
Turning
Threading
Wiper insert
Twice the
feed, same Ra
Parting and
grooving
Rule of thumb
Milling
D
Wiper insert
Same feed,
half Ra
Drilling
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
A 47
Machinability
Other information
39 (1.00)
G
Tool holding
Insert geometry
197 (5.00)
Boring
(m)
236 (6.00)
Turning
Threading
Cutting speed
Tool life
Milling
Boring
Cutting speed vc
Feed
Tool life
Drilling
Feed fn
Cutting depth
Tool life
Tool holding
Machinability
Other information
H
Cutting depth ap
A 48
Turning
Built-up edge
Poor finish
Uneconomical
B
Parting and
grooving
Too high
Rapid cratering
Plastic deformation
Threading
Too high
Too low
Stringers
Uneconomical
Milling
Chip hammering
Boring
Chip welding
Drilling
Insert breakage
Vibrations
Excessive heat
G
Tool holding
Too small
Uneconomical
A 49
Machinability
Other information
Too deep
Turning
External turning
Tool selection and how to apply
B
Parting and
grooving
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
Milling
W
henever possible choose modular
tools.
Drilling
Boring
Lead angle r 3
(Entering angle r = 93)
Feed directions
Tool holding
Machinability
Other information
H
Insert point angle
A 50
60
Insert shape
Turning
C
Threading
Parting and
grooving
Profiling
Versatility and accessibility is the determining factor.
The effective lead angle (r ) (entering angle (kr)) should be
considered for satisfactory machining.
M
ost commonly used lead angle is 3 (entering angle = 93)
because it allows an in-copying angle between 22-27.
Milling
E
Facing
P
ay attention to the cutting speed which will change progressively when feeding towards the centre.
Drilling
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
A 51
Machinability
Other information
Turning
Parting and
grooving
Threading
Milling
Features / Benefits
Produces a thinner chip
- Increased productivity.
Drilling
45
Boring
Tool holding
Machinability
Other information
A 52
Turning
Out-copying
Parting and
grooving
In-copying
r
r
T he maximum in-copying angle beta () is recommended for each tool type and is specified in the catalogs.
Milling
Threading
Drilling
F
Ff = axial
Fp = radial
Boring
Fp = radial
Ff = axial
A 53
Machinability
Other information
Tool holding
G
Forces directed toward the chuck. Less
tendency for vibration.
++
++
++
Wedge
clamp
design
Screw
clamp
design
++
++
++
++
++
=R
ecommended tool
holder system
= Alternative system
Plunging
++
+
Facing
Tooling system
Profiling
Parting and
grooving
Longitudinal
turning
Turning
Milling
Rigid clamp
design
Negative inserts
Threading
Boring
Positive inserts
Drilling
Lever
design
Screw
clamp
design
T-rail
++
Machinability
Other information
Tool holding
A 54
Rigid clamp
design
Top clamp
design
++
Alternative shape
Rhombic 80
++
Rhombic 55
++
Round
Square
Triangular
Trigon 80
Rhombic 35
Rhombic 55
++
Threading
B
Parting and
grooving
Plunging
Facing
++
+
Drilling
Milling
++ =
+=
Profiling
Insert shape
Longitudinal
turning
Turning
+
+
Screw clamping
Screw clamping,
T-rail
G
Tool holding
P lever style
A 55
Machinability
Other information
Rigid clamping
Boring
Turning
Internal turning
Tool selection and how to apply
B
Parting and
grooving
General guidelines
In internal turning (boring operations)
the choice of tool is very much restricted
by the components hole diameter and
length.
Milling
Threading
-C
hoose the largest possible bar diameter and the smallest possible overhang.
Drilling
Boring
Tool holding
Selection factors
Tool and insert geometry
Chip evacuation
Tool requirements
Chip size
Reduced length
Chip control
Increased diameters
Techniques
Optimized shape
Insert geometry
Nose radius
Machinability
Other information
A 56
Turning
Parting and
grooving
Fr
Ft
Feed force, Fa
Fa
Threading
Boring
S
elect a lead angle close to 0 (entering
angle close to 90).
G
Tool holding
Drilling
A 57
Machinability
Other information
Turning
Parting and
grooving
Threading
Profiling
Versatility and accessibility is the determining factor.
The effective lead angle (r) should be considered.
Bars with lead angle of 3, allowing an in-copying angle between 2227, are commonly used.
Milling
Longitudinal turning
A lead angle of close to 0 is recommended.
C
-style (80), S-style (90) and T-style (60) inserts are frequently used.
Boring
Drilling
Back boring
Back boring is a boring operation with reverse feed.
It is used for turning shoulders less than 90.
Tool holding
B
oring bars with 3 lead angles and D-style (55) inserts are
commonly used.
Machinability
Other information
A 58
Longitudinal
turning
Insert shape
Facing
B
Parting and
grooving
Rhombic 80
Rhombic 55
Round
Square
Triangular
++
Trigon 80
Rhombic 35
++
++
+
Threading
+
+
Milling
++ =
+=
Profiling
Turning
Drilling
Negative,
double sided
inserts
A 59
Machinability
Other information
11, positive,
single sided
inserts
Boring
Tool holding
Turning
Parting and
grooving
- Increases accessibility
- Decreases vibration
- Decreases cutting forces.
Round
90
80
80
60
55
35
Threading
Milling
Cutting edge
strength
Accessibility
Vibration tendency
Power consumption
Drilling
Boring
Rule of thumb!
Tool holding
Machinability
Other information
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
Choose a nose
radius which is somewhat less than the
cutting depth.
Turning
M
aximum contact between tool and tool
holder (design, dimensional tolerance).
dmm
B
Parting and
grooving
C
Threading
3-4 x dmm
Milling
Drilling
Best choice
Boring
Acceptable
G
Tool holding
Not recommended
Not recommended
A 61
Machinability
Other information
Turning
EasyFix sleeves
For correct clamping of cylindrical bars
B
Parting and
grooving
Benefits:
Cutting edge in right position
Best cutting action gives better surface finish
Threading
Milling
Drilling
Groove
Boring
Tool holding
Spring plunger
Machinability
Other information
A 62
Turning
Parting and
grooving
Lead (entering)
angle
Threading
Nose radius
Micro and
macro geometry
Milling
Edge design
Drilling
Boring
Nose radius
Choose a nose radius which is somewhat smaller than the cutting depth.
Edge design
Tool holding
A 63
Machinability
Other information
Turning
Chip evacuation
Chip evacuation is a critical factor for successful boring
B
Parting and
grooving
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.
Drilling
C
an cause excessive crater wear and
result in poor tool life and chip jamming.
Long chips
Can cause chip evacuation problems.
Boring
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.
Machinability
Other information
A 64
Turning
B
Parting and
grooving
Steel bar
up to 4 x dmm
Carbide bar
up to 6 x dmm
Short, dampened bar
up to 7 x dmm
C
Threading
10
Clamping
length:
4 x dmm
Milling
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
Boring
Rubber damper
Drilling
G
Tool holding
Cutting head
Steel bar
Dampened bar
A 65
Machinability
Other information
Turning
INSERT
Tolerances
Insert thickness
Nose radius
Parting and
grooving
Code keys
C N M G
C
Threading
4 3 2 - PF
5
1. Insert shape
5. Insert size
Milling
TOOL HOLDERS
External
D C L N R 16 4 D
Drilling
E
B 1 C 2 D
Boring
Internal
S 16 T S C L C R
Tool holding
Machinability
Other information
C3 A
4
5
Bar diameter
Coromant Capto
coupling size
A 66
Code keys
55
4. Insert type
35
80
5. Insert size
B
Parting and
grooving
80
Turning
1. Insert shape
C
7. Nose radius
r
r
r
r
r
r
=
=
=
=
=
=
.008
1/64
1/32
3/64
1/16
3/32
T-MAX P
CoroTurn 107
2
2
3
1
2
2
Threading
0
1
2
3
4
6
Milling
Drilling
B. Clamping system
Right-hand style
L
Left-hand style
Bars:
Boring
Neutral
Rigid clamping (RC) Top and hole clamping Hole clamping Screw clamping
D. Hand of tool
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
H
Machinability
Other information
Turning
INSERT
Tolerances
Insert thickness
Nose radius
Parting and
grooving
Code keys
C N M G 09 03 08 - PF
C
Threading
1. Insert shape
Milling
TOOL HOLDERS
External
D C L N R 16 16 H 09
Drilling
E
B 1 C 2 D
Boring
Internal
A 25 T S C L C R 09
Tool holding
Machinability
Other information
C3 A
Bar diameter
Coromant Capto
coupling size
A 68
Holder style
Code keys
55
4. Insert type
35
80
l mm: 0625
0715
0632
0925
0627
1116
0608
B
Parting and
grooving
80
Turning
1. Insert shape
C
7. Nose radius
=
=
=
=
=
=
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 r
04 r
08 r
12 r
16 r
24 r
Milling
D. Hand of tool
E. Shank height
Hole clamping
Screw clamping
G. Tool length
Boring
Drilling
B. Clamping system
Tool length
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
H
Machinability
Other information
Right-hand style
Tool holding
= l1 in mm
Turning
Parting and
grooving
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 presU
sure coolant.
Threading
D
epth of cut too shallow for
the chosen geometry.
S
elect a smaller nose
radius.
S
elect a holder with as small
a lead angle as possible
(r =0 [r =90]).
C
hoose a geometry
designed for higher feeds,
preferably a single-sided
insert.
Milling
Drilling
Boring
Tool holding
Machinability
Other information
A 70
Troubleshooting
Cause
The chips are breaking
against the component
and marking the finished
surface.
Solution
Select a geometry which
guides the chips away.
Parting and
grooving
Problem
Turning
Surface finish
Burr formation
The cutting edge is not
sharp enough.
Boring
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
H
Machinability
Other information
Milling
Drilling
Threading
Troubleshooting
Turning
Vibration
Parting and
grooving
Cause
- Unsuitable lead angle.
S
elect as small lead
angle as possible (r = 0)
S
elect a positive insert
geometry.
-V
arying or too low cutting
forces due to small depth
of cut.
Milling
Solution
Threading
Problem
Drilling
Boring
Tool holding
Machinability
Other information
A 72
Solution
Reduce the overhang
Parting and
grooving
Cause
Threading
E
xtend the clamping length
of the boring bar.
Milling
U
se EasyFix for cylindrical
bars.
Drilling
Boring
G
Tool holding
A 73
Machinability
Other information
Problem
Turning
B2
Theory
B4
Selection procedure
B7
System overview
B 11
B 15
Troubleshooting
B 36
B3
Turning
Parting and
grooving
Threading
Theory
C
hip evacuation is a critical factor in
parting operations.
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.
Drilling
n
n = spindle speed (rpm)
Tool holding
Machinability
Other information
B4
Theory
Turning
Parting and
grooving
C
utting speed declines to zero at the
center.
Threading
Milling
100 0% of vc
Drilling
Boring
Tool holding
B5
Machinability
Other information
.079
(2mm)
Theory
Turning
Parting and
grooving
n
Threading
Milling
Drilling
Boring
Tool holding
H
Machinability
Other information
B6
Selection procedure
Turning
Parting and
grooving
C
Component
Workpiece material,
chip evacuation
Threading
Milling
Machine parameters
Machine
Choice of tool
Drilling
Type of tool:
- Spring-clamp
- Screw-clamp
- Insert type
How to apply
Boring
Troubleshooting
Remedies and
solutions
B7
Machinability
Other information
Tool holding
Selection procedure
Turning
Component
Parting and
grooving
A
nalyze the dimensions and quality
demands of the groove or face to be
machined.
Threading
Milling
P M K
N S H
achinability
M
Clamping
Chip breaking
Hardness
Alloy elements
Drilling
Material
2. Machine parameters
Condition of the machine
Boring
Tool holding
Machinability
Other information
B8
Selection procedure
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.
B
Parting and
grooving
C
Threading
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
R
amping avoids vibration and minimizes
radial forces.
Boring
R
ound inserts are the strongest inserts
available.
Tool holding
Ramping
B9
Machinability
Other information
Selection procedure
Turning
4. How to apply
Important application considerations
C
enter height is important, .004 inch
(0.1 mm).
B
Parting and
grooving
Threading
Milling
ar
Drilling
5. Troubleshooting
Boring
Tool holding
Machinability
Other information
B 10
System overview
Turning
System overview
5. Face grooving
3. Undercutting
6. Profiling
B
Parting and
grooving
C
Threading
Milling
Drilling
Internal grooving
2. Face grooving
3. Profiling
B 11
H
Machinability
Other information
Tool holding
System overview
Turning
Different systems
Insert type
B
Parting and
grooving
Application
Threading
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
Milling
Turning
Profiling
Drilling
Undercutting
Circlip grooving
Boring
First choice
Tool holding
H
Machinability
Other information
B 12
System overview
Turning
Different systems
.472
(12)
.394
(10)
.984
(25)
C
Threading
.165
(4.2)
Parting and
grooving
.165 .394
(4.2)
(10)
.472 .984
(12)
(25)
Min. hole
diameter,
inch (mm)
Milling
Drilling
F
.472
(12)
.906
(23)
Boring
.244
(6.2)
1.339
(34)
.472 1.181
(12 30)
.906 2.756
(23 70)
1.339
(34 )
First cut
diameter,
inch (mm)
B 13
Machinability
Other information
.244 .709
(6.2 18)
Tool holding
Turning
System overview
Inserts
Overview
B
Parting and
grooving
Application
Threading
Milling
Machining
condition
Parting
(Cut off)
Grooving
Turning
Finishing
CF
GF
TF
Medium
CM
GM
TM
Roughing
CR
Profiling
RM
RO
Drilling
Optimizer
Sharp
Boring
ER treated
Tool holding
Machinability
Other information
B 14
RS
CS
GE
RE
Profiling
AM
Turning
B 16
B 22
B 25
Threading
Parting and
grooving
B 27
B 28
B 31
B 33
B 35
Milling
Drilling
Boring
Tool holding
B 15
Machinability
Other information
Turning
Parting and
grooving
Threading
C
Best stability
O
verhang (ar) should be as small as
possible.
Milling
ar = 8 x la max
Drilling
Internal machining
Shank type:
Boring
C
arbide reinforced dampened bars, up
to 7 x dmm.
Tool holding
G
Inserts:
Use smallest possible width
Use light cutting geometries.
Machinability
Other information
B 16
Turning
C
Threading
Parting and
grooving
Deep parting
Medium parting
Shallow parting
U
se the 3-edge insert
for economic parting in
mass production.
Milling
Drilling
Boring
Tool holding
B 17
Machinability
Other information
ar
Turning
Adjustability
Deep grooving
Double ended
Threading
Features/Benefits
Milling
Smaller diameters
Shallow grooving
Increased rigidity
Drilling
Single ended
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
Machinability
Other information
B 18
Parting and
grooving
Max ar = 8 x la
(width of insert)
Turning
Parting-off bars
Threading
Milling
Material savings
Drilling
Boring
Tool holding
B 19
Machinability
Other information
Turning
Parting and
grooving
Hand of insert
Threading
Hand of insert
Milling
Insert geometry
Drilling
laa
r = 0
Increases strength
Higher feed/productivity
Better surface finish
Straighter cut
Pip stays on part falling off.
Boring
Tool holding
Machinability
Other information
B 20
Turning
B
Parting and
grooving
Threading
Milling
Recommended overhang
dmm
Drilling
Carbide reinforced
dampened bars
l <7 x dmm
dmm
Dampened steel bars
Boring
Carbide bars
l 5 x dmm
G
Tool holding
dmm
Solid steel bars
l 3 x dmm
B 21
Machinability
Other information
C
hoose left or right hand front angle to
control the pip or burr.
Parting and
grooving
Turning
Parting off
When
the front angle is:
- increased, the pip/burr is decreased
- decreased, the chip control and tool life
are improved.
C
entrifugal force will always push away
the parted off component
- Tool will leave material in center (PIP).
Threading
R
L
Milling
Drilling
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).
Boring
Tool holding
Machinability
Other information
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.
Turning
Parting-off tubes
B
Parting and
grooving
Parting-off tubes
Milling
Threading
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.
.040 inch
(1
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
Boring
Drilling
Practical hints
fn
.079
(2mm)
B 23
Machinability
Other information
Turning
Parting and
grooving
Milling
Drilling
Boring
Tool holding
Machinability
Other information
B 24
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
Parting and
grooving
Milling
Drilling
E
conomic and productive method to
produce grooves.
W
iper inserts give extremely high quality
surface on the side of the groove.
Boring
Tool holding
B 25
Machinability
Other information
Turning
Multiple grooving
T he best method for rough grooving
when depth is bigger than width.
B
Parting and
grooving
U
se the insert width to produce full
grooves and then remove the rings.
Threading
Milling
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.
Drilling
Boring
Tool holding
Machinability
Other information
B 26
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.
B
Parting and
grooving
Turning
Circlip grooving
Threading
internal
Internal/external
Cutter diameter
.382 - 1.366 inch
(9.7 34.7 mm)
Cutter diameter
1.535 - 2.480 inch
(39 80 mm)
B 27
Drilling
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
H
Machinability
Other information
3-edge inserts
Turning
Face grooving
Making grooves axially on the faces on a
component requires tools dedicated to the
application.
B
Parting and
grooving
Threading
Milling
Drilling
Boring
C
urved tool for face
grooving, shank 0 style.
Tool holding
Machinability
Other information
B 28
E
xchangable cutting
blades make it possible
to make a special tool
from standard tools.
B
Parting and
grooving
Turning
C
Threading
Milling
Drilling
Boring
Tool holding
B 29
Machinability
Other information
Turning
Parting and
grooving
1
2
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
Roughing
Finishing
Drilling
2
3
Boring
Tool holding
Machinability
Other information
B 30
Turning
Profiling
When machining components with complex
shapes, profiling inserts offer great opportunities for rationalization.
B
Parting and
grooving
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
Drilling
Boring
Ramping
U
se round inserts for outstanding chip control and good
surface finish.
In unstable setups, use ramping to avoid vibrations.
Tool holding
B 31
Machinability
Other information
Turning
Profile turning
Insert radius < component radius
Recommended
Parting and
grooving
Threading
Milling
Drilling
fn1 = parallel cuts max. chip thickness .006 - .016 inch (0.150.40 mm).
fn2 = radius plunging 50% max. chip thickness.
Boring
Tool holding
Machinability
Other information
B 32
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.
Parting and
grooving
Threading
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
Drilling
Roughing
Boring
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
Machinability
Other information
Turning
Finishing
Parting and
grooving
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
Milling
Axial turning
Surface finish
Drilling
Ra max
Boring
R
a value below 20RA (0.5 m) will be
generated with high bearing.
Tool holding
H
Machinability
Other information
Y
ou get the best wiper effect when you
find the right combination between
feed (fn) and blade deflection.
B 34
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).
B
Parting and
grooving
Threading
Angled 45
Milling
Angled
7 ,45 and 70
Drilling
Boring
H
older for external undercutting. Insert with one
cutting edge.
G
Tool holding
H
older for internal undercutting. Insert with two
cutting edges.
B 35
Machinability
Other information
H
older for external undercutting. Insert with two
cutting edges.
Turning
Troubleshooting
Troubleshooting
Tool wear
Parting and
grooving
Problem
Flank wear
Plastic deformation
Crater wear
Chipping
Fracture
Built-up
edge
Threading
Solution
More positive
geometry
++
++
Milling
Tougher grade
Drilling
More wear
resistant grade
++
Increase cutting
speed
Boring
Tool holding
Reduce feed
rate
Choose stronger
geometry
+
++
++
+
++
Machinability
Other information
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
B
Parting and
grooving
Problem
S
elect a special soluble
oil for the material.
Milling
Drilling
Threading
Vibration
C
heck tool condition.
Check tool setup.
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
H
Machinability
Other information
Tool holding
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
Selection procedure
C9
System overview
C 13
How to apply
C 19
Troubleshooting
C 25
C3
Turning
Parting and
grooving
Threading
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.
Rolling
Milling
Molding
Drilling
Boring
Thread turning
Tool holding
Machinability
Other information
C4
Milling
Tapping
Theory
Turning
Definitions of terms
vc = cutting speed (ft/min) (m/min)
Parting and
grooving
Threading
itch, mm or threads
P = p
per inch (t.p.i.)
Drilling
Boring
Tool holding
C5
Machinability
Other information
Theory
Turning
Definitions of terms
1. Root
The bottom surface joining the two
adjacent flanks of the thread crest.
B
Parting and
grooving
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 ()is dependent on and
related to the diameter and pitch (P) of
the thread.
Milling
B
y changing the shim, the flank clearance of the insert is adjusted.
T he angle of inclination is lambda ().
The most common angle of inclination is
1 which is the standard shim in the tool
holder.
Drilling
Boring
Tool holding
A
ggressive cutting data can lead to
movement of insecurely clamped inserts.
Machinability
Other information
C6
Theory
Turning
Parting and
grooving
Threading
D
tan =
d2
Milling
Standard shim = 1
E
Threads/inch
Drilling
Pitch, mm
Boring
Tool holding
Workpiece
diameter
mm
inch
C7
Machinability
Other information
Theory
Turning
Parting and
grooving
Threading
Pitch, mm
Threads/inch
D
3
Milling
Drilling
Boring
Workpiece
diameter
mm
inch
Tool holding
Machinability
Other information
Angle of shim
inclination
Thread profile
Pitch
Internal (O)
External, no marking
C8
Carbide grade
Tool selection
Turning
Parting and
grooving
Dimension and
quality of the
thread
Component
Threading
Milling
Machine parameters
Machine
Choice of tool
Drilling
Type of tool:
- Full profile
- V-profile
- Multi-point
How to apply
Boring
Cutting data,
in-feed etc.
Troubleshooting
Remedies and
solutions
C9
Machinability
Other information
Tool holding
Tool selection
Turning
A
nalyze the dimensions and quality
demands of the thread to be machined.
Parting and
grooving
Component
Pitch size
Threading
P M K
N S H
Milling
Material
Machinability
Chip breaking
Drilling
Hardness
Alloy elements
2. Machine parameters
Condition of the machine
Boring
Tool holding
Machinability
Other information
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
Turning
3. Choice of tools
Different ways to make threads
Full profile inserts
Disadvantages
Each insert can only cut
one pitch.
C
Threading
B
Advantages
Better control over the
thread form.
Less deburring.
Parting and
grooving
Advantages
Flexibility, one insert
can be used for several
pitches.
Disadvantages
Can result in burr formation that needs to be
taken away.
Drilling
Milling
V-profile inserts
Advantages
Reduced number of
infeeds.
Very high productivity.
Disadvantages
Requires stable setups.
Needs sufficient room
behind the last thread.
G
Tool holding
C 11
Machinability
Other information
Multi-point inserts
Boring
Tool selection
Turning
4. How to apply
Important application considerations
The infeed method can have a significant
impact on the thread machining process.
B
Parting and
grooving
It influences:
- chip control
- insert wear
- thread quality
- tool life
C
Threading
Milling
5. Troubleshooting
Some areas to consider
Drilling
Boring
Infeed type
Optimize infeed method, number and
size of pass.
G
Tool holding
Insert geometry
Make sure the right insert geometry is
used (all-purpose, F or C geometries).
H
Machinability
Other information
Insert inclination
Ensure there is sufficient and even
clearance (insert inclination shims).
C 12
System overview
External threading
Turning
System overview
2. Conventional threading
Parting and
grooving
Threading
3
0.5 8 mm
32 3 t.p.i
10 5 t.p.i
Milling
0.2 2 mm
Internal threading
10 5 t.p.i
Boring
0.5 3 mm
56 16 t.p.i
2. Threading mini-bars
Tool holding
3. Conventional threading
1. Carbide rods
C 13
Machinability
Other information
0.5 2.5 mm
32 10 t.p.i
Drilling
0.5 8 mm
32 3 t.p.i
System overview
Turning
Inserts
Parting and
grooving
Threading
Milling
Drilling
Pitch
0.2
32
2.0
10
5.0
mm
t.p.i
8.0
3
1/4
(11)
3/8
(16)
1/2
(22)
5/8
(27)
Boring
Tool holders
1. Coromant Capto cutting units
2. Shank tools
Tool holding
3. Boring bars
4. Exchangable cutting heads
5. Cartridges
Machinability
Other information
C 14
System overview
Turning
Conventional bars
New system
Mini-bars
.157 inch
(4 mm)
.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
Parting and
grooving
.394
(10)
.472
(12)
.984
(25)
2.362
(60)
Min. hole diameter, inch (mm)
Drilling
.157
(4)
Milling
Boring
Tool holding
C 15
Machinability
Other information
Carbide rods
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
Round DIN405
RN
Aerospace
MJ
UNJ
MJ
NJ
API Rounded
API V form 60
RD
V38, 40,
50
Buttress, VAM
BU
Motion
General use
Trapezoidal
ACME
Stub ACME
TR
AC
SA
Application
Insert/thread form
Parting and
grooving
Threading
Milling
Drilling
General usage
Good balance between load bearing
capacity and volume of material.
Boring
Pipe Threads
Ability to bear loads.
Tool holding
Machinability
Other information
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
System overview
Turning
Insert types
Three different types of threading inserts
B
Full profile inserts
Parting and
grooving
C
V-profile inserts - 60 and 55
Threading
Milling
Multi-point inserts
Drilling
C-geometry
Sharp geometry.
Boring
All-purpose geometry
C 17
H
Machinability
Other information
Tool holding
System overview
Turning
B
Parting and
grooving
U
ltra-rigid threading with fixed position
inserts.
T he insert locates in the correct position
with guidance of the rail.
C
Threading
Milling
Quick change
coupling
Boring bar
Coromant
Capto coupling
Drop head
Drilling
Boring
Tool holding
Machinability
Other information
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.
B
Parting and
grooving
Threading
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
Boring
Drilling
Radial infeed
Tool holding
Incremental infeed
C 19
Machinability
Other information
How to apply
Turning
Parting and
grooving
Threading
C
Feed direction
Chip flow
Chip flow
Milling
Feed direction
Feed direction
Drilling
C-geometry
insert
B
etter chip control.
Better surfaces.
For C-geometry insert, modified flank
infeed is the only suitable infeed.
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
Machinability
Other information
C 20
How to apply
Turning
Incremental infeed
E
ven insert wear and longest tool life in
very coarse threads.
C
hips are directed both ways, making
control difficult.
Parting and
grooving
C
Threading
Programming methods
Ways of improving the machining result
Decreasing depth per pass (Constant chip area)
Milling
Drilling
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.
C 21
Machinability
Other information
Boring
How to apply
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.
Parting and
grooving
Turning
Threading
~.005
Drilling
Boring
Tool holding
H
Machinability
Other information
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.
Milling
+.004
0
C 22
How to apply
Turning
Parting and
grooving
Method of threading
Threading
Internal
Milling
External
Left hand
tool/insert
Right hand
tool/insert
Left hand
tool/insert
Drilling
Right hand
tool/insert
Left hand
tool/insert
Right hand
tool/insert
Left hand
tool/insert
Right hand
tool/insert
Right hand
tool/insert
Boring
Left hand
tool/insert
G
Tool holding
Left hand
tool/insert
Left hand
tool/insert
C 23
Machinability
Other information
Right hand
tool/insert
Right hand
tool/insert
Troubleshooting
Turning
Parting and
grooving
Threading
Milling
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.
Drilling
Boring
Tool holding
Machinability
Other information
C 24
Troubleshooting
Problem
Cause
Solution
1. Excessive temperature in
cutting zone.
Plastic deformation
2. Inadequate supply of
coolant.
3. Wrong grade.
3. C
hoose a grade with better
resistance to plastic deformation.
- Unsuitable grade.
-C
utting edge temperature
too low.
Drilling
C
Threading
Parting and
grooving
Milling
Turning
Troubleshooting
3. Wrong grade.
4. Poor chip control.
5. Center height incorrect.
C 25
G
Tool holding
H
Machinability
Other information
Boring
Insert breakage
Troubleshooting
Turning
Problem
Cause
Solution
1. W
rong grade. Choose a
more wear resistant grade.
Parting and
grooving
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.
Milling
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
Boring
G
Tool holding
Machinability
Other information
C 26
Solution
3. Uncontrolled chips.
3. U
se C-geometry and modified flank infeed.
2. U
se C-geometry with modified flank infeed 1.
2. Insert breakage.
Excessive wear.
1. C
orrect tool, shim and
insert combination.
3. Adjust to 90.
Turning
Cause
Shallow profile
Threading
Problem
Parting and
grooving
Troubleshooting
Milling
Drilling
Boring
1. R
educe the number of
infeeds.
Change to F-geometry.
C 27
H
Machinability
Other information
Tool holding
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
Selection procedure
D9
System overview
D 13
D 24
D 29
Troubleshooting
D 36
D3
Turning
Milling theory
Definitions of terms
Spindle speed, cutting speed and cutter diameter
Parting and
grooving
Theory
n = S
pindle speed, rpm
(revolutions per minute)
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
Drilling
Boring
Tool holding
Machinability
Other information
D4
Theory
Turning
B
Parting and
grooving
zc = E
ffective number of teeth (pcs)
[in engagement]
Threading
vf = fz zc n
Milling
inch/min (mm/min)
Drilling
Boring
G
Tool holding
D5
Machinability
Other information
Theory
Turning
Definitions of terms
Depth of cut
ae = R
adial depth of cut (inch) (mm)
[working engagement]
B
Parting and
grooving
Threading
Milling
Drilling
Boring
Tool holding
Machinability
Other information
Inch
Pc =
ap ae vf kc
396 103
Hp
Metric
Pc =
ap ae vf kc
60 106
kW
Inch
Mc =
Pc 16501
n
lbf ft
Metric
Mc =
Pc 30 103
n
Nm
Theory
Turning
B
Parting and
grooving
Boring
Drilling
C
utter diameter should be 20 50% larger than the
width of cut.
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
Milling
H
Machinability
Other information
Threading
Conventional milling
Theory
Turning
Parting and
grooving
Dc = Cutter diameter
ae = working engagement
Threading
Milling
Drilling
Boring
G
Tool holding
Machinability
Other information
D8
Selection procedure
Turning
Selection procedure
Parting and
grooving
Component
Threading
Machine
Milling
Machine parameters
Choice of tool
Drilling
How to apply
Boring
Troubleshooting
D9
Machinability
Other information
Tool holding
Selection procedure
Turning
Geometric shape
Parting and
grooving
Flat surface
Deep cavities
Thin walls/bases
Slots
Threading
P M K
N S H
Milling
Material
Tolerances
Machinability
Dimensional accuracy
Chip forming
Surface finish
Hardness
Part distortion
Alloy elements
Surface integrity
Drilling
Boring
2. Machine parameters
Tool holding
Available power
Long overhang
Age/condition stability
Poor holding
Horizontal/vertical
Axial/radial runout
Tool holding
N
umber of axes/configuration
Workpiece clamping
H
Machinability
Other information
Material
D 10
Selection procedure
Turning
3. Choice of tools
Different ways to optimize milling
Cutters with round inserts
Disadvantages
R
ound inserts require
more stable machines.
V
ery flexible for face milling and profiling.
Parting and
grooving
B
Advantages
C
Threading
H
igh performance multipurpose cutters.
45 face mill
Disadvantages
G
eneral choice for face
milling.
Drilling
Disadvantages
Great versatility.
Boring
Advantages
G
Tool holding
D 11
Machinability
Other information
B
alanced radial and axial
cutting forces.
Milling
Advantages
Selection procedure
Number of cutting
edges/pitch
Parting and
grooving
Turning
4. How to apply
S
electing the right
number of edges or pitch
is very important.
It affects both productivity and stability.
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 2050% larger than
the cut.
Milling
Stability
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.
Vibration
Tool holding
Machinability
Other information
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
Face milling
Parting and
grooving
C
Threading
Milling
Drilling
Dedicated cutters
Face milling cutters for cast iron machining
Boring
Tool holding
D 13
Machinability
Other information
Selection procedure
Turning
Shoulder milling
Cutters for general use
Face and shoulder milling for light
shoulder milling operations
B
Parting and
grooving
Threading
Milling
Drilling
F
Long edge milling cutter
Boring
Dedicated cutters
Edging with square shoulder milling cutters
Tool holding
Machinability
Other information
D 14
System overview
Turning
Profiling
Cutters for general use roughing
Round insert cutter
Parting and
grooving
Threading
Drilling
Boring
Other methods
G
Tool holding
Blade milling
D 15
Machinability
Other information
Turn milling
System overview
Turning
Slot milling
Side and face mill for slot
milling
Parting and
grooving
Threading
Milling
Drilling
Boring
Thread milling
G
Tool holding
Indexable insert
cutter
Indexable insert
end mill
Machinability
Other information
D 16
System overview
Face milling
High-feed milling
B
Parting and
grooving
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
Cutting off
Chamfering
Profile milling
Milling
Turn milling
Drilling
Trochoidal milling
Circular milling
Linear ramping
Boring
Plunge milling
G
Tool holding
Thread milling
D 17
Machinability
Other information
Circular ramping
System overview
Parting and
grooving
Turning
Milling methods
Threading
Milling
Drilling
Face milling
High-feed milling
Shoulder milling
Cutting off
Chamfering
Plunge milling
Boring
Tool holding
Machinability
Other information
D 18
Slot milling
System overview
Turning
Parting and
grooving
Threading
Increased flexibility
Fewer machines/setups to
complete a component
Reduced stability
Longer tool lengths
Lower depth of cut.
Milling
Turn milling
Trochoidal milling
Circular milling
Boring
Profile milling
Drilling
G
Thread milling
Tool holding
Circular ramping
D 19
Machinability
Other information
Linear ramping
System overview
Turning
Parting and
grooving
Threading
Milling
Considerations
Round inserts
10
45
90
ISO 40, 50
ISO 40, 50
ISO 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
Tool holding
Machinability
Other information
D 20
System overview
Turning
Parting and
grooving
90
90
ISO 40, 50
ISO 40, 50
High
High
Medium
Low
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
Drilling
Cutting depth ap
Milling
90
Threading
90
Considerations
Boring
G
Tool holding
Versatility
D 21
Machinability
Other information
Material
System overview
Turning
Parting and
grooving
Threading
Milling
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
Tool holding
Machinability
Other information
D 22
System overview
Turning
Parting and
grooving
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
Small
Small
Very good
4.508 (114.5)
.256 (6.5)
Good
Limited
Good
Good
Milling
Considerations
Drilling
Indexable insert
end mill
Machine/spindle size
Open
Open
Open
Closed
Closed
Closed
Good
Small
Small
Cutting depth ap
Very good
Small
Large
Versatility
Very good
Very good
Very good
Slot closed
Cutting width
D 23
Machinability
Other information
Slot open
Boring
Considerations
Tool holding
Turning
Parting and
grooving
Threading
Milling
Drilling
Corner design
.005
.005
Boring
Tool holding
C
utting edge reinforcement .005 inch (0.13
mm).
Rake angle 30.
Corner reinforcement
H
Machinability
Other information
Chip former
D 24
C
utting edge reinforcement
.005 inch (0.13 mm).
Turning
Cutter pitch
L
Close pitch (-M)
Light (-L)
Medium (-M)
Heavy (-H)
C
Threading
Parting and
grooving
Operation stability
Low
Toughness
Milling
Machining conditions/
Grades
Wear resistant
E
Good conditions
Difficult conditions
Drilling
Average conditions
Type of application
Tool holding
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
D 25
Machinability
Other information
Heavy milling
Operation for maximum stock removal and/or severe
conditions.
Larger depth of cut and feed rate.
Operations requiring highest edge security.
Boring
ap Depth of cut,
inch (mm)
Turning
Parting and
grooving
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
Drilling
Surface
roughness
Standard
insert
U
se wiper inserts for
higher productivity and
improved surface finish.
One wiper
insert
Boring
M
ount the wiper inserts
correctly.
fn1 = .031 x bs1
(fn1 = 0.8 x bs1)
Machinability
Other information
fn
Feed, inch/tooth
(mm/tooth)
bs2
Tool holding
bs1
D 26
.323
(8.2)
.002 inch
(0.05 mm)
S
et the wiper inserts
below other inserts.
Turning
Machining conditions
Parting and
grooving
Average
C
Threading
Difficult
Average
Difficult
Milling
Good
Drilling
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.
O
verhang two to three
times cutter diameter.
O
verhang over three
times cutter diameter.
Continuous cuts.
Interrupted cuts.
Interrupted cuts.
Boring
Difficult conditions
G
Tool holding
Average conditions
D 27
Machinability
Other information
Good conditions
Turning
Parting and
grooving
Threading
Milling
Drilling
Boring
G
ISO
Tool holding
Machinability
Other information
D 28
GC 4200
ISO
GC 2000
ISO
GC 3200
Turning
Parting and
grooving
Threading
Milling
Low
High
Boring
Drilling
Cutter pitch
Wear resistant
Medium (-M)
Machining conditions/
Grades
Heavy (-H)
Tool holding
Light (-L)
Toughness
Good conditions
Average conditions
Difficult conditions
D 29
Machinability
Other information
Turning
Low
High
Parting and
grooving
Cutter pitch
Threading
Milling
Long overhang.
S
mall machines/limited
horsepower.
H
igh number of inserts
for maximum productivity.
Stable conditions.
Short chipping materials.
Heat resistant materials.
D
eep, full slotting
operations.
Drilling
Differential pitch.
Limited stability
Stable
conditions
Boring
First choice
G
Tool holding
Long overhang
Limited
horsepower
Machinability
Other information
D 30
Cast iron
(CMC 08)
Heat
resistant
alloys
(CMC 20)
Turning
B
Parting and
grooving
90 entering angle
Threading
Milling
C
hip thinning effect allows increased productivity.
Drilling
educed vibration on
R
long overhang.
Boring
here 90 form is
W
required.
S
trongest cutting edge
with multiple indexes.
G
Tool holding
eak-fixtured compoW
nents.
G
eneral purpose first
choice.
D 31
Machinability
Other information
Thin-walled components
Turning
Thin-walled components.
Parting and
grooving
Threading
Milling
C
hip thinning effect allows increased
productivity.
fz = 1.41 x hex (Compensating for entering angle).
Drilling
S
trongest cutting edge with multiple
indexes.
Boring
G
Tool holding
Machinability
Other information
D 32
Turning
Parting and
grooving
hex iC
2 ap iC ap 2
Threading
fz =
hex iC Dcap
4 ap iC ap 2 Dcap ae ae 2
Drilling
Boring
Tool holding
Round = depends on ap
D 33
Machinability
Other information
fz =
Milling
Dcap = Dc +
Turning
Parting and
grooving
Given:
Cutting speed, vc =
738 ft/min (225 m/min)
.157
(4 mm)
Table feed, vf
(inch/min) (mm/min)
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)
Milling
Spindle speed
Inch
n=
Drilling
Metric
n=
vc 12
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)
Inch
Q = ap ae vf
Metric
(inch3/min)
Q=
H
Machinability
Other information
225 1000
(rpm)
Metric
vf = n fz zn (inch/min)
Dc
Inch
vc 1000
Q=
ap ae vf
1000
4 85 600
1000
(cm3/min)
= 204 cm3/min
Turning
Pc =
ae ap vf kc
396 103
(Hp)
Pc =
B
ae ap vf kc1
(kW)
60 106
Parting and
grooving
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
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
43039050
38535015
36533000
31529060
23521095
1700
1900
175
300
0.25
0.25
30027545
19518060
1950
2150
2900
3100
200
200
300
380
0.25
0.25
0.25
0.25
23020585
19017055
16515035
1059585
1400
1600
1950
150
200
200
0.25
0.25
0.25
30528050
24522000
18016045
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
Inch
kc = kc1 hm-mc 1
100
Metric
( )
o
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
1950
2850
200
330
0.21
0.21
2000
2450
230
260
0.21
0.21
1700
2450
2150
1800
2450
200
330
330
200
330
0.25
0.25
0.25
0.25
0.25
230
260
0.25
0.25
1800
2250
Specific
cutting force
kc 1
Hardness
Brinell
CB50
hm = Average chip thickness
Max chip thickness
0.1 0.15 0.2
CMC
ISO No.
Material
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)
Tool holding
( )
o
N/mm2
85 4 600 1700
1)
100 mm
125 mm
D 35
MILLING Cutting data
Machinability
Other information
Pc =
Hardness
Brinell
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
CT530
Max chip thickness
0.1 0.15 0.2
Cutting speed vc, m
Boring
CMC
ISO No.
Hardness
Brinell
Threading
Condit
Cutter,
over the
engage
Troubleshooting
Turning
Parting and
grooving
Overhang
Machine with the shortest possible tool
overhang on the spindle.
C
Threading
Milling
Cutting engagement
Ensure there is sufficient insert engagement with narrow workpieces or when
milling over voids.
Drilling
Boring
Cutting direction
Use climb (down) milling whenever possible.
Tool holding
Machinability
Other information
D 36
Turning
Entering angle
Select the most suitable entering angle.
C
Threading
Cutter diameter
Select the right diameter in relation to
the workpiece width.
Cutter position
Position the milling cutter correctly.
Milling
Boring
Coolant
Only use coolant if considered necessary. Milling is generally performed better
without.
Drilling
G
Tool holding
Maintenance
Follow tool maintenance recommendations and monitor tool wear.
D 37
Machinability
Other information
Parting and
grooving
Troubleshooting
Drilling
Drilling covers methods of making cylindrical holes in a
workpiece with metal cutting tools
Theory
E6
Selection procedure
E 15
System overview
E 20
How to apply
E 26
E 37
Troubleshooting
E 42
E3
Turning
Theory
B
Parting and
grooving
Threading
Milling
E
Drilling
Trepanning
Drilling
- Trepanning
- Chamfer drilling
Boring
- Step drilling
Chamfer drilling
Tool holding
Machinability
Other information
E4
Step drilling
Theory
Turning
Parting and
grooving
Threading
1 2 3 4 5
Milling
Boring
Drilling
Tool holding
E5
Machinability
Other information
Theory
Turning
B
Parting and
grooving
Chip evacuation
Threading
Milling
Drilling
Boring
Tool holding
H
Machinability
Other information
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
B
Parting and
grooving
0.5 x vc max
vc max
Milling
Boring
G
Tool holding
vc max
E7
Machinability
Other information
vc = 0
Theory
Turning
Parting and
grooving
C
Threading
HSS drill
Milling
Drilling
2 Chisel edge
3 Primary clearance
4 Secondary clearance
Boring
5 Flute
Tool holding
6 Margin
7 First split
8 Negative chamfer
9 Clearance surface
Machinability
Other information
E8
6
9
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.
Theory
Cutting speed
Turning
Definitions of terms
n = spindle speed (rpm)
Parting and
grooving
C
Inch
Dc n
12
ft/min
Threading
vc =
Metric
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
Boring
G
vc = 0
Tool holding
vc = max
Two edges/rev: z = 2.
E9
Machinability
Other information
Theory
Turning
Parting and
grooving
Threading
Milling
Drilling
Boring
Tool holding
Machinability
Other information
E 10
Theory
Turning
Feed rate
B
Parting and
grooving
Threading
fn = fz 2 inch/r (mm/r)
Milling
Drilling
Boring
Tool holding
E 11
Machinability
Other information
Theory
Turning
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)
Parting and
grooving
Threading
Milling
Inch
fn vc Dc kc1
132 103
Hp
Drilling
Pc =
Metric
Boring
Tool holding
Machinability
Other information
E 12
Pc =
fn vc Dc kc1
240 103
kW
Theory
CoroDrill Delta-C
B
Parting and
grooving
CoroDrill 880
Turning
Pc =
Metric
fn vc Dc kc
132 103
Pc =
Hp
fn vc Dc kc
kW
240 103
r)-mc
100
Drilling
Milling
Inch
C
Threading
0 = 30
Boring
Tool holding
E 13
Machinability
Other information
Theory
Turning
Parting and
grooving
Power
consumption
(Hp) (kW)
kc1 = S
pecific cutting
force (lbf ft/inch2) (N/mm2)
Ff = Feed force (N)
Threading
Milling
Drilling
Mc =
Boring
Inch
Tool holding
Machinability
Other information
E 14
Ff 0.5 kc
Dc
2
fn sin r (N)
Metric
Pc 16501
n
(lbf ft)
Mc =
Pc 30 103
n
(Nm)
Tool selection
Turning
Parting and
grooving
Hole dimension
and quality
C
Component
Threading
Machine
Milling
Machine parameters
Choice of tool
Type of tool
Drilling
How to apply
Boring
Troubleshooting
Remedies and
solutions
E 15
Machinability
Other information
Tool holding
Tool selection
Turning
B
Parting and
grooving
C
Threading
D
Material:
Milling
Drilling
achinability
m
chip breaking
hardness
alloy elements.
Boring
Tool holding
Machinability
Other information
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
Turning
B
Parting and
grooving
Step drilling
Threading
Milling, helical
interpolation
Milling
Advantages
Advantages
Advantages
Relatively flexible.
Very flexible.
Drilling
Disadvantages
Disadvantages
Boring
Less flexibility.
Tool holding
R
equires two tool
positions.
Disadvantages
E 17
Machinability
Other information
Turning
Tool selection
4. How to apply
Important application considerations
B
Parting and
grooving
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
D
Tool runout
Milling
M
inimum tool runout is essential for
successful drilling.
Drilling
Boring
Cutting
speed
Thicker and
stiffer chips
Tool holding
G
More open due to
less friction
Machinability
Other information
H
Feed
E 18
Tool selection
Turning
5. Troubleshooting
B
-C
heck the wear pattern and if necessary adjust cutting
data accordingly.
Chip evacuation
Parting and
grooving
-C
orrect cutting speed and feed rate is essential for high
productivity and tool life.
Milling
Cutting data
Drilling
Boring
Tool holding
E 19
Machinability
Other information
.984 in.
(25mm)
Threading
Turning
Parting and
grooving
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
Milling
Drilling
L/Dc
Boring
Trepanning drill
Tool holding
10xDc
5xDc
Machinability
Other information
E 20
.394
(10)
.787
(20)
1.181
(30)
1.575
(40)
1.969
(50)
4.331
(110)
Drill
diameter, Dc
inch
(mm)
System overview
Turning
Parting and
grooving
Chamfer drilling
Threading
Milling
Other methods
Drilling
Trepanning
Boring
Helical interpolation
G
Tool holding
Radial adjusted
drilling
Plunge drilling
E 21
Machinability
Other information
Solid drilling
System overview
Parting and
grooving
Turning
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.
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).
Threading
Application areas
Milling
Drilling
Boring
Tool holding
Machinability
Other information
E 22
System overview
Turning
C
Threading
Parting and
grooving
Milling
Mounting options
Drilling
F
Coromant Capto coupling
Boring
Cylindrical shank
Whistle Notch
E 23
Machinability
Other information
P-shank
Tool holding
System overview
Turning
Material-optimized drills
Parting and
grooving
Threading
Milling
Special tools
Application-optimized drills
Precision
drill for
hard steel
Chamfer drill
P M K
N S H
P
H
Drilling
P M K
N S H
Solid carbide
drills
Brazed carbide
drills
Indexable
insert drills
Boring
Tool holding
Machinability
Other information
E 24
Selection procedure
Turning
B
Parting and
grooving
Threading
Trepanning drill
Milling
Drilling
Boring
Tool holding
E 25
Machinability
Other information
Turning
How to apply
Indexable insert drills
Setup routine
Use the shortest possible drill.
Parting and
grooving
How to apply
Milling
Drilling
Chip control
Improved chip evacuation is initially achieved by improving chip formation.
Boring
G
Tool holding
Acceptable
Not acceptable
H
Machinability
Other information
A
lso the surface finish may be affected and the insert
or tool may be at risk.
E 26
How to apply
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.
B
Parting and
grooving
Alignment
Milling
Radial adjustment
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).
H
Machinability
Other information
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
How to apply
Turning
Parting and
grooving
C
Threading
Milling
O
ne dot increases/decreases the diameter by .004 inch (0.10 mm).
Increase the diameter by turning the
sleeve clockwise.
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
Tool holding
Machinability
Other information
E 28
How to apply
Turning
Non-rotating drill
.001 inch
C
Threading
B
Parting and
grooving
Alignment
Milling
Drilling
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
Boring
3
E 29
Machinability
Other information
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.
Parting and
grooving
Feed force
Threading
Milling
B
A
Drilling
Boring
Peripheral insert
Tool holding
Feed force
Machinability
Other information
E 30
How to apply
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
B
Parting and
grooving
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
Drilling
F
B. Concave surface
Boring
W
ith entering angle of 289, reduce
feed to 1/3 of original feed rate.
Tool holding
D. Curved surface
Reduce feed 1/3 of original feed rate.
E 31
Machinability
Other information
How to apply
Turning
B
Parting and
grooving
C
Threading
H
owever, reduced feed does allow broad
machining of pre-drilled holes.
Milling
Coolant supply
Internal coolant supply
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.
Boring
Tool holding
Machinability
Other information
E 32
How to apply
Turning
C
Threading
Parting and
grooving
Milling
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
G
Tool holding
E 33
Machinability
Other information
How to apply
Turning
Rotating drill
.0008 inch (0.02 mm)
Parting and
grooving
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
Stationary drill
.0008 inch (0.02 mm)
Milling
Tool holding
collet and tool shank in bad condition
A
will ruin an otherwise perfect setup.
Drilling
M
ake sure that the TIR (Total Indicator
Readout) is within .0008 inch (0.02
mm).
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
Machinability
Other information
E 34
How to apply
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
Parting and
grooving
Milling
Drilling
Boring
Tool holding
E 35
Machinability
Other information
How to apply
Turning
Safety precautions
Internal coolant supply
Safety against
dangerous discs
Rotating stop
is an important
measure
A
rotation stop may be necessary for
rotating drills.
Parting and
grooving
Threading
Milling
Drilling
Boring
Tool holding
Machinability
Other information
E 36
Turning
Milling
C
oolant supply and coolant pressure is
important.
C
Threading
The
machine tool should be in good
condition.
Parting and
grooving
- 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
E 37
Machinability
Other information
Dmax
Drilling
Turning
Parting and
grooving
Threading
Milling
Tolerance
Drilling
Boring
.709
1.181
1830
1.181
1.969
3050
1.969
3.150
5080
3.150
4.724
80120
IT7
IT8
IT9
IT10
IT11
IT12
IT13
Examples
Bearings
1)
Holes for
threading
Normal tap
holes
+.003 inch
(0.07 mm)
+0.00
Example:
Nominal value:
H
Machinability
Other information
.394
.709
1018
Tool holding
.236
.394
610
IT6
1)
.118
.236
36
E 38
0 to plus
(H acc. to ISO)
Turning
Hole
.787 inch
(20 mm) H7
Axle
.787 inch
(20 mm) h7
B
Parting and
grooving
Threading
Milling
Axle tolerance position is denominated by lower case letters corresponding to the hole tolerance. The figure below
gives a complete picture.
Drilling
Most common
Boring
Hole larger
than axle
G
Drive fit
Interface
Tool holding
Play
(bearings)
Slide fit
E 39
Machinability
Other information
Running fit
Turning
B
Parting and
grooving
Threading
R844
Tolerance
R840
R842
R850
IT6
IT7
IT8
IT9
With pre-setting
Milling
IT10
IT11
IT12
IT13
Drilling
Boring
H
Machinability
Other information
Tool holding
Drill tolerance
E 40
Hole tolerance
B
Parting and
grooving
Drill tolerance
Turning
Threading
.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)
Milling
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)
.9843 inch
(25 mm) H10
Boring
1.732 2.086
(44.00 52.99)
0/+.0169
(0/+0.43)
G
Tool holding
.472 1.732
(12.00 43.99)
0/+.0157
(0/+0.40)
E 41
Machinability
Other information
Drilling
Turning
Parting and
grooving
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. Reduce feed.
2. Choose a light cutting geometry to lower the cutting force.
Threading
Milling
Drilling
Boring
Tool holding
Machinability
Other information
H
Mc lbf-ft (Nm)
E 42
Troubleshooting
Solution
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
B
Parting and
grooving
Problem
Turning
1. Reduce feed.
2. Choose a light-cutting geometry to lower the cutting force.
Milling
Drilling
Boring
E 43
Machinability
Other information
Tool holding
Troubleshooting
Turning
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
Parting and
grooving
Problem
C
Threading
Crater wear
Central insert:
Abrasive wear caused by built-up
edge and smearing.
Milling
General:
Choose a more positive geometry.
Drilling
Boring
ab) S
elect a more wear resistant
grade with better resistance
to plastic deformation, i.e.,
GC4014 or GC4024.
ab) Reduce cutting speed.
a) Reduce feed.
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
H
Machinability
Other information
Central insert:
Choose GC1044, if H13A is used.
Reduce feed.
E 44
Troubleshooting
Cause
Solution
B
Parting and
grooving
Problem
Turning
Threading
Milling
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
Drilling
E 45
Machinability
Other information
Troubleshooting
Turning
Parting and
grooving
C
Threading
1 2 3 4 5 6 7 8
Milling
Drilling
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.
Boring
Tool holding
1. Unstable fixturing.
2. TIR too large.
3. Intermittent cutting.
4. Insufficient cutting fluid (thermal
cracking).
5. Unstable tool holding.
H
Machinability
Other information
Solution
Built-up edge
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
Solution
1.
2.
3.
4.
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.
Milling
Parting and
grooving
Cause
Turning
E
Wear on the chisel edge
1. Increase cutting speed.
2. Decrease feed.
3. Check dimensions.
Drilling
G
Tool holding
1. D
ecrease the cutting speed
and/or feed.
2. Increase cutting fluid pressure.
3. Use a harder grade.
E 47
Machinability
Other information
1. C
utting speed and/or feed too
high.
2. Not enough cutting fluid supply.
3. Unsuitable drill/grade.
Boring
F2
Boring
Boring operations involving rotating tools are applied to
machine holes that have been made through methods
such as pre-machining, casting, forging, extrusion,
flame-cutting, etc.
Theory
F4
Selection procedure
F9
System overview
F 14
How to apply
F 21
Troubleshooting
F 25
F3
Turning
Parting and
grooving
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
Theory
Milling
Boring with a
rotating tool
Milling, helical
interpolation
Drilling
Boring
Tool holding
P
rofiling can be carried
out with standard boring
bars.
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).
H
Machinability
Other information
V
ery flexible solution
where one milling cutter
can be used for different
diameters.
F4
S
aves space in the tool
magazine.
Theory
Turning
Definitions of terms
Definitions of cutting data terms
Parting and
grooving
Dc n
12
(ft/min)
Milling
vc =
Metric
1000
E
(m/min)
Drilling
vc =
Dc n
Feed
vf = fn n (inch/min) (mm/min)
Boring
fn = zc fz (inch/r) (mm/r)
Penetration rate
Cutting depth
F5
Tool holding
Inch
H
Machinability
Other information
Cutting speed
Threading
Theory
Turning
Pc Hp (Nm)
C
Threading
Mc lbf ft (Nm)
Milling
Drilling
Boring
Tool holding
Machinability
Other information
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.
Inch
Mc =
Pc 16501
(lbf ft)
Metric
Mc =
Pc =
Pc 30 103
ap fn kc vc
60 103
(Nm)
( )
1
ap
Dc
(Hp)
(kW)
Theory
Turning
R
ough boring operations are performed to open up the
existing hole to prepare for fine boring.
B
Parting and
grooving
Milling
Threading
.9843 in
(25 mm) H7
Drilling
Multi-edge
reamer for high
feed finishing
Boring
Rough boring
tool with multiple edges
G
Tool holding
IT6
IT7
IT8
IT9
F7
Machinability
Other information
Theory
Turning
Parting and
grooving
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
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
Boring
Reaming
A light finishing operation performed with a multi-edge
reamer at high feeds.
Tool holding
Machinability
Other information
F8
Tool selection
Turning
Component
Workpiece
material, shape
and quantity
Parting and
grooving
.9843 in
(25 mm) H7
Threading
Hole dimension
and quality
Machine
Machine
parameters
Milling
Choice of tool
Drilling
Type of tool
How to apply
Cutting data,
coolant, etc.
Boring
Troubleshooting
Remedies and
solutions
Machinability
Other information
Tool holding
Tool selection
Turning
Component
Parting and
grooving
C
Threading
S
elect the tool that covers the boring
diameter range and depth for the
operation, surface finish and tolerance.
Milling
Material
Drilling
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
Tool holding
Machinability
Other information
F 10
Tool selection
Turning
3. Choice of tools
Finishing
Roughing
Parting and
grooving
C
Single-edge
boring
Single-edge
boring
Reaming
Threading
Step boring
Multi-edge boring
Step-boring
Single-edge boring
Productive boring.
Single-edge boring
Reaming
V
ery good surface finish
at high penetration rates.
L ess machine-power
demanding.
Milling
Multi-edge
boring
Drilling
Boring
Engineered tools
Tool holding
F 11
Machinability
Other information
Tool selection
Turning
4. How to apply
Important application considerations
Tool holding
B
Parting and
grooving
C
Threading
Tool considerations
onsider lead (entering) angle, insert
C
geometry and grade.
Milling
Drilling
Boring
Feed, inch/r
(mm/r)
Tool holding
Machinability
Other information
F 12
Tool selection
Turning
5. Troubleshooting
Important application considerations
Insert wear and tool life
C
heck the chip breaking and cutting fluid
supply.
Hole quality and tolerances
.9843 in
(25 mm) H7
C
Threading
Chip evacuation
Parting and
grooving
C
orrect geometry, grade and cutting data
is essential in boring operations.
Drilling
Boring
Tool holding
F 13
Machinability
Other information
Milling
Cutting data
Turning
Parting and
grooving
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
Threading
Milling
Drilling
Boring
Multi-edge reamer
G
Tool holding
Machinability
Other information
F 14
Turning
System overview
Parting and
grooving
C
Diameter range 5.906 - 21.654 inch (150 - 550 mm)
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
Multi-edge reamer
Diameter range .394 - 1.250 inch (10 - 31.75 mm)
Drilling
F
Single-edge boring tool with integrated adapter
Boring
G
Diameter range 5.906 - 38.646 inch (150 - 981.6 mm)
Diameter
Tool holding
F 15
Machinability
Other information
inch 0 .984 1.969 5.906 7.874 9.843 11.811 19.685 21.654 23.622 35.433 39.370
mm
0 25 50 150 200 250 300 500 550 600 900 1000
Turning
Choice of tool
Choice of tools
Roughing
Multi-edge boring
B
Parting and
grooving
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
Finishing
Single-edge boring
Drilling
Reaming
V
ery good surface finish at high penetration rates.
Suitable for mass production.
Boring
Tool holding
Engineered tools
M
any operations in one tool.
The operations can be completed during
one feed motion.
Machinability
Other information
F 16
Choice of tool
B
Parting and
grooving
Turning
Threading
Milling
Drilling
Single-edge boring
Multi-edge boring
Boring
Tool holding
F 17
Machinability
Other information
Choice of tool
Turning
B
Parting and
grooving
Threading
Milling
Drilling
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.
Positive inserts
Negative inserts
Boring
G
Tool holding
0
(90)
0
(90)
5
(95)
H
Machinability
Other information
6
(84)
15
(75)
-5
(95)
F 18
Choice of tool
Turning
B
Parting and
grooving
Threading
Milling
Drilling
G
Tool holding
Boring
Multi-edge reamer
F 19
Machinability
Other information
Choice of tool
Turning
Parting and
grooving
Positive inserts
7 clearance angle
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
Adapters
Choose the shortest possible adapter length.
Boring
Drilling
Tool holding
Machinability
Other information
F 20
How to apply
B
Single-edge fine boring tools have adjustment possibilities to accurately pre-set the
cutting edge within microns.
Parting and
grooving
Turning
How to apply
Threading
B
oring tools for finishing, with one cutting edge, will experience some degree
of radial deflection during machining due
to the cutting forces.
Milling
Tool deflection
A
measuring cut is normally needed,
followed by a final adjustment of the tool.
Drilling
Boring
Tool holding
F 21
Machinability
Other information
How to apply
Turning
Parting and
grooving
A
pply cutting fluid for optimized chip
evacuation, cooling and lubrication.
Affects hole quality and tool life.
C
Threading
Milling
Drilling
Cutting depth,
ap inch (mm)
Boring
G
Tool holding
Machinability
Other information
F 22
How to apply
Turning
B
Parting and
grooving
- 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.
Boring
Drilling
Tool holding
F 23
Machinability
Other information
M
Mcc lbf-ft (Nm)
Milling
Threading
How to apply
Turning
Parting and
grooving
C
Threading
Milling
Drilling
Tool holding
E
mulsion as cutting fluid generates better tool life
than oil.
Use recommended cutting data.
Machinability
Other information
F 24
Troubleshooting
Turning
Troubleshooting
Parting and
grooving
Threading
D
.008 (0.2)
.016 (0.4)
.031-.047 (0.8-1.2)
Milling
inch (mm)
Drilling
C
heck that all units in the tool assembly
are assembled correctly with the correct
torque.
Boring
G
Tool holding
Machinability
Other information
Troubleshooting
Turning
Insert wear
Insert wear patterns and remedies in boring are generally
very similar to turning.
Parting and
grooving
Chip breaking
Cause
Too short, hard
Solution
Increase cutting speed
Decrease feed
Threading
C
hange geometry to a more
open chip breaker
Too long
Increase feed
Decrease cutting speed
Milling
C
hange geometry to a more
closed chip breaker
Surface
Drilling
Tool vibration
Boring
Decrease feed
Decrease speed
Tool holding
G
Feed marks
C
hoose knife edge wiper
insert
Machinability
Other information
Decrease feed
F 26
Troubleshooting
Turning
Solution
C
hange cutting edge and
investigate reason for wear
pattern cutting data, insert
geometry and insert grade.
B
Parting and
grooving
Insert wear
Threading
Cause
Increase speed
Use coolant
Drilling
Boring
G
Tool holding
F 27
Machinability
Other information
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.
G4
G7
Turning centers
G 15
Machining centers
G 23
Multi-task machines
G 29
Chucks
G 33
G3
Turning
Parting and
grooving
Threading
Milling
Drilling
Boring
Tool holding
Machinability
Other information
G4
Turning
C
Threading
B
Parting and
grooving
Milling
U
nfortunately, these systems are not
interchangeable with each other, and are
very limited in their flexibility between
machining centers and CNC lathes.
Boring
M
ost of these systems are not suitable
for multi-task machining operations.
Drilling
Tool holding
G5
Machinability
Other information
Turning
Coromant Capto
A multi-purpose, quick-change modular tooling system
Parting and
grooving
Threading
Milling
Drilling
Solid holders
Boring
Varilock
1980
Coromant Capto/
Basic holders
1990
Standard
G
Tool holding
ISO 26623
Shank holders
Machinability
Other information
G6
Block Tool
System
Coromant Capto/
Clamping units
Turning
Parting and
grooving
Threading
Turning centers
Milling
Multi-task machines
Trends
Boring
Tool holding
G7
Machinability
Other information
Turning
B
Parting and
grooving
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
Milling
E
Only 36% of the machine time is used for metal cutting
Drilling
-S
ervice and maintenance
- Insert change and tool
change
Boring
-M
easuring of the tool
and workpiece
25%
Tool holding
G
Conventional shank
tools
Coromant Capto
quick- change system
H
Machinability
Other information
- Change of workpiece
G8
Turning
Parting and
grooving
Vertical lathes
Threading
Turning centers
Milling
Drilling
Boring
Multi-task machines
Tool holding
G9
Machinability
Other information
Machining centers
Turning
Parting and
grooving
Threading
ISO 40
ISO 50
HSK 100
HSK 63
Milling
Solid
Modular
Drilling
Boring
F
Number of items with modular tools:
4 + 2 + 30 + 10 = 46 items
Tool holding
Machinability
Other information
G 10
Milling
Flange contact
-C
oolant supply through
center
-C
oolant channel in the
coupling.
Drilling
Boring
Coolant channel in
coupling
G
Tool holding
B
Parting and
grooving
Threading
Gripper groove
G 11
Machinability
Other information
Taper polygon
Turning
Parting and
grooving
Threading
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
1.4
Turning
Drilling
3
2
3
3-way locking
Boring
Tool holding
Machinability
Other information
H
C3 C10
G 12
Turning
Parting and
grooving
Threading
Front clamping
Milling
Segment clamping
For modular clamping solutions, e.g., when using extensions and basic holders.
Drilling
Boring
B
C
G 13
G
Tool holding
H
Machinability
Other information
Turning
Transmission of torque
The polygon shape transmits torque without any loose parts such as pins or keys.
Parting and
grooving
Threading
Milling
Drilling
Boring
G
Tool holding
Machinability
Other information
G 14
Turning centers
Turning
Machining centers
Parting and
grooving
Threading
Turning centers
Milling
Multi-task machines
Boring
Drilling
G
Tool holding
G 15
Machinability
Other information
Turning centers
Turning
B
Parting and
grooving
S
everal multi-axis machine tool programs can provide turning results from
roughing and grooving to threading and
finishing.
Threading
Milling
Drilling
Boring
-s
mall batch production, quicker setup
times
- operations with frequent insert changes.
G
Tool holding
Machinability
Other information
G 16
Turning centers
Square shank
Camshaft activated
Automatic unit
Hydraulically operated
B
Parting and
grooving
VDI angled
Camshaft activated
Turning
VDI straight
Camshaft activated
Round shank
Segment clamping
Special applications
Segment clamping
Threading
Milling
Drilling
G
Tool holding
Boring
G 17
Machinability
Other information
Turning centers
Turning
Parting and
grooving
Threading
Milling
Drilling
Boring
Tool holding
Machinability
Other information
G 18
Turning centers
Turning
Parting and
grooving
M
ore available tool length for radial drilling
operations.
Increased production.
Threading
Rationalized tooling.
Milling
Drilling
Tool holding
G 19
Machinability
Other information
Boring
Turning centers
Turning
B
Parting and
grooving
1.
2.
Ergonomic.
E
asy to clean the tip seat outside the
machine.
Threading
0.5 min
1.5 min
Milling
Drilling
Boring
Tool holding
Machinability
Other information
G 20
Turning centers
Turning
B
Parting and
grooving
Threading
A
ngled and straight clamping units for
external and internal operations.
Milling
Drilling
Boring
Tool holding
Example of installations.
G 21
Machinability
Other information
Turning centers
Turning
Parting and
grooving
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
Drilling
Boring
Tool holding
Machinability
Other information
H
Example of installations.
G 22
Machining centers
Turning
B
Parting and
grooving
Machining centers
Threading
Milling
Turning centers
Multi-task machines
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
Boring
Tool holding
G 23
Machinability
Other information
Machining centers
Turning
Parting and
grooving
Threading
Milling
Drilling
Boring
Tool holding
Front clamping
Machinability
Other information
G 24
Machining centers
Turning
Basic holders
Cat V-Flange
DIN 69871
Form B
40
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
Parting and
grooving
DIN 2080
ISO 40
ISO 50
C
Threading
Milling
Drilling
-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
Boring
G 25
Machinability
Other information
Machining centers
Turning
Parting and
grooving
Threading
Milling
Drilling
Boring
G
Tool holding
Machinability
Other information
G 26
Machining centers
Turning
W
ith modular tools it is always possible
to use optimal cutting data for best
productivity!
Threading
Parting and
grooving
Milling
Solid
Boring
Modular
Drilling
Tool holding
Machinability
Other information
Turning
Multi-task machines
B
Parting and
grooving
Machining centers
Threading
D
Turning centers
Milling
Multi-task machines
Drilling
Boring
Tool holding
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.
Machinability
Other information
G 28
Multi-task machines
Turning
C
Threading
ounterclockwise
M04 = C
spindle direction
Parting and
grooving
Milling
Boring
Tool holding
G 29
Machinability
Other information
Multi-task machines
Turning
Parting and
grooving
Threading
Milling
Drilling
Boring
Tool holding
Machinability
Other information
G 30
Multi-task machines
Turning
Parting and
grooving
Threading
Milling
Twin tools
two turning tools in one
Boring
Tool holding
Mini-turrets
four turning tools in one
G 31
H
Machinability
Other information
Multifunctional tools
one milling and four turning tools in one
Drilling
Multi-task machines
Turning
B
Parting and
grooving
Radial
C
Threading
Axial
Milling
Drilling
Boring
Tool holding
G
Tool adapter with blade for
parting off
Machinability
Other information
G 32
Chucks
Turning
Chucks
Parting and
grooving
Shrink fit
adapter
Collet
chuck
Endmill
(Weldon)
adapter
Drill
adapter
C
Threading
Hydraulic
chuck
D
1
6
Milling
Rank
Clamping
area
+++
+++
+++
+++
Runout
+++
Balance
Balanced
by rotational testing
+++
+++
+++
++
+++
+++
+++
+++
Balanced
by rotational testing
Balanced
by design
(C4-C5)
Balanced
by design
(C3-C5)
Balanced
by design
(C3-C5)
No
Tool holding
G 33
H
Machinability
Other information
Boring
Clamping
force
Drilling
Chucks
Turning
Hydraulic chucks
Parting and
grooving
Threading
Milling
Drilling
Clamping
part
Pressure
screw
Boring
Collet
Tool holding
Machinability
Other information
G 34
Piston
Chucks
Parting and
grooving
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.
Milling
h6 shank
Threading
Drilling
h6 shank
Turning
Hydro-mechanical chucks
Boring
G 35
Machinability
Other information
h6/h7
shank
Chucks
Turning
Parting and
grooving
R
unout typically is around .0016 inch (40 m) at the
surface of the chuck.
Can cause vibration problems.
Threading
Milling
Drilling
Boring
Overhang
G
Tool holding
(20%)
Machinability
Other information
Tool protrusion
(50%)
G 36
Chucks
Turning
M
ore critical as tool diameter gets
smaller.
Parting and
grooving
R
unout should be < .001 inch
(< 0.025 mm).
C
Threading
Milling
Boring
G
Tool holding
G 37
Machinability
Other information
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
H 18
H 29
H 44
Other information
Machining economy
H 55
H 68
H 75
H3
Turning
Parting and
grooving
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
Steel
ISO
Stainless steel
ISO
Cast iron
Threading
Workpiece materials
ISO
Aluminum
ISO
ISO
Hardened material
Milling
E
The largest variety of different types of
components is probably in the P-area
as it covers several different sectors in
the industry.
In the M-area, a big part of the application is in gas and oil, tubes, flanges,
process industry and the pharmaceutical business.
Drilling
Boring
Tool holding
Machinability
Other information
H4
Workpiece materials
-C
lassification, metallurgical/mechanical,
of the workpiece material.
- The cutting edge micro- and macro geometry to be used.
ISO
Steel
ISO
Stainless steel
ISO
Cast iron
C
Threading
Parting and
grooving
Turning
ISO
Aluminum
ISO
ISO
Hardened material
Milling
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.
The range is wide, but in general high cutting forces are present.
H5
Boring
G
Tool holding
H
Machinability
Other information
Drilling
Workpiece materials
Turning
Parting and
grooving
Steel
Stainless steel
Cast iron
Aluminum
Milling
Threading
Turning
Application
Workpiece material
Condition
Cutting conditions
Milling
Milling
Drilling
Clamping conditions
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.
Machinability
Other information
Roughing/
Heavy
Medium
Finishing/
Light
H6
Workpiece materials
Turning
Parting and
grooving
Hardness
Cutting environment
C
Threading
Component
Hardness Brinell
Milling
Coolant
Drilling
G
Tool holding
H7
Machinability
Other information
Boring
Dry machining
Turning
Workpiece materials
Parting and
grooving
T hese three basic factors must be considered carefully and adapted for each
machining operation.
C
Threading
Insert grade
Insert geometry
Milling
Drilling
Steel
Boring
Cast iron
Stainless steel
Aluminum
Tool holding
Machinability
Other information
H
* MC = A new material classification that replaces the CMC
(Coromant Material Classification) codes.
H8
Hardened material
Workpiece materials
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.
Parting and
grooving
Example 1:
Milling
Example 2:
The code N1.3.C.AG is interpreted this way:
N = ISO code for non-ferrous metals
Drilling
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
H9
Machinability
Other information
Workpiece materials
Turning
Parting and
grooving
Threading
Milling
What is steel?
- Long-chipping material
-S
teel is the largest group in the metal
cutting area.
-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
Machining characteristics:
Boring
ISO
Tool holding
Material
P1
Unalloyed steel
P2
Low-alloyed steel
(5% alloying elements)
P3
High-alloyed steel
(>5% alloying elements)
P4
Sintered steels
H
Machinability
Other information
MC
H 10
Workpiece materials
Turning
Parting and
grooving
Machining characteristics:
- Long-chipping material
-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
261,000413,250 lbs/inch2
(Molybdenum), and Ti (Titanium).
(18002850 N/mm2)
Milling
Drilling
Threading
Material
P5
Ferritic/Martensitic stainless
steel
M1
M2
Super-austenitic, Ni20%
Tool holding
MC
M
See Technical Guide Chapter H
for detailed MC code listing
H
M3
Duplex (austenitic/ferritic)
H 11
Machinability
Other information
ISO
Boring
Workpiece materials
Turning
Parting and
grooving
Threading
Milling
Machining characteristics:
-C
ast iron is an Fe-C composition with
relatively high content of Si (13%).
-C
arbon content is over 2% which is the
max solubility of C in the Austenitic
phase.
Drilling
-C
r (Chromium), Mo (Molybdenum), and
V (Vanadium) form carbides which increase strength and hardness, but lower
machinability.
ISO
MC
Material
K1
K2
K3
Nodular SG iron
K4
CGI
K5
ADI
Boring
G
Tool holding
Machinability
Other information
H 12
Workpiece materials
Turning
Parting and
grooving
Machining characteristics:
- Long-chipping material
-A
luminum (Al) is sticky and needs sharp
cutting edges
- Specific cutting force:
50,750101,500 lbs/inch2
(350700 N/mm2)
-A
luminum (Al) alloys with up to 22%
silicon (Si) make up the largest part.
Threading
- Composites (Kevlar)
Drilling
ISO
MC
Material
N1
Aluminum-based alloys
Boring
N2
Magnesium-based alloys
N3
Copper-based alloys
N4
Zinc-based alloys
Tool holding
H 13
Machinability
Other information
Turning
Workpiece materials
Parting and
grooving
Threading
Milling
Drilling
Machining characteristics:
- Long-chipping material
Resistant Super Alloys (HRSA)
-- Heat
include a great number of high alloyed
iron, nickel, cobalt or titanium based
materials.
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
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
H
Machinability
Other information
MC
H 14
Workpiece materials
Turning
Parting and
grooving
- Long-chipping material
- T his group contains hardened and tempered steels with hardness >4565 HRC.
- T ypically, however, hard part turned components can be found to be within the
range of 5568 HRC.
Milling
Machining characteristics:
Threading
Drilling
Material
H1
H2
H3
Stellites
Tool holding
MC
H
See Technical Guide Chapter H
for detailed MC code listing
H
H4
Ferro-TiC
H 15
Machinability
Other information
ISO
Boring
Workpiece materials
Turning
Parting and
grooving
870,000
(6000)
C
Threading
725,000
(5000)
Fc
580,000
(4000)
Milling
435,000
(3000)
Drilling
290,000
(2000)
145,000
(1000)
Boring
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)
Machinability
Other information
(1800 2850)
(790 1350)
H 16
(350 1350)
(1300 3100)
(2550 4870)
Fc = kc ap fn
Workpiece materials
Turning
01
10
20
30
40
B
Parting and
grooving
C
Threading
Wear resistance
Milling
Drilling
50
Toughness
Boring
Tool holding
H 17
Machinability
Other information
Turning
B
Parting and
grooving
Threading
Milling
Drilling
Boring
Tool holding
Machinability
Other information
H 18
Turning
B
Parting and
grooving
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
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
Fc = 3750
lbf kp
Ft =1700
(1700 kp)
Milling
fn =1.0
n =0.62
(1700 kp)
E
Ft =1700 kp
Drilling
Ft =1700 kp
Boring
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
H 19
Machinability
Other information
Calculation of Fc
Material: MC P2 (low alloyed steel)
180 HB
kc = 304,563 lbs/in2 (2100N/mm2)
Turning
Parting and
grooving
C
Threading
Milling
Drilling
Boring
G
Tool holding
Machinability
Other information
H 20
Turning
Parting and
grooving
Threading
Milling
.010 in.
(.25 mm)
5
C
utting edge reinforcement .010 inch (0.25
mm)
Boring
20
Drilling
Rake angle 20
Primary land 5
G
Tool holding
.008 in.
(0.2 mm)
H 21
Machinability
Other information
Turning
E
R treatment (Edge Roundness) is done
before coating, and gives the final shape
of the cutting edge (micro-geometry).
Threading
Parting and
grooving
Milling
Generally the ER
corresponds to the
thickness of a hair,
diameter: ~ .0031 inch
(80 m).
Drilling
F
.0039 in. (0.1 mm)
Boring
Negative
land
G
Tool holding
Chamfer
Machinability
Other information
H 22
Turning
Parting and
grooving
C
Threading
Milling
Boring
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.
H 23
Machinability
Other information
Drilling
Turning
Parting and
grooving
Turning
N
eeds a durable edge that can perform
for a long time, and often in continuous
cuts at high temperature.
Threading
Milling
P
M
Milling
V
ariations in cutting edge temperature
due to the interrupted cuts also mean
that the resistance to thermal cracks is
of vital importance.
Drilling
N
F
Boring
Drilling
Tool holding
H
Machinability
Other information
H 24
Turning
B
Parting and
grooving
Threading
Steel
Stainless steel
Milling
Cast iron
Drilling
Boring
Hardened steel
G
Tool holding
H 25
Machinability
Other information
Aluminum
Turning
General geometry
Parting and
grooving
Threading
C
Dedicated inserts
edicated geometries
D
and grades
O
ptimized performance
according to workpiece
machinability
Application area
Milling
Application area
Drilling
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
.004 in.
(0.1 mm)
Machinability
Other information
H 26
.010 in.
(0.25 mm)
Medium turning
Most applications general purpose.
Medium operations to light roughing.
Wide range of D.O.C. and feed rate combinations.
Finishing
Operations at light depths of cut (D.O.C.) and low feed rates.
Operations requiring low cutting forces.
B
Parting and
grooving
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
ap Depth of
cut, inch
(mm)
Turning
Drilling
ISO/ANSI
Milling
P STEEL
Finishing
Medium
Roughing
-WF / GC4215
-PF / GC4215
-WM / GC4205
-PM / GC4215
WR / GC4205
-PR / GC4215
Single
sided
-WF / GC4215
-WM / GC4215
-WR / GC4215
-PF / GC4215
-PM / GC4225
-PR / GC4225
Single
sided
-WR / GC4225
-PR/ GC4235
Material
Dedicated
geometries
Steel
Stainless
steel
Cast iron
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
H
Machinability
Other information
-WF / GC4225
-PF / GC4225
Boring
Double
sided
Turning
Parting and
grooving
ap Depth of
cut, inch
(mm)
Threading
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
Drilling
Boring
Light (-L)
Extra positive
Light machining
Tool holding
Machinability
Other information
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
Turning
B
Parting and
grooving
Threading
Milling
Drilling
Boring
Tool holding
H 29
Machinability
Other information
Turning
CD
Parting and
grooving
Diamond
2
3
CB
Threading
CC
Ceramics
CT
Cermets
Milling
1. Diamond
2. Cubic boron nitride
3. Ceramics
4. Cermets
5. Coated carbide
6. High Speed Steel
GC
Coated carbide
HSS
Drilling
Toughness
Boring
Tool holding
Machinability
Other information
H 30
Turning
Parting and
grooving
C
Threading
Drilling
G
ood combination of abrasive wear
resistance and toughness.
Milling
R
epresents a small portion of the total
grade program.
Boring
G
ood edge security but limited wear
resistance at higher speeds.
Tool holding
H 31
Machinability
Other information
Turning
Parting and
grooving
Threading
Cermet
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
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
Tool holding
Machinability
Other information
H 32
C
Threading
Parting and
grooving
Turning
Drilling
Boring
Milling
Polycrystalline diamond
Tool holding
H 33
Machinability
Other information
Turning
Parting and
grooving
Threading
Milling
E
Carbon steel
Drilling
Min (log)
3.937
(100)
Boring
19.685
(500)
Cemented carbide
G
Tool holding
Coated carbide
Insert geometries, new coatings
New cutting tool materials
Machinability
Other information
H 34
C
emented carbide is a powder metallurgical material consisting of:
Turning
Parting and
grooving
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
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.
Boring
C
oating of cemented carbide was
developed in the 1960s.
Drilling
H 35
Machinability
Other information
Turning
Parting and
grooving
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
Elements:
Milling
Gamma-phase (TiC)
Beta-phase (Co)
Drilling
Alpha-phase (WC)
Alpha-phase
WC (tungsten carbide)
Gamma-phase
(Ti,Ta,Nb)C
(titanium, tantalum,
niobium-carbides)
Beta-phase
Co (cobalt)
Boring
Hair diameter
= .0020-.0028 inch (50-70 m)
Tool holding
Machinability
Other information
H 36
B
Parting and
grooving
Turning
Fundamental characteristics
Amount of binder
Toughness
Threading
Milling
Drilling
WC grain size
Tool holding
H 37
Machinability
Other information
Wear resistant
Boring
Turning
Coating design
Many factors influence the behavior of the
insert:
- Coating process
Parting and
grooving
- Coating material
- Coating thickness
- Post treatment
C
Threading
- Surface morphology.
Milling
Drilling
Wear resistance
Toughness
Boring
Tool holding
GC4205
GC4215
GC4225
GC4235
Machinability
Other information
H
Thicker coatings mean more wear resistance.
Harder substrates mean more deformation resistance.
H 38
Turning
Grade design
Coatings and substrates vary with the type of application
Parting and
grooving
C
K05 K15
P05 P35
M15
M25
M35
Threading
Drilling
Al2O3
Coating for chemical and
thermal wear resistance.
G
Tool holding
Functional gradient
For optimized hardness and
toughness.
Boring
TiCN
MTCVD coating for mechanical wear resistance.
Cemented carbide
Plastic deformation
resistance.
H 39
Machinability
Other information
Turning
Parting and
grooving
TiN
Al2O3
A
l2O3 provides temperature protection
(plastic deformation resistance).
Ti(C,N)
Threading
Milling
Drilling
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 m).
G
Tool holding
Machinability
Other information
H 40
Turning
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
Milling
Mechanical
Parting and
grooving
Symbol
Threading
Type of load
Drilling
Boring
G
Tool holding
Adhesive
PD = Plastic Deformation
H 41
Machinability
Other information
BUE
BUE
Parting and
grooving
Turning
Cause
Cutting speed too high, insufficient wear resistance.
Remedy
Reduce cutting speed, select a more wear resistant
grade.
Threading
Milling
Drilling
Boring
G
Tool holding
Machinability
Other information
H 42
Cause
Cutting temperature too
high, combined with a high
pressure.
Remedy
Select a harder grade,
reduce speed and feed.
B
Parting and
grooving
Plastic deformation
(thermal)
Turning
Chipping (mechanic)
Change the feed, select an
alternative insert geometry.
Milling
Threading
Temperature variations
caused by:
Boring
- intermittent machining
- varying coolant supply
Drilling
Thermal cracks
G
Tool holding
Overload of mechanical
tensile stresses.
H
Machinability
Other information
Edge chipping/breakage
(mechanic)
Turning
B
Parting and
grooving
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
Milling
Drilling
Boring
Tool holding
Machinability
Other information
H 44
Turning
B
Parting and
grooving
Threading
Milling
A new insert
generation
1999
New generation
coatings
1989
1980
Drilling
Functional
gradients
Thick aluminum
oxide coating
1969
Boring
G
Tool holding
Indexable
inserts
First coated
insert
H 45
Machinability
Other information
1957
Turning
Powder production
Parting and
grooving
Threading
Milling
Raw material
Niobium
Drilling
Milling
Co
(7%)
Cobalt
(Ti, W)C
(8%)
Boring
Tool holding
Machinability
Other information
H 46
Titanium
WC Tungsten
(80%) carbide
Spray drying
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)
B
Parting and
grooving
Turning
Tungsten powder
Amount of binder
Drilling
Milling
Toughness
Boring
Tool holding
Wear resistant
WC grain size
H 47
Machinability
Other information
Turning
B
Parting and
grooving
Press force
20 - 50 tons
Threading
Die and
core pin
Milling
Drilling
Inspection
The pressing operation consists of several pieces
of tooling:
- T op and bottom punches
- Core pin
- Cavity.
Boring
Tool holding
Machinability
Other information
H 48
Turning
B
Parting and
grooving
C
Threading
Sintering
Milling
Insert trays
E
Shrinking
rate
Drilling
Inspection
Boring
G
Tool holding
3
1. Unsintered insert
2. Sintered insert
3. Coated insert
H 49
Machinability
Other information
Turning
Free profiling
Profiling
Parting and
grooving
C
Threading
g 00
Bor
Neg. land
Periphery
8 9
4 5
1
Milling
SI
Chamfer
S2
S3
S4
S5
S6
2 3
S7 S8
Borg 00
Drilling
Boring
Tool holding
Machinability
Other information
H 50
Turning
Parting and
grooving
Threading
Milling
Drilling
V
ery good adherence to the carbide
substrate.
Tool holding
Boring
H 51
Machinability
Other information
Turning
Parting and
grooving
Threading
Milling
Drilling
Boring
Tool holding
Machinability
Other information
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.
B
Parting and
grooving
C
Threading
Turning
Milling
~1830F
~1/20 atm
Drilling
~930F
~1/100000 atm
Boring
Thicker coating
Sharper edges
Tougher
Thermal resistant
H 53
Machinability
Other information
Thinner coating
Tool holding
Turning
Parting and
grooving
Visual inspection
Packaging
Threading
Marking
Milling
Labelling
Drilling
Distribution
Gimo
Boring
Tool holding
Machinability
Other information
H 54
Tool holding
Boring
Drilling
Milling
Threading
Parting and
grooving
Machining economy
H 55
Machinability
Other information
Turning
Machining economy
Machining economy
Turning
Productivity definition
C
Threading
= Output / Input
Milling
Drilling
Boring
135
130
120
125
Cost development
Tool holding
115
Machinability
Other information
110
105
100
95
Productivity gap
Price development
H 56
Machining economy
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.
Parting and
grooving
Threading
Milling
Drilling
Boring
G
Tool holding
vf
Q = vc ap fn 12
Q = ap ae vf
H 57
Machinability
Other information
Machining economy
Turning
Parting and
grooving
Metal removal rates for a fixed depth of cut of .118 inch (3.0 mm) using:
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)
Hardness, HB 180
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
H
Machinability
Other information
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)
Machining economy
Turning
Production
60%
Parting and
grooving
Machining 20%
C
Threading
Breakdowns 10%
Holidays, etc.
Workpiece
change 10%
Milling
Machining economy
Drilling
Boring
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 59
Machinability
Other information
Variable costs
Costs incurred only during production:
- cutting tools, consumables (3%)
- workpiece materials 17%.
Machining economy
Turning
Parting and
grooving
Threading
Milling
Decreased cost:
A 30% decrease in price
only reduces total cost per
component by 1%.
Drilling
Boring
Tool holding
Machinability
Other information
H 60
Machining economy
Turning
Parting and
grooving
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
$ 10.00
$ 9.91
$ 9.90
$ 8.55
Milling
Variable
C
Threading
30% 50%
Fixed
Drilling
15%
Boring
1%
G
Tool holding
1%
H 61
Machinability
Other information
Savings
Machining economy
Turning
Machining ecomomy
Parting and
grooving
Threading
Milling
Drilling
Boring
Tool cost
Tool holding
Fixed cost
Machine cost
Machinability
Other information
H
Economic High Efficiency Speed for maximum
speed
Range
production
H 62
Cutting speed
Machining economy
Turning
-A
ll cutting data is based
on 15 min tool life.
10
15
20
25
Correction
factor
1.11
1.0
0.93
0.88 0.84
30
45
60
B
Parting and
grooving
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
-U
se correction factors for
other values according to
the table.
N1 HB2) 75
1.05
1.0 0.95
S2 HB2) 350
1.12
1.0 0.89
H1 HRC3) 60
1.07
1.0 0.97
Drilling
Increased hardness
Boring
-E
.g ISO P HB 180 =
Factor 1.0.
Reduced hardness
ISO/
ANSI MC1) HB2)
G
Tool holding
-A
ll cutting data is based
on the reference materials and the respective
hardness.
H 63
Machinability
Other information
Hardness
Turning
Parting and
grooving
Machining economy
ISO
ISO
ISO
ISO
Threading
Steel, HB180
MC P2
Drilling
Boring
Milling
Tool holding
Machinability
Other information
H 64
K
K
-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
N1 HB2) 75
1.05
1.0 0.95
S2 HB2) 350
1.12
1.0 0.89
H1 HRC3) 60
1.07
1.0 0.97
Parting and
grooving
C
Threading
ISO
Turning
Machining economy
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
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
Boring
- T ensile strength
130,500 lbs/inch2 (900 N/mm2)
Rockwell
G
Tool holding
- DIN 42CrNiMo4
Brinell
H
Machinability
Other information
Customer workpiece
material
Vickers
Milling
D
Tensile strength
Machining economy
Threading
Starting value
Example 2
Milling
Drilling
Example 1
Boring
Example 2
Tool holding
Machinability
Other information
H 66
Parting and
grooving
Turning
Machining economy
Turning
C
orrectly applied, our tools can increase
productivity by at least 20%.
Threading
B
Parting and
grooving
Things to consider
Milling
M
ake use of all available corners on
inserts.
P
roper insert radius in relationship
to D.O.C.
Drilling
S
peeds and feeds within insert
parameters.
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
Machinability
Other information
Machinability
Other information
Tool holding
Boring
Drilling
Milling
Threading
Parting and
grooving
Turning
A
Maintenance & tool wear
H 68
Tool wear
H 69
Maintenance
H 71
Turning
Parting and
grooving
Threading
Milling
Drilling
Damaged inserts
Damaged shims
Damaged components
Boring
Damaged machine
G
Tool holding
Result:
Reduced production
Higher production costs
H 69
Machinability
Other information
D
amaged shims. Shims should not have
chipped corners in the cutting area.
Parting and
grooving
Turning
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.
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
Boring
G
Tool holding
Machinability
Other information
Common sense!
H 70
B
Parting and
grooving
lbs-in (Nm)
Turning
C
Threading
Torx
Milling
Torx Plus
E
Standard Torx
screw
Drilling
G
Tool holding
Boring
H 71
Machinability
Other information
Turning
Parting and
grooving
C
Threading
D
Important!
Milling
Drilling
Tool maintenance
Shim and insert seat
Check shim damage.
C
lean insert seat and damaged location
and support for cutting edge.
Boring
G
Tool holding
It is important to ensure that shim corners have not been knocked off during
machining or handling.
Machinability
Other information
H 72
C
Threading
B
Parting and
grooving
Contact faces
Turning
Tool maintenance
-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
Boring
-S
elect largest possible point angle on
the insert for strength and economy.
H 73
Machinability
Other information
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
Production security
Turning
Insert handling
Inserts
should never be removed from
the original package until they are ready
to be installed.
Parting and
grooving
Threading
Milling
Drilling
tightened.
Tool holding
Machinability
Other information
H 74
Turning
B
Parting and
grooving
Milling
H 78
Drilling
H 80
Boring
H 82
C
Threading
H 76
Milling
Turning
H 84
Boring
Tool holding
H 75
Machinability
Other information
Drilling
Calculator
Turning
Dm n
12
Parting and
grooving
vc =
Threading
n=
vc 12
Dm
Drilling
Boring
Net power, HP
v ap fn kc
Pc = c
33 103
Tool holding
H
Machinability
Other information
lm
fn n
H 76
Unit
Tc =
Designation/
definition
Milling
Symbol
Dm
Machined diameter
inch
fn
inch/r
ap
Cutting depth
inch
vc
Cutting speed
ft/min
Spindle speed
rpm
Pc
Net power
HP
inch3/min
hm
inch
hex
inch
Tc
Period of engagement
min
lm
Machined length
mm
kc
lbs/inch2
Lead angle
degree
Turning
Parting and
grooving
vc =
Dm n
Threading
n=
Dm
Milling
v ap fn kc
Pc = c
60 103
mm/r
ap
Cutting depth
mm
vc
Cutting speed
m/min
Spindle speed
rpm
Drilling
Net power, kW
mm
Pc
Net power
kW
cm3/min
hm
mm
hex
mm
Tc
Period of engagement
min
Boring
Q = vc ap fn
Machined diameter
fn
lm
Machined length
mm
N/mm2
Entering angle
degree
kc
kr
Tool holding
Dm
H 77
Machinability
Other information
lm
fn n
Unit
Tc =
Designation/
definition
Symbol
Turning
Dcap n
12
Milling
fz =
Net power, HP
Tool holding
Boring
Pc =
ae ap vf kc
396 103
Torque, lbf ft
H
Machinability
Other information
vf
n
Mc =
H 78
Pc 16501
n
ae
Working engagement
inch
ap
Cutting depth
inch
Dcap C
utting diameter at cutting
depth ap
Unit
vc 12
Dcap
n=
Designation/
definition
Threading
Symbol
Parting and
grooving
vf = fz n zc
inch
Dm
Machined diameter
(component diameter)
inch
fz
inch
fn
inch
Spindle speed
rpm
vc
Cutting speed
ft/min
vf
Table feed
inch/min
zc
pcs
hex
inch
hm
inch
kc
lbs/inch2
Pc
Net power
HP
Mc
Torque
lbf ft
inch3/min
Lead angle
degree
Turning
B
Parting and
grooving
vf = fz n zc
Cutting speed, m/min
Dcap n
C
Threading
1000
fz =
vf
n
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
mm
Dm
Machined diameter
(component diameter)
mm
fz
mm
fn
mm/r
Drilling
ae
Spindle speed
rpm
vc
Cutting speed
m/min
vf
Table feed
mm/min
zc
pcs
hex
mm
hm
mm
kc
N/mm2
Pc
Net power
kW
Mc
Torque
Nm
cm3/min
kr
Entering angle
degree
Boring
vf
fz =
n zc
n
H 79
Tool holding
D
Unit
vc 1000
Dcap
Designation/
definition
n=
Symbol
H
Machinability
Other information
vc =
Turning
Parting and
grooving
Dc n
Milling
Drilling
vc 12
Dc
Feed force, N
D
Ff 0.5kc c fn sin kr
2
Boring
Q = vc Dc fn 3
Net power, HP
Tool holding
Pc =
vc Dc fn kc
132 103
Torque, lbf ft
H
Machinability
Other information
Dc
Drill diameter
inch
fn
inch/r
Spindle speed
rpm
vc
Cutting speed
ft/min
vf
Penetration rate
inch/min
Ff
Feed force
kc
lbs/inch2
Mc
Torque
lbf ft
Pc
Net power
HP
inch3/min
Lead angle
degree
Unit
12
Threading
vc =
Designation/
definition
Symbol
Mc =
H 80
Pc 16501
Turning
Parting and
grooving
vf = fn n
Dc n
Designation/
definition
Unit
Dc
Drill diameter
mm
fn
mm/r
Spindle speed
rpm
vc
Cutting speed
m/min
vf
Penetration rate
mm/min
Ff
Feed force
kc
N/mm2
Mc
Torque
Nm
Pc
Net power
kW
cm3/min
kr
Entering angle
degree
D
Ff 0.5kc c fn sin kr
2
Net power, kW
G
Tool holding
v Dc fn kc
Pc = c
240 103
Torque, Nm
Mc =
Milling
Feed force, N
Drilling
Dc
Boring
vc 1000
Pc 30 103
n
H 81
Machinability
Other information
Threading
1000
Symbol
vc =
Turning
Parting and
grooving
Dc n
vc =
vc 12
Milling
Dc
Drilling
fn = zc fz
Boring
Q = vc Dc fn 3
Net power, HP
Tool holding
Pc =
vc ap fn kc
132
103
Torque, lbf ft
H
Machinability
Other information
Dc
Drill diameter
inch
fn
inch/r
Spindle speed
rpm
vc
Cutting speed
ft/min
vf
Table speed
inch/min
Ff
Feed force
kc
lbs/inch2
Mc
Torque
lbf ft
Pc
Net power
HP
inch3/min
Lead angle
degree
pcs
Unit
Threading
12
Designation/
definition
Symbol
Mc =
H 82
ap
Dc
zc
Feed force, N
Pc 16501
Ff 0.5 kc ap fn sin r
Turning
Parting and
grooving
vf = fn n
Dc n
Symbol
Designation/
definition
Unit
Dc
Drill diameter
mm
fn
mm/r
Spindle speed
rpm
vc
Cutting speed
m/min
vf
Table speed
mm/min
Ff
Feed force
kc
N/mm2
Mc
Torque
Nm
Pc
Net power
kW
cm3/min
kr
Entering angle
degree
pcs
fn = zc fz
vc Dc fn
4
Net power, kW
Pc =
vc ap fn kc
60 103
Torque, Nm
Mc =
ap
Dc
zc
Feed force, N
Pc 30 103
Milling
Drilling
Dc
Boring
n=
Tool holding
Threading
1000
Ff 0.5 kc ap fn sin r
H 83
Machinability
Other information
vc =
Calculator
Turning
Parting and
grooving
Threading
The Sandvik Coromant cutting data calculator is designed to solve most calculation
problems encountered in the metal cutting
area.
Milling
Size 80x125x15 mm
Drilling
Boring
Machinability
Other information
Tool holding
H 84