Workpiece Material: D2 Workpiece Hardness: HRc Workpiece Tolerance: " Surface Finish Tolerance: Ra 16 µin

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2 Workpiece Material: D2 Workpiece Hardness: HRc Workpiece Tolerance: " urface Finish Tolerance: Ra 16 µin

3 Technical Info. Index Welcome to the vast product fering from Becker Diamond Germany. To achieve optimum application success, closely follow the enclosed selection checklists. Maximum machining permance Becker products is achieved through a calculated selection required materials, proper macro edge geometries. lease be advised that machining Becker tools will be significantly different from what you have become accustomed to normal carbide tooling. Due to the physical properties the Becker materials, the range micro edge geometries, it is important that you completely rethink your machining approach when determining selection criteria. When selecting the Becker grades from our comprehensive range, a complex permance prile the machining result is required. Due to the different variations tipped corner styles, macro micro edge geometries, careful preplanning is required to ensure that the best tool is selected the given application. The overall machining system should also be reconsidered in order to achieve full permance from the Becker product. Use the most rigid accurate tooling systems available. Machinery equipment should be compatible the machining tasks. articular attention must be paid to the general rigidity, the slideways, spindles workholding systems. When all working parameters are optimized, you can achieve surface finishes in a nanometer range as a stard using Monocrystalline Diamond non ferrous metals CB hard hardened steel. Using our Ultrahard Cutting Materials election Criteria... page 3 Check List Determining the Cutting Materials Grades (i.e. Hard Cutting)... page 3 Workpiece Material Groups (DI IO 513)... page 4 Groups Cutting Materials... page 5 Range Application (DI IO 513) For Material Groups,, M,K,,, H... page 6 Designation Tipped Inserts, IO, BECKER Comparison... page 7 Variations Tipped Corners all Ultrahard Cutting Materials... page 8 & 9 Wear Resistance Toughness, Comparison all our Ultrahard Cutting Materials... page 10 ositive Top Rake Geometries... page 11 IO Insert omenclature... page 12 & 13 Flank Wear Characteristics our Ultrahard Cutting Materials... page 14 Cutting Edge Geometry & urface Finish urface Roughness Rt & Feed Rates... page 15 Ultrahard Cutting Materials Grades Materials ermance... page 16 & 17 Cutting Data Turning : intered teel, owdered Alloys... page 18 Cutting Data Turning K: Cast Iron, Grey & odular Cast Iron... page 19 Cutting Data Turning : onferrous Metals & onmetallics... page 20 & 21 Cutting Data Turning : uperalloys & Titanium... page 22 Cutting Data Turning H: Hard Materials... page 23 & 24 Cutting Data Milling K: Cast Iron, Grey & odular Cast Iron... page 25 Cutting Data Milling : onferrous Metals & onmetallics... page 26 & 27 Cutting Data Milling H: Hard Materials... page 28 Trouble hooting CD Applications... page 29 Trouble hooting CB Applications... page 30 2

4 Using our Ultrahard Cutting Materials election Criteria Check List Determining the Cutting Materials Grades (i.e. Hard Cutting) 1.) Determine the material group as per DI IO page 4 2.) Determine the range application your material group as per DI IO page 6 3.) Then determine the data your area application based on the surface quality required, machining application... page ) Check your selection material based on the grade description... page ) Determine the correct insert type including tipped corner style... page 89 6.) Based on nose radius finish requirements, determine feed rate... page 15 Example: Turning casehardened steel HRc 62 ap=0.01", cut in stable circumstances, a surface quality Ra=24µ" must be achieved (At Ra=24µ" the overall machining environment must be checked suitability) 1st tep Material group H 2nd tep Range application H20 Choose material spec. hardness on page 4 3rd tep Cutting material: B40 (T) at Vc= FM ap=.01" Based on depth cut, choose your range application on page 6 4th tep ose radius required Theoretical urface Roughness Corner Radius Feed Rate (f=inch/rev) Ra µin Rt µin r =.008 r =.016 r =.031 r =.047 r = With application range finish in mind, choose grade specs. range on page 23 With corner radius in mind, choose feed rate required on page 15 * lease note that these recommendations are guidelines based on rigid part setup, good machine rigidity, general machining practices. 3

5 Workpiece Material Groups (DI IO 513) Identification letter & colour M K H Main Materials teel intered powdered Range applications tainless teel ** Cast Iron Grey Cast Iron GG 10 GG 35 odular Cast Iron GGG 40 GGG 40.3 GGG 50 GGG 60 GGG 70 onferrous Metals onmetallics Aluminum, Low + Highilicon Aluminum, MMC's, Magnesium, CopperCopper, Brass, Bronze, recious metals, lastics, GR, CR, Carbon Graphite composits, Ceramics other highabrasive onmetallics uper Titanium: Heat resistant special based on ickel or Cobalt, Titanium Titanium Hard Materials: Carburized or fully hardened steels from 48 to 65 HRc H, tool steel, 300 & 400 series stainless cold hot work steel, spring steel, ballbearing steel, chilled cast iron, chilled cast iron rolls, chilled cast iron, hardfacing sintered carbide K01 K01 K05 K05 K05 K10 K H01 H01 H01 H01 H05 H05 H05 H K25 K25 K20 K20 K40 K35 K H20 H25 H35 H40 H15 H25 H30 H40 IO BECKER Grade BC17 BC15 B10 BC1 CB or CD not suitable this application range. For stainless steels above 48 HRc, refer to application range H BC10 BC15 BC17 BC25 B10 B25 BC1 DM D D D DCL DC DC BC10 BC15 DM B10 BC25 BC1 BC40 BC25 B40 B25 BC17 BC30 BC20 BC1 4

6 Groups Cutting Materials As per DI IO 513 (2001) there are now additional identification letters carbide (also cermet) ceramic. Furthermore new identification letters the ultrahard materials olycrystalline Cubic Boron itride, Monocrystalline olycrystalline Diamond have been introduced. Groups materials (DI IO 513) HW= HF= HT= HC= CA= CM= C= CR= CC= DM= D= = = BC= Uncoated carbide Fine grained carbide Cermet, TiC, or Ti As above, but coated Ceramic, main content Al O 2 3 Mixed ceramic, main content Al O, plus components other than oxides 2 3 iliconnitride ceramic, main content i 3 4 Ceramic, main content Al O, 2 3 Ceramics as above, but coated Monocrystalline Diamond olycrystalline Diamond olycrystalline Cubic Boron itride low content CB olycrystalline Cubic Boron itride high content CB olycrystalline Cubic Boron itride as above, but coated 5

7 6 Range Application (DI IO 513) Material Groups, K,,, H

8 Designation tipped inserts IO BECKER Comparison IO BECKER Designation Design Amount tipped corners A EW MW MC DC 1 tipped corner, carbide A EW MC 1 tipped corner, solid grades C *** 2 tipped corner, carbide D C CM 1 tipped edge, solid grades F VM Full face E *** Double sided full face BC B olid 7

9 8 Variations Tipped Corners all Ultrahard Cutting Materials IO BECKER Designation esign D n descriptio ip T e rad G O I A EW MW grades, CB Carbide CB thickness.039".024 = layer BC15, BC10, BC17 BC25 BC20, BC40 BC30, 2 A C M grades, CB Carbide CB thickness.039".024 = layer BC15, BC10, BC17 BC25 BC20, BC40 BC30, 3 A C M grades, CB Carbide CB thickness.039".024 = layer BC15, BC10, BC17 BC25 BC20, BC40 BC30, A DCL DC DC grades CD Carbide DC DCL, DC D D 3 A C M s grade CD Carbide DC DCL, DC D D A EW grades CB olid reincement out B10 BC1, B40 B25, 2 A MCgrades CB olid reincement out B10 BC1, B40 B25, A C MD grade Diamond Monocrystalline olid reincement out DC M M D D Cgrades CB olid reincement out B10 BC1, B40 B25,

10 9 Variations Tipped Corners all Ultrahard Cutting Materials IO BECKER Designation esign D n descriptio ip T e rad G O I 2 D M Cgrades CB olid reincement out B10 BC1, B40 B25, 3 D M Cgrades CB olid reincement out B10 BC1, B40 B25, 4 D M Cgrades CB olid reincement out B10 BC1, B40 B25, F M V grades, CB Carbide Fullface BC15, BC10, BC17 BC25 BC20, BC40 BC30, F M V grades DC Carbide Fullface DC DC, D BC B grades CB olid reincement out B10 BC1, B40 B25, ** BCG BG grades CB olid edge whole reincement out B10 BC1, B40 B25, * * BCG grades CB Carbide edge whole BC15, BC10, BC17 BC25 BC20, BC40 BC30, ** DCG DCG grades DC Carbide edge whole DC DC, D

11 10 Wear Resistance Toughness, Comparison all our Ultrahard Cutting Materials

12 11 ositive Top Rake Geometries Rake op T s dvantage A e Disadvantag insert negative 1) (R/L) angle rake positive 2) edge sharp 3) Materials: Cutting speed high very 1) cut depth large 2) pressure no 3) burrfree absolutely 4) limits tolerance small very 5) life tool high very 6) surface reduction little 1) positive by caused finish angle rake insert positive 1) (R/L) angle rake positive 2) edge sharp 3) Materials: Cutting DC DC depth large extremely 1) cut pressure low 2) burrfree 3) limits tolerance small 4) surface reduction little 1) positive by caused finish angle rake insert positive 1) () angle rake positive 2) edge sharp 3) Materials: Cutting boring DC BC pressure low 1) burrfree 2) limits tolerance small 3) overhang high 4) speed high 5) surface reduction little 1) positive by caused finish angle rake insert positive 1) () angle rake positive 2) edge sharp 3) Materials: Cutting BC DC, DC, pressure low 1) burrfree 2) limits tolerance small 3) speed high 4) surface reduction little 1) positive by caused finish angle rake insert negative 1) () angle rake positive 2) edge sharp 3) Materials: Cutting B BC, cut depth great 1) pressure low 2) limits tolerance small 3) speed high 4) surface reduction little 1) positive by caused finish angle rake

13 12 IO Insert omenclature

14 IO Insert omenclature 13

15 Flank Wear Characteristics our Ultrahard Cutting Materials 1) Monocrystalline Diamond (DM) Monocrystalline diamond is the hardest known mineral. It s outsting abrasive hardness highest homogeneity enable the manufacture ultra sharp notch free micro edge qualities, (as it is ground from a single crystal) not achievable using other materials. The sharpness the edge produces a slight pressure out any heat generated during machining. The unsurpassable wear resistance retains the perfect micro edge quality over an extremely long tool life. cannot be used on aluminium fillers. 2) CD olycrystalline Diamond (D) The core structure (ultrafine to coarse grain) the olycrystalline Diamond provides a higher toughness, yet lower wear resistance reduced micro edge quality than Monocrystalline Diamond. The reaction behaviour is identical, yet the higher toughness extends the application range considerably. Materials a low to very high content (from 2% to 70%) abrasives fillers can be machined excellent tool life. 3) CB olycrystalline Cubic Boron itride ( ) olycrystalline Cubic Boron itride is the second hardest material next to Diamond, however, it has far less in common Diamond. Reaction resistance reaches 1,250 C which makes this material have a very high wear resistance, toughness, compression strength thermal hardness ideal selfinduced hot mode hardened steels. Flank Wear Ultrahard Cutting Materials Flank wear has a significant influence on the life all tools. Due to the excellent flank wear resistance all Becker materials, they are clearly superior to conventional materials in many fields. Typically, the Becker product will exhibit negligible flank wear if any at all, thereby resulting in extremely long tool life. The following drawing shows the difference tool life under the same machining conditions inserts a clearance angle 7 respectively 11. Tool life the insert 11 angle will be 1.6 times longer than that 7 bee they reach the same width flank wear. The following aspects should be taken into account in order to choose the adequate edge geometry. Under normal working conditions, abrasion will usually cause a certain degree flank wear. Mono polycrystalline diamonds, however, are susceptible to abrasion caused by oxidation at a heat exceeding 650 C. The cause flank wear is due to the extremely high thermal conductivity diamonds. It is theree recommended to select the smallest possible clearance angle all diamond tools (if mation burrs is no importance). This selection will increase passive pressure, leading to a better surface finish. In contrast, CB s low thermal conductivity flank wear is usually not only caused by abrasion, but also oxidation, diffusion, or adhesion, when applied high speed (HC) also selfinduced hot mode hardened steel. With this point in mind, the correct clearance angle external internal turning is pivotal regards to the friction between flank the work piece. The passive pressure the temperature it is reaching can be controlled not only by the clearance angle, but also by the micro edge geometry. In order to obtain maximum tool life, interaction those facts must be considered. 14

16 Cutting Edge Geometry & urface Finish urface Roughness Rt & Feed Rates One can simply calculate the theoretical surface roughness Rt also known as R max Rz. (In practice it usually runs up to four times the Ra value). The theoretical value, however, is again based on a perfect edge geometry a wide minor edge angle. Using Becker CD when machining nonferrous metals nonmetallics or CB grey cast iron results in hardly any flank wear or demation the edge due to the excellent flank wear resistance our tools. It is theree possible to complete the precise data the required surface roughness, provided the environment in itself will not hamper the machining as such. In practice, the values roughness will typically be less than the theoretical calculation when hard CB. This is due to a simple reason: the process itself is influenced by self induced hot mode which can cause an extremely high passive pressure. Theoretical urface Roughness Corner Radius Feed Rate (f=inch/rev) Ra µin Rt µin r =.008 r =.016 r =.031 r =.047 r = The practical application proves that the theoretically calculated value can hardly be achieved, since the environmental conditions tend to be imperfect. Unstable machining conditions, incorrect workholding, chucking, faulty or wrong tool system, wrong speed depth cut etc. will impair the results. Conversely, working towards near perfect working conditions can result in an improved surface finish due to improved optimized edge geometries. In particular, the general reduction the minor edge angle, as well as the microgeometries, CB ( more pressure) should be mentioned. In order to obtain the various stages excellent surface finishes while hard, the Tl styles are great influence. For a mirrorfinish surface nonferrous metals nonmetallics, Becker is able to supply even inserts a TL, if necessary. With regards to highpermance all types, Becker has developed a variety inserts WIER geometry internal, external milling processes. The WIER edge replaces the abovementioned minor edge, reducing its angle to a minimum, thereby reducing the theoretically computed surface roughness by 2 to 4 times. In practice this is the alternative highpermance hightech : 1) 24x higher feed rate = same surface finish 2) same feed rate = 24x improved surface finish Wiper inserts are available : FormCut MonoCut MiniCut IOHardCut In addition to the improvements gained in productivity by decreased flank wear, Becker products will result in significant gains in product quality. 15

17 16 Ultrahard Cutting Materials Grades Materials ermance rades G O I e ermanc omposition C n Applicatio CD & Diamond olycrystalline Mono DC M M D Cutting structure. no diamond monocrystalline olid microdamages, out sharp extremely is edge results burrfree allowing pressure, no generating resistant wear flank Extremely zero. to close tolerances low toughness. conductivity, maximum thermal pure all uperfinishing non metals nonferrous abrasive no metallics silicon. or reincement Tech) High (HC DCL D grit ultrafine diamond carbide olycrystalline, pressure minimal sharpness, edge high size, resistance wear flank Good tolerances. close allowing toughness. nonferrous pure all Finishing nonmetallics materials abrasive verylow content silicon. or reincement DC D size, grit fine diamond carbide olycrystalline, pressure low sharpness edge good resistance wear flank Increased tolerances. close allowing toughness. purpose general Finishing metals nonferrous all low content nonmetallics silicon. or reincement abrasive DC D size, grit coarse diamond carbide olycrystalline allowing pressure low sharpness edge good flank High milling. permances Best tolerances. close toughness. resistance wear purpose general Finishing, nonmetallics all milling content high medium to silicon. or reincement abrasive CB Content High itride Boron Cubic olycrystalline BC1 H B high grade itride Boron Cubic polycrystalline olid Designed size. medium grit CB content stability, thermal resistance, wear flank exceptional roughing toughness strength compression HC. HC iron. cast grey finishing iron cast Grey iron cast Chilled ihard uper powdered intered B10 H B high grade itride Boron Cubic polycrystalline olid HC HC, size. grit fine CB content excellent causing (GG 25) iron cast grey superfinishing toughness. resistance flankwear iron cast Grey GG25 uper powdered intered BC10 H B grade itride Boron Cubic carbide olycrystalline flank perfect size, grit fine CB content high superfinishing HC toughness. resistance wear. super finishing (GG25) iron cast grey iron cast Grey GG25 uper powdered intered BC15 H B grade itride Boron Cubic carbide olycrystalline favourable The size. grit fine CB content high wear flank good very, powdered sintered grade toughness. resistance iron cast Grey uper powdered intered BC17 H B grade itride Boron Cubic carbide olycrystalline excels grade This size. grit fine CB content high purpose general application: fields main two in hardened hard iron, cast nodular finishing coolant. flood using 4854) (HRc steel iron cast odular GGG70) (GGG40 Hard 54) 48 (HRc powdered intered

18 17 Ultrahard Cutting Materials Grades Materials ermance rades G O I e ermanc omposition C n Applicatio CB Low Content itride Boron Cubic olycrystalline BC20 L B grade itride Boron Cubic carbide olycrystalline Engineered size. grit fine CB low content highest when 65) 56 (HRc steel hardened hard in permance Good 32µin. 8µin (Ra crucial is finish surface. as well as interruptions heavy steels Hardened 65) 56 (HRc dry 32µin 8µin Ra.020".006" ap= B25 L B low content itride Boron Cubic olycrystalline olid strength, compression Highest size. grit fine CB (HRc hard when resistance wear flank toughness Thermal.079")..012" = (ap cut. depth high 5665) uitable attained. cut st a reduced is conductivity Also. heavy as well as speed. low very a at iron cast grey finishing steels Hardened 65) 56 (HRc dry 125µin 32µin Ra.079".012" ap= iron cast Grey sfm) (Vc BC25 L B itride Boron Cubic carbide olycrystalline wear Excellent size. grit fine CB low content hard toughness strength compression resistance, purpose General 5462) (HRc. 32µin Ra finish surface at slightly low very a at iron cast grey finishing Also, 125µin. speed. steels Hardened 65) 56 (HRc dry 125µin 32µin Ra.016".003" ap= iron cast Grey sfm) (Vc BC30 L B itride Boron Cubic carbide olycrystalline wear Excellent size. grit fine CB low content hard toughness strength compression resistance, uitable coolant) flood applying (HRc. finish surface at heavily 63µin. 32µin Ra steels Hardened 65) 56 (HRc coolant flood 63µin 32µin Ra.016".003" ap= B40 L B low content itride Boron Cubic olycrystalline olid resistance, wear Extreme size. grit ultrafine CB hard dry toughness strength compression cut. depth lower rates feed higher at 65) 56 (HRc. slightly at cut st Very steels Hardened 65) 56 (HRc dry 32µin 8µin Ra.060".012" ap= BC40 L B low content itride Boron Cubic olycrystalline olid dry resistance wear erfect size. grit ultrafine CB cut. low depth rates feed higher at hard. slightly Continuous steels Hardened 62) 56 (HRc dry 63µin 32µin Ra.012".002" ap=

19 Cutting Data Turning : intered teel, owdered Turning Materials tee l sintere d powdered Conditions chip removal Turning R ange application V c s ee page s ee page (HC ) see page 6 Vc: FM Vc: F M Vc: F M BC15 (T) BC15 (T ) BC15 (T ) BC15 (T ) BC10 (T ) BC1 (T ) B10 (T ) BC1 (T ) BC15 (F) BC15 (F ) BC15 (T ) BC1 (T ) BC15 (T ) BC17 (T ) BC1 (T ) BC1 (T ) BC1 (T ) BC17 (F) BC17 (T ) BC10 (F ) BC15 (T ) BC17 (T ) B10 (T ) BC15 (T) BC15 (T ) BC15 (T ) BC1 (T ) BC1 (T ) BC17 (T ) BC1 (T ) BC1 (T ) BC1 (T ) BC10 (T) BC10 (T ) BC17 (T ) B10 (T ) B10 (T ) CB Grades, osition 1: T= (TL) rimary Choice turning, osition 2: F= (harp) Alternate Choice turning only 18

20 Cutting Data Turning K: Cast Iron, Grey & odular Cast Iron Turning Materials C ast iron s K cas t (grey iron) GG10 GG15 GG20 C ast iron s K cas t (grey iron) GG25 GG30 GG35 ast iron s K C cas t (nodular iron) GGG40 GGG50 GGG60 GGG70 Conditions c hip removal R ange application K01 K4 0 V c K 01 K15 s ee page 6 K 10 K2 5 s ee page 6 K 20 K40 (HC+HC ) see page 6 Turning Vc: FM Vc: F M Vc: F M BC15 (T) BC15 (T ) BC25 (T ) BC15 (T ) BC15 (T ) BC25 (T ) BC1 (T ) B10 (T ) B25 (T ) BC10 (F) BC10 (F ) BC10 (F ) B10 (T ) BC1 (T ) BC15 (F) BC15 (T ) BC25 (F ) BC10 (T ) BC10 (F ) BC25 (F ) BC1 (T ) B10 (T ) B25 (T ) BC10 (F) BC10 (F ) B10 (T ) B10 (T ) BC1 (T ) BC15 (T) BC15 (T ) BC25 (T ) BC10 (T ) BC10 (T ) BC25 (T ) BC1 (T ) BC1 (T ) B25 (T ) BC10 (T) BC10 (T ) B10 (T ) B10 (T ) B10 (T ) BC15 (T) BC15 (T ) BC25 (T ) BC15 (T ) BC15 (T ) BC25 (T ) B10 (T ) B10 (T ) B25 (T ) BC10 (F) BC10 (F ) BC10 (T ) BC1 (T ) BC1 (T ) BC10 (F) BC10 (F ) BC25 (F ) BC10 (T ) BC15 (T ) BC25 (F ) B10 (T ) BC1 (T ) B25 (T ) BC10 (F) BC10 (F ) BC25 (T ) BC1 (T ) B10 (T ) BC10 (T) BC10 (T ) BC25 (T ) BC10 (T ) BC10 (T ) BC25 (T ) BC1 (T ) BC1 (T ) B25 (T ) B10 (T) B10 (T ) B10 (T ) BC17 (T) BC17 (T ) BC1 (T ) BC17 (T ) BC1 (T) BC1 (T) BC17 (F ) BC1 (T ) BC17 (F ) BC1 (T ) BC17 (T ) BC17 (T) BC17 (T ) BC1 (T ) T= BC1 (T) BC17 (T ) BC1 (T ) BC17 (T ) BC1 (T ) BC17 (T ) CB Grades, osition 1: (TL) BC15 (T) BC15 (T ) BC1 (T ) rimary Choice turning, osition 2: F= (harp) Alternate Choice turning only 19

21 Cutting Data Turning : onferrous Metals & onmetallics Turning Materials onferrou s metal s Aluminum silicon out onferrou s metal s Aluminum than 12% less silicon onferrou s metal s Aluminum more than 12% silicon Conditions chip removal Turning (highspeed) R ange application Rt + V c (HC) s ee page (HC ) s ee page (HC+HC ) see page 6 3.2µin R t (Rz) µ R t (Rz) µ Rt (Rz) µ 400µin 3.2µin 400µin 3.2µin 400µin D C D C MD C D C D C MD C D C D C M DC DC L D C M D C DC L D C M D C DC L D C D C D C MD C D C D C MD C D C D C DC DC DC DC DC DC D C DC D C DC D C DC DC DC DC DC DC DC DC DC DC DC DC DC DC DC DC DC Coolant: when Air (plastics) or out flood coolant cooling, the (metals), it is surface finish, tool life only however, is that is reduced not affected. 20

22 Cutting Data Turning : onferrous Metals & onmetallics Turning Materials onferrou s metal s Copper copper brass, bronze, precious metals on metallic s pure plactics out re incement on metallic s plastics re incement (ie/ GR, CR) Conditions c hip removal R ange application Rt + V c Turning (highspeed) 3.2µin (HC) s ee page (HC ) s ee page (HC+HC ) see page 6 R t (Rz) µ R t (Rz) µ Rt (Rz) µ 400µin 3.2µin 400µin 3.2µin 400µin DC L D C MD C D C DC MD C D C DC M DC DC L D C M D C DC L DC M D C D C DC D C D C MD C D C DC MD C D C DC M DC DC L D C M D C DC L D C M D C DC L D C DC L D C MD C DC L D C MD C DC L D C M DC DC L D C M D C DC L D C M D C DC L D C DC MD C DC DC DC DC M DC DC M D C DC DC DC DC DC MD C DC DC DC Coolant: when Air (plastics) or out flood coolant cooling, the (metals), it is surface finish, tool life only however, is that is reduced not affected. 21

23 Cutting Data Turning : uperalloys & Titanium Turning Materials uper heat resistant nickel base Inconel 718, imonic, Hastelloy, Waspaloy uper titanium titanium Conditions c hip removal R ange application V c s ee page s ee page see page 6 Turning Vc: FM Vc: F M Vc: F M BC15 (T) BC25 (T ) BC15 (T ) BC25 (T ) B10 (T ) B25 (T ) BC15 (F) BC10 (F ) BC20 (F ) BC10 (F ) BC15 (T ) B10 (T ) B10 (T ) BC15 (F) BC25 (F ) BC15 (T ) BC10 (T ) B25 (T ) BC15 (T) BC10 (T ) BC10 (T ) BC1 (T ) BC10 (T ) BC10 (T ) BC1 (T ) BC1 (T ) B10 (T ) BC15 (T) BC15 (T ) BC1 (T ) BC25 (T) BC25 (T ) T= CB Grades, osition 1: (TL) MD C DC MD C MD C DC B25 (T ) DC BC1 (T ) DC BC1 (T ) BC25 (T ) BC25 (T) B25 (T ) rimary Choice turning, osition 2: F= (harp) Alternate Choice turning only 22

24 Turning Cutting Data Turning H: Hard Materials Materials H H ar d material s hardened steel HRc 4854 hard turning H H ar d material s hardened steel HRc 5460 hard turning H H ar d material s hardened steel HRc 5865 hard turning Conditions c hip removal R ange application H01 H4 0 Ra + V c H 01 H15 s ee page 6 H 05 H2 0 s ee page 6 H 20 H40 (HC ) see page 6 Turning Ra µin Ra µi n Ra µi n BC25 (F) BC25 (F ) B25 (F ) B40 (T) BC17 (T ) BC25 (F ) B40 (T ) BC17 (T ) BC25 (F ) BC20 (T ) B40 (T ) B25 (T ) BC20 (T) BC17 (T ) BC25 (T ) BC20 (T ) BC17 (T ) BC25 (T ) BC20 (T ) B40 (T ) B25 (T ) BC30 (T) BC25 (F ) BC30 (T ) BC25 (F ) B25 (T ) B25 (F ) B40 (T) BC40 (T ) BC40 (F ) B40 (T ) B25 (T ) BC40 (F ) B40 (T ) B25 (T ) B25 (T ) BC20 (T) B40 (T ) BC25 (T ) BC20 (T ) B25 (T ) BC25 (T ) BC20 (T ) B25 (T ) B25 (T ) BC40 (T) BC25 (T ) BC30 (T ) BC25 (T ) B40 (T ) B25 (T ) B40 (T) BC40 (T ) BC25 (T ) B40 (T ) BC30 (T ) BC25 (T ) B40 (T ) B40 (T ) B25 (T ) BC20 (T) BC30 (T ) BC25 (T ) BC20 (T ) BC30 (T ) BC25 (T ) BC20 (T ) B25 (T ) B25 (T ) T= (TL) turning, F= (harp) turning only 23

25 Cutting Data Turning H: Hard Materials Turning Materials H H ar d material s Chilled cast irons chilled cast iron rolls chilled cast iron ihard H H ar d material s hardfacing H ar d H s material sintered c arbid e Conditions c hip removal R ange application H01 H4 0 V c H 01 H15 s ee page 6 H 05 H2 0 s ee page 6 H 25 H40 (HC ) see page 6 Turning Vc: FM Vc: F M Vc: F M B10 (T) B10 (T ) BC1 (T ) BC1 (T ) BC1 (T ) BC1 (T ) BC1 (T ) B10 (T) B10 (T ) BC1 (T) BC1 (T ) BC1 (T ) BC1 (T ) BC1 (T ) BC1 (T ) BC1 (T ) BC1 (T ) B10 (T) B10 (T ) BC1 (T) BC1 (T ) BC1 (T ) BC1 (T ) BC1 (T ) BC1 (T ) BC10 (T) B10 (T ) BC10 (T ) B10 (T ) B10 (T ) B10 (T ) B25 (T) DC BC1 (T ) BC1 (T) BC1 (T ) CB Grades, osition 1: T= (TL) rimary Choice turning, osition 2: F= (harp) Alternate Choice turning only 24

26 Cutting Data Milling K: Cast Iron, Grey & odular Cast Iron Highpeed Milling Materials Conditions c hip removal R ange application K01 K4 0 V c C ast iron s K cas t (grey iron) GG10 GG15 GG20 Highspeed milling K 01 K15 (HC) s ee page 6 K 10 K25 (HC ) s ee page 6 K 20 K40 (HC+HC ) see page 6 Vc: FM Vc: F M Vc: F M BC1 (T) BC1 (T ) BC1 (T ) BC10 (T) BC17 (T ) BC25 (T ) BC10 (T ) BC17 (T ) BC25 (T ) BC1 (T ) BC25 (T ) BC15 (T) BC1 (T ) BC10 (T ) BC10 (T) BC17 (T ) BC25 (T ) BC1 (T ) BC17 (T ) BC25 (T ) BC1 (T ) BC25 (T ) BC15 (T) BC10 (T ) BC10 (T ) C ast iron s K cas t (grey iron) GG25 GG30 GG35 ast iron s K C cas t (nodular iron) GGG40 GGG50 GGG60 GGG70 BC15 (T) BC15 (T ) BC1 (T ) BC10 (T) BC17 (T ) BC25 (T ) BC10 (T ) BC25 (T ) BC1 (T ) BC25 (T ) BC15 (T) BC1 (T ) BC10 (T ) BC10 (T) BC17 (T ) BC25 (T ) BC1 (T ) BC25 (T ) BC1 (T ) BC25 (T ) BC15 (T) BC10 (T ) BC10 (T ) BC17 (T) BC25 (T ) BC1 (T ) BC17 (T ) BC1 (T ) BC17 (T ) BC17 (T) BC1 (T ) BC17 (T ) BC1 (T ) BC17 (T ) CB Grades, osition Milling: 1: rimary Choice osition out coolant, Tl version 2: Alternate only Choice 25

27 Cutting Data Milling : onferrous Metals & onmetallics Highpeed Milling Materials Conditions c hip removal R ange application Rt + V c onferrou s metal s Aluminum silicon out Highspeed milling 3.2µin (HC) s ee page (HC ) s ee page (HC+HC ) see page 6 R t (Rz) µ R t (Rz) µ Rt (Rz) µ 400µin 3.2µin 400µin 3.2µin 400µin DC DC MD C DC DC MD C DC DC M DC DC DC M D C DC DC M D C DC DC DC DC MD C DC DC MD C DC DC onferrou s metal s Aluminum than 12% less silicon DC DC DC DC DC DC DC DC DC DC DC DC DC DC DC DC DC DC onferrou s metal s Aluminum more than 12% silicon Coolant: when Air (plastics) or out DC DC DC DC DC DC DC DC DC flood coolant cooling, the (metals), it is surface finish, tool life only however, is that is reduced not affected. 26

28 Cutting Data Milling : onferrous Metals & onmetallics Highpeed Milling Materials Conditions c hip removal R ange application Rt + V c onferrou s metal s Copper copper brass, bronze, precious metals Highspeed milling 3.2µin 80µin (HC) s ee page (HC ) s ee page (HC+HC ) see page 6 R t (Rz) µ R t (Rz) µ Rt (Rz) µ on pur e metallics plastics reout DC MD C DC MD C DC incement (i.e. plexiglass) 400µin 3.2µin 80µin 400µin 3.2µin 80µin DC MD C DC MD C DC M DC DC M D C DC M D C DC M DC DC M D C DC M D C DC DC MD C DC MD C DC M DC DC M D C DC M D C DC µin on metallic s plastics re incement (i.e. GR, CR) Coolant: when DC DC DC DC DC DC DC DC DC Air (plastics) or out flood coolant cooling, the (metals), it is surface finish, tool life only however, is that is reduced not affected. 27

29 Cutting Data Milling H: Hard Materials Highpeed Milling Materials Conditions c hip removal R ange application H01 H4 0 Ra + V c H H ar d material s hardened steel HRc 5460 hard milling Highspeed milling H 01 H15 s ee page 6 H 05 H2 0 s ee page 6 H 20 H40 (HC ) see page 6 Ra µin Ra µi n Ra µi n B40 (T) BC17 (T ) BC25 (T ) B40 (T ) BC17 (T ) BC25 (T ) B25 (T ) B25 (T ) BC20 (T) BC30 (T ) BC25 (T ) BC20 (T ) BC30 (T ) B25 (T ) B25 (T ) B25 (T ) H H ar d material s hardened steel HRc 5865 hard milling B40 (T) BC17 (T ) BC25 (T ) B40 (T ) BC17 (T ) B25 (T ) B25 (T ) B25 (T ) BC20 (T) BC30 (T ) BC25 (T ) BC20 (T ) BC30 (T ) B25 (T ) B25 (T ) B25 (T ) T= CB Grades, osition (TL) 1: rimary Choice turning, osition 2: F= (harp) Alternate Choice turning only 28

30 Trouble hooting CD Applications Trouble hooting CD Applications roblem Cause uggested Action V ibration 1. Check rigidity tool & setup oor surface quality T oo high feed rate 2. Lower feed rate, increase nose radius or change to wiper W rong grade 3. Choose finer grain size remature wear W rong speed 1. Decrease speed (Check data tables) W rong grade 2. Choose coarser grain size V ibration 1. Check rigidity tool & setup Edge chipping W rong data 2. Check speeds & feeds in data you application W rong grade 3. Choose coarser grain size Tip dislodging 1. Increase coolant to tip Excessive temperature 2. Decrease speed 3. Reduce depth cut In addition to the recommendations in this catalogue, the 4. Increase tip size Rigid machines setups Minimum tool over hangs Choose most positive edge angle possible Use coolant metalics Use air nonmetalics following general rules apply to CD applications: 29

31 Trouble hooting CB Applications Trouble hooting CB Applications roblem Cause uggested Action V ibration 1. Check rigidity tool & setup oor surface quality T oo high feed 2. Lower feed rate, increase nose radius or change to wiper T oo sharp insert 3. Increase chamfer angle W rong grade 4. Choose finer grain size W rong speed 1. Increase speed (Check data tables) remature wear T oo sharp insert 2. Increase chamfer angle W rong grade 3. Choose finer grain size V ibration 1. Check rigidity tool & setup Edge chipping I nterruption 2. Increase chamfer angle hone W rong grade 3. Choose coarser grain size oor setup 1. Check rigidity tool & setup T oo light feed 2. Increase feed / or D.O.C. Vibration T oo much pressure 3. Choose more positive insert geometry / edge angle I mproper edge prep 4. Reduce chamfer angle T oo much pressure 5. Reduce nose radius In addition to the recommendations in this catalogue, the Rigid machines setups Minimum tool over hangs Choose largest edge angle possible egative inserts wherever possible following general rules apply to CB applications: 30