Alloy Steel Application Material Group

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1 Alloy Steel Application Material Group

2 General Information Examples of Workpiece Materials - Categorisation into Application Material Groups (AMG) Application Material Group (AMG) Hardness Tensile HB Strength N/mm 2 Normal Chip Form EN Werkstoff DIN Number 1.4 Alloy steel <250 <850 long EN CrMo 4 EN , , CrMo4, 100Cr6, 34CrNiMo6, S Alloy steel/hardened and tempered steel >250 <350 >850 <1200 long EN ISO HS6-5-2 EN ISO HS Alloy steel/hardened and tempered steel >350 >1200 <1620 long EN ISO HS , , , , , , MnCrW12, 55NiCrMoV6, X210Cr12, S MnCrW12, X210Cr12, S Application Material Group (AMG) BS SS USA UNS JIS 1.4 Alloy steel 708M40/42, 817M40 534A99, BM2, BT , , , A2, 4340 M42, M2 G41270, G41470 T30102, T11342 SCM4, SCM5 1.5 Alloy steel/hardened and tempered steel B01, BM2, BT42, 826 M40, 830M , , 2550, 2722, , L6, M42, D3, A2 M2, 4140, 8630 G86300, T30102 T11302, T30403, T11342 SKD2, SKD1 1.6 Alloy steel/hardened and tempered steel M40, 830M , , HARDOX , L6, M42, D3, 4140, 8130 T30403, G41400, J14047 SKD2, SKD1 2

3 Contents Classification of workpiece materials 2 Application Material Groups 4 Introduction to Alloy Steels 5 Machinability of Alloy Steels 6 Hints when machining Alloy Steels 6 AMG AMG AMG General Hints on Drilling 10 Drill Feed Chart 11 Drill Selection 12 General Hints on Tapping 14 Drill diameters for cutting taps 15 Tap Selection 16 General Hints on Milling 18 Milling parameters 19 Applications 20 Milling Feed Charts 20 Milling Cutters Selection 24 Table of cutting speeds 26 General Information 3

4 General Information Application Material Groups Application Material Groups ( AMGs ) are designed to assist in the selection of the optimum cutting tool for a particular application. Dormer classifies materials into 10 major Application Material Groups. Each major group is divided into subgroups on the basis of material properties, such as hardness and strength, and chip formation. This booklet concentrates on sub-groups Alloy Steels. Examples of national designations within each sub-group are shown on page 2. This booklet contains a selection of tools that are rated excellent for machining Alloy Steels. Please see the Dormer catalogue or Product Selector for the full range, or contact your local Dormer representative or Technical Helpdesk if you need further advice. 4

5 Introduction to Alloy Steels Alloy steels are steels with alloying elements other than carbon and iron. When various alloying elements are added to steel, these usually become stronger and harder than plain carbon steels, such as AMG The factors to consider when machining alloy steels are: 1) The analysis of the steel generally, the higher the alloy addition, the more difficult it is to machine the material (see table on page 6). 2) The structure and hardness often this group of steels will respond to heat treatment, so the hardness and metallurgical condition must be known before machining starts. 3) Surface finish a poor surface finish (eg. heavy oxide, scale) will lead to rapid tool wear. Machinability of Alloy Steels The actual alloying elements within a steel have a profound effect on its properties. The table below shows the effect on machinability. Effects of Alloy Addition Negative effect Positive effect Manganese (Mn) Lead (Pb) Nickel (Ni) Sulphur (S) Cobalt (Co) Phosperous (P) Vanadium (V) Carbon (C) < 0.3 % Carbon (C) > 0.6 % Molybdenum (Mo) Niobium (Nb) Tungsten (W) Carbon between 0.3 to 0.6% 5 General Information

6 General Information When the various alloys are all added up together, if the total is less than 5%, the steel is considered as a low alloy steel. Above 5%, the steel is regarded as a high alloy steel. Carbon is regarded as the dominant element that determines much of the mechanical properties and machinability of a steel. For information specific to each sub-group, see pages 7-9. Hints when machining Alloy Steels These sub-groups of steel materials are extensive, which makes it important to find out the properties of the material to be machined. Use the Dormer Product Selector to find the correct AMG classification, which in turn will help you to find the correct tool for the application. A high alloyed steel can be abrasive or hard. To reduce rapid wear on the cutting surface, use coated tools and carbide tools. Tool steels can be hardened to various degrees. It is important to be aware of both material grade and hardness in order to select the correct tool configuration for the application. 6

7 1.4 Alloy Steel (generally low-alloy steels with a total alloy content of 2 4%) Hardness <250 HB Tensile strength <850 N/mm 2 Typical Composition The very low-alloy steels within this group are generally high strength structural steels with a total alloy content of up to 2%. These steels are not usually heat-treated. Typical tensile strengths of 400 N/mm 2 and hardness values of approximately 230 HB are normal. As the alloy content increases slightly, then generally ductility reduces and with a total alloy content of 2 4%, hardness of 250 HB and tensile strengths to 850 N/mm 2 are found. General Information Examples of uses Typical uses of AMG 1.4 are axles, shafts, structural steels, tubes and forgings. 7

8 General Information 1.5 Alloy steel Hardened and tempered Hardness >250 <350 HB Tensile strength >850 <1200 N/mm 2 Typical Composition Alloy steels within this range are those which have been hardened and tempered to give enhanced tensile strengths. Also included are the highly alloyed tool steels in their annealed condition. Nickel, chrome alloy steels, with a total alloy content of 3-4% can be heat treated to give various hardness and tensile strengths by tailoring the tempering temperature to give the desired balance between hardness and ductility. Alloy tool steels with high carbon levels and a total alloy content of more than 5% also fall into this grouping, provided they are in the fully annealed (softened) state. Examples of uses Typical uses of AMG 1.5 are gears, connecting rods, swivel arms and transmission parts. 8

9 1.6 Alloy steel Hardened and tempered Hardness >350 HB Tensile strength >1200 <1620 N/mm 2 Typical Composition General Information This grouping covers alloy steels which are heat-treated to give more hardness but with the loss of toughness or ductility. Whilst many of the actual steel grades are similar to those within AMG 1.5, the heat treatment is designed to give higher tensile strengths. Also included are the wear-resistant or abrasion resistant alloy steels (eg. Hardox 400). The increased hardness of these steels will make machining more difficult, so care must be taken to select the optimum cutting conditions. Examples of uses Typical uses of these steels are gears, machine tool parts, dies, cylinders and cropping blades. 9

10 General Hints on Drilling 1. Select the most appropriate drill for the application, bearing in mind the material to be machined, the capability of the machine tool and the coolant to be used. 2. Flexibility within the component and machine tool spindle can cause damage to the drill as well as the component and machine - ensure maximum stability at all times. This can be improved by selecting the shortest possible drill for the application. 3. Tool holding is an important aspect of the drilling operation and the drill cannot be allowed to slip or move in the tool holder. 4. The use of suitable coolants and lubricants are recommended as required by the particular drilling operation. When using coolants and lubricants, ensure a copious supply, especially at the drill point. 5. Swarf evacuation whilst drilling is essential in ensuring the correct drilling procedure. Never allow the swarf to become stationary in the flute. 6. When regrinding a drill, always makes sure that the correct point geometry is produced and that any wear has been removed. 10

11 Ø [mm] D E F G H I J K L M U V W X mm/rev ± 25% 11

12 A117 A520 R022 R520 A551 A / G 32I 55V 80X 18F 21G 45U 55X 11E 11E 45U 45W 40I 24G 13E 40I 24G 13E Excellent Good 12

13 A777 A510 A553 A554 R002 R510 R553 R /8 24F 30H 45H 45H 55U 80W 115U 100U 17E 21F 28F 28F 45T 55V 90U 80U 10D 11D 15D 15D 45T 45V 65T 55T

14 General Hints on Tapping 1. Select the correct design of tap for the component material and type of hole, i.e. through or blind, from the Application Material Groups chart. 2. Ensure the component is securely clamped - lateral movement may cause tap breakage or poor quality threads. 3. Select the correct size of drill (see opposite). Always ensure that work hardening of the component material is kept to a minimum. 4. Select the correct cutting speed as shown in the tap selection pages, the catalogue or the Product Selector. 5. Use appropriate cutting fluid for correct application. 6. In NC applications ensure that the feed value chosen for the program is correct. When using a tapping attachment, 95% to 97% of the pitch is recommended to allow the tap to generate its own pitch. 7. Where possible, hold the tap in a good quality torque limiting tapping attachment, which ensures free axial movement of the tap and presents it squarely to the hole. It also protects the tap from breakage if accidentally bottomed in a blind hole. 8. Ensure smooth entry of the tap into the hole, as an uneven feed may cause bell mouthing. 14

15 Drill Diameters for Cutting Taps - Recommendation tables METRIC COARSE THREAD Max. DRILL DRILL Internal Pitch Diam. Diam. Diam. M mm mm mm inch / / / H / Q / Y / / / / / / / /64 METRIC COARSE THREAD FOR ADX/CDX TAP DRILL Pitch Diameter M mm mm Drill diameter can be calculated from: D = D nom - P D = Drill diameter (mm) D nom = Tap nominal diameter (mm) P = Tap pitch (mm) RECOMMENDED DIAMETERS WHEN USING DORMER ADX AND CDX DRILLS The above table for drill diameters refer to ordinary standard drills. Modern drills such as Dormer ADX and CDX produce a smaller and more accurate hole which makes it necessary to increase the diameter of the drill in order to avoid breakage of the tap. Please see the small table to the left.

16 DIN Other thread forms available. E340 E341 E464 E465 E324 E326 M3 - M10 M12 - M20 M3 - M10 M12 - M20 M3 - M10 M12 Excellent Good

17 Please see Dormer catalogue. ISO E342 E343 E314 E316 E402 E049 E050 E044 M3 - M10 M12 - M20 M3 - M10 M12 M3 - M30 M3 - M20 M3 - M20 M8 - M

18 General Hints on Milling 1. Where possible, use climb milling (down milling) for longer tool life. Climb milling allows easier chip disposal, less wear, improved surface finish and lower power requirements compared to conventional milling (up milling). 2. Always use a cutter in good condition. 3. Use well-maintained machine tools with sufficient power. 4. Use correct clamping system according to working operation and type of tool. 5. Check for damage or wear on the tool shank or in the holder itself. 6. Use the shortest cutters recommended for your application and work as close to the machine head as possible. 7. For optimum productivity, use coated or Solid Carbide cutters. 18

19 Milling parameters 1. Identify the type of end milling to be carried out - type of end mill - type of centre 2. Consider the condition and the age of the machine tool. 3. Select the best end mill dimensions in order to minimize the deflection and bending stress - the highest rigidity - the largest mill diameter - avoid excessive overhand of the tool from the tool holder. 4. Choose the number of flutes - more flutes - decreased space for chips - increased rigidity - allows faster table feed - less flutes - increased space for chips - decreased rigidity - easy chip ejection. 5. Determining the correct cutting speed and feed rate can only be done when the following factors are known: - type of material to be machined - end mill material - power available at the spindle - type of finish. 19

20 Application Slotting Roughing Ball nose Finishing For details on how to use the feed charts in the tables which follow, please see below. 20

21 Ø mm mm/z ± 25% ,5D D B 0,004 0,007 0,012 0,015 0,022 0,026 0,039 0,054 0,065 0,076 0,086 0,087 0,086 0,089 0,095 0,098 0,097 0,095 0,097 0,097 C 0,003 0,006 0,011 0,014 0,019 0,023 0,035 0,049 0,058 0,068 0,078 0,079 0,078 0,080 0,085 0,088 0,087 0,086 0,087 0,087 D 0,8D H 0,023 0,031 0,032 0,039 0,045 0,051 0,058 0,064 0,064 0,049 0,048 0,049 0,048 0,050 0,051 I 0,021 0,028 0,029 0,035 0,041 0,046 0,052 0,058 0,058 0,044 0,043 0,044 0,043 0,045 0,046 1,5D 0,25D N 0,007 0,011 0,016 0,021 0,028 0,037 0,051 0,062 0,072 0,082 0,093 0,103 0,081 0,093 0,077 0,082 0,087 0,099 0,096 O 0,006 0,010 0,015 0,019 0,025 0,033 0,046 0,056 0,065 0,074 0,083 0,092 0,073 0,083 0,069 0,074 0,079 0,089 0,087 1,5D 0,1D T 0,009 0,014 0,021 0,026 0,035 0,046 0,064 0,077 0,090 0,103 0,116 0,129 0,102 0,116 0,096 0,103 0,110 0,123 0,120 U 0,008 0,012 0,019 0,023 0,032 0,041 0,058 0,070 0,081 0,092 0,104 0,116 0,092 0,104 0,087 0,092 0,099 0,111 0,108 21

22 Z > ,5 0,05 1,5 0,1 1 0,5 0,5 1 0, ,5 S241, S276, S332, S250, S251, S503, S190, S290 Ø mm mm/z ± 25% >0, A B C A B C A B C A B C B

23 2 & 4 4 Z ,1-0,5mm 0,1-0,5mm 0,01-0,1 1 1,5 0,1 1,5 0,25 A BC A BC S017, S044 Ø mm mm/z ± 25% A B C A B C

24 C353 C352 C907 C428 C921 S044 S017 z3 z3 z3-6 z3-6 z3-6 z4 z B 79B 79T 79H 79N 153B 153B 60C 54C 54U 54I 54O 120B 120B 26C 24C 24U 24I 24O 77B 77B a z Excellent Good 24

25 S241 S276 S332 S250 S251 S503 S190 S290 z4 z4 z4 z4 z4 z2 z2 z B 153B 80B 175B 145B 250B 250B 250B B 115B 60B 130B 110B 200B 200B 200B B 92B 105B 85B 180B 180B 180B a z 25

26 General Information Table of Cutting Speeds, <10mm PERIPHERAL CUTTING SPEED Metres/Min. Feet/Min. REVOLUTIONS PER MINUTE (RPM) Tool Diameter inch mm 1, , , , , ,18 1/ , , , ,76 3/ , , ,35 1/ , ,94 5/ , , ,53 3/ ,

27 Table of Cutting Speeds, >10mm PERIPHERAL CUTTING SPEED Metres/Min. Feet/Min. REVOLUTIONS PER MINUTE (RPM) Tool Diameter inch mm 11,11 7/ , ,70 1/ , ,29 9/ , ,88 5/ , ,46 11 / , ,05 3/ , , , , , , , , , General Information

Price/1. Price/1. Price/1. 1/ 8 3/ 8 1 1/ 2 1/ 8 10g -4580K / 4 3/ 4 2 1/ 2 1/ 4 30g -4660K / / 2 3/ 8 60g -4740K 291.

Price/1. Price/1. Price/1. 1/ 8 3/ 8 1 1/ 2 1/ 8 10g -4580K / 4 3/ 4 2 1/ 2 1/ 4 30g -4660K / / 2 3/ 8 60g -4740K 291. 2 Flute For optimum performance and maximum swarf removal when plunging, slotting and routing in most materials including brass, aluminium, non-ferrous and other soft materials. Manufactured to USCTi Standards.

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