Prirucnik

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D E FI N ITI ON OF BA S IC CONCE CU T T IN G GR A D ES PR A M E T CHO ICE OF T U R N IN G T O OL CHO ICE O F MIL L IN G T O O L CHO ICE OF D R IL L ING WE AR O F CU T T IN G IN S E R T S GR A D E GRO U P S EQU IV A L E N T T A BL ES ESC

CONTENT

1. Introduction 2

2. Deﬁ nition of basic concepts and calculational formulas 3

3. Cutting grades Pramet

3.1 Grades with MTCVD coating 7

3.2 Grades with PVD coating 8

3.3 Uncoated grades 9

3.4 Comparative table - MTCVD grades 10

Comparative table - PVD grades (for turning) 11

Comparative table - PVD grades (for milling) 12

4. Choice of turning tool

4.1 Tool holder choice 13

4.2 Choice of cutting insert 15

4.3 Choice of chip former 19

4.4 Choice of cutting conditions 24

Tables 25

4.5 Turning of recesses, parting, CTP system for copying and recessing turning 43

4.6 Threading 46

5. Choice of milling tool

5.1 Choice of milling cutter 53

5.2 Choice of cutting insert 56

Tables 58

5.4 Special milling technology 70

6. Drilling

6.1 Procedure for optimum tool choice 74

Tables 75

6.3 Drilling of holes with larger or smaller diameter than nominal drill diameter 78

6.4 Practical recommendations 82

6.5 Use of cutting ﬂ uids at drilling with cutting inserts 83

6.6 Troubleshooting 84

7. Wear of cutting inserts

7.1 Types of wear 85

7.2 Mechanisms of wear formation 86

7.3 Some wear types and recommended measures for their removal 88

8. Classiﬁ cation of machined materials and tables of equivalents

Category of materials 92

8.1 Table of equivalents - group P 93

8.2 Table of equivalents - group M 96

8.3 Table of equivalents - group K 97

8.4 Table of equivalents - group N 98

8.5 Table of equivalents - group S 99

8.6 Table of equivalents - group H 99

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1.

Introduction

The Handbook for machining with cemented carbide tools PRAMET is determined for workers of technologi-cal divisions, technologists, programmers, machine operators. It is instrumental towards the basic for choice of optimum tools, working and cutting conditions for turning, milling and drilling by means of tools with indexable cutting inserts Pramet.

These tools are delivered in a wide assortment of shapes, dimensions and grades of cutting inserts, before all coated inserts, but also uncoated ones. A condition for effective utilization of these tools, that means an achievement of maximum cutting performance for solution of concrete technological problems, are reliable basic documents which make possible to reach this objective under minimum machining costs.

At using tools in engineering practice before all we encounter a wide range of materials to be machined. The tools are also applied under various engagement conditions, i.e. beginning with ﬁ ne machining, through ﬁ nishing machining, up to heavy roughing. With regard to this considerable conditions variability, we believe that it is necessary to provide technologists a systematically arranged complex of some basic pieces of knowledge concerning the machinability of engineering materials and wear of cutting edges of tools with indexable cutting inserts made from cemented carbide (hereafter only Inserts).

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D E FI N ITI ON O F B A S IC C O N C CU T T IN G GR A D ES PR A M E T CHO ICE OF T U R N IN G T O OL CHO ICE O F MIL L IN G T O O L CHO ICE OF D R IL L ING WE AR O F CU T T IN G IN S E R T S GR A D E GRO U P S EQU IV A L E N T T A BL ES 3 ESC Operation chart

Turning

Milling

Drilling

To be machined surface

Surface from which material layer is removed and changed into chips.

Cut surface

Surface being created on workpiece by main and adjoining cutting edge and creates passage between the surface to be machined and already machined surface.

Machined surface

New created surface originated by removal of material layer.

Cutting speed

It is a vector sum of all speeds – but because of simplicity we take as cutting speed the speed of main rotary motion which is done by workpiece at turning, by tool at milling and by workpiece or tool at drilling.

v

c

=

π.D.n

1000

vc = cutting speed [m.min-1]

D = machined surface diameter [mm] n = numb. of workpiece revolutions [1.min-1_]

D = mill diameter [mm] n = number of tool revolutions [1.min-1_]

D = drill diameter [mm] (drilled hole diameter)

n = number of tool [1.min-1_]

or workpiece revolutions

Feed

It is a motion which is made by tool or workpiece, its speed is given in mm/rev or in mm/min and also in mm/tooth.

Feed per revolution

f

ot

=

f

min

n

[mm.rev

-1

_]

fot = feed per revolution [mm.rev-1]

fmin = feed per minute [mm.min-1]

n = number of spindle revolutions [1.min-1_]

Sometimes Fmin means feed speed Vf

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D E FI N ITI ON OF BA S IC CONCE P T S CU T T IN G GR A D ES PR A M E T CHO ICE OF T U R N IN G T O OL CHO ICE O F MIL L IN G T O O L CHO ICE OF D R IL L ING WE AR O F CU T T IN G IN S E R T S GR A D E GRO U P S EQU IV A L E N T T A BL ES 4 ESC ESC Cutting depth ap (ae)

2.

Deﬁ nition of basic concepts and calculational formulas

Turning

Milling

Drilling

Feed per tooth

Not indicated

(f

z

= f

ot

)

f

z

=

[mm.tooth

-1

]

f

ot

f

min

z n.z

fz = feed per tooth [mm.tooth-1]

fot = feed per revolution [mm.rev -1]

fmin = feed per minute [mm.min-1]

n = number of spindle revolutions [1.min-1_]

z = number of teeth [1]

Infeed

is a motion by which the tool is set into working position for a certain cutting depth ap, ae respectively.

Chip cross-section

Herewith, the cross-section of removed material layer is understood; its amount is one of factors having the inﬂ uence on the load character of cutting edge and on the absolute intensity of cutting force.

A = f

ot

. a

p

[mm

2

]

fot = feed per revolution [mm.rev-1]

ap = cutting depth [mm]

A = chip cross-section [mm2_]

A = f

z

. a

p

[mm

2

]

A = f

ot

. a

p

[mm

2

]

fz = feed per revolution [mm.tooth-1]

A = chip cross-section [mm2_]

fot = feed per revolution [mm.rev-1]

A = chip cross-section [mm2_] at boring into full material

or at enlargement of a hole pre-bored to diameter d

a

p

= [mm]

D

2 a

p

= [mm]

D-d

2

fz = feed per tooth [mm.tooth-1]

fot = feed per revolution [mm.rev -1]

z = number of teeth [1]

f

z

=

f

ot

z

[mm.tooth

-1

_]

Axial cutting depth ap is measured

in direction of cutter of axis of revolution

Radial cutting depth ae (width of milled

surface) is measured in the surface normal to the cutter axis.

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Medium chip thickness

Not indicated Not indicated

Chip thickness

h = f . sin κ

r

[mm]

or for round inserts is calculated

D = insert diameter [mm]

h

max

= f

z

[mm]

a

p

D

Chip thickness depends on the cutting edge shape of insert (on the position of functional part of cutting edge, respectively).

is decisive for intensity of speciﬁ c cutting resistance and herewith also for power stress of cutting edge; its width b, at the same feed and cutting depth, is dependent on the approach angle magnitude of the main cutting edge κr.

Roughness of machined surface

Not indicated At the face milling, the roughness

of machined surface is mostly de-pendent on mutual position (axial run-out) of individual cutting edges of a cutter; furthermore, it is inﬂ u-enced by the cutting edge geometry (by the used insert grade), by cutting conditions and properties of machi-ning materials.

h

m

= f

z

sin κ

r

57,3

a

e

D.arc sin

a

_D

e

Medium roughness of machined surface Ra

Theoretical value of maximum surface unevenness

R

max

= [µm]

125.f

ot2

r

e

R

a

= [µm]

43,9.f

ot1,88

r

e0,97 feed f [mm.rev-1_] 0,2 0,4 0,5 0,8 1,0 1,2 1,5 1,6 2,4 0,10 2,7 1,4 1,1 0,7 0,6 -0,12 3,9 2,0 1,6 1,0 0,8 0,65 -0,16 6,7 3,4 2,7 1,8 1,4 1,2 0,95 0,9 0,6 0,20 10,1 5,2 4,2 2,6 2,1 1,8 1,4 1,35 0,9 0,25 15,4 7,9 6,3 4,0 3,2 2,7 2,2 2,0 1,4 0,30 -11,1 8,9 5,7 4,6 3,8 3,1 2,9 1,9 0,35 -14,8 11,9 7,6 6,0 5,1 4,1 3,9 2,6 0,40 -15,3 9,7 7,8 6,6 5,3 5,2 3,4 roughness Ra [µm]

Turning

Milling

Drilling

The chip thickness h changes during one revolution depending on the engagement angle ϕ according to the relation hϕ = fz ⋅ sinϕ. The curve illustrated this relation is a sinusoid. The maximum chip thickness fz is

achieved in the cutter axis.

It can be calculated from equation

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With decreasing chip thickness the speciﬁ c cutting resistance increasses!!!

R

max

= h

max

=

f

e2

4.D

The roughness in axial direction (in direction of axial cutter feed) is to be determined from the following empirical relation:

2.

Deﬁ nition of basic concepts and calculational formulas

Turning

Milling

Drilling

fe = spacing feed (step) [mm]

D = cutter diameter [mm]

fz = feed per tooth [mm]

rε = radius of nose curvature [mm]

Volume of removed material

Q = a

p

.f

ot

.v

c

[cm

3

.min

-1

]

Q = volume of removed material [cm3_.min-1_]

ap = cutting depth [mm]

fot = feed per a revolution [mm.rev-1]

vc = cutting speed [m.min-1]

It is one of the leading criteria for the assessment of economy of cutting process; it can be calculated from the following equations:

ap = axial cutting depth [mm]

ae = radial cutting depth [mm]

fmin = feed per a minute [mm.min-1]

D = drill or hole diameter [mm]

Q = [cm

a

p

.a

e

.f

min 3

_.min

-1

_]

1000

πD

2

4000

Needed input of machine driving motor

Pc = needed input [kW]

ap = cutting depth [mm]

f = feed [mm.rev-1_]

kc = speciﬁ c cutting resistance [MPa]

η = lathe efﬁ ciency usually 0,7-0,8 x = factor for inﬂ uence of material to be

machined

It is a limit criterion for optimizing with respect to the maximum possible machine utilization. For the calculation of cutting performance, the sort of machined material or so called the speciﬁ c cutting resistance plays a very important role.

To be simple we also quote formula for a rough calculation where the value of speciﬁ c cutting resistance is not to be introduced.

ap = axial cutting depth [mm]

ae = radial cutting depth [mm]

fmin = feed per minute [mm.min-1]

kc = speciﬁ c cutting resistance [MPa]

kγ = correction factor for effective orthogonal rake angle γ0

η = cutter miller efﬁ ciency usually 0,75 x = factor for inﬂ uence of material to be

machined

D = drill or hole diameter [mm]

f = feed [mm.rev-1_]

c = index which represents the infl uence of chip thickness h (≈ feed f) on the magnitude of specifi c cutting resistance kc1 = specifi c cutting resistance at feed

≈ chip thickness h = 1 mm [MPa] vc = cutting speed [m.min-1]

η = machine efﬁ ciency usually 0,7- 0,8 x = factor for inﬂ uence of material to be

machined material factor x steel 48 cast iron 60 Al 240 material factor x steel 24000 cast iron 30000 Al 120000 material factor x steel 20 cast iron 25 Al 100

At vertical (recessing) milling, we distinguish the roughness in the radial direction (waviness), which depends on the spacing size (on the step) –i.e. on the cutter feed fe in radial direction. It is calculated from the following equation:

R

a

= 43,9 [mm]

f

z1,88

r

ε0,97

Q = f

min

[cm

3

.min

-1

]

[µm]

P

c

=

a

p

.f.k

c

.v

c

60.10

3

_{. η}

[kW]

P

c

=

a

p

.f.v

c

x

[kW]

P

c

=

a

p

.a

e

.f

min

.k

c

.k

γ

60.10

6

_{. η}

[kW]

P

c

=

a

p

.a

e

.f

x

[kW]

P

c

=

k

c1

.f

1-c

.D.v

c

24.10

4

_{. η}

[kW]

P

c

=

D.f.v

c

x

[kW]

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66

2

0 6630

6640

50

2

6

Material with the highest wear resistance from series 6000.

Suitable for fi nishing up to semi-roughing turning of cast iron, carbon and alloy steels. It can be also (conditionally) used for fi ne and fi nishing turning of hardened and stain-less steels.

All-purpose grade for turning of steels with a wide application ﬁ eld.

Also convenient for machining of cast iron and stainless steels.

It connects a good wear resistance with high toughness.

The toughest grade of series 6000. Use for operations with a strong mechanical stress of cutting edge. Interrupted cut, rough skin of forgings and castings. Machining of stainless steels. Parting, recessing and copy turning (CTP) of common and stainless steels. Furthermore, we also recommend this grade for peripheral inserts of drilling tools.

This grade is primarily intended for machining of carbon and alloy steels and cast irons with medium and higher cutting speeds and medium feeds.

It is a grade with high wear resistance that is given by a specially developed substrate material and conceptually by a new coating sort.

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3

Cutting grades Pramet

80

1

6

80

2

6

80

30 8040

Grade for ﬁ ne up to semi-roughing turning of common, stainless and treated steels (HRC>55).

Furthermore, for machining of heat-resistant and creep-resistant steels. It can be also used for turning of alloys and cast irons upon the basis of Al and Cu.

In the ﬁ eld of milling we recommend this grade for machining of both common, heat-resistant, creep-resistant steels and also alloys by lower up to medium feeds.

This grade has a predominant position for milling of stainless steels, but it can be also used for machining of common carbon steels and alloy steels and cast steels with higher and medium feeds, medium and higher speeds.

It can be used for machining of cast irons and according to the sort of insert also for milling of Al and Cu or alloys of non-ferrous metals.

Convenient both for common and copy milling.

This grade ﬁ nds its very wide application ﬁ eld, especially because of its high operation reliability.

It is intended for inserts for threading, parting, recessing and copy turning (CTP). It is used at machining of common and stainless steels; furthermore for ﬁ ne and ﬁ nishing turning of stainless and high alloy steels and superalloys.

Besides threading, one of its main application ﬁ elds is drilling, where it is used both for internal and peripheral inserts.

It is the toughest grade intended for extremely interrupted cuts and bad engagement conditions.

In the ﬁ eld of milling it can be recommended as the ﬁ rst choice for tools which are intended for machining of carbon steels and alloy steels.

Furthermore, it ﬁ nds its use at turning and milling of cast irons and especially at heavy machinable alloys upon the basis of Ni, Co and Fe. Machining of casting and forging skin.

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HF

7 H1

0 S2

6 S3

0 S45

Turning of grey cast iron, malleable nodular cast iron, stainless, creep-resistant and heat resistant steels and special alloys. Turning of Al and Cu alloys and treated steels (HRC > 55).

Milling of grey cast iron, malleable cast iron, Al alloys, non-ferrous metals, woods and plastics. Machining with higher and medium speeds at light and medium milling.

Finish-milling, semi-roughing of steel and cast steel. Machining with higher and medium speeds at light and medium milling. Basic uncoated grade for milling of steel.

Medium milling of steels and cast steel with medium and lower cutting speeds at less favourable conditions.

Milling of steels, stainless and cast steel. Machining al low cutting speeds and heavy roughing. For roughing of workpieces with uneven cutting depth and unclean surface under more difﬁ cult conditions.

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3

3.4 Comparative table of MTCVD-grades

Comparative table of application ﬁ elds of foreign cutting grades with grades of the basic series for turning

6630

6620

6640

TP05 TP10 TP15 TP20 TP25 TP30 TP35 TP40 SECO T15M TP100 TP100 TP200 TP200 TP200 TP300 TP300 TX100 TX150 TP200 TP300 GC4015 COROMANT GC3005 GC2015 GC4025 GC4025 GC4025 GC4035 GC4035 GC235 GC3015 GC3020 GC3025 GC2025 GC2025 GC2025 GC2025 GC2035 KC9010 KC9025 CM4 KENNAMETAL KC910 KC850 KC9020 KC935 KC9040 KC9045 KC250 KC990 KC950 CW2 CL4 HERTEL CP1 CPX CM2 CM3 CM5 13E CM4 GM10 GM25 HITACHI HC5000 (MG10) (MG25)

IC815 IC825 IC656 IC635

ISCAR IC428 IC805 IC9015 IC8025 IC9025

IC848 IC8048 IC835 IC3028

KYOCERA CR7015 CR600 CR7025 CA225

UC5005 U420 U625

MITSUBISHI U610 UC6010 UC6010 US735

UE6005 U510 UC6025

ON125

SAFETY OR1500 ORX OR110 OR500 OR50

OR2500

AC05 AC05A AC10

SUMITOMO AC108 AC2000 AC25 AC300

AC105 AC105G AC15

TELEDYNE NL25 MP37 MP26 MP15 Sr117 Sr127 Sr137 Gm40 TIZIT Sr17 Gm517 Gm520 Gm517 Gm527 Gm537 Gm540 T715X T803 T725X TOSHIBA T5020 T7010 T7020 T813 T7015 T822 T7025 HK150 TN150 TN200 TN250 WIDIA TN25M TN350 HK35 TN7035 TN7005 TN7015 TN7015 TN7025 V01 SV235 VALENITE SV310 SV315 VN8 SV325 V1N VN5 (SV200)

WTA13 WAP20 WTA43 WTA53

WALTER WTA23 WTA33 WAM20

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8030

8016

8040

* = uncoated CP200 CP200 CP200 SECO CP25 CP25 CP25 CP50 CP50 CP50 GC1020 GC1020 GC1020 COROMANT GC1010 GC1010 GC1025 GC1025 GC1025 S6* S6* KC732 KC732 KC732 KENNAMETAL KC730 KC730 KC730 KC720 KC720 KC720 KC722 KC722 KC722 HERTEL CS5 CS5 CS5 PVA* PVA* HC843 HC843 HC843 HC843 HITACHI HC844 HC844 HC844 HC844

IC220 IC220 IC220 IC250 IC250 IC228 IC228 IC228

ISCAR IC308 IC308 IC328 IC328 IC328

IC354 IC354 IC354 IC354

PR630 PR630 PR630

KYOCERA PR660 PR660 PR660

UP20M UP20M UP20M

MITSUBISHI UTi20T* UTi20T* UTi20T*

STi40T* STi40T* STi40T*

KX15 KX15 KX15

SAFETY KX20 KX20 KX20

KX25 KX25 KX25

EH510Z

SUMITOMO EH510

A30N* A30N* A30N* A30N*

TELEDYNE TP21 TP21 TP21

TIZIT

S40T* S40T* S40T* S40T* S40T*

AH110 AH110 AH110 GH330 GH330 GH330

TOSHIBA AH120 AH120 AH120 AH120

AH740 AH740 AH740 GH340 GH340 GH340

TTX* TTX*

WIDIA TTM* TTM* TTM*

TTR* TTR* TTR* TTR*

VC927 VC927

VALENITE UC907 UC907 UC905 UC905 UC905

VC902 VC902 VC902 VC902

WXK10 WXK10 WXK10

WALTER WXM25 WXM25 WXM25 WK40* WK40*

WXM35 WXM35 WXM35 WXM35

3.4 Comparative table of PVD-grades

Comparative table of application ﬁ elds of foreign cutting grades with grades of the basic series for turning

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3 8026

8016

8040

F20M CP25 T60M F40M SECO CP20 F25M F30M F40M CP50 F15M F25M F30M GC1015 GC1020 GC1020 GC1020 GC1025 GC2030 COROMANT GC1015 GC1025 GC1120 GC1020 GC2030 KC710 KC721M KC725M KC720 KENNAMETAL KC732 KC730 KC740 KCF22 KC705M KC709M KC730 KC740 CS5 CS5 HERTEL CM2

CY15 HC844 CY25 CZ250 CY250

HITACHI

HC830

IC250 IC950 IC354 IC928 IC328

ISCAR IC220 IC308 IC228

IC910 IC508 IC3028

KIENINGER

CKA128 CKC128

UP20M

MITSUBISHI M20

UP10H

P25TiAlN P25TiAlN P25TiAlN P40TiAlN P40TiAlN

POKOLM P25TiAlN

K10

OR725 SAFETY

OR820

AC325 AC330 ACZ320 K50L

SUMITOMO KC130C EH10Z EH20Z AH330 GH330 T260 TOSHIBA GH336 T221 TPC25 HCP25 WIDIA VC905 VC935 VALENITE VC901 VC929 VC928 WXM22 WXP35 WALTER

3.4 Comparative table of PVD-grades

Comparative table of application ﬁ elds of foreign cutting grades with grades of the basic series for milling

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4.1 Tool holder choice

4.1.1 Tool holder choice with regard to the clamping technique

The PRAMET TOOLS offer includes tool holders, adjustable holders, turret heads and adjustable holders for external longitudinal, facing, copy turning, and naturally also for internal turning.

Tool holders are classiﬁ ed according to the inserts clamping system into six groups that are schematically illustrated in the following passage.

ISO P - This system serves for the clamping of negative inserts with cylindrical hole, both with chip formers and/or without them. The insert clamping is achieved as a result of an angle lever that after tightening the screw presses the insert down to the holder bed. Tool holders with this clamping system of inserts ensure a reliable and exact clamping of an insert. They perform the best and also the most frequent use at external turning operations, namely both ﬁ nishing and roughing ones. Alternatively this type of clamping can be also used for holders intended for internal turning of holes with larger diameters.

ISO M – This system is used for the clamping of cutting inserts of the same type as that of the system ISO P. In this case an insert is set onto a strong pin to which it is pressed by a clamp that is also ﬁ xing at the same time the top of insert. This clamping system is suitable mainly for holders with supposed enhanced dynamic load. These holders are used almost exclusively for the external turning.

ISO C - This system serves for the clamping of both negative and positive inserts without holes, namely with both chip formers (pre-pressed, ground and side-pressed ones) and without them. The insert is ﬁ xed in the bed of a tool holder by a screw-held clamp, under which there is still embedded a side-pressed chip former at some insert types. Holders with this clamping system are used for both the external and internal surface machining. At present the clamping system C loses its importance. Especially at tools for internal turning it is replaced by the system S with beneﬁ t.

ISO S - This clamping system is mainly used for small cross-section tools, designed for both external and internal turning (drilling). In this case a special screw, going through an insert cone hole, achieves the clamping. By tightening this screw an insert is ﬁ xed in the tool bed. This solution is especially convenient because there is no obstacle for chip ﬂ ow.

ISO X – This marking identifies tools with so called special clamping system (i.e. it is different at individual tool manufacturers and suppliers). In our case we have identiﬁ ed under this marking tool holders that use the cutting resistance to clamp an insert into the self-locking bed. This clamping system is used for tools intended for parting and recessing.

ISO G – This clamping system is used at tools for recess turning and at tools for copy turning (system CTP). The insert is pushed into the holder bed by a clamp from the top. The contact surface in the holder, in the clamp and also in the insert is shaped in such a way that it hinders the insert displacing by a feeding component of cutting speed.

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4

Choice of turning tool

The choice of tool holder cross-section is given in most cases by possibilities of the machine tool; but in case where it is possible to carry out an optimum choice of the tool holder cross-section, we bring the following nomogram which makes possible to do an optimum choice of a tool holder cross-section with regard to used cutting conditions (feed and cutting depth) and holder overhang.

An example for using the nomogram:

In the ﬁ rst step we connect the selected (or maximum) cutting depth ap (Point A) with selected (or again with maximum used) feed f (Point B). From the intersection of the central line and the connection of these two points (Point C), we draw an abscissa into the point that indicates the holder overhang (Point D). At the other axis from the right we read the conve-nient cross-section of tool holder (Point E).

Cutting depth ap [mm] Feed f [mm.rev-1_] Holder overhang [mm] Holder cross-section [mm] 4.1.2 Cross-section (square) choice of tool holder

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4.2 Choice of indexable cutting insert

4.2.2 Choice of size of indexable cutting insert

The maximum allowable cutting depth ap max depends on the one hand on the main dimension of an indexable insert and also on the approach angle κr under which the insert is clamped in a tool holder; naturally, it also depends on the functional characteristics of the pre-formed chip former.

The maximum values of cutting depths ap max for turning with round inserts depending on the diameter d are mentioned in the following Table.

Ø d = I.C.

a

p max

06 2,5

08 3,0

Shape and size

10 3,5

of inserts

12 5,0

RP, RC..., RN..

13 5,5 15 6,5 16 7,0 19 8,0 20 8,5 25 10,5 32 16,0

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4

In the following Table the maximum allowable values apmax for various shapes of cutting inserts and various angles κr at turning are given.

Shape and size

of insert

Maximum allowable cutting

edge length in engagement

a

pmax

[mm]

Lmax [mm]

K

r

= 90°

_{= 105°}

K

r

= 75°

K

_{= 120°}

r

= 60°

K

_{= 135°}

r

= 45°

VC 11 0,25L 2,8 2,8 2,7 2,4 -16 4,2 4,2 4,0 3,7 -VN 11 2,8 2,8 - - -16 4,1 4,1 - - -DC 07 0,25L 2,0 2,0 1,9 1,7 -11 2,9 2,9 2,8 2,5 -DN 11 2,9 2,9 2,8 2,5 -15 3,9 3,9 3,8 3,4 -KN 16 4,7 4,7 - 3,9 -19 4,7 4,7 - 3,9 -TC 11 0,33L 3,6 3,6 - - -16 5,5 5,5 - - -TN 11 3,6 3,6 - - -16 5,5 5,5 - 4,8 -22 7,3 7,3 - 6,4 -27 9,1 9,1 - 7,9 -CC 06 0,66L 4,2 4,2 4,1 - 3,0 09 6,4 6,4 6,2 - -12 8,5 8,5 8,2 - -CN 12 8,5 8,5 8,2 - -16 10,6 10,6 10,5 - -εr = 80° 19 12,7 12,7 12,3 - -25 16,5 16,5 16,0 - -CN 12 0,66L 8,5 - 8,2 - -16 10,6 - 10,3 - -εr = 100° 19 12,7 - 12,3 - -25 16,5 - 16,0 - -WC 06 0,5L 3,3 3,3 - - -08 4,4 4,4 - - -WN 06 0,5L 3,3 3,3 - - -08 4,4 4,4 - - -SC 09 0,66L 6,3 6,1 - 4,5 12 8,4 8,1 - 6,0 SN 12 0,66L 8,4 8,1 - 6,0 15 10,4 10,0 - 7,1 19 12,6 12,2 - 8,9 25 16,8 16,3 - 12,0

(18)

For determination of the thickness of a cutting indexable insert we again use a simple nomogram. For a selected combination of the feed and cutting depth we determine the insert thickness from the intersection at the central (inclined) axis for the interrupted or uninterrupted cut. We choose an insert with the nearest higher thickness.

(19)

4

4.2.2.2 Choice of insert tip radius

The insert tip radius rε (the last group of two digits in the insert code according to ISO) should be chosen as large as possible. Its size, together with the insert tip angle εr, is given by the basic insert shape and has inﬂ uence on the resistance of the cutting edge to plastic deformation of the tip. The larger the tip radius rε is, the bigger is the resistance to the plastic deformation – to a total tip destruction as a result of an exceeding the thermal stability limit of the insert material. The larger value of rε enables the use of larger feeds, but it also requires a higher stiffness of the system machine-tool-workpiece. At less stiff workpiece there is a danger of vibrations generation by using inserts with larger tip radius rε.

For the ﬁ rst choice of the insert tip radius the following nomogram can be used:

Example for using the nomogram:

For the selected or for the highest feed at which the given insert will operate (Point A), and for the selected cutting depth ap (Point B) (we select again the highest one), we subtract the size of tip radius on central axes, namely with respect to the fact if it is a case of interrupted or continuous cut (Point C).

(20)

At the choice of cutting depth it must be paid attention to the fact that the smallest used depth is the same or preferably larger than the radius of selected cutting insert.

With the tip radius increase, the roughness of machined surface goes down.

The maximum acceptable feed values f from the point of possibility of origin the cutting edge deformation depending on the radius rε for various indexable inserts with various shapes are mentioned in the following Table.

Insert shape

Maximum acceptable feed f [mm.rev-1_]

rε = 0,2 rε = 0,4 rε = 0,5 rε = 0,8 rε = 1,0 rε = 1,2 rε = 1,5 rε = 1,6 rε = 2,4 VC

0,07

0,14

-

0,28

-

0,42

-

0,56

-DC, DN

0,09

0,18

-

0,36

-

0,54

-

0,72

-KN

-

0,23

-

0,45

-

0,68

-

-TC.. TN

0,10

0,20

-

0,40

-

0,60

-

0,80

-CC.. TN εr = 80°

0,15

0,30

-

0,60

-

0,90

-

1,20

-WC, WN

0,15

0,30

-

0,60

-

0,90

-

1,20

-SC, SN

0,17

0,34

-

0,68

-

1,02

-

1,34

2,04

CC, CN εr = 100°

0,18

0,36

-

0,72

-

1,08

-

1,44

-4.3 Choice of chip former

The shape of removed chip depends on many factors. It is a case of characteristics of the material to be machined, of its strength, toughness and microstructure, characteristics of cutting material, especially its frictional characteristics (at face), static and dynamic characteristics of machine tool, cutting ﬂ uid, cutting edge geometry, cutting conditions and the sort of chip former, thus practically of all factors of the cutting process which are decisive in their combination for generation of either short split transportable chip or continuous or bundled chip which quickly ﬁ lls up the workspace of the machine and becomes an obstruction which practically hinders the machine work.

A certain type of chip former forms and breaks the chip only in a certain feed and cutting depth range. The minimum feed at which the chip former starts to operate, depends before all on the width of stabilization facet x and its angle γx. The maximum feed at which the chip former function ends, depends at grooved chip former on the distance between the outgoing edge of a groove and cutting edge b and on the groove depth h.

The thickness of the removed layer a (at approach angle κr = 90° matches the feed) is distinctly smaller than the facet width x; then it comes to the chip contact only at facet. The chip cannot enter the chip former; h e n c e i t c a n n o t b e f o r m e d s e e schematic drawing).

If it is used a higher feed f (bigger thickness of removed layer a), when x < a,(f) the chip enters the chip former and is formed by it-incurved under a certain radius R (see drawing).

x << a (see drawing); ﬁ rst it comes

to too hard (excessive) forming (crushing) and by further increase in feed the chip already passes by the chip former without any inﬂ uence on its shape (there is no forming).

(21)

The function of a certain type of the chip former is restricted only to a certain range of cutting conditions. For this reason the respective chip formers are outlined into complex series which enable the coverage of the range for most frequently used combinations cutting depth-feed (see the following Figure), and at the same time it is accepted that the functional ranges of respective members of this series overlap.

(22)

(23)

4

(24)

(25)

4.4 Choice of cutting conditions

In the following passage we try to facilitate the choice of a convenient tool and choice of starting (initial cutting conditions). 1. In the ﬁ rst step we classify the material to be machined into one of the six groups according to the ISO 513

(pages 92 – 99).

2. We classify the given operation according to its character into a group (ﬁ ne and ﬁ nishing turning, semi-roughing, rouging or heavy roughing) (page 29).

3. In the ﬁ rst Table for the given group of materials to be machined we choose a combination material-chip former for an insert being chosen ahead (pages 25 – 42).

4. Then in the following Tables we choose the starting cutting speed and possible corrections (for machine condition, hardness of machined material ……..) (pages 25 – 42).

Values of cutting speeds speciﬁ ed in the Tables are valid for machining without application of cutting ﬂ uids.

The basic values of cutting speeds mentioned in the Tables for fi ne, fi nishing, semi-roughing and roughing turning are specifi ed for the cutting edge life T= 15 min (for heavy roughing there is cutting edge life T = 45 min). If a diverse value of tool life is required, T < 15 min or T > 15 min, the tabular value vc is multiplied by a coeffi cient kvT according to the Correction Tables which are quoted in the Tables for respective machinability groups.

If the hardness HB of workpiece differs from the basic hardness mentioned in the Table caption, the value v15 is multiplied by a factor kvHB.

The following product then gives the resulting cutting speed:

v

T

= v

Ttab

.k

vX

.k

vT

.k

vHB

.(k

vM

)

4

(26)

Machined material main group ISO

INDEXABLE INSERT TYPE ACCORDING ISO

WORKING CONDITIONS TURNING

FINE AND FINISHING TURNING SEMI-ROUGHING TURNING ROUGHING TURNING HEAVY ROUGHING TURNING PARTING

AND RECESSING THREADING f = 0,05 ÷ 0,2 [mm.rev-1_] ap = 0,2 ÷ 2,0 [mm] f = 0,2 ÷ 0,4 [mm.rev-1_] ap = 1,5 ÷ 4,0 [mm] f = 0,4 ÷ 0,8 [mm.rev-1_] ap = 4,0 ÷ 10,0 [mm] f > 1,0 [mm.rev-1_] ap > 10,0 [mm] f = 0,05 ÷ 0,3 [mm.rev-1_] -machined sur face

uninterrupted cut casting, forging interrupted cut machined sur

face

rolled product

face

rolled product

uninterrupted cut casting, forging interrupted cut uninterrupted cut casting, forging interrupted cut _{peripheral recesses}

and parting _{face recesses} and parting

-P

..A ..M ..G ..U ..N CNMA CNMM CNMG DNMA DNMM DNMG DNMU SNMA SNMM SNMG SNMX TNMA TNMM TNMG VNMU RNMA RNMM RNMG WNMA WNMM WNMG I 8016 F I 6630 F I 6620 M I 6630 M I 6620 R I 6630 R I 6630 HR I 8040 HR I I I II 6620 F II 8016 F II 8016 F II 6620 R II 6640 M II 6620 R II 6640 HR II 6640 HR II II II III III 8030 F III 6630 NR III 6630 NR III 6630 NR III 8040 HR III III 8040

SR, XR III III III

..X KNUX I I I 6620 72 I 6630 72 I 6620 74 I I I I I I II II II 6620 73 II 6640 74 II 6630 74 II II II II II II ..W ..T CCMW CCMT SCMW SCMT DCMW DCMT TCMW TCMT VCMW VCMT WCMW WCMT RCMW RCMT RCMX I 8016 UM I 6630 UM I 6620 UR I 6630 UR I I I I I I I II 6620 UM II 8016 UM II 6620 47 II 6630 47 II II II II II II II III III 8030 UM III 6630 UR III 8030

UR III III III III III III III

..R ..N SPMR SPGR SPUN SPGN TPMR TPGR TPUN TPGN I 8016 49 I 6630 46 I 6620 47 I 6630 47 I I I I I I I II 6620 49 II 6630 47 II 6630 47, 48 II 6640 47, 48 II II II II II II II III III 6640 46, 47 III III 8030

47, 48 III III III III III III III

..X LFMX, LFUX, LCMX TN16E I 8030 I 8030 I 6640 I 6640 I I I I I 6640 I 8030 I II - II 6640 II 8030 II 8030 II II II II II 8030 II 6640 II TN11... TN16... TN22 I I I I I I I I I I I 8030 25

4

C h oic e o f t u rn in g t o ol

(27)

DEFINITION OF BASIC CONCEPTS CUTTING GRADES PRAMET CHOICE OF TURNING TOOL CHOICE OF MILLING TOOL CHOICE OF DRILLING WEAR OF CUTTING INSERTS GRADE GROUPS EQUIVALENT TABLES 26 ESC ESC

4 Grade

6620

6630

6640

Insert

shape

Range of feeds and cutting depth

Level Feed

f

[mm.rev-1_] Cutting depth

a

p [mm]

S...

C...

W..

T...

D...

K..

V...

(L...)

R...

S...

C...

W..

T...

D...

K..

V...

(L...)

R...

S...

C...

W..

T...

D...

K..

V...

(L...)

R...

Fine and ﬁ nishing turning I 0,05 1,0 - - - -V15 [m.min-1_] II 0,10 355 335 315 390 - - - - 250 235 220 275 III 0,20 320 300 280 350 290 275 255 320 210 195 185 230 Semi-roughing turning I 0,20 2,5 305 285 270 335 275 260 240 300 195 185 170 215 II 0,30 245 230 215 270 235 220 205 260 170 160 150 185 III 0,40 215 200 190 235 210 195 185 230 155 145 135 170 Roughing turning I 0,40 5,0 200 190 175 220 195 185 170 215 145 135 130 160 II 0,60 165 155 145 180 165 155 - 180 125 120 - 140 III 0,80 145 135 130 160 145 135 - 160 115 110 - 125 Heavy roughing turning I 0,80 12 - - - - 110 105 - - 90 85 - -V45 [m.min-1_] II 1,00 - - - - 100 95 - - 80 75 - -III 1,30 - - - - 90 85 - - 75 70 - -Parting, peripheral recesses and copying (CTP) 0,10 - - - -V15 [m.min-1_] 0,15 - - - -0,20 - - - -0,30 - - - -Face and internal recesses 0,10 - - - -0,15 - - - -0,20 - - - -0,30 - - - -Threading - - - -- - - -- - -

-P

HB = 180 14b 9b ÷ 16b CORRECTION FACTOR kvx

Forging and casting skin 0,70÷0,80 Internal turning 0,75÷0,85 Interrupted cut 0,80÷0,90 Good machine condition 1,05÷1,20 Bad machine condition 0,85÷0,95

TOOL LIFE CORRECTION kvT

Tmin kvT Tmin kvT

10 1,10 30 0,84 15 1,00 45 0,76 20 0,93 60 0,71

TOOL LIFR CORRECTION FOR HEAVY ROUGHING

30 1,10 60 0,93 45 1,00

CORRECTION FOR WORKPIECE HARDNESS

HB kvHB HB kvHB 120 1,18 220 0,90 140 1,12 240 0,86 160 1,05 260 0,82 180 1,00 280 0,80 200 0,95 300 0,77

(28)

27

4 Grade

8016

8030

8040

Insert

shape

Level Feed

f

a

p [mm]

S...

C...

W..

T...

D...

K..

V...

(L...)

R...

S...

C...

W..

T...

D...

K..

V...

(L...)

R...

S...

C...

W..

T...

D...

K..

V...

(L...)

R...

Fine and ﬁ nishing turning I 0,05 1,0 375 350 330 410 250 235 220 275 - - - -V15 [m.min-1_] II 0,10 - - - - 240 225 210 265 - - - -III 0,20 - - - - 230 215 200 250 - - - -Semi-roughing turning I 0,20 2,5 - - - - 225 210 200 245 165 155 135 180 II 0,30 - - - - 190 180 165 210 130 120 115 145 III 0,40 - - - - 170 160 150 185 110 105 95 120 Roughing turning I 0,40 5,0 - - - - 155 145 135 170 105 100 90 115 II 0,60 - - - - 135 125 120 150 80 75 - 90 III 0,80 - - - - 120 115 105 130 70 65 - 75 Heavy roughing turning I 0,80 12 - - - - 85 80 - - 45 40 - -V45 [m.min-1_] II 1,00 - - - - 75 70 - - 40 35 - -III 1,30 - - - - 70 65 - - 35 30 - -Parting, peripheral recesses and copying (CTP) 0,10 - - - 180 - - - - -V15 [m.min-1_] 0,15 - - - 165 - - - - -0,20 - - - 155 - - - - -0,30 - - - 140 - - - - -Face and internal recesses 0,10 - - - 110 - - - - -0,15 - - - 105 - - - - -0,20 - - - 100 - - - - -0,30 - - - 90 - - - - -Threading - - - 165 - - - -- - - 155 - - - -- - - 135 - - -

-P

HB = 180 14b 9b ÷ 16b CORRECTION FACTOR kvx

15 1,00 45 0,76

30 1,10 60 0,93 45 1,00

HB kvHB HB kvHB 120 1,18 220 0,90 140 1,12 240 0,86 160 1,05 260 0,82 180 1,00 280 0,80 200 0,95 300 0,77

(29)

4

AND RECESSING THREADING f = 0,05 ÷ 0,2 [mm.rev-1_] ap = 0,2 ÷ 2,0 [mm] f = 0,2 ÷ 0,4 [mm.rev1_] ap = 1,5 ÷ 4,0 [mm] f = 0,4 ÷ 0,8 [mm.rev-1_] ap = 4,0 ÷ 10,0 [mm] f > 1,0 [mm.rev-1_] ap > 10,0 [mm] f = 0,05 ÷ 0,3 [mm.rev-1_] -machined sur face

face

rolled product

face

rolled product

-M

..A ..M ..G ..U ..N CNMA CNMM CNMG DNMA DNMM DNMG DNMU SNMA SNMM SNMG SNMX TNMA TNMM TNMG VNMU RNMA RNMM RNMG WNMA WNMM WNMG I 8016 F I 6640 F I 6630 M I 6630 M I 6630 NR I 8030 NR I 8030 HR I 8040 HR I I I II II 8030 F II 8030 M II 8030 NR II 6630 DR II 6630 DR II 6630 HR II 6640 HR II II II

III III III 6630

NR III 6640 NR III 6630 R III 8030 R III III 8040

SR, XR III III III

..X KNUX I I I 6630 73 I 6630 73 I 6630 74 I I I I I I II II II 6630 74 II 6630 74 II II II II II II II ..W ..T CCMW CCMT SCMW SCMT DCMW DCMT TCMW TCMT VCMW VCMT WCMW WCMT RCMW RCMT RCMX I 8016 UM I 6630 UM I 6630 UR I 8030 UR I I I I I I I II II 8030 UM II 8030 UR II 6630 UR II II II II II II II III III 8030 UR III 6630 47 III 6630

47 III III III III III III III

..R ..N SPMR SPGR SPUN SPGN TPMR TPGR TPUN TPGN I 8016 49 I 6630 46 I 6630 47 I 6630 47 I I I I I I I II II 6630 47 II 6630 48 II 6640 47, 48 II II II II II II II III III 6640 46, 47 III III 8030

47, 48 III III III III III III III

..X LFMX, LFUX, LCMX

TN16E

I 8030 I 8030 I 6640 I 6640 I I I I I 6640 I 8030 I

II - II 6640 II 8030 II 8030 II II II II II 8030 II 6640 II

(30)

29

4 Grade

6620

6630

6640

Insert

shape

Level Feed

f

a

p [mm]

S...

C...

W..

T...

D...

K..

V...

(L...)

R...

S...

C...

W..

T...

D...

K..

V...

(L...)

R...

S...

C...

W..

T...

D...

K..

V...

(L...)

R...

Fine and ﬁ nishing turning I 0,05 1,0 - - - 280 265 265 -V15 [m.min-1_] II 0,10 - - - - 205 195 180 225 III 0,20 205 195 180 225 155 145 135 170 Semi-roughing turning I 0,20 2,5 190 180 165 210 150 140 130 165 II 0,30 160 150 140 175 110 105 95 120 III 0,40 145 135 130 160 85 80 75 95 Roughing turning I 0,40 5,0 135 125 120 150 80 75 70 90 II 0,60 115 110 - 125 60 55 50 65 III 0,80 100 95 - 110 50 45 40 55 Heavy roughing turning I 0,80 12 55 50 - - 25 20 - -V45 [m.min-1_] II 1,00 50 45 - - 20 15 - -III 1,30 45 40 - - 15 10 - -Parting, peripheral recesses and copying (CTP) 0,10 - - - 110 -V15 [m.min-1_] 0,15 - - - 102 -0,20 - - - 96 -0,30 - - - 87 -Face and internal recesses 0,10 - - - 75 -0,15 - - - 70 -0,20 - - - 68 -0,30 - - - 60 -Threading - - - -- - - -- - -

-M

HB = 180 ÷ 210 8b 5b ÷11b CORRECTION FACTOR kvx

10 1,10 30 0,84 15 1,00 45 0,76 20 0,93 60 0,71

30 1,10 60 0,93 45 1,00

HB kvHB HB kvHB <150 1,40 270-300 0,72 150-180 1,18 300-330 0,68 180-210 1,00 330-360 0,66 210-240 0,87 360-390 0,62 240-270 0,79

(31)

4 Grade

8016

8030

8040

Insert

shape

Level Feed

f

a

p [mm]

S...

C...

W..

T...

D...

K..

V...

R...

S...

C...

W..

T...

D...

K..

V...

(L...)

R...

S...

C...

W..

T...

D...

K..

V...

R...

Fine and ﬁ nishing turning I 0,05 1,0 140 130 125 155 125 120 110 140 - - - -V15 [m.min-1_] II 0,10 135 125 120 150 115 110 100 125 110 105 95 120 III 0,20 125 115 110 140 105 100 90 115 85 80 75 95 Semi-roughing turning I 0,20 2,5 - - - - 100 95 88 110 80 75 70 90 II 0,30 - - - - 80 75 70 90 70 65 60 75 III 0,40 - - - - 70 65 60 75 65 60 55 70 Roughing turning I 0,40 5,0 - - - - 65 60 55 70 60 55 50 65 II 0,60 - - - - 55 50 45 60 50 45 40 55 III 0,80 - - - - 50 45 40 55 45 40 35 50 Heavy roughing turning I 0,80 12 - - - - 35 35 - - 35 30 - -V45 [m.min-1_] II 1,00 - - - - 25 25 - - 30 30 - -III 1,30 - - - - 20 20 - - 25 25 - -Parting, peripheral recesses and copying (CTP) 0,10 - - - 105 - - - - -V15 [m.min-1_] 0,15 - - - 95 - - - - -0,20 - - - 91 - - - - -0,30 - - - 82 - - - - -Face and internal recesses 0,10 - - - 75 - - - - -0,15 - - - 67 - - - - -0,20 - - - 64 - - - - -0,30 - - - 55 - - - - -Threading - - - 130 - - - -- - - 120 - - - -- - - 110 - - -

-M

HB = 180 ÷ 210 8b 5b ÷ 11b CORRECTION FACTOR kvx

10 1,10 30 0,84 15 1,00 45 0,76 20 0,93 60 0,71

30 1,10 60 0,93 45 1,00

HB kvHB HB kvHB <150 1,40 270-300 0,72 150-180 1,18 300-330 0,68 180-210 1,00 330-360 0,66 210-240 0,87 360-390 0,62 240-270 0,79

(32)

31

4

face

rolled product

face

rolled product

-K

..A ..M ..G ..U ..N CNMA CNMM CNMG DNMA DNMM DNMG DNMU SNMA SNMM SNMG SNMX TNMA TNMM TNMG VNMU RNMA RNMM RNMG WNMA WNMM WNMG I 8016 F I 6630 F I 6620 M I 6630 M I 6620 R I 6630 R I 6630 HR I 6640 HR I I I II II 6640 R II 6620 II 6640 R II 6620 II 6640 R II II 8040 HR II II II

III III III III III III 8040

HR III III III III III

..X KNUX I I 6640 72 I 6620 73 I 6640 73 I 6620 74 I 6640 74 I I I I I II II 6630 72 II II II II II II II II II ..W ..T CCMW CCMT SCMW SCMT DCMW DCMT TCMW TCMT VCMW VCMT WCMW WCMT RCMW RCMT RCMX I 8016 UM I 6630 UM I 6630 UR I 6630 UR I I I I I I I II II 8016 II 6620 II 8016 II II II II II II II

III III III III III III III III III III III

..R ..N SPMR SPGR SPUN SPGN TPMR TPGR TPUN TPGN I 8016 I 8030 47 I 8016 I 8030 47 I I I I I I I II 6620 46, 47 II 6630 47, 48 II 6620 46, 47 II 6640 46, 47 II II II II II II II

..X LFMX, LFUX, LCMX

TN16E

I 8030 I 8030 I 8030 I 8030 I I I I I 8030 I 8030 I

II - II 6640 II 6640 II 6640 II II II II II 6640 II 6640 II

(33)

4 Grade

6620

6630

6640

Insert

shape

Level Feed

f

a

p [mm]

S...

C...

W..

T...

D...

K..

V...

(L...)

R...

S...

C...

W..

T...

D...

K..

V...

(L...)

R...

S...

C...

W..

T...

D...

K..

V...

(L...)

R...

Fine and ﬁ nishing turning I 0,05 1,0 - - - -V15 [m.min-1_] II 0,10 340 320 300 375 275 260 240 305 200 190 175 220 III 0,20 290 275 255 320 260 245 230 286 175 165 155 195 Semi-roughing turning I 0,20 2,5 275 260 240 300 250 235 220 275 170 160 150 185 II 0,30 250 235 220 275 205 195 180 225 135 125 120 150 III 0,40 230 215 200 255 185 175 165 205 115 110 100 125 Roughing turning I 0,40 5,0 215 200 190 235 170 160 150 185 105 100 90 115 II 0,60 195 185 170 215 145 135 130 160 85 80 75 95 III 0,80 185 175 165 205 125 120 110 140 75 70 65 80 Heavy roughing turning I 0,80 12 - - - - 85 80 - - 45 40 - -V45 [m.min-1_] II 1,00 - - - - 75 70 - - 40 35 - -III 1,30 - - - - 70 65 - - 35 30 - -Parting, peripheral recesses and copying (CTP) 0,10 - - - 110 -V15 [m.min-1_] 0,15 - - - 100 -0,20 - - - 90 -0,30 - - - 80 -Face and internal recesses 0,10 - - - 80 -0,15 - - - 70 -0,20 - - - 65 -0,30 - - - 60 -Threading - - - -- - - -- - -

-K

CAST IRONS Grey, malleable, nodular, creep-resistant

and special cast iron

CORRECTION FACTOR kvx

10 1,10 30 0,84 15 1,00 45 0,76 20 0,93 60 0,71

30 1,10 60 0,93 45 1,00

Workpiece hardness HB

kvHB - Sort of cast iron

grey nodular creep-resist.

150-180 1,40 1,15 -180-200 1,25 1,08 -200-220 1,10 1,03 -220-240 1,00 1,00 -240-280 0,86 0,95 -280-330 0,60 0,85 -260-300 - - 1,25 300-360 - - 1,00 360-450 - - 0,75 MATERIAL CORRECTION

Sort of cast iron kvM

grey 1,00

nodular 0,85 malleable 0,95 creep-resistant 0,40

(34)

33

4 Grade

8016

8030

Insert

shape

Level Feed

f

a

p [mm]

S...

C...

W..

T...

D...

K..

V...

(L...)

R...

S...

C...

W..

T...

D...

K..

V...

(L...)

R...

S...

C...

W..

T...

D...

K..

V...

R...

Fine and ﬁ nishing turning I 0,05 1,0 260 245 230 285 145 135 130 160 - - - -V15 [m.min-1_] II 0,10 230 215 200 255 135 125 120 150 - - - -III 0,20 - - - -Semi-roughing turning I 0,20 2,5 - - - -II 0,30 - - - -III 0,40 - - - -Roughing turning I 0,40 5,0 - - - -II 0,60 - - - -III 0,80 - - - -Heavy roughing turning I 0,80 12 - - - -V45 [m.min-1_] II 1,00 - - - -III 1,30 - - - -Parting, peripheral recesses and copying (CTP) 0,10 - - - 100 - - - - -V15 [m.min-1_] 0,15 - - - 90 - - - - -0,20 - - - 80 - - - - -0,30 - - - 70 - - - - -Face and internal recesses 0,10 - - - 70 - - - - -0,15 - - - 65 - - - - -0,20 - - - 60 - - - - -0,30 - - - 50 - - - - -Threading - - - 150 - - - -- - - 130 - - - -- - - 120 - - -

-K

CAST IRONS Grey, malleable, nodular, creep-resistant

and special cast iron

CORRECTION FACTOR kvx

10 1,10 30 0,84 15 1,00 45 0,76 20 0,93 60 0,71

30 1,10 60 0,93 45 1,00

Workpiece hardness HB

kvHB - Sort of cast iron

grey nodular creep-resist.

150-180 1,40 1,15 -180-200 1,25 1,08 -200-220 1,10 1,03 -220-240 1,00 1,00 -240-280 0,86 0,95 -280-330 0,60 0,85 -260-300 - - 1,25 300-360 - - 1,00 360-450 - - 0,75 MATERIAL CORRECTION

Sort of cast iron kvM

grey 1,00

nodular 0,85 malleable 0,95 creep-resistant 0,40

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DEFINITION OF BASIC CONCEPTS CUTTING GRADES PRAMET CHOICE OF TURNING TOOL CHOICE OF MILLING TOOL CHOICE OF DRILLING WEAR OF CUTTING INSERTS GRADE GROUPS EQUIVALENT TABLES Machined material main group ISO

face

rolled product

face

rolled product

-N

..A ..M ..G ..U ..N CNMA CNMM CNMG DNMA DNMM DNMG DNMU SNMA SNMM SNMG SNMX TNMA TNMM TNMG VNMU RNMA RNMM RNMG WNMA WNMM WNMG I I PKD I PKD I PKD I I I I I I I II II II II II II II II II II II

..X KNUX I I I 8016 72 I 8016 73 I 8016 74 I 8016 74 I I I I I II II II HF7 73 II HF7 74 II HF7 74 II II II II II II ..W ..T CCMW CCMT SCMW SCMT DCMW DCMT TCMW TCMT VCMW VCMT WCMW WCMT RCMW RCMT RCMX I I 8016 Al I 8016 Al I 8016 Al I 8016 Al I 8016 Al I I I I I II II HF7 Al II HF7 Al II HF7 Al II HF7 Al II HF7 Al II II II II II

III III PKD III PKD III PKD III III III III III III III

..R ..N SPMR SPGR SPUN SPGN TPMR TPGR TPUN TPGN I I 8030 47 I 8016 I 8030 47 I 8016 I 8030 47, 48 I I I I I II II 8016 II 8030 47 II 8016 II 8030 47, 48 II 8016 II II II II II

..X LFMX, LFUX, LCMX TN16E I 8030 I 8030 I 8030 I 8030 I I I I I 8030 I 8030 I II II II II II II II II II II II TN11... TN16... TN22 I I I I I I I I I I I 8030 34 ESC ESC

4

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35

4 Grade

Al alloys wrought, heat-treated HB = 100 Al alloys with amount Si > 12%

8016, 8030

HF7

PCD

Insert

shape

Level Feed

f

a

p [mm]

S...

C...

W..

T...

D...

K..

V...

(L...)

R...

S...

C...

W..

T...

D...

K..

V...

R...

S...

C...

W..

T...

D...

K..

V...

R...

Fine and ﬁ nishing turning I 0,10 1,0 900 - - - 700 - - - 850 - - -V15 [m.min-1_] II 0,15 800 - - - 650 - - - 600 - - -III 0,20 750 - - - 600 - - - 550 - - -Semi-roughing turning I 0,20 2,5 750 - - - 550 - - - 700 - - -II 0,30 600 - - - 480 - - - 550 - - -III 0,40 550 - - - 400 - - - 500 - - -Roughing turning I 0,40 5,0 450 - - - 400 - - - 500 - - -II 0,60 400 - - - 350 - - - 450 - - -III 0,80 300 - - - 300 - - - 400 - - -Heavy roughing turning I 0,80 12 - - - -V45 [m.min-1_] II 1,00 - - - -III 1,30 - - - -Parting, peripheral recesses and copying (CTP) 0,10 - - 650 - - - -V15 [m.min-1_] 0,15 - - 550 - - - -0,20 - - 450 - - - -0,30 - - 400 - - - -Face and internal recesses 0,10 - - 500 - - - -0,15 - - 450 - - - -0,20 - - 360 - - - -0,30 - - 320 - - - -Threading - 400 - - - -- 350 - - - -- 250 - - -

-N

Al alloys Cu alloys CORRECTION FACTOR kvx

Al alloys

Material kvN

Al alloys wrought non-hardened HB 60 2,6

Al alloys wrought hardened HB 100 1,0

Al alloys cast non-hardened HB 75 0,9

Al alloys cast hardened HB 90 0,6

Al alloys cast non-hardened HB 130 >12% Si PCD

Cu alloys

material kvN

Brass for automatic machine (>1% Pb) 1,8

Brass HB 90 0,76