Reference R1 ~ R7. Reference

Transcription

1 Technical Guidance

2 Reerence R1 ~ R7 Steel and Non-Ferrous Metal Symbols Chart... R2 Hardness Scale Comparison Chart... R4 Standard o Tapers... R5 Finished Surace Roughness... R6 Tolerance Chart or Round Matching Parts... R7 R1 Reerence

3 Reerence Steel and Non-Ferrous Metal Symbols Chart Carbon Steels High Speed Steels Austenitic Stainless Steels JIS AISI DIN JIS AISI DIN JIS AISI DIN S1C 11 C1 SKH2 T1 SUS21 AISI 21 S15C 115 C15 SKH3 T4 SUS22 AISI 22 S2C 12 C22 SKH1 T15 SUS31 AISI 31 S25C 125 C25 SKH51 M2 S6-5-2 SUS32 AISI 32 S3C 13 C3 SKH52 M3 1 SUS32B AISI 32B S35C 135 C35 SKH53 M3 2 S6-5-3 SUS33 AISI 33 DINX1CrNiS189 S4C 14 C4 SKH54 M4 SUS33Se AISI 33Se S45C 145 C45 SKH56 M36 SUS34 AISI 34 DINX5CrNi181 S5C 149 C5 S55C 155 C55 Ni-Cr-Mo Steels SNCM SNCM SNCM415 SNCM SNCM SNCM447 Cr Steels SCr415 SCr42 SCr Cr4 SCr Cr4 SCr Cr4 SCr Cr-Mo Steels SCM415 SCM42 SCM SCM CrMo4 SCM CrMo4 Alloy Tool Steels SKS11 F2 SKS51 L6 SKS43 W2-9 1/2 SKS44 W2-8 1/2 SKD1 D3 X21Cr12 SKD11 D2 Grey Cast Iron FC1 2 GG-1 FC15 25 GG-15 FC2 3 GG-2 FC25 35 GG-25 FC3 4 GG-3 FC35 5 GG-35 Nodular Cast Iron FCD4 GGG-4 FCD45 6/4/ 8 GGG-4.3 FCD5 65/45/12 GGG-5 FCD6 8/55/6 GGG-6 FCD7 1/7/3 GGG-7 SUS34L AISI 34L DINX2CrNi1911 SUS34NI AISI 34N SUS35 AISI 35 DINX5CrNi1812 SUS38 AISI 38 SUS39S AISI 39S SUS31S AISI 31S SUS316 AISI 316 DINX5CrNiMo17122 SUS316L AISI 316L DINX2CrNiMo17132 SUS316N AISI 316N SUS317 AISI 317 SUS317L AISI 317L DINX2CrNiMo18164 SUS321 AISI 321 SUS347 AISI 347 DINX6CrNiNb181 SUS384 AISI 384 Heat Resisting Steels SUH31 SUH35 SUH36 SUH37 SUH38 SUH39 AISI 39 SUH31 AISI 31 DINCrNi252 SUH33 AISI 33 Reerence SCM Mn Steels and Mn-Cr Steels or Structural Use SMn SMn SMn SMn SMnC42 SMnC443 Cr-Mo Steels SK1 W1-13 SK2 W1-11 1/2 SK3 W1-1 C15W1 SK4 W1-9 SK5 W1-8 C8W1 SK6 W1-7 C8W1 SK7 C7W2 Ferritic Stainless Steels SUS45 AISI 45 DINX6CrAl13 SUS429 AISI 429 SUS43 AISI 43 DINX6Cr17 SUS43F AISI 43F DINX12CrMoS17 SUS434 AISI 434 Martensitic Stainless Steels SUS43 AISI 43 SUS41 AISI 41 DINX1Cr13 SUS416 AISI 416 SUS42JI AISI 42 DINX2Cr13 SUS42F AISI 42F SUS431 AISI 431 DINX2CrNi172 SUS44A AISI 44A SUS44B AISI 44B SUS44C AISI 44C Ferritic Heat Resisting Steels SUH21 DINCrAl125 SUH49 AISI 49 DINX6CrTi12 SUH446 AISI 446 Martensitic Heat Resisting Steels SUH1 SUH3 SUH4 SUH11 SUH6 R2

4 Reerence Steel and Non-Ferrous Metal Symbols Chart Classiications and Symbols o Steels Class Material Symbol Symbol's Rationale Non-Ferrous Metals Class Material Symbol Structural Steels Rolled Steels or welded structures SM "M" or "Marine" - Usually used in welded marine structures Re-rolled Steels SRB "R" or "Re-rolled" and "B" or "Bar" Rolled Steels or general structures SS "S" or "Steel" and or "Structure" Light gauge sections or general structures SSC "C" or "Cold" Steel Sheets Hot rolled mild steel sheets / plates in coil orm SPH "P" or "Plate" and "H" or "Hot" Carbon steel tubes or piping SGP "GP" or "Gas Pipe" Carbon steel tubes or boiler and heat exchangers STB "T" or "Tube" and "B" or "Boiler" Copper and Copper Alloys Copper and Copper alloys - Sheets, plates and strips Copper and Copper alloys - Welded pipes and tubes CxxxxP CxxxxPP CxxxxR CxxxxBD CxxxxBDS CxxxxBE CxxxxBF Steel Tubes Seamless steel tubes or high pressure gas cylinders STH "H" or "High Pressure" Carbon steel tubes or general structures STK "K" or "Kozo"- Japanese word meaning "structure" Carbon steel tubes or machine structural uses STKM "M" or "Machine" Alloy steel tubes or structures STKS "S" or "Special" Alloy steel tubes or pipings STPA "P" or "Piping" and "A" or "Alloy" Carbon steel tubes or pressure pipings STPG "G" or "General" Carbon steel tubes or high temperature pipings STPT "T" or " Temperatures" Carbon steel tubes or high pressure pipings SPS "S" ater "SP" is abbreviation or "Special" Aluminium and Aluminium Alloys Aluminium and Al alloys - Sheets, plates and strips AxxxxP AxxxxPC AxxxxBE Aluminium and Al alloys AxxxxBD - Rods, bars and wires AxxxxW Aluminium and Al alloys - Extruded shapes AxxxxS Aluminium and Al alloy orgings AxxxxFD AxxxxFH Stainless steel tubes or pipings SUS-TP "T" or "Tube" and "P" pr "Piping" Carbon steels or machine structural uses SxxC "C" or "Carbon" Magnesium Alloys Magnesium alloy sheets and plates MP Steel or Machine Structures Tool Steels Special Steels Stainless Steels Aluminium Chromium Molybdenum steels SACM "A" or "Al", "C" or "Cr" and "M" or "Mo" Chromium Molybdenum steels SCM "C" or "Cr" and "M" or "Mo" Chromium steels SCr "Cr" or "Chromium" Nickel Chromium steels SNC "N" or "Nickel" and "C" or "Chromium" Nickel Chromium Molybdenium steels SNCM "M" or "Molybdenium" Manganese steels or structural use Manganese Chromium steels SMn SMnC "Mn" or "Manganese" "C" or "Chromium" Carbon tool steels SK "K" or "Kogu"- Japanese word meaning "tool" Hollow drill steels SKC "C" or "Chisel" "S" or "Special" Alloy tool steel "D" or "Die" SKS SKD SKT "T" or "Tanzo"- Japanese word or "orging" High speed tool steels SKH "H" or "High speed" Free cutting suluric steels SUM "M" or "Machinability" High Carbon Chromium bearing steels SUJ "J" or "Jikuuke"- Japanese word meaning "bearing" Spring steels SUP "P" or "Spring" Stainless steels SUS "S" ater "SU" is abbreviation or "Stainless" Nickel Alloys Wrought Titanium Castings Nickel-Copper alloy sheets and plates NCuP Nickel-Copper alloy rods and bars NCuB Titanium rods and bars TB Brass castings YBsCx High strength Brass castings HBsCx Bronze castings BCx Phosphorus Bronze castings PCBx Aluminium Bronze castings AlBCx Aluminium alloy castings AC Magnesium alloy castings MC Zinc alloy die castings ZDCx Aluminium alloy die castings ADC Magnesium alloy die castings MDC Heat-resistant Steels Heat-resistant steels SUH "U" or "Special Usage" and "H" or "Heat" Heat-resistant steel bars SUHB "B" or "Bar" Heat-resistant steel sheets SUHP "P" or "Plate" Carbon steel orgings or general use SF "F" or "Forging" White metals WJ Aluminium alloy castings or bearings AJ Copper-Lead alloy castings or bearings KJ Forged Steels Carbon steel booms and billets or orgings SFB Chromium Molybdenium steel orgings SFCM "B" or "Billet" "C" or "Chromium" and "M" or "Molybdenium" Nickel Chromium Molybdenium steel orgings SFNCM "N" or "Nickel" Grey cast irons FC "F" or "Ferrous" and "C" or "Casting" Cast Irons Spherical graphite / Ductile cast irons FCD "D" or "Ductile" Blackheart malleable cast irons FCMB "M" or "Malleable" and "B" or "Black" Whiteheart malleable cast irons FCMW "W" or "White" Pearlite malleable cast irons FCMP "P" or "Pearlite" Cast Steels Carbon cast steels SC "C" or "Casting" Stainless cast steels SCS "S" or "Stainless" Heat-resistant cast steels SCH "H" or "Heat" High Manganese cast steels SCMnH "Mn" or "Manganese" and "H" or "High" Reerence R3

5 Reerence Hardness Scale Comparision Chart Reerence Brinell Hardness (HB) 3,kg R4 "A" Scale 6kg (Brale) Rockwell Hardness "B" Scale 1kg ( 1 /1" Ball) "C" Scale 15kg (Brale) "D" Scale 1kg (Brale) Traverse ickers Shore Rupture Hardness Hardness Strength 5kg (kg/mm 2 ) (11.) (19.) (18.5) Brinell Hardness (HB) 3,kg "A" Scale 6kg (Brale) Rockwell Hardness "B" Scale 1kg ( 1 /1" Ball) "C" Scale 15kg (Brale) "D" Scale 1kg (Brale) Traverse ickers Shore Rupture Hardness Hardness Strength 5kg (kg/mm 2 ) (18.) (17.5) (17.) (16.) (15.5) (14.5) (14.) (13.) (12.) (11.) (18.8) (17.5) (16.) (15.2) (13.8) (12.7) (11.5) (1.) (9.) (8.) (6.4) (5.4) (4.4) (3.3) (.9) ) Figures within the ( ) are not commonly used 2) Rockwell A, C and D scales utilises a diamond brale

6 Reerence Standard o Tapers Morse Taper ød1 a ød α (Fig 1) With Tang Type R b ød1 C ød2 r 8 18' (Fig 2) Drawing Thread Type K S r ød1,, a ød ød3 ød2 ød1 6 α t Morse Taper Number Morse Taper Number (Units in mm) Taper Taper Tang Taper* Angle D1 Shape (α ) D d d1 + l1 l2 d2 C e b R r (Estimated) (Estimated) (Max) (Max) (Max) (Max) (Max) '27" '43" '5" '16" '15" Fig '26" '36" '22" Taper Taper Thread Taper* Angle D1 Shape (α ) D d d1 + l1 l2 d2 K t d3 r (Estimated) (Estimated) (Max) (Max) (Max) (Max) (Max) '27" '43" M '5" M '16" M '15" M Fig '26" M '36" M '22" M * The ractional values are the taper standards. + Diameters (D1) and (d1) are calculated rom the values o (D) and other values o the taper. (alues are rounded up to one decimal place) Bottle Grip Taper American Standard Taper (National Taper) Fig 1 Fig 2 L t1 L t4 t5 t2 t3 t b1 6 d5 d2 d3 g A Face 7/24 Taper d4 b1 D2 D1 6 ød1 ø,,,,,,,, 7/24 Taper ød,, a b Bottle Grip Taper (Units in mm) Taper No. D1 D2 t1 t2 t3 t4 t5 d1 (Standard) d2 d3 d4 L l2 l3 l4 g b1 t7 Reerence Shape BT M BT M Fig 1 BT M BT M American Standard Taper (National Taper) (Units in mm) Taper No. Nominal Diameter D d1 L l1 l2 l3 g a t b Shape /4" /2" /4" /8" Fig /4" " /4" /4" d5 l1 R5 Reerence

7 Reerence Finished Surace Roughness Types o Surace Roughness Measurements Types Symbol Method o Determination Maximum Height Ten-point Mean Roughness Calculated Roughness Ry Rz Ra This is the value (expressed in µm) measured rom the deepest valley to the highest peak o the reerence line, l, extracted rom the proile. (Disregard unusually high peaks and deep valleys as they are considered as laws.) From the proile, extract a portion to be the reerence line, l. Select the 5 highest peak and 5 deepest valleys. Measure the distance between the two lines and express it in µm. This method is to obtain a center line between the peaks and valleys within the reerence line, l. Fold along the center line to superimpose the valleys against the peaks. (Shaded portions with dashed outline on the right igure). Take the total shaded area and divided it by l in µm. Yp1 Descriptive Figure Yv1 Rp Yp2 Yv2 Ry Yp3 Yv3 Yp4 Rv Yv4 Roughness Curve Yp5 m Yv5 m Ra,,,,,,,,,,,,,,,,,,,,,,,, Designated values o the above types o surace roughness, standard reerence length values and the triangular symbol classiications are shown on the table on the right. Designated values or Ry (.5S).1S.2S.4S Designated values or Rz (.5Z).1Z.2Z.4Z Designated values or Ra (.13a).25a.5a.1a Standard reerence length values, l (mm).8s.8z.2a S 3.2S 6.3S 12.5S (18S) 25S (35S) 5S (7S) 1S (14S) 2S (28S) 4S (56S) 1.6Z 3.2Z 6.3Z 12.5Z (18Z) 25Z (35Z) 5Z (7Z) 1Z (14Z) 2Z (28Z) 4Z (56Z).4a.8a 1.6a.8 3.2a 6.3a a 25a (5a) (1a) Triangular Symbols Remarks: The designated values in the brackets do not apply unless otherwise stated. Reerence R6

8 Reerence Tolerance Chart or Round Matching Parts Tolerance or Shank Sizes Diameter, D(mm) Tolerance Class (µm) >D D b9 c9 d8 d9 e7 e8 e g5 g6 h5 h6 h7 h8 h Tolerance or Hole Sizes Diameter, D(mm) Tolerance Class (µm) >D D B1 C9 C1 D8 D9 D1 E7 E8 E9 F6 F7 F8 G6 G7 H6 H7 H H H Reerence R7

9 Turning Guidance T1 ~ T8 Selecting Cutting Conditions & Cutting... T2 Inluences o Cutting Edge Geometries... T3 General Guide Lines or Turning Tools... T4 Tool Lie... T5 Tool Failures and Their Counter-Measures... T6 Analysis o Chip Control on Turning... T7 Factors on Chip Control & Their Inluences... T8 T1 Turning

10 Turning Guidance Selecting Cutting Conditions & Cutting < Selection O Cutting Conditions > Cutting Conditions & Item Their Inluence Speed Feed Depth o Cut Inluencing Matters Work Eiciency, Tool Lie, Cutting Power Consumption & Surace Roughness Work Eiciency, Chip Control, Tool Lie, Cutting Power Consumption & Surace Roughness Working Eiciency, Chip Control, Cutting Power Consumption & Dimensional Accuracy Selecting Cutting Parameters Calculation o Cutting Speed, Table Feed & Cutting Time Calculating Rotating speed given the Cutting speed: N : Spindle Speed (rpm) N = 1 x : Cutting Speed (m/min) π x D D : Work Diameter (mm) π : 3.14 I extracting the Cutting Speed rom the Rotating Speed: π x D x N = The symbols are as 1 described in the above. Calculating the actual Table Feed (F) F = x N Finally, Calculating the actual Cutting Time (T) in mins. L T = F Where F is in mm/min Where L is the total cutting length Tool Materials and Cutting Speed Ratio HSS Carbide Coated Cermet Ceramic 1 3~6 5~15 5~1 1~25 N : Work Rotating speed (rpm) : Cutting speed (m/min) : Feedrate (mm/rev) d : Depth o cut (mm) D: Workpiece diameter (mm) Speed Ratio Related to Surace and Machining Conditions o The Work Turned Casting & Continuous Interuppted Surace Forging Faces Machining Machining < Cutting > Three Component Forces: Three Component Forces O Cutting Factors Aecting Cutting Factors Inluencing Cutting Factor Decrease < --Cutting --> Increase 1. Workpiece Low < -- Tensile Strength --> High 2. Cutting Area Small < -- Cutting Area --> Large 3. Cutting speed High < -- Cutting Speed --> Low 4. Rake Angle Large < -- Rake Angle --> Small (Positive) (Negative) 5. Approach Angle Small < -- Approach angle --> Large Relation Between Tensile Strength & Cutting Tensile Strength (kg/mm 2 ) 3~4 4~5 5~6 6~7 7~8 9~1 Determination O Cutting P1: Principal or Tangential Component Force P2: Feed Component Force P3: Back Component Force Determination o the Cutting P1 = Ps x q P1: Cutting (kg) Ps: Speciic Cutting (kg/mm 2 ) q: Area o the chip (mm 2 ) Cutting Ratio Cutting Area & Cutting Cutting Speed & Cutting Turning Determination O Power Requirement T2 Determination o Power Requirement W =..d.ps 6.12 x 13.η H = W.75 W : Power Requirement (kw) : Speed (m/min) : Feedrate (mm/rev) d : Depth o Cut (mm) η : Mechanical Eiciency H : Required Horsepower (HP) Approximate Ps value Normal Steel : 25~3 kg/mm2 Cast Iron : 15kg/mm2 Rake Angle & Cutting

11 Turning Guidance Inluences o Cutting Edge Geometries Edge Forms & Their Inluences Kind O Edge Forms 1. Back Rake 2. Top or Side Rake 3. Clearance Angle 4. Trail Angle 5. Approach Angle 6. Nose Radius Strength O Cutting Edge Cutting Edge Temperature Cutting Cutting Ability Tool Lie Surace Finished Chatter Chip Flow Direction Relation Between Rake Angle & Cutting Relation Between Rake Angle (α ) and Cutting Inluence O The Approach Angle : Approach Angle and Chip Thickness Chip Thickness and Speciic Cutting or Carbon Steels. *Relation To The Undeormed Chip Thickness. *Chip Thickness & Speciic Cutting. *Approach Angle & 3 Component Forces. Approach Angle and Three Component Forces Work Material: SCM44 (Hs38) Insert: TNGA22412 Conditions: = 1m/min =.45 mm/rev d = 4mm Inluence O the Nose Radius : *Nose Radius & 3 Component Forces *Nose Radius & Strength Nose Radius and Three Component Forces Work Material : SCM44 (Hs38) Insert: TNGA 224 Holder: PTGNR Conditions : = 1m/min d = 4 mm =.45 mm/rev Relation Between Nose Radius and Strength Workpiece : Grooved Material (Hs38) Conditions : =1m/min Insert : SNGA 124 ST1P d= 2 mm Holder : PSBNR =.2 mm/rev T3 Turning

12 Turning Guidance General Guide Lines or Turning Tools Surace Roughness Theoretical (Geometric) Surace Roughness Rmax = 2 8r Rmax : Surace Roughness (mm) : Feed (mm/rev) r : Nose Radius (mm) Steps To Improve Finished Suraces: 1. Enlarge the nose radius. 2. Optimise the cutting speed and eed. (To set conditions so that the built-up edge may not occur.) 3. Optimise the insert grade ariation o Surace Roughness According To The Nose Radius & Feed Actual Surace Roughness: In Case o Steels, Theoretical Roughness x 1.5~3 In Case o Cast irons, Theoretical Roughness x 3~5 Growth O The Built-Up Edge & Its Remedies Built-up edge is a state that while cutting, a portion o the workpiece piles up and adheres to the cutting edge due to work hardening. As an excessively harder degenerated substance than the base metal, the deposited material than acts as the cutting edge. Inluence o Built-up Edge Cycle o Built-up Edge 1. Deterioration o Surace Roughness And Accuracy. 2. Increase Edge Chipping Steps to Prevent Built-up Edge 1. Raise the cutting temperature by increasing the speed and eed. 2. Apply cutting luids that have a satisactory EP perormance. 3. Use coated or cermet tools. 4. Enlarge the rake angle. Dierent Edge Treatments & Their Eects Dierent Edge Treatments Inluence o the Width o Negative Land Inluence o the Honing Amount Figure Description Honing Turning Factors That Cause Chattering & Some O Its Remedies T4 r : Honing Amount θ : Angle O Negative Land l : Width O Negative Land Remedies Negative Land (Chamer Honing) Combined Honing Sharp Edge (w/o Edge Treatment) Poor Workpiece Rigidity Poor Tool Rigidity Poor Machine Rigidity Poor Cutting Conditions Poor Edge Design - Improve clamping. - Use a thicker shank. - Reduce backlash in - Select correct cutting - Reduce clearance - Use ixed steady. - Reduce the overhang. the main spindle conditions. angle. - Improve rigidity o the - Use a carbide shank Bearing - Change speed to - Reduce approach tail center. holder. - Eliminate backlash avoid the sympathetic angle. - Check that toolholder in machine slides vibration point. - Increase the end is held properly. cutting edge angle. - Reduce the nose radius. - Make the rake angle larger. - Hone the cutting edge slightly.

13 Turning Guidance Tool Lie Wear Process Curve Flank Wear Crater Wear B : Width o Flank Wear (Mean) C : Maximum Wear o Nose Radius N : Notch Wear Initial wear is very ast. It then evens out to a more gradual pattern until a limit is reached. From that limit point, the wear increases substantially. KT : Depth o Crater wear B : Width o land KM : Distance between the centre o the Crater wear and Cutting edge. Crater wear is more progressive, there is no sudden breakdown pattern. Lie Curve (-T Lines) At our speeds 1, 2, 3 and 4, the relative tool lives or a given lank wear B or crater KT are indicated as T1, T2, T3 and T4 respectively, using log-log graph paper. Flank Wear Flank Wear Lie Curve Wearing Process Tool Lie Equation Tool Lie Equation (Taylor's Equation) T n = C : Cutting speed T : Tool Lie n & C : Constants Determined by the Work Material, Tool Material, Tool Design, etc. Alternative Tool Lie Criteria 1. When surace inish deteriorates unacceptably. 2. When a ixed amount o tool wear is reached, (see the right hand table) 3. When work piece dimension is not tolerable. 4. When power consumption reaches a limit. 5. Sparking or chip discolouration and disiguration. 6. Cutting Time or Number o components produced. Width o lank wear or general lie determination or cemented carbides. Width o Wear (mm) ~ 1.25 Applications Finish Cutting o Nonerrous Alloys, Fine and Light Cut, etc. Cutting o Special Steels and The Like. Normal Cutting o Cast Irons, Steels, etc. Rough Cutting o Common Cast Irons. Turning T5

14 Turning Guidance Tool Failures and Their Counter-Measures Characteristic O Tool Failure No. Failure Cause 1~ Flank Wear Chipping Physical Partial Fracture Crater Wear Plastic Deormation Chemical Thermal Crack Built-up Edge Due to the scratching eect o hard grains contained within the work material. Fine breakages caused by high pressure cutting, chatter and vibration, etc. Due to mechanical impact when an excessive orce is applied to the cutting edge. Due to a combination o galling and welding between the chips and the top rake. The cutting edge is deormed due to its sotening at high temperature. Thermal atigue rom the heating and cooling cycle during interrupted cutting. The deposition and adhesion o the hardened work material on the cutting edge. Failure & Countermeasures Failure Excessive Flank Wear Edge Failure Excessive Crater Wear Cutting Edge Chipping Partial Fracture O Cutting Edges Tool Material Cutting Conditions Tool Material Tool design Cutting Conditions Tool Material Tool design Cutting Conditions Tool Material Tool design Cutting Conditions Basic Counter-measures - Use a more wear-resistant grade Coated Carbide Carbide --> Cermet - Decrease Speed { - Use a crater-resistant grade. Carbide > Coated (K--> M--> P) Cermet - Enlarge the rake angle - Select the correct chip breaker - Decrease speed, reduce the depth o cut and eedrate. - Use tougher grades. I carbides: P1 -> P2 -> P3 K1 -> K1 -> K2 - I built-up edge occurs, change to a less susceptible grade eg. cermets. - Reinorce the cutting edge eg. Honing. - Reduce the rake angle. - Increase speed (I there is edge buildup). - Use tougher grades. For carbides: P1 -> P2 -> P3 K1 -> K1 -> K2 - Use the holder with a larger approach angle. - Use a holder with a larger shank size. - Reduce the depth o cut and eedrate. Recommended Insert Grade: Steel Application Example Cast Iron Finishing T11A (Cermet) BN25 (CBN) Rough AC2 AC5G (Alumina (Alumina Coated) Coated) NS26C (Ceramic) Recommended Insert Grade: Steel Cast Iron Finishing T11A (Cermet) BN25 (CBN) Rough AC2 AC5G (Alumina Machining (Alumina Coated) Coated) Use MU Type Chip Breaker Recommended Insert Grade: Steel Cast Iron Finishing T12A (Cermet) AC5G (Coated) Rough AC3 AC5G (Alumina Machining (Alumina Coated) Coated) NS26 (Ceramic) Edge Treatment : All o our inserts have been honed in advance. Recommended Insert Grade: Steel Cast Iron Rough Machining AC2 /AC3 AC5G (Coated) Insert : Use UX Type Breaker Holder : Use Lever-lock Type NS26C (Ceramic) Built-up Edge Tool Material Cutting Conditions - Change to a grade which is more adhesion resistant. - Increase the cutting speed and eed. - Use cutting luids. Recommended Insert Grades : Cermets Turning Plastic Deormation Tool Material Cutting Conditions - Change to high thermal resistant grades. - Reduce the cutting speed and eed. Recommended Insert Grades : AC2 or AC3 T6

15 Turning Guidance Analysis o Chip Control on Turning Classiication O Chip Formation & Their Inluences Shape Categories or Chips Depth o Cut Excess Slight Curled Length A B C D E No Curling Over 5 mm Up to and including 5 mm 1 to 5 Turns Below 1 Turn Hal Turn Inluence O Chip Shapes Inluence Chip Shape Type A Type B Type C Type D Type E Tool lie Wear Chipping O X O X O O O O O X Quality Finished O O O O X Surace O O O O X O O O O X Machining X O O O O Transer Part Chips X X O O O Power Consumption Cutting Saety O X O O O O O O X X Overall Evaluation X O Excellent Excellent X O:Superior X:Inerior Remarks Continuous Random Shape Continuous Regular Shape Good Good Excessively Broken Chip Good chip control : Types C and D Unsatisactory chip control: - Type A : Twines around the tool and work material, causes the machine to stop, quality impairment on the machined surace or problems in saety. Type B : Causes perormance reduction o the chip's automatic transer system or even edge chipping. Type E : Causes such troubles as spray o chips, unsatisactory inished surace due to chattering, chipping o the cutting edges or increase in cutting resistance and heat generation. Factors To Determine Chip Formation (a) I Outlet Angle η = (b) I Outlet Angle η = 15 - Factors: Outlet Angle and Cutting Direction - Chip Forms According to The Combination o Factors Outlet Angle Cutting Direction I n = I n = / Upward Only Sideways Only Upward + Sideways Cylindrical Form Washer-Like Form Conical Form Spiral Form Types O Chip Breaking Figure o Chip Breaking Type Meanings Formation O Chips Flow Type Shear Type Tear Type Crack Type Work Obstructive Type Scroll Type Flank Obstructive Type Side Curl Type - Cause by the eect o the upward curl only, i the rake is too small. - Chip broken because it struck against the work end ace. - Caused by the upward curling orce when the rake angle is large. - Rolls in without breaking ater striking against the work end ace. - Removed spirally by the mixing o upward and sideways curls. - Strikes against the lank and breaks. - Occurs i the sideways curling actor is superior. - Strikes against the lank o the tool and breaks. Inluence Examples Condition Form Continuous Chip and satisactory surace inish Normal Cutting or Steels, Light Alloys, and Alloyed Cast Irons aa chip is Chip with the sliced -o at appearance o the shear angle being torn o. The workpiece surace is damaged. Low speed cutting or Steels and Stainless Steels Fine Cutting or Steels and Cast Irons at Excessively Low Speed The swar cracks beore reaching cutting edge,which then separates it rom parent work piece body. Cutting or General Purpose Cast Irons, Rocks, and Carbonous Materials Large <-- Work Deormation --> Small Large < Rake Angle > Small Slight < Depth o cut > Excess High <----- Cutting Speed -----> Low Turning T7

16 Turning Guidance Factors on Chip Control & Their Inluences Inluence On The Cutting Speed & Feed - The eective range o the chip breaker is reduced with the cutting speed being increased. Workpiece : S45C (Hs38) Insert : SNMG1248N-UX Holder : PSBNR At high speeds and small eedrates, lengthened chips will result. Cutting Conditions: d = 3 mm - At high speeds and large eedrates, packed chips will result. Inluence O The Feed & Cutting Depth - With small depths and small eeds, longer chips will be ormed. - With deeper depths and larger eeds, short chips will result. Workpiece : S45C (Hs38) Insert : SNMG1248N-UX Holder : PSBNR Cutting Conditions: = 15 m/min Inluence O The Nose Radius - Chips become unsusceptible to breakage when the nose radius is larger and the cutting depth is less. - Chips become thinner as the nose radius gets larger but their control is poor. Workpiece : S45C (Hs38) Insert : CNMG124 N-UX Holder : PCLNR Cutting Conditions: = 12 m/min =.3 mm/rev Inluence O The Side Cutting Edge Angle - I the side cutting edge angle becomes larger, the outlet angle and chips become larger and thinner respectively which makes the diicult to control. Workpiece : S45C (Hs38) Insert : SNMG1248N-UX Holder: PSBNR (Side Cutting edge angle 15 ) PSSNR (Side Cutting edge angle 45 ) Cutting Conditions: = 15 m/min d = 3 mm Inluence On The Rake Angle - Chips become thicker when the rake angle gets smaller but they are easier to control. For Small Top Rake Angle (α1) - The shear angle is small (φ1) - The chip is thick (t1) For Large Top Rake Angle (α2) - The shear angle is large (φ2) - The chip is thin (t2) Turning T8

17 Milling Guidance M1 ~ M7 Milling Cutter Nomenclature & Clamping Method... M2 Inluences o Cutting Edge Geometries... M3 Surace Finish... M4 Cutter Size & Number o Teeth... M5 Power Requirement, Cutting Conditions & Grades Selection... M6 Trouble Shooting Guide or Milling... M7 M1 Milling

18 Milling Guidance Milling Cutter Nomenclature & Clamping Method Cutter Parts Name Clamping Method or Each Cutter Size Cutter Body Adaptor External Diameter Internal Diameter Chart Type Figure D (mm) d (mm) (See diagram below) Chart 1 Arbor Type A Chart 2 Arbor Type A Chart 2 Arbor Type A Chart 2 Arbor Type A Chart 3 Centering Plug Type B Chart 3 Centering Plug Type B Chart 4 Centering Plug Type B Clamping Method : Type A Cutter Body Coniguration Diagrams Figure 1 Figure 2 Figure 3 Figure 4 Clamping Method : Type B Milling ( D: External Diameter, D 1 : External Diameter o Body, D 2 :External Diameter o Boss, d: Hole Diameter, F: Height, E: Thickness, a: Width o Key Way, b: Depth o Key Way) M2

19 Milling Guidance Inluences o Cutting Edge Geometries arious Cutting Angles & Their Functions Description Code Functions Inluences A.R Controls chip removal direction, R.R eects adhesion o the chips and thrust orce etc. 1. Axial Rake Angle 2. Radial Rake Angle 3. Approach Angle A.A Controls chip thickness and chip removal direction Rake angles can vary rom positive to negative (large to small) with typical combinations o positive and negative, positive and positive or negative and negative conigurations. The eect o the large approach angle is to reduce the chip thickness and cutting orce. 4. True Rake Angle T.A Eective Rake Angle 5. Inclination Angle 6. Wiper Flat Clearance Angle 7. Clearance Angle I.A F.A Ready Chart or True Rake Angles True Rake Angle T Controls chip removal direction Controls surace inish Controls edge strength, tool lie and chattering, etc - With a positive (large) angle, cutting ability and adhesion resistance are improved but the strength o the cutting edge is weakened. - With negative (small) angle, the strength o the cutting edge is improved but chips will tend to adhere more easily. - With a positive (large) angle, the chip removal is satisactory with less cutting resistance but the strength o the corner is weaker. A smaller clearance angle will produce a better surace inish. Ready Chart or Inclination Angles Inclination Angle I Example in using the above chart : Given: A(Axial Rake Angle) = +1 R(Radial Rake Angle) = -3 C(Approach Angle) = 6 Formula: tan T = tan R.cos C + tan A.sin C Combinations O Principal Angles & Their Features The eects o the various angle conigurations with relation to chip ormation and chip removal. A.R : Axial Rake angle R.R : Radial Rake angle A.A : Approach angle : Chip removal direction : Direction o cutter rotation Advantage Disadvantage Applications Typical Cutter (Sample) Chip orms Workpiece: SCM435 Condition : = 13m/min =.23 mm/tooth d = 3 mm Solution: T (True Rake Angle) taken rom the chart is = -8 Negative - Positive Cutter Double - Positive Cutter Double - Negative Cutter Best coniguration or chip removal with good cutting action Only single-sided inserts are available Suitable or Steels, Cast Irons Stainless Steels, Die Steels, etc. Example in using the above chart: Given: A(Axial Rake Angle) = -1 R(Radial Rake Angle) = +15 C(Approach Angle) = 25 Good Cutting Action Formula: tan I = tan A.cos C - tan R.sin C Less Cutting Edge Strength Only single-sided inserts are available. General Milling o Steels Low rigidity workpiece Economical using double sided inserts. Poor Cutting Action Milling o Cast Iron UFO Type DPG Type DNF Type Solution: I (Inclination Angle) taken rom the chart is = -15 M3 Milling

20 Milling Guidance Surace Finish Accuracy on Run-Out o teeth and Surace Finish The cutting edges o a cutter with multiple cutting positions will inevitably have some slight deviations. This is deined as the accuracy or runout o the teeth o which there are two kinds namely: the Axial Run-out o end cutting edges and Radial Run-out o peripheral cutting edges. O these two the axial run-out o end cutting edges in particular is an inluential actor o surace roughness. a. Axial Run-Out o The End Cutting Edges A dierence between the maximum and minimum cutting edge positions projected in the axial direction when rotating with reerence at the cutter center. - Comparison With Theoretical and Actual Roughness When Cutting With A General Cutter (Example): b. Radial Run-Out o The Peripheral Cutting Edges A dierence between the maximum and minimum cutting edge positions projected in the radial direction, when rotating with reerence at the cutter center. a: Axial Run-Out o End Cutting Edge : Feed per Tooth Theoretical Roughness Actual Roughness - Workpiece: Carbon Steel - Cutter dia. :16 mm No. o Teeth: 6 - Depth o Cut : 1mm Improving Run-Out o teeth: 1. Improve the dimensional tolerance o the inserts. - Accuracy o the inserts: (Units: mm) 2. Improve the dimensional Class A B T accuracy o the cutter body and its various components. F C K Improving Surace Finish: 1. Milling inserts with wiper lat Projecting one o the inserts more than the others so as to act as a wiper. - Inserts with Linear Wiper Flat (Face Angle: approx. 15'~1 o ) - Inserts with Curved Wiper Flat (Curvature is about 5 mm in radius) - Surace roughness by cutting edges without wiper lat: - Surace roughness by cutting edges with linear wiper lat: - Surace Roughness by The Wiper Flat System (Depending On Face Angles) : - Workpiece: Alloy Steel - Cutter: DPG516R (Single tooth) - = 154 m/min =.234 mm/tooth d = 2 mm - Face angles: A = 28' B = 6' 2. Built-in Wiper Insert System A method in which 1 or 2 inserts with a smooth curved edge (wiper inserts) are projected ractionally more than the others so that the working suraces are wiped lat. (UFO Type, DNF Type, etc.) h : Projected Amount o Wiper Insert Steels :.3~.7 mm Cast Irons :.7~.12mm = Feed per one revolution - Example O The Wiper Chip's Eect : - Workpiece: Cast Iron - Cutter: DPG41R - Insert: SPCH42R - Axial run-out:.15 mm - Radial run-out:.4 mm = 15 m/min =.29 mm/tooth (1.45 mm/rev) Milling 3. Where No Wiper Inserts Are Available Reposition inserts to achieve highest 2, 3 or 4 inserts equispaced around the cutter body so that each such high inserts can precede whatever number o lower inserts. Total eedrate/tooth should not bemore than 8% o wiper lat width. Hc: Surace Roughness by Standard inserts Hw: Surace Roughness by Wiper Inserts C: Standard inserts only D: With one wiper insert M4

21 Milling Guidance Cutter Size & Number o Teeth Selection o Cutter Size 1. Engage Angle Workpiece Steel +2 ~ -1 3 : 2 Cast Iron Below +5 5 : 4 Light Alloy Below +4 5 : 3 The above recommendations are based on a φ15mm cutter o on a 1mm wide steel block. 2. Mechanical Rigidity Machine Horsepower Optimum Engage Angle Ratio between the diameter o the cutter and the width o the workpiece Adaptive Cutter Size 3~5 PS 8 ~ 1 mm 7.5~1 PS 1 ~ 16 mm 15~3 PS 16 ~ 2 mm Feed Direction o Workpiece The engage angle (E) is deined as depicted above. - As tool lie will be shortened i E is large thereore a smaller E is preerable. - In order to change E : 1. Enlarge the size o the milling cutter. 2. Re-position o milling cutter. Relation With Tool Lie Relation with Cutter Position Relation with Cutter Size Large Cutter: Small Cutter: 3. Processing Time It is more eicient to select a correct cutter diameter as time can be wasted waiting or the cutter to run o the workpiece i too large a diameter is used. Selecting The Number o Teeth 1. Number o Simultaneous - Relationship Between The Number o Simultaneous Cutting Edges and Cutting Force: Cutting Edges - The minimum number o cutting edges simultaneously engaged in the workpiece should be about 2~4 teeth. - Less than this requirement will cause the work to shit due to impacts which may lead to insert ailure or more inerior surace roughness. - More than the requirement may cause deormation o the work, chattering and vibration. or 1 tooth in contact 1 tooth constantly in contact 1 or 2 teeth in contact Constantly 2 teeth in contact 2 to 3 teeth in contact. 2. Work Materials Workpiece Steel Cast Iron Light Alloy Number o Teeth Dx1~1.5 Dx2-1~Dx4 Dx1+α Cutter example and the number o teeth UFO416 (8 teeth) DHGF416 (11 teeth) APG416 (8 teeth) D: Nominal diameter o the cutter - Considerations o Work Materials: - Maximize the number o teeth or high eed milling o Cast Irons. (Rigidity o the machine and clamping must be suicient.) - For steels, the number o teeth should be reduced but eed per tooth should be increased. (Wide chip pockets and rigid cutter body are necessary) - Improve the eiciency o milling non-errous alloys by increasing the speed. - Examples O The Combination O Typical Cutters & Number O Teeth Application Steel Cast Iron Light Alloy High Feed Cutter Nominal Size UFO DHGF APG DP (Z) 1mm (4") mm (6") mm (8") mm(12") Other Conditions 1. For narrow workpieces, increase the number o teeth so that at least one tooth is always cutting. 2. When using unsteady machines and workpieces, the number o teeth should be reduced. Milling M5

22 Milling Guidance Power Requirement, Cutting Conditions & Grades Selection Power & Cutting 1. Determination o Power Requirement (Reer to the chart on the right) - Determination O The Power Requirement W = Ps x Q 6.12 x 13 - Speciic cutting resistance based on eed in relation to the work material. 2. Chip Removal 3. Factors Inluencing Cutting Cutting Factor will be... - I the inclination angle Reduced becomes large, - I the true rake angle Reduced becomes large, - I the cutting edge is Increased excessively honed, - I the approach angle Slightly becomes large, Increased - Determination O Horse Power Requirement H = W.75 - Calculation O Chip Removal Amount Q = L X F X d 1 W: Power Requirement (Kw) H: Horsepower Requirement (HP) Q: Chip Removal Amount (cm3/min) L : Width o cut (mm) F : Feed per minute (mm/min) d : Depth o Cut (mm) Ps: Speciic Cutting eg.steel : 25~3 Cast Iron:15 (Reer to chart on the right) 4. Comparison o Cutting Among Typical SEC-ACE MILLS Cutter Type UFO APG DPG Calculation Method o Cutting Conditions Edge angle A.R. R.R. A.A 15 o -4 o 45 o 18 o -2 o 25 o 8 o o 15 o - Calculation O Cutting Speed Cutting (kg) Work : Alloy Steel (HB25) Machine : Machining Center (15 HP) Conditions: =12m/min =.3mm/tooth d = 3mm = = π x D x N 1 - Calculation O The Feed F = x Z x N F Z.N : Cutting Speed (m/min) π : 3.14 D: Cutter Diameter (mm) N: Revolution (rpm) F: Feed (mm/min) : Feed per tooth (mm/tooth) Z: Number o Teeth Selection o Insert Grade 1. Requirements: - Good Wear Resistant eg. Coated grade - Good Toughness eg. Tough carbide grade - Good to Thermal cracks eg. Tough carbide grade - Adhesion resistant eg. Cermet grade Milling 2. Recommended Insert Grade Depends on Work Material M6

23 Milling Guidance Trouble Shooting Guide or Milling Suggested Remedies or Common Faults Trouble Excessive Flank Wear Insert Grade Basic Remedies - Use more wear-resistant Grade. Carbide P3 ---> P2 ---> Coated K2 ---> K1 Cermet Cutting - Decrease speed and increase eed. Conditions Proven Remedies - Recommended Insert Grade Steel Cast Iron Light Alloy Finishing T25A (Cermet) G1E (Carbide) DA22(SumiDia) A3N (Carbide) Roughing AC23 (Coated) G1E (Carbide) EH2Z (Coated) Excessive Crater Wear Insert Grade - Use more crater-resistant grade. Carbide (K ---> M ---> P) ---> Cermet Coated - Recommended Insert Grade Steel Cast Iron Light Alloy Finishing T25A (Cermet) G1E (Carbide) DA22(SumiDia) Edge Failure Cutting Edge Chipping Cutting Conditions Insert Grade Insert Design - Decrease speed and reduce tahe depth o cut and eed. - Use tougher grade. Carbide P3 ---> P2 ---> P3 K1 ---> K1 ---> K2 - Use negative-positive edge type cutter with a large approach angle. - Reinorce the cutting edges (by honing). Roughing AC23 (Coated) AC211 (Carbide) EH2Z (Coated) - Recommended Insert Grade : Steel Cast Iron Roughing A3N (Carbide) G1E (Carbide) - Recommended Cutter : SEC-UFO Type Partial Fracture o Cutting Edges Cutting - Reduce eed. Conditions Insert Grade Insert Design - Excessively low speed or eed, use a grade which is more adhesion resistant. - Thermal cracking, use a more thermal resistant grade. - Use negative-positive (or negative) edge type cutter with a large approach angle. - Enlarge the insert size (thickness in particular) - Recommended Insert Grades : Steel Cast Iron Finishing T25A (Cermet) G1E (Carbide) Roughing AC325 (Coated) ACZ31 (Coated) EH2Z (Coated) - Recommended Cutters : SEC-UFO Type - Insert Thickness : From 3.18mm to 4.76mm Cutting Conditions - Select conditions suitable to applications. Unsatisactory Surace Finish Insert Grade Tool Design Cutting Conditions - Use a more adhesion resistant grade. Carbide ---> Cermet - Improve axial run-out o the cutting edges. (Use cutter with less run-out on edges with proper setting o the inserts ) - Use wiper insert. - Use a special purpose cutter or inishing. - Increase speed. - Recommended Cutters & Insert Grades : Steel Cast Iron Light Alloy General Cutter UFO Type DHGF Type APG Type Purpose Insert T25A (Cermet) G1E (Carbide) EH2Z For Cutter PF Type PF Type APG Type Finishing Insert T12A (Cermet) Ceramic Insert (With Wiper Chip) Only DA2 (SumiDia) Others Chattering Unsatisactory Chip Control Tool Design Cutting Conditions Others Tool Design - Use positive cutter with a large rake angle. - Use irregular pitched cutter. - Reduce eed. - Improve clamping o the workpiece and cutter. - Use Negative (R.R)-Positive (A.R) Cutter - Reduce the number o teeth - Enlarge the chip pocket - Recommended Cutters : For Steel : UFO Type, EHG Type For Light Alloys : APG Type For Cast Iron : DHG Tyoe - Recommended Cutters : UFO Type, EHG Type Edge Chipping on Workpiece Tool Design Cutting Conditions - Enlarge the approach angle - Reduce eed - Recommended Cutters : UFO Type, EHG Type Burr on Workpiece Tool Design - Use a positive cutter - Recommended Cutters : UFO Type, EHG Type Cutting Conditions - Increase speed Milling M7

24 Endmilling Guidance E1 ~ E1 Endmill Nomenclature... E2 Sumitomo s Endmills & Cutting Conditions... E3 Cutting Proile & Perormance... E4 Cutting Proile & Accuracy... E5 Perormance Characteristics... E6 Cutting Fluid... E7 Features and Perormance o PD Coated Carbide Endmills... E8 High Speed Endmilling... E9 Trouble Shooting Guide or Endmilling... E1 E1 Endmilling

25 Endmilling Guidance Endmill Nomenclature Technical Terms Edge Shapes Endmilling E2 No. Endmill Type Feature o The Type o Endmills Applications 1 Square Endmills - Angle o its peripheral cutting edges is 9 o - For milling key ways and "i"-shaped grooves. 2 Radius Endmills - Corners between peripheral cuting edges and end - For applications between cutting edges have a radius. 1 & 3. 3 Ball Nose Endmills - End cutting edges are spherical in shape. - For copying operations o die moulds, etc. 4 Taper Endmills - Side cutting edges are tapered at an angle. - For milling die punches. 5 Taper Ball Nose Endmills - Combination o 3 and 4. - For copying operations on die moulds, etc. 6 Roughing Endmills - Side cutting edges have jaggered teeth - For roughing operations. 7 Formed Endmills - Side cutting edges have a pre-ormed proile - For special side proiles.

26 Endmilling Guidance Sumitomo s Endmills & Cutting Conditions Sumitomo s Endmills - Solid Endmills 1. Spiral Endmill - SSM,HHM,HHMR,SSHE 2. High Helix Endmill - HSM 3. Ballnose Endmill - SSB,SHB 4. Cermet Ballnose Endmill - SFB-T 5. Cermet Endmill - SFM-T 6. Tapered Endmill - STRM 7. Tapered Endmill - STM 8. Brazed Endmill - MES 9. Endmill or Graphite (Ballnose) - GBM 1. Endmill or Graphite (Square) - GSM - Indexable Type 1. SEC-Repeater Wavemill - WRM 2. SEC-Wavemill - WEM 3. SEC-Multi Mill - UFO 4. SEC-Wavemill - WMM 5. SEC-Bore Endmill - HKE 6. SEC-ACE Ballnose Endmill - RBM 6 7. SEC-Wavemill - WBMR 8. SEC-Wavemill - WBMR 9. SEC Helical Endmill - CMS 1. SEC Chamering Endmill - SCP Calculation O Cutting Conditions or Normal Endmills 1. Cutting Conditions 2. Feed 3. Depth o Cut - Calculation o Cutting Speed = π x D x N 1 N = 1 x π x D - Feed Calculation F = N x r r = F N F = N x t x Z t = r = Z - Depth o Cut Ad = Axial depth o cut Rd = Radial width o cut F N x Z : Cutting speed π : 3.14 D: Endmill diameter (mm) N: Spindle speed (rpm) F: Feedrate (mm/min) r: Feed per revolution (mm/rev) t: Feed per tooth (mm/teeth) Z: Number o teeth Calculation O Cutting Conditions or Ballnose Endmills 1. Boundary o Cutting - Calculation o Boundary o Cutting D1 = 2 x 2 x R x Ad - Ad2 2. Cutting Speed 3. Feed - Calculation o Speeds and Feedrate or the Ballnose endmills are the same as those or Normal endmills E3 Endmilling

27 Endmilling Guidance Cutting Proile & Perormance Cutting Directions 1. Up cut 2. Down cut - Corner Milling - Grooving Perormance Comparison - Abrasion Rate o Teeth - Surace Roughness - Cutting Conditions Work : SCM435 (Hs 36~37) Tool : SSM21 (φ1mm, 2 teeth) Conditions: = 5 m/min =.5 mm/tooth Ad = 15 mm Rd = 5 mm Corner Milling Dry cut Chip Control SSM28 SSM48 KSM28 SFM28 HSM38 Corner Milling Down Cut Up Cut Work: Pre-hardened Steel (HRC4) Cutting Conditions - Corner milling : = 25 m/min =.16 mm/rev Ad = 12 mm Rd =.8 mm Endmilling E4 Grooving Cutting Conditions - Grooving: = 25 m/min =.5 mm/rev Ad = 8 mm Rd = 8 mm

28 Endmilling Guidance Cutting Proile & Accuracy Precision 1. Bending o machined surace 2. Straightness 3. Roughness 4. Waviness 5. Displacement Relation Between Cutting Condition and Bending o Machined Surace Corner Milling Work: Pre-Hardened steel Condition: = 25 m/min Ad = 12 mm Rd =.8 mm Grooving Work: Pre-Hardened steel Condition: = 25 m/min Ad = 8 mm Rd = 8 mm Feed Direction.16 mm/rev.11 mm/rev Feed Direction.5 mm/rev.3 mm/rev Cat. No. Up Cut Down Cut Up Cut Down Cut Cat. No. Up Cut Down Cut Up Cut Down Cut HSM38 SFM28 KSM28 SSM48 SSM28 HSM38 SFM28 KSM28 SSM48 SSM28 E5 Endmilling

29 Endmilling Guidance Perormance Characteristics Number o Teeth Perormance Condition Perormance Parameters No. o teeth 2 4 Perormance Condition Perormance Parameters No. o teeth 2 4 Tool Strength Twist Rigidity Bending Rigidity Chip Control Chip Packing Chip Removal Surace Roughness Tool Lie S5C (HB2) ~ SKD11 (HB32) Roughness Undulation Bending o Machined Surace Fixed Feed (mm/tooth) Fixed Eiciency Finishing Breakage Wear Breakage Wear Boring Grooving Cornering Counter Boring Surace Roughness Hole Expansion Chip Removal Groove Expansion Key Way Grooving Surace Roughness Chattering Cutting Range Light Cutting Alloy Steels Heavy Cutting : Excellent : Good Work Material Cast Irons Non-errous alloys Hard-To-Cut Materials Helix Angles Helix Angle 3 o 6 o Cutting Surace Roughness Tool Lie Bending o Torque Bending ertical Roughness Undulation Machined Flank Peripheral Force Surace Wear Wear Breakage Catalogue No. SSM 2 / SSM 4 HSM 3 : Excellent : Good : Fair Helix Angle and Cutting Force Cutting Force (Kg) X (Feed Force) Y (Back Force) Z (ertical Force) SSM28 SSM48 HSM38 SSM28 SSM48 HSM38 SSM28 SSM48 HSM38 Work: Pre-hardened steel Tool : SSM28 (3 o ) SSM48 (3 o ) HSM38 (6 o ) Condition: = 25 m/min =.8 mm/teeth Dry cut Flute Length Depth o cut (mm) Endmill SSM45 Flute Length 12 mm Work: S5C (HB23) Condition: = 3 m/min =.2 mm/rev Down cut LSM45 Flute Length 18 mm Endmilling ELSM45 Flute Length 3 mm Cannot be machined E6

30 Endmilling Guidance Cutting Fluid Features Water Soluble Cutting Fluid Non-water Soluble Cutting Fluid Chlorinated oil Solution type Soluble type Emulsion type Sulo-chlorinated oil Lubricity Adhesion Iniltration Cooling Eect Rust Prevention Smoking Odour Cutting Fluid and Tool Lie Test Example: Machine : Mazak 15 Work material : 1) Stainless Steel 2) Alloyed Steel Tooling : SSM25 (dia: 5 mm, 2 teeth, Helix angle: 3 o ) Cutting Conditions: Cutting Speed: 3, 5, 7 m/min Feedrate :.3 mm/rev Depth o cut : Ad = 7. mm Rd = 1. mm Cutting Direction : Down cut Cutting Fluid : Non-water soluble cutting luid Results 1) Stainless Steel (HB 18) Findings: - Cutting luid does not inluence cutting perormance o coated endmills. Perormance is stable under any cutting speed. - Non-coated endmills are not practical to use at = 3 m/min because o chipping. Better perormance with non-water soluble luid as cutting speed increases. A more practical cutting speed is 5 m/min but it has a rather limited application range. 2) Die-mould Steel (HRC 48) Findings: - Non-water soluble luid is slightly better or coated endmills. Perormance is basically stable under any cutting speed. - Apparently non-water soluble luid is more stable or uncoated endmills. At lower cutting speeds, perormance is better. Non-water soluble luids are more practical or uncoated endmills at cutting speeds below 3m/min E7 Endmilling

31 Endmilling Guidance Features and Perormance o PD Coated Carbide Endmills Wide Range o Cutting Speeds Work: SUS34 (HB 18) Endmill size: Dia 5 mm, 2 lutes H.S.S Uncoated Coated Cutting Conditions: Feedrate :.3 mm/rev Depth o cut : Ad= 7mm Rd= 1mm Results: - Coated endmills show the least lank wear without welding and are stable at any speeds. - Uncoated endmills were out perormed by H.S.S at low cutting speeds (= 2m/min) and show lank wear at high cutting speeds. Their perormance was best at around = 5m/min. - H.S.S endmills work at speeds o less than = 2m/min but early racture occurs at over = 5m/min. Excellent Surace Roughness Results: - Coated endmills produce an excellent surace roughness o about 2~3 µm. This is due to the wear resistance o the coated layer. Optimum Machining or Hard-to-cut Materials Results: - Coated endmills show the least lank wear and could perorm over 3 times better than uncoated endmills. - Uncoated endmills can work only at around = 3 m/min Endmilling E8

32 Endmilling Guidance High Speed Endmilling Perormance Comparison by grade A high speed cutting perormance comparison between carbide, coated carbide and H.S.S endmills were conducted. ( Note: At cutting speeds o over 7 m/min, an endmill with edge treatment is most eicient.) Cutting Conditions Work Tool : SCM44 (HRC3) : SSM28, SSM28ZX, H.S.S Tool (8 mm, 2 teeth) Cutting speed ()= 3, 5, 7, 1 m/min Feedrate ( )=.4 mm/teeth Depth o cut (d): Ad = 12 mm Rd =.8 mm Up cut, Water soluble luid E9 Endmilling

33 Endmilling Guidance Trouble Shooting Guide or Endmilling Standard Steps or Common Problems Trouble Basic Remedies Details Excessive wear on periphery and end cutting edges Tool material Cutting conditions - Use higher wear-resistant grades - Decrease speed and increase eed - Examine cutting luids - For solid endmills - change rom uncoated to coated endmills eg. SSM-ZX type - Cutting luids - change rom water soluble type to non-water soluble type. Edge Failure Chipping o the cutting edges Cutting conditions Machine and others - Reduce eedrate - Use down-cut milling - Reduce the depth-o-cut - Remove backlash on the machine - Stronger clamping o the workpiece - Reduce the amount o overhang Tool breakage while cutting Cutting conditions Tool - Increase speed - Decrease eedrate - Decrease depth-o-cut - Shorten the length o cut - Reduce the amount o overhang - I the spindle speed is not ast enough, use an arbor speed inducer Tool material - Use materials that have a high Young's Modulus Unsatisactory surace inish Poor surace inish: - Surace roughness - Surace waviness - Surace squareness Chattering marks Tool Cutting conditions Others Cutting conditions Others - Enlarge the helix angle - Increase the number o lutes - Shorten the length o cut - Reduce eedrate - Reduce the depth-o-cut - Use up-cut milling - Prevent build-up on the cutting edge - Decrease speed - Use down-cut milling - Use cutting luid - Ensure that both the workpiece and tool are properly secured - Use High-Helix Spiral Endmills (HSM type) - Change the endmill rom 2 teeth to 4 teeth (ex. SSM2 type change to SSM4 type) - Check the clearances between the chuck, collet and endmill Others Packing o chips Tool Cutting conditions - Reduce the number o lutes - Reduce eedrate - Reduce the depth o cut - Change the endmill rom 4 teeth to 2 teeth (ex. SSM4 type change to SSM2 type) Endmilling E1

34 Drilling Guidance D1 ~ D11 Twist Drill Nomenclature... D2 Comparison Table o Each Multidrill Type... D2 arieties o Classiication or Drills... D4 Machine Rigidity... D5 Clamping Selection... D6 Oil Coolant... D7 Hole Accuracy... D8 Relationship Between Hole Depth & Cutting... D9 Remarks on Using Longer Drills (KDS-DA, KDS-FA)... D1 Trouble Shooting Guide & Remedies or Twist Drills... D11 D1 Drilling

35 Drilling Guidance Twist Drill Nomenclature Comparison Table o Each Multidrill Type 1. Point Angle Point Angle Characteristics & Consequences Small Large Small > Torque Thrust Burr > > > > > Large Small Large MultiDrill K Type MultiDrill P Type MultiDrill HK Type MultiDrill G Type MultiDrill A Type MultiDrill BA Type Point Angle and Cutting 2. Helix Angle Helix Angle Good Bad Small > Cutting Chip Twist Flow Rigidity > > ----> > ----> Bad Good Large Point Angle & Burr 3. Back Taper Big Small Few Drilling Back Taper Small -----> Cutting -----> Big -----> Number o Regrinds -----> Many D2

36 Drilling Guidance 4. Relie Angle Characteristics & Consequences 15 Small Small Large MultiDrill K Type MultiDrill P Type MultiDrill HK Type MultiDrill G Type MultiDrill A Type MultiDrill BA Type Minimum Relie Angle 5. Web Thickness Relie Angle % -----> -----> -----> Cutting Tool Run Edge Wear Out -----> -----> -----> Large Large Stable Large Large Strong 12 ~ 8 Web Thickness and Thrust (Eect o the Thinning) Web Thickness 25% 2% 18% 1% > > -----> > -----> Twist Bending Thrust Rigidity > Small Small Weak 6. Chisel Width 7. Flute Width Ratio Chisel Width Flute Width Ratio Wide Narrow (Zero) 2..5 Large Diicult Weak > Centripe- Thrust tance Rigidity > > -----> > > Small Easy Strong Small Weak Good > > > Twist Bending Chip Rigidity Removal > > > Large Strong Bad The thinning makes concentrating thrust small. This means easy cutting, good chip removal and longer tool lie. Small Chisel Width by the Thinning (Thinning Example) 8. Edge Treatment Width 9. Edge Treatment Angle Edge Treatment Width Edge Treatment Angle Wide Zero Big Zero Large > Cutting > Small Large > Cutting > Small Strong > Strength o the edge > Weak Strong > Edge Strength > Weak S Type: Standard web thinning N Type: Mainly on thinner webs X Type: For hard-to-cut material and deep holes Edge Treatment Width & Cutting Drill: MultiDrill KDS215MA Edge Treatment Width: :.15 mm :.23 mm Work: S5C (HB23) Cutting Conditions: = 5 m/min Water Soluble Oil D3 Drilling

37 Drilling Guidance arieties o Classiication or Drills 1. Classiication According to Type No. Type Descriptions Illustrations 1 Solid Drill A drill which is wholly composed o the same material eg. hard alloys. 2 Solid Carbide-End A drill which has a carbide portion o a deined length brazed to its tip. (1) (2) 2. Classiication According to Shank Conigurations 3. Classiication According to The Length 4. Classiication According to The Helix Angle 5. Classiication According to Proiles 6. Classiication According to Functions and Applications 3 Tipped Drill A drill that has brazed carbide tips. 4 Throw-Away Tipped A drill which uses throw-away inserts which Drill are mechanically clamped on its tip. 5 Straight Shank Drill A drill with a cylindrical ormed shank. (There are also straight shank drills with tennon or threaded drivers.) 6 Taper Shank Drill A drill with a Morse taper shank. (There are also threaded morse taper shank drills.) 7 Stub Drill A drill with a much shorter overall length as compared to a normal drill o the same diameter. 8 Regular Length Drill A drill with a standard market length. 9 Long Drill A drill with a longer overall length as compared to a normal drill o the same diameter. 1 Twist Drill A drill with let or right handed lutes twisting along the length o its body. 11 Straight Fluted Drill A drill with no twists in its lutes. 12 Oil Hole Drill A drill with through-tool coolant holes. 13 Sub-land Step Drill A drill with two diameter sizes with an individual lute or each diameter size. 14 Double Margin Drill A drill with two luted lands. 15 Flat Drill A straight luted drill with a plate-like cutting portion. 16 Step Drill A drill designed to perorm step drilling or to produce a countersunk hole. 17 Core Drill A drill which has no center point cutting but is used or inishing or reaming o predrilled holes. 18 Center Drill A drill is used or making pilot holes. 19 Gun Drill A long drill used on a special machine or drilling o very long holes. 2 Spade Drill A straight luted drill having a plate-liked ormed cutting portion, usually mechanically held inixed to the body. 21 Pivot Drill A drill with its diameter size dierent rom its shank diameter. 22 Micro Drill A small sized drill used to drill circuit boards or electronic equipment. (3) (4) (5) (6) (7) (8) (9) (1) (11) (12) (13) (14) (15) (16) (17) (18) (19) (2) (21) (22) 7. Classiication According to Materials o The Cutting Portion High Speed Steel A drill made wholly out o H.S.S. material. eg. SKH9, SKH55, M7, M33, etc Drill Carbide Drill A drill made wholly out o Carbide material. eg. Carbides - K1 & K2, ultracorpuscle alloys etc. Drilling D4 Coated Drill The above-mentioned drills with coating eg. Corresponding to our Multidrills Others A drill with either a sintered CBN or PCD eg. Corresponding to our SumiDia drill tip. drills.

38 Drilling Guidance Machine Rigidity Machine Capacity 1. Power Consumption & Thrust Formula or Multi Drills Carbide Drills are used or high eiciency cutting. In order to realize their capabilities ully, use rigid and powerul machines. Power Consumption = (HB x D.68 x 1.27 x.59) / 36 Thrust =.24 x HB x D.68 x.61 Power Consumption (kw) HB: Brinell Hardness : elocity (m/min) Thrust (kg.) D : Drill Diameter : Feedrate (mm/rev) On the designing the machine, please multiply 1.6 on Power Consumption and 1.4 on Thrust. 2. Power Consumption &Thrust Formula or WDS-Drill Spindle When using above chart, please consider the motor power and machine rigidity especially during high eiciency drilling (high thrust) where it requires high rigidity o the spindle. Although it is important to consider the horsepower requirements, the structure and o the main spindle axle is also an important actor or considerations. In general machining centres, rigidity o the machine's coniguration are as speciied: 1) BT5 > BT45 > BT4 2) single axle>plural axle Clamping As high eiciency drilling enhances a large horizontal cutting orce in addition to large thrust and torque orces, it is thereore essential to have a rigid and stable clamping. D5 Drilling

39 Drilling Guidance Clamping Selection 1) Delection Accuracy 2) Rigid Clamping Both are very important actors or carbide drilling, it is thereore important to select a suitable clamping system as recommended below. 1) External Coolant Spindle Head Drill Shank Tapered Straight Straight with Tang Straight with Flat ace Tapered Holder Taper Holder Sleeve Milling Chuck Collet Holder Drill Chuck QC Type Taper Holder stub holder Sleeve Side Lock Holder Chucking Brazed Carbide- Tipped Drill + Drill MultiDrill (Type K,P,G) MultiDrill (Type A,FA) Economical Solid Carbide Drill :Excellent :Good :Poor 2) Internal Coolant 3) Correct Operation Drilling D6

40 Drilling Guidance Oil Coolant 1. Selection O Oil To maximise the hole accuracy and tool lie, the most suitable cutting luid or MULTI DRILLS is non-water soluble (neat) cutting oil but one must be careul about the development o smoke and ire. Please supply in adequate volume. Neat oil is not suitable at high speeds. (>4 m/min). At high speeds, the most suitable cutting luid is water-emulsiiable, high density oil. (7-1 times dilution.) Soluble oil and Chemical luids are not recommended. 2. Features Lubricity Adhesion Permeability Cooling Capability Rust Smoke Retardant Odor Water Soluble Oil Emulsiiable Oil Soluble Oil Solution Oil + Non Water Soluble Oil Chlorinated Oil Sulo-Chlorinated Oil 3. Oil Supply Internal Supply For Milling Application Special Purpose Machine Machining Centre Internal Supply Holder With Rotating Oil Supply Higher oil pressure and large amounts o oil are desirable. Min. pressure is 3~5 kg/cm 2. Min. volume is 2~5 l/min. Lathes Holder External ertical Horizontal 4. Examples Brake Hose Part Low Carbon Steel (HB15~16) Work Drill Machine Conditions Results Remarks MDS11SK Dia. 11mm NC Lathe =66m/min =.35mm/rev -Productivity was 2.2 times higher -Tool lie was 6.7 times higher - Good hole accuracy which can omit reaming process Construction Machine Part Low Carbon Steel (HB15) KDS24LA Dia. 24mm Machining Centre =65m/min =.35mm/rev -1.6 times tool lie by using emulsiiable oil Machine Part Alloy Steel (HB28) KDS194LA Dia. 19.4mm NC Lathe =6m/min =.25mm/rev -1 times dilution is good. -5 times may be too dense Drilling D7

41 Drilling Guidance Hole Accuracy 1) Selection o the Drill Diameter The chart below shows the actual expansion o the hole diameter or various types o materials, please consider these expansion when selecting a drill. Drill Sot Steel General Steel Ductile Cast Iron Cast Iron Aluminium Alloy Steel MDS Type +2 ~ +5 ~ +3 ~ +4 ~ +4-1 ~ +4 KDS Type +2 ~ ~ ~ ~ +5 ~ +4 Example : I you want to drill a hole o diameter 13.1 ~ on sot steel, the drill diameter to be selected should be φ13.1 (MDS131MP) 2) Run-Out o the Drill Run-out o the drill at the edge and near the center are important. A: Dierence ater thinning B: Lip Height Dierence 3) Delection Accuracy (Tool rotating) The run-out o the drill ater chucking should be within.3mm. The big run-out will cause oversized holes and when used on a machine with low rigidity, it may cause drill breakage. 4) Delection Accuracy (Work rotating) On a lathe, the run-out at both positions A and B should be within.3mm. Drilling 5) Uneven Work Suraces D8 I the surace o the workpiece is not lat at the entrance and exit points, the eedrate should be reduced to about.1~.5 mm/rev.

42 Drilling Guidance Relationship Between Hole Depth & Cutting Control the Cutting Chip removal is very diicult in one-pass deep hole drilling. Clogged chips in the lute makes cutting orces higher and it may lead to drill breakage. Solution by Flute Design Conventional Design Deep Hole Application Horse Power (KW) Drill size:φ2mm Material : High Carbon Steel Conditions: = 6m/min =.25mm/rev d = 14mm Design Solution by Step-Feed Normal Drilling Step Feed [Type 1] Step Feed [Type 2] Cutting Thrust Torque Drill : MDS8MK Material : High Carbon Steel Conditions: = 5m/min =.25mm/rev d = 38mm Drill path Step-eeding has two objectives: 1) Chip ormation and 2) chip removal. Low speed drilling by HSS, solid carbide or twist drills requires step-eeding [Type 2] to ease chip removal. Conversely, high speed drilling with MultiDrills requires step-eeding [Type 1] to assist in chip ormation. D9 Drilling

43 Drilling Guidance Remarks on Using Longer Drills (KDS-DA, KDS-FA) Problem High speed cutting with longer sized drills leads to the delection o the drill, bending o drilled hole and drill breakage. Two Solutions Drilling D1

44 Drilling Guidance Trouble Shooting Guide & Remedies or Twist Drills Standard Step or Common Problems Trouble Basic Remedies Proven Remedies Excessive Wear o the Cutting Edge Tool Conditions Cutting Fluid - Enlarge the clearance angle. - Use higher wear-resisting tool material. - Set the correct cutting speeds. - Use more eicient cutting luids with high lubricity. - Clearance angle o 1 ~12 or steels - Change to PD-coated MultiDrills - Change to emlusiiable type coolant, higher viscosity or heavy duty drilling Chisel Point Chipping Tool Conditions - Machine correct the web thinning and honing. - Shorten the overall length o drill and overhang. - Reduce the eedrate (more on entry). - Water-soluble luid or heavy duty drilling (Emulsiiable Type) Drill Failures Chipping o Peripheral Cutting Edge Deposition, Wear o Margin Part Cutting Fluid Tool Conditions - Change to correct cutting luid. - Increase edge honing. - Decrease cutting speed. - Reduce eed during entrance or break-through. Cutting Fluid - Change to correct cutting luid with a minimum o 5 bars pressure. Tool - Slightly enlarge the back taper on diameter. - Narrow the width o margin Cutting Fluid - Supply cutting luids suiciently minimum o 5 bars Others - Early regrinding - Direction o coolant supply should be correct - Water-soluble luid or heavy duty drilling (Emulsiiable Type) - Water-soluble luid or heavy duty drilling (Emulsiiable Type) Fracture o Drill Body Tool Conditions Cutting Fluid Others - Use a more rigid drill. - Slightly enlarge the back taper on diameter and narrow the margin width. - Decrease the cutting speed and eedrate. - Increase the coolant low rate to min 5 bars. - Avoid packing o chips by pecking. - Increase rigidity o the machine. - Increase clamping rigidity o the work. - Use MultiDrill K Types - Increase the number o pecks per cycle Unsatisactory Working Accuracies Unsatisactory Chip Control Others Excessive Over- Sized Holes Poor Surace Finish Drill Wondering Packing o Chips Stringy Swar Chattering During Drilling Tool Conditions Cutting Fluid Tool Conditions Cutting Fluid Tool Conditions Cutting Fluid Conditions Tool - Correctly grind the point coniguration. - Decrease the cutting speed and eed. - Reduce the oil pressure and low rate. - Increase rigidity o the machine. - Increase the cutting speed when built-up edge occurs. - Adjust the eedrate proportionally. - Supply suicient cutting luids. - Eliminate the eccentricity o right and let cutting lips. - Correct delection and run-out o the drill - Introduce peck-drilling. - Decrease speed and increase eedrate. - I through-tool coolant system is used, increase the coolant pressure and low rate. - Decrease the cutting speed. - Increase eedrate. - Reduce the clearance angle. - Use a more rigid drill. - Eliminate the eccentricity o the chisel edge - Minimise the dierence between lip heights (within.2 mm) - Use Multi Drill K Type - Use sulurised oil as the cutting luid - Minimise the dierence between lip heights (within.2 mm) - Use the guide bush (not suitable or MultiDrills) - Change to MultiDrill K Type D11 Drilling

45 Exotic Materials Guidance X1 ~ X8 Insert Grades & Cutting Conditions or Exotic Materials... X2 Application Examples... X4 Machinability o Hard to Cut Materials... X6 Machining o Stainless Steel... X7 Cutting Quench-Hardened Steels... X8 X1 Exotic Mat.

46 Exotic Materials Guidance Insert Grades & Cutting Conditions or Exotic Materials Turning [ Cutting Speed () : m/min, Feed rate () : mm/rev ] Type Stainless Steels Work Materials General Machining and Roughing Finishing Examples SUS41 SUS34 Recommended Insert Grades AC3 AC34 EH1Z (Coated) AC3 AC34 EH1Z (Coated) Recommended Insert Grades T11A (Cermet) EH2Z (Coated) Inconel 718 EH2Z (Coated) BN6 (CBN) Nickel Alloys Inconel 718 Hastelloy B EH1Z (Coated) EH1Z (Coated) BN6 (CBN) BN6 (CBN) Nimonic 8A EH1Z (Coated) BN6 (CBN) Cobalt Alloys EH1Z (Coated) BN6 (CBN) Ferrite Alloys AC2 (Coated) BN6 (CBN) Pure Titanium EH1Z (Coated) BN6 (CBN) Titanium Alloys Ti-6Al-4 EH1Z (Coated) BN6 (CBN) Stellite EH1Z (Coated) BN6 (CBN) Shape Memory Alloy EH1Z (Coated) BN6 (CBN) Heat Resistant Sintered Alloys (alve Seat Ring) EH1Z (Coated) BNX4 (CBN) Quench Hardened Steels High Manganese Steels Hardened Blister Steels (Over HRC55) SCMnH3 EH1Z (Coated) NB9S (Ceramics) BNX2 BN25 BN3 (CBN) BNX2 BN25 BN3 (CBN) Exotic Mat. X2 Carbide FRP 85WC-15Co CFRP Carbon Fiber Reinorced Plastic EH1Z (Coated) EH1Z (Coated) DA9 (PCD) DA15 (PCD)

47 Exotic Materials Guidance Milling [ Cutting Speed () : m/min, Feed rate () : mm/t ] Work Materials Recommended Tools Recommended Cutting Conditions Type Example Cutter Type Grades Stainless Steels Hot Rolled Stainless Steel Strips (AISI) UFO-Type T13Z (Coated Cermet) AC325 (Coated Carbide) Nickel Base Heat Resistant & Corrosion Resistant Materials Inconel 718 GRC-Type EH2(Z) (K1 Coated Carbide) Titanium Alloys Ti6Al-4 GRC-Type EH2(Z) (K1 Coated Carbide) Quench Hardened Steels SKD61 Sumiboron Facemill BNM-Type BN25 (CBN) High Manganese Steels SCMnH3 UFO-Type A3N (P3 Carbide) EndMilling [ Cutting Speed () : m/min, Feed rate () : mm/rev ] Work Materials Recommended Tools Recommended Cutting Conditions Type Example Endmill Type Grades Stainless Steels Hot Rolled Stainless Steel Strips (AISI) Coated Solid Spiral Endmill SSM-ZX Type Coated Carbide Nickel Base Heat Resistant & Corrision Resistant Materials Inconel 718 High Lead Coated Endmill HSM-ZX Type Coated Carbide Titanium Alloys Ti6Al-4 Coated Spiral Endmill SSM-ZX Type Coated Carbide Quench Hardened Steels Alloy Tool Steels (AISI) Sumiboron Endmill BNES-Type BNBS-Type BNX3 (CBN) Drilling Work Materials Recommended Tools Recommended Cutting Conditions Type Example Drill Type Grades Stainless Steels Stainless Steel Wires (AISI) MultiDrill HK-Type MultiDrill K-Type MultiDrill A-Type ZX Coated ZX Coated Coated [ Cutting Speed () : m/min, Feed rate () : mm/rev ] X3 Exotic Mat.

48 Exotic Materials Guidance Application Examples Turning Application Work Tool Cutting Conditions = Speed 1) Part Name 3) Tool Name = Feed 2) Materials 4) Grade d = Depth o Cut Results Stainless Steels = 9~11 1) alve Parts 3) CNMG1248N-UP =.25 2) SUS34 4) AC3, AC34 d = 2.5~3.5 = 1 1) Seat Ring 3) CNMG1248N-UP =.25 2) SUS34 4) AC3, AC34 d = 4~5 Smoother cut and superior chip-control than conventional chip breakers Superior anti-notch wear and better chip control than conventional chip breakers Hastelloy 1) Aerospace Parts 2) Nimonic 75 (Ni6%, Cr2%, Co, C, etc) Exotic Materials (Co2%, Cr2%, Ni47%) 3) CNMG1248N-UP 4) EH2Z = 45 =.15 d =.25 Wear resistance and chip control is superior as compared to the competitor's Titanium Alloys 2) Titanium Alloy (Ti-6Al-4) 3) SNMG1248N-UP 4) EH1Z EH2Z (K1 Coated Carbide) = 3 m/min =.15 mm/rev d = 1. mm Wet (Water Soluble) Stellite 1) alve 2) Combination o Hot Rolled Stainless Steel Strips (AISI) and stellite 3) CNMG1248N-UG 4) EH1Z = 2~4 m/min =.1 mm/rev d = 1~2 mm Dry EH1Z: 5 pcs/corner Competitor's K1 Carbide: 2 pcs/corner (EH1Z grade gives a smoother cut and good surace inish on both stellite and stainless parts) P/M Sintered Alloys 1) alve Seat 2) P/M Sintered Alloy 3) Special Holder (Carbide Shank) 4) BNX4 (CBN) = 56 m/min =.1 mm/rev d =.3 mm Wet Tool Lie o BNX4 is twice that o competitor's CBN grade Quench Hardened Steels 1) Crank Web Pin Hole 2) JIS S48C (HRC55~62) 3) SumiBoron Insert SPGN9312 4) BN25 = 9 m/min =.7 mm/rev d =.15 mm Wet Tool Lie: 4 pcs Surace Finish: 3~4 µm (Rmax) Diameter Compensation: 1 pcs each Inconel 718 = 4 m/min 1) Aircrat Part 3) CNMG19612N-MU =.15 mm/rev 2) Inconel 718 4) EH1Z d = 1.5 mm Exotic Mat. Carbide 1) Round bar 2) Carbide G6 3) SumiDia Insert SNGN1248 4) DA9 (PCD) = 1 m/min =.65 mm/rev d =.5 mm Dry Machining time per regrind is approx 2 minutes X4

49 Exotic Materials Guidance Milling Tool Selection and Work Application (mm) Work Materials Tools Cutting Conditions 3) Cutter Cat. No. = Cutting Speed 1) Part Name 4) Insert Cat. No. = eed/tooth 2) Materials (Grade) d = Depth o Cut Results Inconel Stainless Steels 1)Machine Tool Parts 2)Casted Stainless Steel 1)Thin Structural Work 2) Inconel 625 3) UFO416R 4) SFEN12T3AZTN (AC325) 3) GRC616R 4) RGEN24SN (EH2) Competitor's Cutter: ø16 mm (Coated Inserts) = 176 m/min N = 35 rpm F = 55 mm/min =.2 mm/tooth d = 2 mm = 4~5 m/min =.2~.3 mm/tooth d = 3~5 mm Competitor's Cutter = 2 m/min =.25 mm/tooth d = 5 mm Eiciency is 22% higher when compared to conventional cutters with 25 o posi-inserts ery stable machining without chattering and chipping o the cutting edges. Our cutter perormed or over 35 minutes Initially there were sparks and ater 2 minutes, the competitor's inserts were totally broken. 1) Plate 2) MONEL 4 3) UFO41R 4) SFEN12T3AZTN (AC325) = 25 m/min N = 796 rpm F = 498 mm/min =.125 mm/tooth d = 5 mm Wet Using a cutter with 15 o posi round-insert is diicult because the chips adhere to the cutting edge. As the rake angle o UFO is much higher and perormance o chip exhaust is superior, they get 37% higher eiciency. Titanium Alloys 1) Block 2) Titanium-Alloy ( Ti-6Al-4) 3) GRC616R 4) RGEN24SN (EH2) = 3 m/min =.2 mm/tooth d = 3~4 mm Perormed or over 4 minutes. Titanium Alloys 1) ) Ti-6Al-4 (HRC32~34) 3) UFO416R 4) SFEN12T3AZTN (EH2Z) = 54 m/min N = 113 rpm F = 181 mm/min =.2 mm/tooth d = 2.5 mm As compared with G1E grade inserts, the Z-coated inserts provided 17% higher eiciency and 2% longer tool lie. Die Steels 1) Block 2) SKD11 1) Forging Die Part 2) HAP72 (HRC4) 3) UFO463ER 4) SFKN12T3AZTN (AC325) 3) UFO41R 4) SFEN12T3AZTN (A3N) = 2 m/min N = 11 rpm F = 1 mm/min =.2 mm/tooth d =.8 mm 2 pass/area = 182 m/min N = 58 rpm F = 35 mm/min =.11 mm/tooth d = 3 mm Even when machining the orged surace, the UFO cutter cuts smoothly and provides a good surace inish. Machining was impossible using 15 o or 2 o posi-insert cutters but with UFO cutter, there wass no problem under these conditions. X5 Exotic Mat.

50 Exotic Materials Guidance Machinability o Hard to Cut Materials < Machinability > Machinability Denotes... Machinability and Machining o hard-to-cut Materials: 1) Less cutting tool ailures and longer tool lie 3) Satisactory inishing o products 2) Smaller cutting resistance and power 4) Satisactory chip control consumption Machinability Index An index designed in the U.S.A. in which machinability is expressed by taking notice o the tool lie only. Machinability is numerically shown and thereore it is used as the standard to determine suitability o cutting. The material becomes diicult to cut as the numeric value decreases. 45 and below is designated as hard-to cut-work material. Machinability Index O Typical Materials Steel Workpiece Copper Alloy Properties o Workpieces Easy Work- Hardening Property High Strength Prone to Build-up Mild Medium Hard Low Alloy Steel Cast Iron < Problems O Hard To Cut Materials & Remedies > For Heat and Corrosion Resistant Alloys Machinability Machinability Machinability Index Workpiece Index Workpiece Index 1 ~ 7 85 ~ 7 65 ~ 5 6 ~ 5 65 ~ 5 7 ~ 5 Problems in Cutting Excessive Wear O Tools High Cutting Temperature High Cutting Partial Fracture or Chipping o Cutting Edges Stainless Steel Ferritic Martensitic Austenitic Alloy Tool Steel High Maganese Steel Titanium Alloy Properties Required or Tools High Wear High Heat High Edge Strength High Deposition Proo Property 65 ~ 5 55 ~ 4 5 ~ 35 3 ~ 25 4 ~ 3 3 ~ 2 Remedy in Tool Design Rake Angle Reduce Enlarge Clearance Angle Enlarge Reduce Heat and Corrosion Resisting Alloys Side Cutting Edge Angle Nose Radius Enlarge Enlarge Enlarge Fe A ~ 1 Base Inconel 91 Ni Nimonic 8A 16 ~ 6 Base Inconel 91 Cr L ~ 6 Base Stellite 21 Enlarge Enlarge Enlarge Enlarge Others Selection o Tool Material Sintered Diamond Sintered CBN Ceramic Cermet Coated Carbide K Class K Class Sticky Unsatisactory Surace Finish Unsatisactory Chip Control Satisactory Chip Control Chip Breaker For Hardened Materials (Quench-Hardened Steels, Carbides, etc) Properties o Workpieces Problems in Cutting Properties Required or Tools Remedy in Tool Design Rake Angle Clearance Angle Side Cutting Edge Angle Nose Radius Others Selection o Tool Material Sintered Diamond Sintered CBN Ceramic Cermet Coated Carbide Excessively Hard Excessive Wear o Tools High Wear Enlarge Enlarge Containing Hard Grains High Cutting High Edge Strength Reduce Reduce Enlarge Enlarge K Class Partial Fracture or Chipping o Cutting Edges Exotic Mat. Common Considerations For Cutting Hard-to-Cut Work Materials X6 - Machines : All backlash should be eliminated with exceptional axial rigidity. - Tools : Use a larger shank size and minimise the overhang to increase rigidity. - Workpiece : Assure ittings and protection rom run-out and chatter.

51 Exotic Materials Guidance Machining o Stainless Steel Classiication & Properties Classiication Alias Material (JIS) Machinability Machinability Quench Magnetism Typical Applications Index Hardened Martensitic 13 Chrome SUS41, etc Rather Bad 55~4 Yes Yes Tableware, Cutlery, Gauges Ferritic 18 Chrome SUS43, etc Fairly Good 65~5 No Yes alves, Parts or Pumps Austenitic 18-8 Stainless SUS34, etc Bad 5~35 No No Industrial Parts, Kitchen Appliances Precipitation SUS631, etc Rather bad Hardening Reasons For Cutting Diiculty & Inluence Turning Stainless Steels Cause Excessive Work-Hardening Low Heat Conductivity Excessive Deposition with Tools Inluence on Tools Chipping o the lank and increased nose wear. Poor heat dissipation and plastic deormation o edges. Deposition o chips causes chipping o cutting edges and tearing o work surace. 1) Tool Design (Rake Angle). 2) Recommended insert materials. 3) Recommended Cutting Conditions. Recommended Rake Angle : 12 ~18 Right-hand Fig. shows relation between the rake angle and properties in the case o SUS34 For Finishing: T12A (Cermet) EH1Z (PD Coated) For General Cutting: AC2 (Coated) AC3 (Coated) Cutting Surace Roughness Flank Wear Face Wear =ariable, =.25mm/rev, d=1.5mm =1m/min, =.42mm/rev, d=2mm Chip Control (Chip Breaker "UP" Type or Turning Stainless Steels) Milling Stainless Steels 1) Recommended Cutter 2) Recommended insert materials 3) Recommended Cutting Conditions Features o UP Type Breaker and Coniguration Capable o wide-ranged chip control. In addition, it shows steady perormance due to the strengthened cutting edges. This is a special breaker developed specially or the machining o stainless steels. SEC-ACE Mill UFO Type Unique design or superior sharpness and excellent chip removal. It has a Negative- Positive geometry with an approach angle o 45 - A3N (Carbide P3) - AC325 (Coated) - AC23 (Coated) Comparison o Wear UP Geometry Conventional Geometry Workpiece: SUS34 Tool: PCLNR2525 CNMG1248 (AC3) Cutting Conditions: = 4~1 (m/min) =.35 (mm/rev) d = 2. (mm) T = 1 (min) Interrupted Cutting Workpiece: SUS34 Cutter: UFO416 Insert: SFKN12T3AZTN Grades: A3N, AC325 Cutting Conditions: = 15~2 m/min =.3 mm/tooth d = 3 mm, Dry End-Milling Stainless Steels 1) Recommended Endmills 2) Recommended Tool Material 3) Recommended Cutting Conditions SSM-ZX Type - Coated solid spiral endmills ZX-Coating - TiAlN compounds coated on the carbide base material, having 3~5 times longer lie than normal. Conditions - Cutting speed () = 3~7 m/min, Feedrate () =.15~.5 mm/tooth. X7 Exotic Mat.

52 Exotic Materials Guidance Cutting Quench-Hardened Steels < Quench-Hardened Steels & CBN > Features O Quench Quench-hardened steels with martensite content are excessively hard and strong. Thereore, the cutting Hardened Steels resistance, especially thrust orce, is high. Machining Quench- Hardened Steels (New CBN tools replace; grinding with cutting) Sintered CBN (Sumiboron) The conventional inishing process or hardened steels has been dependent upon grinding but due to the development o CBN tools which provide better capabilities, more and more users are converting to CBN or inishing o hardened steels Sintered CBN is a new material or cutting tools which is composed mainly o cubic boron nitride and sintered at ultrahigh pressure and temperature SumiBoron is a sintered CBN tool developed by Sumitomo Material Hardness (Hv) Features Applications (Workpieces) BN25 BN3 BNX2 BN6 31 ~ ~ ~ ~ 42 High Wear & Fracture High Toughness & Chipping High Toughness & Hot Hardness Good Thermal Cracking & Toughness Hardened Steel: Continuous ~ Light Interrupted Cut Hardened Steel: Medium ~ Heavy Interrupted Cut High Eiciency Cutting Hardened Steel & High Speed Cast Iron Turning Merits o conversion rom grinding to cutting: Reducing the cutting time. Reducing the cost o equipment. Able to perorm various operations. Hardness O Tool Materials At High Temperature < Cutting Quench-Hardened Steels By CBN > Cutting o Quench- Hardened Steels and Tool Lie Tool Lie Diagram In Cutting Carburize- Quenched Steel Comparison Between Suraces Finished By Grinding & Cutting With BN25 Workpiece: SNCM8 (HrC5) 84 Oil-Quenched, 2 Tempered Surace Roughness Tool Conditions Comparison Between Suraces Finished By Grinding & Cutting Machining Accuracies Cutting Conditions: Depth o Cut,.2 mm; eed,.12 mm/rev Wet; Tool Coniguration, -5,-6,5,6,15,15,.8R Carbide K1 ails within 2 minutes at 6 m/min, while BN25 has a longer lie, some 1 minutes at 1 m/min Cutting Speed:15m/min Sumiboron BN25 Depth o Cut:.2 mm SNGN1248 Feed:.1 mm/rev Dry System Peripheral Speed o Wheel: 145 m/min Peripheral Speed WA6K o Work: 3 m/min Depth o Cut:.15 mm Use o water soluble grinding luid BN25 produces an extremely regular and ine surace inish compared to grinding Dimensional Fluctuation in Boring (The workpiece is rotated by a general purpose lathe) Grinding Cutting Exotic Mat. Milling & Tool Lie SumiBoron Endmill Example SumiBoron Jig Boring Tool Example X8 No. o cut workpieces Workpiece: SCM415 (HRC65), Tool: SumiBoron BN25 cutting Speed: 1 m/min, Depth o Cut:.1 mm, Feed:.8 mm/rev, Dry System The deviation o hole diameter corresponds to a receded amount o the cutting edges due to tool wear and complies with a tolerance width o Class H7 ater cutting 2 pcs. Tool Lie In Milling An Example O The Sumiboron Endmill : Workpiece Applied Tool & Conditions Results Workpiece: SKD61 (HRC65) Tool: Double-Negative Cutting Conditions: Depth o Cut,.2 mm; Feed,.8 mm/tooth Mean Flank Wear:.2 mm Reerence An Actual Example o The Sumiboron Jig Boring Tool Workpiece: Quenched Parts (Precision Boring) Workpiece: SKS3HRC58~5 Tool: SumiBoron Jig Boring Tool SJB18 (Dia. 8) BNE125T (25 mm Endmill) N = 1,3 rpm ( = 14 m/min) b =.1 mm d = 7 mm F = 1 mm/min =.8 mm/rev Down-cut Cutting Conditions: =3m/min d=.1mm =.5mm/rev Dry Cutting or 3 min Cutting length: 3 m Minute Wear Results Machining Time : Surace Roughness (Rmax): Bore Concentricity : Bore Consistency :.5 min/pcs 1.7 µm 1/1 mm 5/1 (3pcs)