2.1 2.2 2.3

Stainless SteelApplication Material Group

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© DORMER 2006All rights reserved under the “Dormer” registered trademark. Although every effort has been made to ensure the accuracy of the information contained herein, no responsibility for loss or damage occasioned to any person acting from action as a result of any material in this publication can be accepted by the editors, publishers or product manufacturers.

2

BS

SSU

SAU

NS

JIS

2.1

303

S21

416

S37

2301

, 231

2, 2

314

2346

, 238

030

3, 4

1643

0FS

3030

0, S

4160

0S

4302

0S

US

304L

, SU

S43

0F

2.2

304

S15

, 321

S17

31

6 S

, 320

S12

2310

, 233

3, 2

337

2343

, 235

3, 2

377

304,

321

, 316

S30

400,

S32

100

S31

600

SU

S30

4, S

US

321

2.3

317

S16

, 316

S16

2324

, 238

7, 2

570

409,

430

, 436

S40

900,

S43

00,

S43

600

SU

S29

, SU

S33

SU

S43

HB

EN

DIN

2.1

<250

<850

EN

10

088-

3 - X

14C

rMoS

171.

4305

, 1.4

104

X10

CrN

iS18

9,

X12

CrM

oS17

2.2

<250

<850

EN

10

088-

2,0

-3

- 1.4

301+

AT

1.43

01, 1

.454

1,

1.45

71X

5CrN

i89,

X

10C

rNiM

oTi1

810

2.3

<300

<100

0E

N 1

0 08

8-3

- 1.4

460

1.44

60, 1

.451

2,

1.45

82X

BC

rNiM

o275

, X

4CrN

iMoN

6257

Gen

eral

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Exa

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3

Contents

Classification of workpiece materials 2Application Material Groups 4Introduction to Stainless Steels 5Machinability of Stainless Steels 5 Hints when machining Stainless Steels 6AMG 2.1 7AMG 2.2 8AMG 2.3 9General Hints on Drilling 10Drill Feed Chart 11Drill Selection 12General Hints on Tapping 14Drill diameters for cutting taps 15Tap Selection 16General Hints on Milling 18Milling parameters 19Applications 20Milling Feed Charts 20Milling Cutters Selection 24Table of cutting speeds 26

Gen

eral

Info

rmat

ion

4

Application Material Groups

Application Material Groups (“AMGs”) are designed to assist in the selection of the optimum cutting tool for a particular application.

Dormer classifies materials into 10 major Application Material Groups. Each major group is divided into sub-groups on the basis of material properties, such as hardness and strength, and chip formation. This booklet concentrates on sub-groups 2.1 – 2.3 – Stainless Steels.

Examples of national designations within each sub-group are shown on page 2.

This booklet contains a selection of tools that are rated “excellent” for machining Stainless Steels. Please see the Dormer catalogue or Product Selector for the full range, or contact your local Dormer representative or Technical Helpdesk if you need further advice.

Gen

eral

Info

rmat

ion

5

Introduction to Stainless Steels

Stainless steels are alloyed steels used primarily because of their corrosion resistance. Their main alloying element is chromium (Cr). The chromium in the stainless steel forms an ultra-thin oxide film on the surface. As a general rule, corrosion resistance and resistance to oxidation increase in line with chromium content. Other alloying elements, such as nickel and molybdenum, are added to change the structure, increase corrosion resistance and improve strength.

Why are Stainless Steels seen as difficult to machine?

• Most stainless steel materials work harden during deformation, i.e. the process of producing a chip. The work hardening decreases rapidly with an increasing distance from the surface. Hardness values close to the machined surface can increase by up to 100% of the original hardness value if using the incorrect tool.

• Stainless steels are poor heat conductors, which leads to high cutting edge temperatures compared to a steel, in for example, AMG 1.3 with similar levels of hardness.

• High toughness leads to high torque, which in turn results in a high work load for a tap or drill. When combined with the effects of work hardening and poor heat conductivity, the cutting tool has to perform in a relatively hostile environment.

• The materials have a tendency to smear the surface of the cutting tool.

• Chip breaking and swarf management problems, due to the high toughness of the stainless steel.

Gen

eral

Info

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ion

6

Important when machining Stainless Steels

• For drilling operations, use ADX or CDX drills with internal coolant capability. This will counter the work hardening that occurs when machining Stainless Steel. With internal cooling, the work hardening is kept to a minimum, about 10%.

• High feed rates transfer more heat away from the machining area. This is a very important consideration for a trouble-free machining operation.

• When it comes to choosing the correct cutting speed, always start in the lower region of Dormer recommendations. This is due to the fact that different material batches may require different cutting speeds. Also keep in mind that for deeper holes, cutting speed should be reduced by 10-20%, for the chosen application.

• When threading in DUPLEX or in high alloyed stainless steel, keep the cutting speed in the lower region of Dormer recommendations.

• Use preferably a neat cutting oil. If an emulsion is the only option for the operation, a minimum 8% concentration is recommended.

• First choice should always be a coated tool since they have a greater tendency to resist built-up edges.

• Avoid using tools with worn cutting edges, since this will increase work hardening.

Gen

eral

Info

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ion

7

2.1 Free machining Stainless SteelHardness <250 HBTensile strength <850 N/mm2

Typical Composition

The alloys in this sub-group are ferro-magnetic in structure and are not hardenable by heat treatment. They have good machinability and often have good strength. Common alloys contain 11-29% chromium and very low quantities of carbon. Sulphur may be added to improve machinability.

Examples of uses

Stainless steels with 11% chromium content combine a moderate resistance to corrosion with good fabrication properties, to make them widely used in automotive exhaust systems.

Stainless steels with 16-17% chromium content are used for automotive trim, cooking utensils and in food processing applications.

Stainless steels with 18-29% chromium content are used in applications, which require high resistance to oxidation and corrosion, such as parts for furnaces.

Gen

eral

Info

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8

2.2Austenitic Hardness <250 HBTensile strength <850 N/mm2

Typical Composition

The alloys in this sub-group form the most common group of stainless steels, accounting for over 70% of production. They are non-magnetic at normal temperatures and not hardenable by heat treatment. They are characterised by a high coefficient of elongation and their machinability is medium to low. The addition of nickel changes the structure of these alloys from ferritic to austenitic. The most common type of austenitic stainless steel is the 18/8-type (18% Chromium, 8% Nickel), which has good resistance to corrosion. Molybdenum can be added to give improved mechanical properties. Higher alloyed austenitic stainless steel, for example with a chromium content of 26% and a Nickel content of 22%, also have the benefit of improved resistance to corrosion. However, increasing alloy content reduces machinability.

Examples of uses

Examples of applications for austenitic stainless steels are the chemical and petro-chemical industries, marine environment, cutlery manufacture, food processing, power generation and other hot, corrosive environments. The durability, low maintenance and attractive appearance of these stainless steels has led to them being used increasingly in architecture and construction, with many modern buildings favouring stainless steels in roofing and facades.

Gen

eral

Info

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ion

9

2.3 Ferritic + Austenitic/Duplex, Martensitic and Precipitation Hardening Stainless Steels Hardness <300 HB Tensile strength <1000 N/mm2

Ferritic + Austenitic/DuplexThe structure of these stainless steels is a hybrid of the structures of Ferritic and Austenitic, giving them high corrosion resistance and a balanced micro-structure with approximately equal proportions of ferrite and austenite. They have a higher yield strength and tensile strength than stainless steels in groups 2.1 and 2.2. They are often used for dynamically stressed machine parts, such as suction rolls for paper machines. They also find application in the oil, gas and petrochemical industries, as well as offshore industry. They contain relatively high chromium levels (18-28%) and moderate amounts of nickel (4.5–8%) and have low machinability.

MartensiticMartensitic stainless steels are magnetic and hardenable, retaining good mechanical properties. Typically they contain 12–14% chromium with a moderate carbon content. Their main applications are in cutlery manufacture, aerospace and general engineering. Most grades in the annealed (softened) condition are relatively easy-to-machine, but grades with nickel and higher carbon levels have low machinability.

Precipitation hardening stainless steelsThese possess the highest strength of all stainless steel groups and are obtained by heat treatment. Like stainless steels in 2.1, they are difficult to machine.

Gen

eral

Info

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10

General Hints on Drilling

1. Select the most appropriate drill for the application, bearing in mind the material to be machined, the capability of the machine tool and the coolant to be used.

2. Flexibility within the component and machine tool spindle can cause damage to the drill as well as the component and machine - ensure maximum stability at all times. This can be improved by selecting the shortest possible drill for the application.

3. Tool holding is an important aspect of the drilling operation and the drill cannot be allowed to slip or move in the tool holder.

4. The use of suitable coolants and lubricants are recommended as required by the particular drilling operation. When using coolants and lubricants, ensure a copious supply, especially at the drill point.

5. Swarf evacuation whilst drilling is essential in ensuring the correct drilling procedure. Never allow the swarf to become stationary in the flute.

6. When regrinding a drill, always makes sure that the correct point geometry is produced and that any wear has been removed.

Ø [m

m]

12

34

56

810

1215

1620

2530

4050

D0.

016

0.03

80.

053

0.06

00.

068

0.07

80.

098

0.11

90.

130

0.14

90.

155

0.18

80.

210

0.22

80.

253

0.27

5E

0.01

70.

043

0.06

20.

071

0.08

00.

092

0.11

50.

140

0.15

00.

173

0.18

00.

215

0.24

00.

260

0.28

50.

31F

0.01

80.

050

0.07

30.

084

0.09

50.

109

0.13

80.

165

0.17

80.

202

0.21

00.

248

0.27

50.

295

0.32

0.34

3G

0.01

90.

056

0.08

40.

096

0.10

90.

126

0.16

00.

190

0.20

50.

231

0.24

00.

280

0.31

00.

330

0.35

50.

375

H0.

020

0.06

60.

102

0.11

60.

130

0.15

00.

190

0.22

80.

243

0.27

10.

280

0.32

00.

355

0.37

50.

398

0.41

8I

0.02

10.

076

0.11

90.

134

0.15

00.

173

0.22

00.

265

0.28

00.

310

0.32

00.

360

0.40

00.

420

0.44

0.46

J0.

024

0.08

40.

135

0.15

20.

170

0.19

70.

250

0.29

80.

315

0.34

90.

360

0.40

50.

445

0.46

50.

485

0.50

3K

0.02

60.

092

0.15

00.

170

0.19

00.

220

0.28

00.

330

0.35

00.

388

0.40

00.

450

0.49

00.

510

0.53

0.54

5L

0.02

80.

101

0.16

50.

186

0.20

80.

240

0.30

50.

360

0.38

50.

419

0.43

00.

485

0.52

50.

545

0.56

80.

588

M0.

030

0.11

00.

180

0.20

20.

225

0.26

00.

330

0.39

00.

420

0.45

00.

460

0.52

00.

560

0.58

00.

605

0.63

U0.

026

0.04

80.

070

0.08

00.

090

0.10

70.

140

0.17

00.

200

0.22

30.

230

0.24

0V

0.03

80.

069

0.10

00.

115

0.13

00.

153

0.20

00.

250

0.28

00.

310

0.32

00.

340

W0.

049

0.08

90.

130

0.15

00.

170

0.20

00.

260

0.33

00.

380

0.41

80.

430

0.45

0X

0.05

60.

103

0.15

00.

180

0.21

00.

250

0.33

00.

420

0.48

00.

533

0.55

00.

580

11

mm

/rev

± 25

%

2.12.22.3

12

A117 A520 A552 R457 R557 A108 A509 A577 A553 A554 R453 R563

1.0 - 13.0 3.0 - 13.0 5.0 - 20.0 3.0 - 16.0 5.0 - 20.0 1.0 - 16.0 3.0 - 16.0 1.5 - 14.0 5.0 - 20.0 5.0 - 30.0 3.0 - 16.0 3.0 - 16.0

■22F ■30I ■32H ■55V ■80W ●15E ●23G ■32G ■40G ■40G ■55V ■110V■11H ■16I ●17J ■35V ■50U ■9G ■14I ■15K ■19I ■19I ■35V ■65V■15D ■20G ●23H ●30U ■45U ■10D ■16F ■21G ●27G ●27G ●30U ■50U

■ ●

ExcellentGood

13

A117 A520 A552 R457 R557 A108 A509 A577 A553 A554 R453 R563

1.0 - 13.0 3.0 - 13.0 5.0 - 20.0 3.0 - 16.0 5.0 - 20.0 1.0 - 16.0 3.0 - 16.0 1.5 - 14.0 5.0 - 20.0 5.0 - 30.0 3.0 - 16.0 3.0 - 16.0

■22F ■30I ■32H ■55V ■80W ●15E ●23G ■32G ■40G ■40G ■55V ■110V■11H ■16I ●17J ■35V ■50U ■9G ■14I ■15K ■19I ■19I ■35V ■65V■15D ■20G ●23H ●30U ■45U ■10D ■16F ■21G ●27G ●27G ●30U ■50U

2.12.22.3

14

General Hints on Tapping

1. Select the correct design of tap for the component material and type of hole, i.e. through or blind, from the Application Material Groups chart.

2. Ensure the component is securely clamped - lateral movement may cause tap breakage or poor quality threads.

3. Select the correct size of drill (see opposite). Always ensure that work hardening of the component material is kept to a minimum.

4. Select the correct cutting speed as shown in the tap selection pages, the catalogue or the Product Selector.

5. Use appropriate cutting fluid for correct application.

6. In NC applications ensure that the feed value chosen for the program is correct. When using a tapping attachment, 95% to 97% of the pitch is recommended to allow the tap to generate its own pitch.

7. Where possible, hold the tap in a good quality torque limiting tapping attachment, which ensures free axial movement of the tap and presents it squarely to the hole. It also protects the tap from breakage if accidentally ‘bottomed’ in a blind hole.

8. Ensure smooth entry of the tap into the hole, as an uneven feed may cause ‘bell mouthing’.

M mm mm mm1.6 0.35 1.321 1.25 3/641.8 0.35 1.521 1.45 542 0.4 1.679 1.6 1/162.2 0.45 1.833 1.75 502.5 0.45 2.138 2.05 463 0.5 2.599 2.5 403.5 0.6 3.010 2.9 334 0.7 3.422 3.3 304.5 0.75 3.878 3.8 275 0.8 4.334 4.2 196 1 5.153 5 97 1 6.153 6 15/648 1.25 6.912 6.8 H9 1.25 7.912 7.8 5/1610 1.5 8.676 8.5 Q11 1.5 9.676 9.5 3/812 1.75 10.441 10.3 Y14 2 12.210 12 15/3216 2 14.210 14 35/6418 2.5 15.744 15.5 39/6420 2.5 17.744 17.5 11/1622 2.5 19.744 19.5 49/6424 3 21.252 21 53/6427 3 24.252 24 61/6430 3.5 26.771 26.5 1.3/64

15

D = Dnom- P

M mm mm

4 0.70 3.405 0.80 4.306 1.00 5.108 1.25 6.9010 1.50 8.7012 1.75 10.4014 2.00 12.2516 2.00 14.25

Drill diameter can be calculated from:

METRIC COARSE THREAD

RECOMMENDED DIAMETERS WHEN USING DORMER ADX AND CDX DRILLS

The above table for drill diameters refer to ordinary standard drills. Modern drills such as Dormer ADX and CDX produce a smaller and more accurate hole which makes it necessary to increase the diameter of the drill in order to avoid breakage of the tap.Please see the small table to the left.

D = Drill diameter (mm)

Dnom = Tap nominal diameter (mm)

P = Tap pitch (mm)

METRIC COARSE THREAD FOR ADX/CDX

Max. DRILL DRILLInternal

Pitch Diam. Diam. Diam.inch

TAP DRILLPitch Diameter

Drill Diameters for Cutting Taps - Recommendation tables

2.12.22.3

DIN

16

E454 E455 E344 E345 E403 E346 E347

M3 - M10 M12 - M20 M3 - M10 M12

- M30 M3 - M20 M3 - M10 M12 - M30

■14 ■14 ■8 ■8 ■14 ■8 ■8■10 ■10 ■7 ■7 ■10 ■7 ■7■6 ■6 ■5 ■5 ■6 ■5 ■5

■ ●

ExcellentGood

Other thread types available. Please see Dormer catalogue.

E045 E046 E047 E048

M3 - M20 M3 - M20 M3 - M20 M3 - M20

■8 ■14 ■8 ■14■7 ■10 ■7 ■10■5 ■6 ■5 ■6

ISO

2.12.22.3

17

18

General Hints on Milling

1. Where possible, use climb milling (down milling) for longer tool life. Climb milling allows easier chip disposal, less wear, improved surface finish and lower power requirements compared to conventional milling (up milling).

2. Always use a cutter in good condition.

3. Use well-maintained machine tools with sufficient power.

4. Use correct clamping system according to working operation and type of tool.

5. Check for damage or wear on the tool shank or in the holder itself.

6. Use the shortest cutters recommended for your application and work as close to the machine head as possible.

7. For optimum productivity, use coated or Solid Carbide cutters.

19

Milling parameters

1. Identify the type of end milling to be carried out - type of end mill - type of centre

2. Consider the condition and the age of the machine tool.

3. Select the best end mill dimensions in order to minimize the deflection and bending stress

- the highest rigidity - the largest mill diameter - avoid excessive overhand of the tool from the tool

holder.

4. Choose the number of flutes - more flutes - decreased space for chips - increased rigidity - allows faster table feed - less flutes - increased space for chips - decreased rigidity - easy chip ejection.

5. Determining the correct cutting speed and feed rate can only be done when the following factors are known:

- type of material to be machined - end mill material - power available at the spindle - type of finish.

20

For details on how to use the feed charts in the tables which follow, please see below.

Slotting Roughing

Ball nose Finishing

Application

Ø m

mm

m/z

± 2

5%1

23

45

68

1012

1416

1820

2225

2830

3236

40↕

0,5D

↔ D

E0,

007

0,01

20,

018

0,02

40,

035

0,04

20,

063

0,08

70,

105

0,12

20,

140

0,14

10,

140

0,14

40,

153

0,17

10,

157

0,16

80,

157

0,17

5

F0,

007

0,00

90,

013

0,01

80,

021

0,02

50,

033

0,04

10,

050

0,05

50,

064

0,07

20,

079

0,07

90,

085

0,08

50,

085

0,08

50,

085

0,08

5

↕ D

↔ 0

,8D

K0,

035

0,04

70,

065

0,07

90,

092

0,10

50,

088

0,09

80,

097

0,11

00,

110

0,11

00,

110

0,11

50,

118

L0,

010

0,01

30,

017

0,02

00,

025

0,02

80,

030

0,03

20,

033

0,03

40,

036

0,03

80,

039

0,04

00,

042

↕ 1,

5D↔

0,2

5DN

0,00

70,

011

0,01

60,

021

0,02

80,

037

0,05

10,

062

0,07

20,

082

0,09

30,

103

0,08

10,

093

0,07

70,

082

0,08

70,

099

0,09

6

Q0,

009

0,01

40,

021

0,02

60,

036

0,04

80,

066

0,07

90,

092

0,10

60,

089

0,09

90,

098

0,11

10,

111

0,11

90,

127

0,14

30,

139

R0,

012

0,01

60,

020

0,02

50,

029

0,03

80,

047

0,05

60,

065

0,07

30,

083

0,09

20,

092

0,09

20,

092

0,09

20,

104

0,10

40,

108

↕ 1,

5D↔

0,1

DX

0,01

20,

017

0,02

60,

033

0,04

50,

059

0,08

20,

099

0,11

50,

132

0,11

10,

124

0,12

20,

139

0,13

90,

148

0,15

80,

178

0,17

3

Y0,

015

0,02

00,

025

0,03

10,

036

0,04

70,

059

0,07

00,

081

0,09

20,

104

0,11

50,

115

0,11

50,

115

0,11

50,

130

0,13

00,

136

21

Z

Ø m

m

m

m/z

±

25%

>0,5

0.6

0.8

12

34

56

810

1214

1618

20

>4

↕ 1,

5↔

0,0

5

A0.

015

0.02

00.

025

0.03

00.

035

0.04

00.

050

0.06

0

B0.

045

0.05

00.

060

0.07

50.

080

0.09

00.

100

0.11

0

C0.

065

0.07

50.

090

0.11

00.

120

0.13

00.

150

0.17

0

3-4

↕ 1,

5↔

0,1

A0.

010

0.02

00.

030

0.04

00.

045

0.05

00.

060

0.07

50.

080

0.09

00.

100

0.12

0

B0.

015

0.03

00.

040

0.05

50.

065

0.07

50.

090

0.11

00.

120

0.13

00.

150

0.17

0

C0.

015

0.03

00.

040

0.05

50.

085

0.10

00.

120

0.14

00.

150

0.17

00.

200

0.22

0

3-4

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