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11/82COPYRIGHT 2008, Seco Tools AB WorkpieceWorkpiece materialsmaterials
Duplex SS 42CrMo4 Ca-treated 316L
22/82COPYRIGHT 2008, Seco Tools AB
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Carbon steel -Free cutting steel
Carbon steelAlloysteel
TitaniumAlloys
Specialhigh temp
alloys
Cobalt basedalloys
Nickel basedalloys
AusteniticSS
Chemical, petrochemical, medical, gas and paper industry
General construction steel
Energy production, aviation and space travel
WorkpieceWorkpiece materialmaterial
33/82COPYRIGHT 2008, Seco Tools AB
P
Non-alloy steel and cast steelLow-alloy steel and cast steelHigh-alloy steeland cast steelSS and cast steel (fer/mar)
Stainless steel (austenitic)
Grey cast ironDuctile cast ironNodular cast iron (ferritic/perlitic)
Non-ferrous metalsAluminium and aluminium alloys
Super alloysTitanium and titanium based alloys
Hard cast ironHardened steel
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Mechanical properties
Materialstructure
Self-hardening
Inclusions
Thermal conductivity
Chemicalcomposition
Workpieceorigination
WorkpieceWorkpiece materialmaterial
44/82COPYRIGHT 2008, Seco Tools AB
Surface integrity
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0 50 100 150 200 250
0
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400
600
800
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Environment
Tool wearChip formation f
vc
29803000302030403060308031003120
0 2 4 6 8 10
Fy
FxFz
Cutting forces
MachinabilityMachinability
55/82COPYRIGHT 2008, Seco Tools AB
Machining method
Machinability
vc f
Mechanical properties
Workpieceraw material
Materialstructure
Workhardening
Inclusions
Thermal conductivity
Chemicalcomposition
Workpiece material
Machine
Clamping Cooling
Human factor
Toolholders
Cutting geometryCutting conditions
Cutting material
MachinabilityMachinability
66/82COPYRIGHT 2008, Seco Tools AB
Material to be machinedsteel SS GCI etc.
The processroughing - 1/2 rough - finishing
The correct insertThe correct insert
Carbide grade
Cutting speedVc
Cutting depthap
Feedf
Geometry
MachinabilityMachinability
77/82COPYRIGHT 2008, Seco Tools AB
The The cuttingcutting processprocess
88/82COPYRIGHT 2008, Seco Tools AB
The cutting force can be divided into: Axial force component Radial force component Tangential force component
The tangential force determines the cutting force.
The combination of tangential and radial force is the main cause of any vibration and workpiece deformation.
Tangential force
Radial forceAxial force
The The cuttingcutting processprocessCutting forces
99/82COPYRIGHT 2008, Seco Tools AB
The The cuttingcutting processprocess
0 1 000 2 000 3 000 4 000 5 000 6 000 7 000
kc11 (N/mm)
Steel
Stainless steel
Cast iron
Non-ferrous materials
Superalloys
Hard materials
Fc = Kc11 * b * h 1-mc
Kc11 = specific cutting forceb = chip width
h = chip thickness
(Typical example )
10
10/82COPYRIGHT 2008, Seco Tools AB
Low carbon steel and aluminium, Group 16.
Soft Continuous chips, difficult to
machine. Decrease ductility to increase
machinability.
Materials with high ductility
Materials with low ductility
DO
D1
LO
L1
DO
LO
Gray cast iron, Gr.12. Hard Discontinuous chips. Increase ductility to increase
machinability.
WorkpieceWorkpiece materialsmaterials
11
11/82COPYRIGHT 2008, Seco Tools AB
diameter(proportional to penetration)
High hardness materials
Tool steel, Group 6 Hardened Steel, Group 7 Superalloys, Group 21 Cast iron, Group 15
Low hardness materials
Aluminum, Group 16 Low carbon steel, Group 1
Materials that work harden
Stainless steel, Groups 8, 9, 10 & 11 Superalloys, Groups 20, 21
WorkpieceWorkpiece materialsmaterials
12/82COPYRIGHT 2008, Seco Tools AB
WorkpieceWorkpiece materialsmaterials
Long chips (Ductility (%))
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) Difficultto machine
Easyto machine
Ni Ni alloyalloy superalloysuperalloyTi Ti alloyalloy
Hardened
Hardenedsteelsteel
High High alloy
alloy steelsteel
UnalloyedUnalloyed steelsteelAluminiumAluminium
StainlessStainless steel
steelDuctileDuctile ironiron
CastCast iron
iron
CastCast alualu alloyalloy
13
13/82COPYRIGHT 2008, Seco Tools AB
Temperature
Heat conductivity of tool material and workpiece material.
Cutting speed.
Geometry of cutting edge.
This temperature (gradient) Largely determines the wear
factor and tool life.
The The cuttingcutting processprocess
14
14/82COPYRIGHT 2008, Seco Tools AB
Copper, Group 18
Aluminium, Group 16
Low carbon steel, Group 1
Titanium, Group 22
Superalloys, Groups 20, 21
Materials with high thermal conductivity
Materials with low thermal conductivity
ThermalThermal conductivityconductivity
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15/82COPYRIGHT 2008, Seco Tools AB
- Surface finish: Rt,Ra- Residual tension: Pressure or tensile forces- Self-hardening: Retention of austenite/hard martensite- Heat affected zone (HAZ): Lower hardness
Surface integrity is the general term used to describe the properties and the condition of a machined workpiece with regard to the surface and sub- surface.
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-600-400
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0 50 100 150 200 250
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Depth under the surface (m)
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800
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Compression
Tension
SurfaceSurface integrityintegrity
(Typical example )
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16/82COPYRIGHT 2008, Seco Tools AB
Self- hardening
ToolWorkpiece material
Self- hardening
Tool
Work- piecematerial
SurfaceSurface integrityintegrity
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17/82COPYRIGHT 2008, Seco Tools AB
SurfaceSurface integrityintegrity
18
18/82COPYRIGHT 2008, Seco Tools AB
Crack
Great influence on fatigue properties
Crack
Tension Compression
Influencing factors are the cutting speed, cutting edge wear, cutting edge angle and cutting method (radial turning or classical), the cutting depth, the feed and the nose radius.
SurfaceSurface stressesstresses
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19/82COPYRIGHT 2008, Seco Tools AB
Depth from surface
SurfaceSurface stressesstresses
(Typical example )
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20/82COPYRIGHT 2008, Seco Tools AB
Material Machinability Rating9S20 cold rolled steel 100
Ductile cast iron 35
Stainless steel 440 50
Aluminium 2024-T 150
9S20 is assigned a rating of 100 and other materials are compared to this standard.
MachinabilityMachinability ratingrating
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21/82COPYRIGHT 2008, Seco Tools AB
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Non-alloy steeland cast steel. < 600 N/mm2Low-alloy steel and cast steel < 900 N/mm2High-alloy steeland cast steel > 900 N/mm2Stainless steel and cast steel (fer/mar) < 750 N/mm2
Stainless steel (austenitic) > 750 N/mm2
Grey cast ironDuctile cast ironNodular cast iron (ferritic/perlitic)
Non-Ferrous metalsAluminium and aluminium based alloys
SuperalloysTitanium and titanium based alloys
Hard cast iron > 60 ShoreHardened steel > 45 HRC
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MachinabilityMachinability ratingrating
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22/82COPYRIGHT 2008, Seco Tools AB
Stainless steel
Steel
Grey cast iron
Aluminium & alloys
Super alloys and titanium
Machinability
MachinabilityMachinability ratingrating
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23/82COPYRIGHT 2008, Seco Tools AB
Workpiece materials applications cutting materials
Areas of application for the various cutting materials1. Influence on cutting conditions.2. Influence on properties of cutting materials.
Cutting material
Class colour
Sub- groups
P01
P10
P20
P40
P50
Material to be machined
Steel, steel castings
Steel, steel castings
Steel, steel castingsMalleable cast iron with long chips
Steel, steel castings with sand inclusion and cavities
Steel, steel castingsMalleable cast iron with long chips
Steel, steel castings of medium or low tensile strength, with sand inclusion and cavities
Application
Finish turning and boring; high cutting speeds, small chip section, accuracy of dimensions and fine finish vibration-free operation.
Turning, copying, threading and milling, high cutting speeds, small or medium chip sections.
Turning, copying, milling, medium cutting speeds and chip sections
Turning, milling, planing, medium or low cutting speeds, medium or large chip sections, and machining in unfavorable conditions.
Turning, planing, slotting, low cutting speeds, large chip section with the possibility of large cutting angles for machining in unfavorable conditions.
For operations demanding very tough carbide; turning, planing, slotting, low cutting speeds, large chip sections with the possibility of large cutting angles for machining in unfavorable conditions.
PSteel
Change in properties
Cuttting conditions
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P30
MachinabilityMachinability ratingrating
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24/82COPYRIGHT 2008, Seco Tools AB
MachinabilityMachinability ratingrating
(Typical example )MN 2006 Turning page 31
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25/82COPYRIGHT 2008, Seco Tools AB
Mild and alloy steels1 to 6
Rule of thumb: Within a family of workpiece material groups, machining difficulty increases as the group number increases.
Titanium alloys22
Superalloys /High temperature alloys20 to 21
Non-ferrous alloys16 to 19
Cast irons11 to 15
Stainless steels8 to 11
Hardened Steel7
Family NameGroup Number
MachinabilityMachinability ratingrating
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26/82COPYRIGHT 2008, Seco Tools AB
Groups 1 through 7 0.028 to 2.0% carbon Small amounts of other
metals Nickel Chromium Manganese
Mild and Alloy SteelsMild and Alloy Steels
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27/82COPYRIGHT 2008, Seco Tools AB
Properties Carbon content < 0.28% Tough, cheap, and impact resistant Easily worked Soft and gummy
Machining 50 to 100% machinability rating Stringy, continuous chips Watch for BUE Easy to machine at high cutting speeds High speed: MTCVD (AL2O3) Med. speed: CVD (TiC, TiN) Low speed: PVD (TiCN)
Uses Hub caps, stampings, wheels
Group 1: Mild and Alloy SteelsGroup 1: Mild and Alloy Steels
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28/82COPYRIGHT 2008, Seco Tools AB
Properties Carbon content: 0.28 to 0.50% Harder and stronger Tough, cheap, and impact resistant Easily worked, soft and gummy
Machining 45 to 65% machinability rating Stringy, continuous chips Watch for BUE Moderately difficult to machine High speed: MTCVD (AL2O3) Med. speed: CVD (TiC, TiN) Low speed: PVD (TiCN)
Uses I-beams, auto frames, axle housings
Group 3: Ordinary Carbon SteelsGroup 3: Ordinary Carbon Steels
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29/82COPYRIGHT 2008, Seco Tools AB
Properties Carbon content: 0.50 to 2.0% Small amounts of nickel, molybdenum, chromium, and/or
vanadium. Very high hardness. Tougher and stronger.
Machining 35 to 65% machinability rating. Difficult to machine. Watch insert flank wear. Reduce cutting speed. High speed: MTCVD (AL2O3) Medium speed: CVD (TiC, TiN) Low speed: PVD (TiCN) If RC > 45, use CBN
Uses Tool steel, springs, bearings, dies, punches
Group 6: Tool SteelsGroup 6: Tool Steels
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30/82COPYRIGHT 2008, Seco Tools AB
Stainless SteelsStainless Steels
Groups 8 through 11. At least 10.5% chromium. Less than 1.2% carbon. Properties which increase from
Group 8 to 9 to 10 to 11. Corrosion resistance. Hardness. Temperature resistance.
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31/82COPYRIGHT 2008, Seco Tools AB
Chromium Oxygen
Alloyed steel with maximum 1.2% carbon and at least 10.5% chromium.
Cr2 O3
Stainless SteelsStainless Steels
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32/82COPYRIGHT 2008, Seco Tools AB
Stainless steel structures
The microstructure and alloy elements are the determining factors. They determine properties such as heat resistance,
corrosion resistance, oxidation resistance.And also the machinability!!
AusteniticFerritic Martensitic Duplex
Stainless SteelsStainless Steels
Ferritic stainess steel (400 series, e.g. 405, 430, 442) (low carbon steel + Cr).
Martensitic stainless steel (400 series, e.g. 403, 416, 422) (ferritic stainless steel + C).
Precipitation hardened stainless steel (PH-steel, e.g. 15-5PH, 17-4PH, PH13-8Mo))(martensitic stainless steel + Cu, Al, Nb).
Austenitic stainless steel (300 series, e.g. 301, 304, 316) (ferritic stainless steel + Ni).
Duplex stainless steel (200 series)(austenitic stainless steel - Ni + Mn, N).
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33/82COPYRIGHT 2008, Seco Tools AB
0
20
40
60
80
100
120
Ferritic SS Martensitic SS Austensitic SS Duplex SS PH SS
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Influence of material structure
Stainless SteelsStainless Steels
(Typical example )
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34/82COPYRIGHT 2008, Seco Tools AB
Machinability
Mo Cr N Ni C Ti Mn S Ca Pb
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Stainless SteelsStainless Steels
Build up edge problems. Hard, very homogenous surfaces (scales). Poor surface finish. Burring. Poor chip formation and difficult chip removal.
35
35/82COPYRIGHT 2008, Seco Tools AB
The PRE factor is a criterion for the corrosion resistance
The resistance of the stainless steel to pitting is indicated by the PRE factor (Pitting Resistance Equivalent).
The PRE factor determines heavily the machinability
PRE factor = % Cr + 3.3 x % Mo + 30 x % NPRE factor = % Cr + % Ni (when no Mo or N)
Stainless SteelsStainless Steels
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36/82COPYRIGHT 2008, Seco Tools AB
AusteniticDuplexMartensitic - austeniticMartensitic
PRE value
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Reference cutting speed- 30 minutes tool life- b/h = 10- flat insert- untreated cutting edge- uncoated P20
Stainless SteelsStainless Steels
(Typical example )
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37/82COPYRIGHT 2008, Seco Tools AB
The heat which needs to be removed in the chip and the workpiece is concentrated in the insert in stainless steel.(plastic deformation)
Low thermal conductivity
Stainless SteelsStainless Steels
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38/82COPYRIGHT 2008, Seco Tools AB
Self-hardening (surface hardening)
If the tension in the stainless steel exceeds the elongationlimit, stainless steel will show self-hardening.
This is the case in the shearing zone.
This is made worse through formation of Cr2 O3 (quickly and always).
Distance from the surface
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Stainless SteelsStainless Steels
(Typical example )
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39/82COPYRIGHT 2008, Seco Tools AB
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Temperature / cutting speed
Cutting Build up edge
Oxidation
Diffusion
FrictionTotalTechnically optimum
CuttingCutting speed speed zoneszones
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40/82COPYRIGHT 2008, Seco Tools AB
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Cutting speed
11 22 33
Cutting build up edge
60 m/min 100 m/min
CuttingCutting speed speed zoneszones
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41/82COPYRIGHT 2008, Seco Tools AB
Cutting speed zone 1
Use TiN or TiCN coated (PVD) tough inserts or uncoated tough inserts (P25-P40, K20).
Use cooling to keep the temperature down.
Use small chip sections (sharp inserts).
High tool life is possible.
Long finishing times Low productivity and high costs.
Reliability questionable.
Low productivity zone 40 - 60 (m/min)
CuttingCutting speed speed zoneszones
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42/82COPYRIGHT 2008, Seco Tools AB
Build up edge wear zone 60 - 100 (m/min)
ChipChip
Burs on chipBurs on chip
Build up edgeBuild up edgeBurs on Burs on workpieceworkpiece
Great build up edge in this area.Avoid cutting speed zone 2.
Cutting speed zone 2
CuttingCutting speed speed zoneszones
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43/82COPYRIGHT 2008, Seco Tools AB
Use tough coated inserts (P25C) or wear resistant uncoated inserts (P15) or cermet.
Use inserts with big positive rake (approx. 200).
Aim for large chip sections (f > 0.15 (mm/t), ap > 1 (mm)).
Do not use cooling except if there could be problems with chip removal.
Roughing High productivity zone 100 - 300 (m/min)
Cutting speed zone 3
CuttingCutting speed speed zoneszones
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44/82COPYRIGHT 2008, Seco Tools AB
Cutting speeds approx. 25% higher than in roughing.
Use cermet, P15 (uncoated), PVD coated micrograin grades.
Feed f = 0.05 - 0.15 (mm/t) and ap > 0.5 (mm).
If f < 0.05 (mm/t) en ap < 0.5 (mm) use uncoated K20.
Use abundant coolant to keep the temperature low.
In contour milling with small radial cutting depths, apply a cutting depth factor and do not use coolant.
Finishing High productivity zone 120 - 350 [m/min]
Cutting speed zone 3
CuttingCutting speed speed zoneszones
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45/82COPYRIGHT 2008, Seco Tools AB
Machining in stainless steel requires five times as many cutting edges as the same process in classical steel.
Be careful with other problems such as interrupted cuts and casting scales.
Also pay attention to: Austenitic structure Duplex structure Nitrogen reinforced structure Precipitation hardened SS Pre-processing
Avoid false economies
Stainless SteelsStainless Steels
Turning (previous)Insert wear
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46/82COPYRIGHT 2008, Seco Tools AB
Chip formation
BurringSticky chipping
Build up edge (wear)
StainlessStainless steelsteel turningturning
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47/82COPYRIGHT 2008, Seco Tools AB
AISI 304AISI 304 Ck 45Ck 45
AISI 304 Ca
Chip formation
StainlessStainless steelsteel turningturning
48
48/82COPYRIGHT 2008, Seco Tools AB
Machine
Select maximum stability and capacity.
Avoid worn machines for accurate work.
StainlessStainless steelsteel turningturning
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49/82COPYRIGHT 2008, Seco Tools AB
Toolholder
Select the largest possible shank section.
Select a strong insert clamping system.
Minimize the projection length.Select sound seating.
StainlessStainless steelsteel turningturning
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50/82COPYRIGHT 2008, Seco Tools AB
Working method
Select varying cutting depths for heavy and lengthy roughing processes.
Roughing with entering angle of 75 or 45.Then finish with 90.
StainlessStainless steelsteel turningturning
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51/82COPYRIGHT 2008, Seco Tools AB
Working method
For heavy roughing, use variable cutting depths.
StainlessStainless steelsteel turningturning
52
52/82COPYRIGHT 2008, Seco Tools AB
Rough workpiece
First chamfer if possible. In burnished pieces, always begin by removing burnished residue.
StainlessStainless steelsteel turningturning
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53/82COPYRIGHT 2008, Seco Tools AB
Inserts
Select strong inserts with sharp geometries (entering angle).
Select large nose radius.
Select internal positive single sided inserts and external double sided negative inserts.
StainlessStainless steelsteel turningturning
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54/82COPYRIGHT 2008, Seco Tools AB
Cutting conditions
Use large cutting depths.
Use large feeds.
Change inserts regularly (not too much wear).
StainlessStainless steelsteel turningturning
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55/82COPYRIGHT 2008, Seco Tools AB
1. Smooth cutting process is important (smooth cutting geometry, large rake angle, sharp yet reinforced cutting edges (small T phase/honing)).
2. Good chip removal.
3. Cutting under the hard surface layer.
4. Use down-milling.
5. Limit heat development
1. cooling (at the right place).
2. thick chip (0.08 mm min hm ) to gain sufficient mass for maximum heat removal.
6. Average chip thickness (very important)
1. cutter positioning (10% D on exit side of workpiece).
2. feed = > T - phase/honing.
7. Cutting depth at least 1 mm and no finishing passes (unless absolutely essential) (friction).
8. Maximum carbide mass (to remove heat).
Some advice
StainlessStainless steelsteel millingmilling
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56/82COPYRIGHT 2008, Seco Tools AB
Some advice feed and cutting depth
average chip thickness (hm) is very important and critical for tool life (verify with cutting edge geometry - M/ME).
Inco / SS (+ feed / + tool life) (titanium, if short tool life, reduce feed).
if inserts with T-phase are used, the feed must be greater than this phase.
avoid feed = 0 (helical interpolation milling instead of drilling).
small cutting depths shorten the tool life.
minimum cutting depth 1 mm.
the smaller the cutting depth, the higher the cutting speed required (correct cutting temperature) (cutting speed factor in contour milling).
StainlessStainless steelsteel millingmilling
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57/82COPYRIGHT 2008, Seco Tools AB
Some advice cutting speed High cutting speed method
15 to 20 minutes tool life. Low cutting speed method
45 to 60 minutes tool life. High pressure cooling >50 bar
Higher cutting speed. Low tool life - 45 to 100 minutes.
Use high cutting speed if possible.
Most stainless steels are easily machined, except PH-SS and cooling is not necessarymost of the time.
Good chip evacuation (removal of chips from the workpiece).
1. Low cutting speed (low temperature) Vc = 30 - 60 m/min.2. Build-up in cutting edge zone.3. High cutting speed (high temperature) Vc = 100 - 300 m/min.
High cutting speed method Low cutting speed method
StainlessStainless steelsteel millingmilling
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58/82COPYRIGHT 2008, Seco Tools AB
Group 8: Stainless SteelsGroup 8: Stainless Steels
Properties Little or no alloying elements other than carbon and chromium.
Good corrosion and temperature resistance.
Machining 40 to 65% machinability rating. Easy to machine. Soft, continuous chips. Watch for BUE (built-up edge). Use positive rake tools. Cobalt enriched zone. MTCVD coatings.
Uses Cookware, surgical tools, pump components.
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59/82COPYRIGHT 2008, Seco Tools AB
Group 9: Stainless SteelsGroup 9: Stainless Steels
Properties May contain nickel, molybdenum, sulphur, and vanadium.
Increased hardness. Increased corrosion and temperature resistance.
Machining 30 to 45% machinability rating. More difficult to machine. Stringy, brittle chips. Watch for notching at DOC line. Use positive rake tools Cobalt enriched zone. MTCVD coating.
Uses Piping pumps, process equipment.
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60/82COPYRIGHT 2008, Seco Tools AB
Group 10 and 11: Stainless SteelsGroup 10 and 11: Stainless Steels
Properties May contain nitrogen and titanium. Excellent corrosion and temperature resistance. Very high hardness.
Machining 25 to 70% machinability rating. Very difficult to machine. Watch for surface work hardening. Flank wear and edge chipping are typical failure
modes. Use positive rake tools. Cobalt enriched zone. MTCVD coatings. CBN and ceramics.
Uses Piping, pumps, process equipment in demanding conditions.
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61/82COPYRIGHT 2008, Seco Tools AB
Cast IronsCast Irons
Groups 12 through 15 Greater than 2.0% carbon Tend to be abrasive to
machine May also contain:
Magnesium Silicon Sulphur Phosphorus
Brake drums
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62/82COPYRIGHT 2008, Seco Tools AB
Group 12: Cast IronsGroup 12: Cast Irons
Properties Carbon in form of flakes. Abrasive Low to medium hardness. Strong and cheap to produce.
Machining 40 to 70% machinability rating. Moderately difficult to machine. Discontinuous chips. Machine at high cutting speeds. High speeds: AL2O3. Medium speeds: CVD (TiC, TiCN, AL2O3). Low speeds: PVD (TiAIN) and CVD (TiC).
Uses Engine blocks, inexpensive castings.
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63/82COPYRIGHT 2008, Seco Tools AB
Groups 13 & 14: Cast IronsGroups 13 & 14: Cast Irons
Properties Cerium and magnesium cause carbon to form spheroids. Harder and more abrasive. More ductile, less brittle.
Machining Discontinuous chips. High speed: AL2O3; CBN; ceramic (SiN). Medium speed: CVD (TiC, TiCN, AL2O3). Low speed: PVD (TiAIN) and CVD (TiC).
Uses Crankshafts, structural parts, pulleys, brakes.
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64/82COPYRIGHT 2008, Seco Tools AB
Group 15: Cast IronsGroup 15: Cast IronsProperties Silicon causes carbon to form spheroids.
Called ductile cast iron. Excellent tensile strength. Good wear resistance. Cheaper and lighter than steel.
Machining 35 to 60% machinability rating. High cutting forces. Analogous to interrupted-cut. Discontinuous chips. Negative rake for strength. High speed: AL2O3; CBN; ceramic (SiN). Medium speed: CVD (TiC, TiCN, AL2O3). Low speed: PVD (TiAIN) and CVD (TiC).
Uses Gears, truck springs, turbo-compressor housings, crankshafts.
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65/82COPYRIGHT 2008, Seco Tools AB
Aluminium piston
NonNon--Ferrous AlloysFerrous Alloys
Groups 16 through 19. Less than 50% iron. Most metals are soft
(except for tungsten carbide).
Machinability varies over a wide range.
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66/82COPYRIGHT 2008, Seco Tools AB
Low density. High strength. Good thermal conductivity. Good corrosion resistance.
1xxx 99% Al 2xxx + Cu 3xxx + Mn 4xxx + Si 5xxx + Mg 6xxx + Mg, Si 7xxx + Zn 8xxx + Other elements
AluminiumAluminium
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67/82COPYRIGHT 2008, Seco Tools AB
General Carbide grade or PCD. Polished rake surface. Positive rake angle. Coarse pitch cutter. Large chip evacuation grooves.
Cutting speed 600 to 2000 (max) m/min with carbide inserts. 1500 - 6000 m/min with PCD inserts.
Feed 0.15 to 0.50 mm/rev.
AluminiumAluminiumSome advice
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68/82COPYRIGHT 2008, Seco Tools AB
Build-up of cutting edge Adjust cutting speed / use coolant / very positive geometry.
Chip control and evacuation Open pitch cutter when milling. Wash chips away with coolant.
Burring Use micro-sharp cutting edges.
Abrasive wear Carbide grade or PCD.
Finishing With coolant, not for roughing.
Close pitch cutters For large table feed, but needs power.
AluminiumAluminiumSome advice
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Group 16: Aluminum (
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Group 17: Aluminum (>16% Group 17: Aluminum (>16% SiSi))
Properties Alloyed to enhance strength. Good wear resistance. Increased hardness. Very abrasive. Group 17 includes aluminum-bronze, cupro-nickel,
and magnesium-bronze.
Machining 60 to 180% machinability rating. Non-free machining. Machine at slower cutting speeds.
Uses Engine blocks.
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Group 18: Difficult NonGroup 18: Difficult Non--FerrousFerrous
Properties Group 18 includes difficult to machine alloys of copper, babbit, and bronze.
Good strength. Good corrosion resistance. High ductility and toughness. Very abrasive.
Machining 60 to 180% machinability rating. Watch for BUE. Tends to tear.
Uses Bushings, bearings, valve seats.
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Group 19: Super Hard AlloysGroup 19: Super Hard Alloys
Properties Group 19 includes tungsten carbide. Very high hardness. Very high strength. Abrasive
Machining 5 to 15% machinability rating. Machine at very slow cutting speeds.
Uses Dies, punches, and wear parts.
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SuperalloysSuperalloys/High Temperature Alloys/High Temperature Alloys
Groups 20 through 21. Good corrosion resistance. High strength. Maintain properties at
elevated temperatures.
Very difficult to machine.
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Nickel, iron and cobalt alloys, the most important propertiesbeing: Exceptional strength. Corrosion resistance at high temperatures.
SuperalloysSuperalloys/High Temperature Alloys/High Temperature Alloys
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.Superalloys
Inconel 600WaspoloyRen N4
MAR-M-247Inconel 718Inconel 706Hastelloy X
Nickel based
Nickel-iron based MAR-M 509X40
Haynes 188FSX-414
Cobalt based
A-286Discaloy
Haynes 556
Iron based
SuperalloysSuperalloys/High Temperature Alloys/High Temperature Alloys
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Titanium AlloysTitanium Alloys
Titanium
Alpha alloy Alpha-Beta alloy Beta alloy
HCP BCCMix
High strength/weight ratio. High strength/creep resistance up to 500C. Excellent corrosion resistance.
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Machinability of superalloys
More heat generation upon machining (structure) and low thermal conductivity. This means higher cutting temperatures.
Increasing strength at higher temperatures (basic property) (cutting temperature). This means higher cutting forces.
Difficult chip control (greater toughness). Carbide precipitates (due to heat treatment). Work-hardening (hard layer).
Machinability of titanium alloys
Low thermal conductivity. This means higher cutting temperatures. Small Youngs modulus (workpiece deformation, tolerances, vibrations). Chemically very reactive (oxidation) (ignition and combustion during machining).
SuperalloysSuperalloys and Titanium Alloysand Titanium Alloys
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General recommendations
Machine in softest possible state. Positive rakes. Sharp cutting edges. Strong basic geometry (nose radius). Stable working conditions. Avoid workpiece deformation. Use small entering angles. Single-pass cutting or varying cutting depth.
SuperalloysSuperalloys and Titanium Alloysand Titanium Alloys
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Group 20: Group 20: SuperalloysSuperalloys
Properties Hardness < 35RC. Group 20 includes nickel, cobalt, and iron alloys. Very high hardness. Very abrasive.
Machining 9 to 45% machinability rating. Machine at very slow cutting speeds. Work hardens rapidly. Notching at DOC line. High cutting forces and temperatures. Watch for BUE.
Uses Prosthetics, heat exchangers, aviation, maritime, plumbing.
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Group 21: Group 21: SuperalloysSuperalloys
Properties Hardness > 35RC. Group 21 includes nickel, cobalt, iron alloys,
Inconel600, HastelloyX, Monel400. Extremely high hardness. Very abrasive. Similar issues as Group 20 but to a greater degree.
Machining 9 to 15% machinability rating. Machine at extremely slow cutting speeds. Work hardens rapidly. Notching at DOC line. High cutting forces and temperatures. Watch for BUE.
Uses Jet engines.
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Properties Group 22 includes titanium, niobium, tantalum, molybdenum, and tungsten.
High temperature resistance. Poor oxidation resistance in air. High thermal conductivity. Flex readily. Sometimes flammable. May react with tool materials. Low coefficient of thermal expansion.
Machining 5 to 30% machinability rating. Machine at very low cutting speeds. Watch for BUE.
Uses Aircraft frames, nuclear plants.
Group 22: Refractory MetalsGroup 22: Refractory Metals
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Workpiece materialsSlide Number 2Slide Number 3Slide Number 4Slide Number 5Slide Number 6Slide Number 7Slide Number 8Slide Number 9Slide Number 10Slide Number 11Slide Number 12Slide Number 13Slide Number 14Slide Number 15Slide Number 16Slide Number 17Slide Number 18Slide Number 19Slide Number 20Slide Number 21Slide Number 22Workpiece materials applications cutting materialsSlide Number 24Slide Number 25Mild and Alloy SteelsGroup 1: Mild and Alloy SteelsGroup 3: Ordinary Carbon SteelsGroup 6: Tool SteelsStainless SteelsStainless SteelsSlide Number 32Slide Number 33Slide Number 34Stainless SteelsSlide Number 36Slide Number 37Slide Number 38Slide Number 39Slide Number 40Slide Number 41Slide Number 42Slide Number 43Slide Number 44Slide Number 45Slide Number 46Slide Number 47Slide Number 48Slide Number 50Slide Number 51Slide Number 52Slide Number 53Slide Number 54Slide Number 55Slide Number 56Slide Number 57Group 8: Stainless SteelsGroup 9: Stainless SteelsGroup 10 and 11: Stainless SteelsCast IronsGroup 12: Cast IronsGroups 13 & 14: Cast IronsGroup 15: Cast IronsNon-Ferrous AlloysAluminiumAluminiumAluminiumGroup 16: Aluminum (16% Si)Group 18: Difficult Non-FerrousGroup 19: Super Hard AlloysSuperalloys/High Temperature AlloysSuperalloys/High Temperature AlloysSuperalloys/High Temperature AlloysTitanium AlloysSuperalloys and Titanium AlloysSuperalloys and Titanium AlloysGroup 20: SuperalloysGroup 21: SuperalloysGroup 22: Refractory MetalsQuestions?