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1 1/82 COPYRIGHT © 2008, Seco Tools AB Workpiece Workpiece materials materials Duplex SS 42CrMo4 Ca-treated 316L

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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

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    Surface integrity

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    Environment

    Tool wearChip formation f

    vc

    29803000302030403060308031003120

    0 2 4 6 8 10

    Fy

    FxFz

    Cutting forces

    MachinabilityMachinability

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    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

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    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

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    The The cuttingcutting processprocess

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    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

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    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

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    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

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    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

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    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

  • 15

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    - 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.

    -800

    -600-400

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    Depth under the surface (m)

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    Compression

    Tension

    SurfaceSurface integrityintegrity

    (Typical example )

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    Self- hardening

    ToolWorkpiece material

    Self- hardening

    Tool

    Work- piecematerial

    SurfaceSurface integrityintegrity

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    SurfaceSurface integrityintegrity

  • 18

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    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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    Depth from surface

    SurfaceSurface stressesstresses

    (Typical example )

  • 20

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    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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    P

    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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    Stainless steel

    Steel

    Grey cast iron

    Aluminium & alloys

    Super alloys and titanium

    Machinability

    MachinabilityMachinability ratingrating

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    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

  • 24

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    MachinabilityMachinability ratingrating

    (Typical example )MN 2006 Turning page 31

  • 25

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    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

  • 26

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    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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    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

  • 28

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    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

  • 29

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    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

  • 30

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    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.

  • 31

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    Chromium Oxygen

    Alloyed steel with maximum 1.2% carbon and at least 10.5% chromium.

    Cr2 O3

    Stainless SteelsStainless Steels

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    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).

  • 33

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    0

    20

    40

    60

    80

    100

    120

    Ferritic SS Martensitic SS Austensitic SS Duplex SS PH SS

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    (

    %

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    Influence of material structure

    Stainless SteelsStainless Steels

    (Typical example )

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    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

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    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

  • 36

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    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 )

  • 37

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    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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    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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    Temperature / cutting speed

    Cutting Build up edge

    Oxidation

    Diffusion

    FrictionTotalTechnically optimum

    CuttingCutting speed speed zoneszones

  • 40

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    Cutting speed

    11 22 33

    Cutting build up edge

    60 m/min 100 m/min

    CuttingCutting speed speed zoneszones

  • 41

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    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

  • 42

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    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

  • 43

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    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

  • 44

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    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

  • 45

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    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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    Chip formation

    BurringSticky chipping

    Build up edge (wear)

    StainlessStainless steelsteel turningturning

  • 47

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    AISI 304AISI 304 Ck 45Ck 45

    AISI 304 Ca

    Chip formation

    StainlessStainless steelsteel turningturning

  • 48

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    Machine

    Select maximum stability and capacity.

    Avoid worn machines for accurate work.

    StainlessStainless steelsteel turningturning

  • 49

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    Toolholder

    Select the largest possible shank section.

    Select a strong insert clamping system.

    Minimize the projection length.Select sound seating.

    StainlessStainless steelsteel turningturning

  • 50

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    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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    Working method

    For heavy roughing, use variable cutting depths.

    StainlessStainless steelsteel turningturning

  • 52

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    Rough workpiece

    First chamfer if possible. In burnished pieces, always begin by removing burnished residue.

    StainlessStainless steelsteel turningturning

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    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

  • 54

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    Cutting conditions

    Use large cutting depths.

    Use large feeds.

    Change inserts regularly (not too much wear).

    StainlessStainless steelsteel turningturning

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    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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    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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    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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    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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    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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    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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    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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    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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    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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    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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    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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    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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    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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    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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    82/82COPYRIGHT 2008, Seco Tools AB Questions?Questions?

    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?