Content

Turning Drilling
Theory A 4 Theory E 7
Selection procedure A 12 Selection procedure E 15
System overview A 16 System overview E 20
Choice of inserts A 22 How to apply E 26
Choice of tools Hole quality and tolerances E 37
- External A 50 Troubleshooting E 42
- Internal A 56
Code keys A 66
Boring
Troubleshooting A 68
Theory F 4
Selection procedure F 9
Parting & Grooving
System overview F 14
Theory B 4 Choice of tools F 16
Selection procedure B 7 How to apply F 21
System overview B 11 Troubleshooting F 25
Parting & grooving - how to apply B 15
- Parting off B 22
Tool holding
- General grooving B 25
- Circlip grooving B 27 History and background G 4
- Face grooving B 28 Why modular tooling G 7
- Profiling B 31 Turning centres G 15
- Turning B 33 Machining centres G 23
- Undercutting B 35 Multi-task machines G 28
Troubleshooting B 36 Chucks G 33

Threading Machinability
Theory C 4 Workpiece materials H 4
Selection procedure C 9 The cutting edge H 18
System overview C 13 Cutting tool materials H 29
How to apply C 19 Manufacturing of cemented carbide H 44
Troubleshooting C 25
Other information
Milling
Machining economy H 55
Theory D 4 Maintenance & tool wear H 68
Selection procedure D 9 Formulas and definitions H 75
System overview D 13 Cutting data calculator H 80
Choice of insert – how to apply D 24
Choice of tools – how to apply D 29
Troubleshooting D 36

1
A2
Turning

Turning generates cylindrical and rounded forms with a

single-point tool. In most cases the tool is stationary with
the workpiece rotating.

• Theory A4

• Selection procedure A 12

• System overview A 16

• Choice of inserts – how to apply A 22

• Choice of tools – how to apply

- External A 50
- Internal A 56

• Code keys A 66

• Troubleshooting A 68

A3
 A Theory

General turning operations

Turning

Turning is the combination of two movements – rotation of

B the workpiece and feed movement of the tool.
The feed movement of the tool can be along the axis of
Parting and

the workpiece, which means the diameter of the part will

grooving

be turned down to a smaller size. Alternatively, the tool

can be fed towards the centre (facing off), at the end of
the part.
C
Often feeds are combinations of these two directions,
resulting in tapered or curved surfaces.
Threading

Turning and facing as axial and radial tool movements.

Milling

E
Drilling

F
Boring

Three common turning operations:

G
- Longitudinal turning
Tool holding

- Facing
- Profiling.

H
Other information
Machinability

A4
 Theory
A

Definitions of terms

Turning
Spindle speed
B
n (rpm) The spindle speed rpm (revolution per
minute) is the rotation of the chuck and

Parting and
workpiece.

grooving
C

Threading
Cutting speed
D
The cutting speed is the surface speed,
m/min, at which the tool moves along the
vc (m/min) workpiece in metres per minute

Milling
E

Definition of cutting speed

Drilling
n The definition of cutting speed as the result
of the diameter, pi (π) and spindle speed in F
revolutions per minute (rpm). The circumfer-
ence (C) is the distance the cutting edge
moves in a revolution.
Boring

C vc = cutting speed (m/min)

Dm = machined diameter (mm)
G

n = spindle speed (rpm)

Tool holding

Circumference, C = π x Dm (mm)

π × Dm × n m/min
H
vc =
Other information

1000
Machinability

A5
 A Theory

Calculation of the circumference

Turning

• Circumference = π x diameter (mm)

• π (pi) = 3.14
B
Parting and
grooving

Example:

Dm2 = 100 mm
C Circumference = 3.14 x 100
= 314 mm
Threading

Dm1 = 50 mm
Circumference = 3.14 x 50
= 157 mm
D
Milling

Example of cutting speed differations

E The cutting speed differs depending on the workpiece diameter.

Given:
Spindle speed, n = 2000 rpm
Drilling

Diameter, Dm1 = 50 mm

F Diameter, Dm2 = 80 mm

π × Dm × n
Boring

vc = m/min
1000
G

3.14 × 50 × 2000
Tool holding

vc1 = = 314 m/min

1000

3.14 × 80 × 2000
H vc2 = = 502 m/min
1000
Other information
Machinability

A6
 Theory
A

Definitions of terms

Turning
Spindle speed
The workpiece rotates in the lathe, with
a certain spindle speed (n), at a certain B
number of revolutions per minute (rpm).

Parting and
grooving
Surface/cutting speed
The cutting speed (vc) in m/min at which
the periphery of the cut workpiece diam- C
eter passes the cutting edge.

Threading
Feed
The cutting feed (fn) in mm/r is the move-
n = spindle speed (rpm) ment of the tool in relation to the revolving D
vc = cutting speed (m/min) workpiece. This is a key value in deter-
mining the quality of the surface being
fn = cutting feed (mm/r) machined and for ensuring that the chip
formation is within the scope of the tool

Milling
ap = depth of cut (mm)
geometry. This value influences, not only
κr = entering angle how thick the chip is, but also how the chip
forms against the insert geometry. E

Depth of cut

Drilling
The cutting depth (ap) in mm is half of the
difference between the un-cut and cut di-
ameter of the workpiece. The cutting depth F
is always measured at right angles to the
feed direction of the tool. Boring

Entering angle
The cutting edge approach to the work- G
piece is expressed through the entering
angle (κr). This is the angle between the
Tool holding

cutting edge and the direction of feed and

is an important angle in the basic selec-
tion of a turning tool for an operation.
H
Other information
Machinability

A7
 A Theory

Calculating cutting data

Turning

Cutting speed
Example of how to calculate the spindle speed (n) from
B
cutting speed (vc).

Given:
Parting and
grooving

Cutting speed, vc = 400 m/min

Diameter Dm = 100 mm
C

vc × 1000
n= r/min
Threading

π × Dm

D 400 ×1000
n= = 1274 r/min
3.14 × 100

Inclination and rake angles

Milling

Rake angle
E
The rake angle gamma (γ) is a measure
of the edge in relation to the cut. The rake
angle of the insert itself is usually positive
λ and the clearance face is in the form of
Drilling

a radius, chamfer or land and affects tool

strength, power consumpion, finishing abil-
F γ
ity of the tool, vibration tendency and chip
formation.
Boring

Inclination angle
G The inclination angle lamda (λ) is the an-
gle the insert is mounted in the tool holder.
When mounted in the tool holder, the
Tool holding

insert geometry and inclination in the tool

holder will determine the resulting cutting
angle with which the cutting edge cuts.
H
Other information
Machinability

A8
 Theory
A

Cutting depth and chip formation

Turning
ap B
ap
κr

Parting and
grooving
C
The cutting depth (ap) is the length the Chip formation varies with depth of cut,
edge goes into the workpiece. entering angle, feed, material and insert

Threading
geometry.

Feed rate and the effective cutting edge length

Milling
E

Drilling
F

Feed rate Cutting edge length

Boring

The feed rate (fn) is the

distance the edge moves The effective cutting edge length (la) relates to cutting
along the cut per revolu- depth and entering angle. G
tion.
Tool holding

H
Other information
Machinability

A9
 A Theory

Insert shape selection, entering angle and chip thickness

Turning

The entering angle (κr) of the tool and the nose radius
(re) of the insert effect the chip formation in that the chip
B cross-section changes. The chip thickness is reduced and
the width increased with a smaller angle.
Parting and

The direction of chip flow is also changed.

grooving

C
CNMG DNMG WNMG

Entering angle κr: Entering angle κr: Entering angle κr:

Threading

95°, 75° 107°30', 93°, 62°30' 95°

D SNMG RCMT TNMG

Entering angle κr: Entering angle κr: Entering angle κr:

Milling

45°, 75° Variable 93°, 91°, 60°

E VNMG

Entering angle κr:

117°30', 107°30', 72°30'
Drilling

Entering angle κr
Boring

• Is defined by the holder tip seat in com-

bination with insert shape selected.
G
Maximum chip thickness hex
Tool holding

• Reduces relative to the feed rate as the

entering angle reduces.

κr = 45° hex ≈ fn
H hex ≈ fn x 0.71
Other information
Machinability

A 10
 Theory
A

The effect of entering angle on chip thickness

Turning
Maximum chip thickness hex reduces relative to the feed
rate as the entry angle reduces.
B

Parting and
grooving
κr κr κr κr
C
Entering angle κr 90° - 95 75° 60° 48.7°
45°

Threading
Chip thickness 0.75 (max)
1 0.96 0.87 0.71
compared to feed 0.39 (average

D
Contact length la
2 2.08 2.3 2.82 5.1
at ap 2 mm

Milling
Calculating power consumption E
The net power (Pc) in kW required for
metal cutting is mainly of interest when n = spindle speed (rpm)
roughing, then it is essential to ensure
vc = cutting speed (m/min)

Drilling
that the machine has sufficient power for
the operation. The efficiency factor of the fn = cutting feed (mm/rev)
machine is also of great importance. F
ap = depth of cut (mm)
For information about the kc value, see
kc = specific cutting force (N/mm2)
page H 16.
Pc = net power (kW)
Boring

G
Tool holding

vc × ap × fn × kc
Pc = kW
60 × 103 H
Other information
Machinability

A 11
 A Selection procedure

Selection procedure
Turning

B Production planning process

Parting and
grooving

Dimension and type of

operation
C

1 Component
Workpiece material and
Threading

quantity

Machine parameters
2
Milling

Machine

E
Type of turning tool:
- External/internal
- Longitudinal
3
Drilling

Choice of tool - Profiling

- Facing
F

Cutting data, tool

path, etc.
4
Boring

How to apply

G
Tool holding

5 Troubleshooting Remedies and solutions

H
Other information
Machinability

A 12
 Selection procedure
A

1. Component and the workpiece material

Turning
Parameters to be considered
Component B
•A  nalyse the dimensions and quality demands of the
surface to be machined.

Parting and
grooving
• Type of operation (longitudinal, profiling and facing).
• External, internal
• Roughing, medium or finishing
• Tool paths
C
• No of passes
• Tolerances

Threading
D

P M K Material
N S H •  achinability
M

Milling
• Cast or pre-machined
• Chip breaking
• Hardness E
• Alloy elements

2. Machine parameters

Drilling
Condition of the machine
F
Some important machine considerations:
- Stability, power and torque, especially for
larger diameters
- Component clamping
Boring

- Tool position
- Tool changing times/number of tools in turret G
- Spindle speeed (rpm) limitations, bar feed magazine
- Sub spindle, or tail stock available?
Tool holding

- Use all possible support

- Easy to program
- Cutting fluid pressure.
H
Other information
Machinability

A 13
 A Selection procedure

3. Choice of tools
Turning

Different ways to optimize turning

Turning with rhombic inserts
B
Advantages Disadvantages
• Operational versatility. • Can cause vibration
Parting and

• Large entering angle. when turning slender

grooving

• For turning and facing. components.

• Good roughing strength.
C
Threading

Turning with wiper inserts

D
Advantages Disadvantages
• Increase feed and gain • In back turning and profil-
productivity. ing the wiper edge is not
• Use normal feed rate and effective.
Milling

gain surface quality.

• Productivity booster.
E
Drilling

New ways in profile turning

F Advantages
• Increase feed and gain
productivity.
• Use normal feed rate and
Boring

gain surface quality.

• Productivity booster
G • Tolerance
• Set-up time
Tool holding

Rigid insert location with

T-rails.

H
Other information
Machinability

A 14
 Selection procedure
A

4. How to apply

Turning
Important application considerations

The tool path has a significant impact on

B
the machining process.
It influences:

Parting and
- Chip control

grooving
- Insert wear
- Surface quality
- Tool life. C

In practice, the tool holder, insert geometry,

grade, workpiece material and tool path

Threading
influences the cycle time and productivity
considerably.
D

5. Troubleshooting

Milling
Some areas to consider
E
Insert style
• Use positive inserts for lower cutting forces in
general and for internal turning.

Drilling
Chip breaking
• Optimize the chip breaking by changing the
Negative style Positive style depth of cut, the feed or the insert geometry. F
Nose radius
• The depth of cut should be no less than 2/3
of the nose radius (re).
Boring

Insert wear
• Make sure that the flank wear does not ex- G
ceed the general recommendation of 0.3 mm.
Tool holding

ap re H
Other information
Machinability

A 15
 A System overview

External turning, negative inserts

Turning

1. Longitudinal turning
B
2. Profiling
3. Facing
Parting and
grooving

1 2
Threading

D
Milling

Overview of tool holders

Drilling

F
Boring

G
•N  egative insert •N  egative insert
Tool holding

• Rigid clamping system • Lever clamping system

• Modular/shank tools • Modular/shank tools

H
Other information
Machinability

A 16
 System overview
A

External turning, positive inserts

Turning
1. Longitudinal turning
B
2. Profiling
3. Facing

Parting and
grooving
C
1
2

Threading
3
D

Milling
E

Overview of tool holders

Drilling
F

Boring

•P  ositive insert •P  ositive insert •N  egative/positive •P  ositive insert G

• Screw clamping • Screw clamping insert • Screw clamping
system system • All clamping sys- system
Tool holding

• Modular/shank • T-rail interface tems • Modular/shank

tools • Modular/shank • Cutting heads tools
tools • Modular/shank
tools H
Other information
Machinability

A 17
 A System overview

Internal turning, negative/positive inserts

Turning

1. Longitudinal turning
B
2. Profiling

2 3. Longitudinal turning
1
Parting and

"Mini bars"
3
grooving

C
Threading

D
Overview of internal tool holders
Milling

•  egative/positive inserts
N •  egative insert
N •  egative insert
N
Drilling

• Dampened boring bars • Rigid clamping system • Lever clamping system

• Min. hole 40 mm • Min. hole 25 mm • Min. hole 20 mm
F • Boring bars • Modular/boring bars • Modular/boring bars
Boring

G
Tool holding

•  egative/positive insert
N •  ositive insert
P •D  ampened boring bars
• All clamping systems • Screw clamping system • Min. hole 13 mm
• Cutting heads • Cutting heads • Boring bars
H • Min. hole 20 mm • Min. hole 6 mm
• Modular/boring bars
Other information

• Dampened modular/bor-
ing bars
Machinability

A 18
 System overview
A

Tools for small part machining

Turning
1. External turning
B
2. External turning
(Sliding head machines)

Parting and
1 3. Internal turning

grooving
2 (Exchangeable inserts)
4. Internal turning
C
5. Internal turning
5 (Carbide rods)

Threading
4 3

D
Overview of tool holders
External tools

Milling
E

•P  ositive insert • Quick change tools •P  ositive insert

Drilling
• Screw clamping system • Positive insert • Screw clamping system
• Shank tools • Screw clamping system
F

Internal tools
Boring

G
Tool holding

•P  ositive insert •P  ositive insert •  ositive insert

• Screw clamping system
• Min. hole 6 mm
P
• Screw clamping system • Carbide rods
• Min. hole 10 mm • Min. hole 0.3 mm H
• Machine adapted bars
Other information
Machinability

A 19
 A System overview

Overview of insert clamping systems

Turning

Clamping of negative basic-shape inserts

B
Parting and
grooving

C
Rigid clamping system Lever clamping system
Threading

Clamping of positive basic-shape inserts

D
Milling

E Screw clamping system

Drilling

Screw clamping system

Boring

Clamping of positive T-rail inserts

G
Tool holding

T-rails
H
Other information

Screw clamping system

5°/7°
Machinability

A 20
 System overview
A

Modern insert clamping for turning tools

Turning
Rigid clamping

• Negative inserts B

• Excellent clamping

Parting and
• Easy indexing

grooving
C

Lever clamping

Threading
• Negative inserts
• Free chip flow D
• Easy indexing

Milling
E
Screw clamping

• Positive inserts

Drilling
• Secure clamping of
the insert
F
• Free chip flow
Boring

Screw clamping system, T-rail G

• Positive inserts
Tool holding

• Very secure clamping

• High accuracy
H
Other information
Machinability

A 21
 A Choice of inserts

Choice of inserts
Turning

• Basic factors A 23
Parting and
grooving

• Insert geometries A 32
C
• Insert grades A 39
Threading

• Insert shape, size, nose radius A 42

• Cutting data effect on tool life A 48

D
Milling

E
Drilling

F
Boring

G
Tool holding

H
Other information
Machinability

A 22
 Choice of inserts – basic factors
A

The complex world of metal cutting

Turning
Getting metal cutting processes right means knowing
the workpiece material, then choosing the correct insert B
geometry and grade to suit the specific application.

Parting and
grooving
Workpiece material
• T he interaction between
an optimized insert C
geometry and grade for a
certain workpiece mate-
rial is the key to success-

Threading
ful machining.
• T hese three main basic
factors must be carefully D
considered and adapted
for the machining opera-
tion in question.

Milling
• T he knowledge and un-
derstanding how to play
with these factors is of E
vital importance.

Drilling
Grade Geometry

The machining starts at the cutting edge

Boring

G
Tool holding

H
Typical chip breaking
Other information

sequences with high speed

Machinability

imaging.

A 23
 A Choice of inserts – basic factors

Six material groups

Turning

In the metal cutting industry there is a Therefore workpiece materials have

numeros amount of component designs been divided into 6 major groups in
B made from different materials. Each mate- accordance with the ISO-standard, where
rial has its own unique characteristics each group has unique properties regard-
influenced by the alloying elements, heat ing machinability.
treatment, hardness etc. This strongly
Parting and
grooving

influence the choice of cutting tool

geometry, grade and cutting data.

Workpiece material groups

Threading

Steel • ISO P – Steel is the largest material

D P group in the metal cutting area, ranging
from unalloyed to high-alloyed mate-
rial including steel castings and ferritic
and martensitic stainless steels. The
machinability is normally good, but dif-
Milling

fers a lot depending on material

hardness, carbon content etc.
E
Drilling

• ISO M – Stainless steels are materials

Stainless
Boring

M steel
alloyed with a minimum of 12% chro-
mium, other alloys are e.g. nickel and
G molybdenum. Different conditions such
as ferritic, martensitic, austenitic and
austenitic-ferritic (duplex), makes the
Tool holding

family large. Common for all these types

are that they expose cutting edges to a
great deal of heat, notch wear and built-
up edge.
H
Other information
Machinability


A 24
 Choice of inserts – basic factors
A

 • ISO K – Cast iron is, contrary to steel, a

Cast iron short-chipping type of material. Grey cast
K

Turning
iron (GCI) and malleable cast irons (MCI)
are quite easy to machine while nodular
cast iron (NCI) compact cast iron (CGI) B
and austempered cast iron (ADI) are
more difficult. All cast irons contain sili-
con carbide (SiC) which is very abrasive

Parting and
grooving
to the cutting edge.

Aluminium • ISO N – Non-ferrous metals are softer

N types of metals such as aluminium, cop-

Threading
per, brass etc. Aluminium with a silicon
content (Si) of 13% is very abrasive.
Generally high cutting speeds and long
tool life can be expected for inserts with D
sharp edges.

Milling
E
Heat resistant • ISO S – Heat Resistant Super Alloys
S alloys include a great number of high-alloyed
iron, nickel, cobalt and titanium-based

Drilling
materials. They are sticky, create built-up
edge, workharden and generate heat i.e.
very similar to the ISO M-area but much
more difficult to cut and with shorter tool F
life for the cutting edges.
Boring

Hardened • ISO H – This group covers steels with a G

H steel hardness between 45-65 HRc and also
chilled cast iron around 400-600 HB.
Tool holding

The hardness makes them all difficult to

machine. The materials generate heat
during cutting and are very abrasive to
the cutting edge.
H
Other information
Machinability

A 25
 A Choice of inserts – basic factors

Cutting forces
Turning

Another expression of the differences tion of how much power is needed for an
in the six material groups is through the operation.
B force (FT) needed to shear off a specific
kc1 specific cutting force for average chip
chip cross-section, in certain conditions.
thickness 1 mm.
This value, the specific cutting force value
Parting and

(kc), is indicated for various types of work-

grooving

piece materials and used in the calcula-

P Steel
Threading

• P materials have a kc1 variation of:

Milling

1500-3100 N/mm2.

E
M Stainless steel
Drilling

 materials have a kc1 variation of:

•M
1800-2850 N/mm2.
Boring

K Cast iron
G
Tool holding

H
 materials have a kc1 variation of:
•K
Other information

790-1350 N/mm2.

Machinability

A 26
 Choice of inserts – basic factors
A

Turning
N Aluminium

Parting and
grooving
•N
 materials have a kc1 variation of:
C
350-1350 N/mm2.

Threading
S Heat resistant super alloys

Milling
 materials have a kc1 variation of:
•S
- 2400-3100 mm2 for HRSA
- 1300-1400 mm2 for titanium alloys
E

H Hardeened material

Drilling
F

• H materials have a kc1 variation of:

Boring

2550 – 4870 N/mm2.

G
Tool holding

H
Other information
Machinability

A 27
 A Choice of inserts – basic factors

Chip formation
Turning

There are three patterns for a chip to break

after it has been cut.
B

Self-breaking Against the tool Against the workpiece

Parting and
grooving

C
Threading

D
Milling

Self-breaking, where the Chips breaking against the Chips breaking against the
material, in combina- tool, where the chip curves workpiece, where the chip
Drilling

tion with how the chip is
curved, leads to the chips
F being parted as they come
off the insert.
Boring
around until it makes
contact with the clearance
face of the insert or tool
holder, and the resulting
strain snaps it. Although
often accepted, this
snaps when making con-
tact with the surface that
has just been machined.
This type of chip breaking
is usually not suitable in
applications where a good

method can in some cases surface finish is needed,

lead to chip hammering, because of possible
where the chip damages damage caused to the
G
the insert. component.
Tool holding

H
Other information


Machinability

A 28
 Choice of inserts – basic factors
A

Chip formation varies with different parameters

Turning
Chip formation varies with depth of cut, feed, material
and tool geometry.
B

Self-breaking Against the tool Against the workpiece

Parting and
grooving
ap
ap
κr C

Threading
D

Insert rake angle

Milling
The rake angle (γ) can be either negative or positive.
Based on this, there are negative and positive inserts, E
where the clearance angles are either zero or several de-
grees plus. This determines how the insert can be tilted
in the tool holder, giving rise to a negative or positive
cutting action.

Drilling
F

Positive cutting action Negative cutting action

Boring

γ γ G
Tool holding

H
Other information


Machinability

A 29
 A Choice of inserts – basic factors

 Insert rake angle

Turning

There is a distinction in cutting edge geom- -A

 positive insert has an wedge angle of
etry between negative and positive insert less than 90°.
geometry:
B The negative insert has to be inclined
- A negative insert has a wedge angle of
negatively in the tool holder so as to
90° seen in a cross-section of the basic
provide a clearance angle tangential to the
shape of the cutting edge.
Parting and

workpiece while the positive insert has

grooving

this clearance built-in.

C Negative style
•  ouble/single sided
D Note: The clearance
• Edge strength angle is the angle
between the front
Threading

• Zero clearance face of the insert

• External/internal machining and the vertical axis
• Heavy cutting conditions of the workpiece.
D

Positive style
•  ingle sided
S
Milling

• Low cutting forces

• Side clearance
E
• Internal/external machining
• Slender shafts, small bores
Drilling

Insert geometries

F Metal cutting is very much the science of removing

chips from the workpiece material in the right way.
Chips have to be shaped and broken off into lengths
that are managable in the machine.
Boring

• In milling and drilling a lot of parameters influence the

G chip formation compared to turning.
• Turning is a single-cut operation with a stationary tool
and a rotating workpiece.
Tool holding

• The insert rake angle, geometry and feed play an

important role in the chip formation process.
• Removing heat from the cutting zone through the chip
(80%) is a key issue.
H
Other information
Machinability

A 30
 Choice of inserts – geometries
A

The design of a modern insert

Turning
Definitions of terms and geometry design
B

Nose cutting edge design Main cutting edge design

Parting and
grooving
0.25 20° C
5°
Macro geometry with
chip breaker •C
 utting edge rein-

Threading
forcement 0.25 mm
• Rake angle 20°
Geometry for small
cutting depths • Primary land 5° D

Milling
E
The reinforcement of the cutting edge
The ER-treatment (Edge Roundness) gives the cutting

Drilling
edge the final micro-geometry.

•E
 R-treatment is done before coating, and F
gives the final shape of the cutting edge
(micro-geometry).
• T he relationship between W/H is what
Boring

makes inserts suitable for different

applications.
G
Tool holding

H
Other information
Machinability

A 31
 A Choice of inserts – geometries

The working area of an insert geometry

Turning

A chip-breaking diagram for an insert

B geometry is defined by acceptable chip-
breaking for feed and depth of cut.
Parting and

Cutting depth,
•C
 utting depth (ap) and feed (fn) must be
grooving

ap mm
adapted to the chip-breaking area of the
geometry to get acceptable chip control.
C
•C
 hip breaking which is too hard can lead
to insert breakage.
•C
 hips which are too long can lead to
Threading

disturbances in the machining process

and bad surface finish.
D

Feed, fn mm/r
Milling

Three main application areas in turning

E
R = Roughing Roughing
M = Medium machining • Maximum stock removal and/or severe
conditions.
F = Finishing
Drilling

• Large cutting depth and feed rate combi-

Cutting depth,
nations.
F ap mm
• High cutting forces.
Medium machining
• Most applications – general purpose.
Boring

• Medium operations to light roughing.

G
• Wide range of cutting depth and feed
rate combinations.
Tool holding

Finishing
• Small cutting depths and low feed rates.

Feed, fn mm/r
• Low cutting forces.
H
Other information
Machinability

A 32
 Choice of inserts – geometries
A

Chip breaking application areas

Turning
Turning of low alloy steel
Cutting depth, Roughing – R
ap mm High depth of cut and feed rate combina- B
CNMG 120408 tions. Operations requiring the highest
edge security.

Parting and
grooving
Medium – M
Medium operations to light roughing.
C
Wide range of depth of cut and feed rate
combinations.

Threading
Finishing – F
Operations at light depths of cut and low
feed rates. D
Feed, fn mm/r Operations requiring low cutting forces.

Milling
Chip breaking diagram
E
Roughing of low alloy Chip beaking area:
steel
P R
ap = 5.0 (1.0 - 7.5 ) mm
fn = 0.5 (0.25 - 0.7) mm/r

Drilling
Cutting depth,
ap mm CNMM 120412-PR
F
The red marked
area indicates the
chip breaking area
Boring

which gives accept-

able chip breaking.

G
Tool holding

H
Other information

Feed, fn mm/r

Machinability

A 33
 A Choice of inserts – geometries

 Medium machining of Chip beaking area:

low alloy steel P M
Turning

ap = 3.0 (0.5 - 5.5) mm

fn = 0.3 (0.15 - 0.5) mm/r

B
Cutting depth,
ap mm CNMG 120408-PM
Parting and
grooving

C
Threading

Feed, fn mm/r
Milling

E
Finishing of low alloy Chip beaking area:
steel
P F ap = 0.4 (0.25 - 1.5) mm
fn = 0.15 (0.07 - 0.3) mm/r
Drilling

Cutting depth,
ap mm CNMG 120404-PF
F
Boring

G
Tool holding

H
Other information

Feed, fn mm/r
Machinability

A 34
 Choice of inserts – geometries
A

Selection of inserts

Turning
Considerations when selecting inserts
It is important to select the correct insert
size, insert shape, geometry and insert B
nose radius to achieve good chip control.
•S
 elect the largest possible point angle

Parting and
grooving
on the insert for strength and economy.
•S
 elect the largest possible nose radius
l for insert strength. C
•S
 elect a smaller nose radius if there is a
tendency for vibration.
re

Threading
l = cutting edge length (insert size)
re = nose radius D

Milling
Dedicated inserts for the ISO P, M and K area E
The different micro and macro-geometries are adapted to the
various requirements in the applications.

Drilling
Workpiece Finishing Medium Roughing
material
F

Boring

G
Tool holding

H
Other information
Machinability

A 35
 A Choice of inserts – geometries

Geometry description
Turning

Every insert has a working area with optimized chip control.

A geometry description and application information is also
B available.

Geometry working Geometry Application

Parting and

area description
grooving

-PM CNMG 12 04 08-PM -PM – for medium turning

ap = 0.5 – 5,5 mm with broad capability for steel.
C fn = 0.15 – 0.5 mm/r Feed: 0.1 – 0.65 mm/r.
Depth of cut: 0.4 – 8.6 mm.
Operations: turning, facing and profiling.
Advantages: all-round, reliable with problem-free
Threading

ap
6.0
machining.
Components: axles, shafts, hubs, gears, etc.
5.0
Limitations: depth of cut and feed, risk of over-
4.0
loading the cutting edge.
D 3.0 General recommendations: Combine with a wear
2.0 resistant grade (GC4225) for best productivity.
1.0 Possible optimization: geometry WMX.
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 fn
Milling

E
From universal to optimized turning inserts

Universal inserts
Drilling

• Universal geometry.
F • Optimizing with grades.
• Performance compromised.
Boring

Application area
G

Optimized inserts
Tool holding

• Dedicated geometries
and grades.

H • Optimized performance
according to workpiece
Other information

machinability.
Machinability

Application area

A 36
 Choice of inserts – geometries
A

Dedicated turning inserts

For steel, stainless, cast iron, aluminium, heat resistant

Turning
super alloys and hardened steel.

Parting and
Negative basic-shape inserts Positive basic-shape inserts

grooving
ISO Finishing Medium Roughing Finishing Medium Roughing
C

Threading
D
M

Milling
K E

Drilling
N
F

S
Boring

H
Tool holding

H
Other information
Machinability

A 37
 A Choice of inserts – geometries

Inserts for general turning

Turning

The choice of different insert concepts

Negative, double/single-sided inserts •A

 negative insert has a
B
wedge angle of 90° seen in
Plain inserts a cross-section of the basic
shape of the cutting edge.
Parting and
grooving

•A
 vailable as double/single-
sided inserts with P-hole or
plain.
C Double Single Without With hole
sided sided hole
Threading

Positive, single-sided inserts •A

 positive insert has a
wedge angle less than 90°.
D
•A
 vailable with 7° or 11°
clearance angle.
• The
 positive T-rail inserts
have a clearance angle of
Milling

Positive Positive Positive T-rail 5 or 7°.

11° 7° clamping
E

Chip forming at high pressure and temperatures

Drilling

The choice of cutting material and grade is critical

F for success
The ideal cutting tool material should:
-b
 e hard to resist flank wear and
Boring

deformation.
- be tough to resist bulk breakage.
G
-n
 ot chemically interact with the workpiece
material.
Tool holding

-b
 e chemically stable to resist oxidation
and diffusion.
-h
 ave good resistance to sudden thermal
H changes.
Other information
Machinability

A 38
 Choice of inserts – grades
A

The main range of cutting tool materials

Turning
The most common cutting tool materials are divided into
the following main groups: B
- Uncoated cemented carbide (HW) • CN N
 itride ceramics containing prima-
rily silicon nitride (Si3N4).

Parting and
- Coated cemented carbides (HC)

grooving
• CC Ceramics as above, but coated.
- Cermets (HT, HC)
- Cubic boron nitrides (BN)
• HT U
 ncoated cermet containing
C
primarily titanium carbides (TiC) - Polycrystalline diamonds (DP, HC)
or titanium nitrides (TiN) or both
• HC P
 olycrystalline diamonds, but
•HC Cermet as above, but coated coated.

Threading
- Ceramics (CA, CM, CN, CC)
• CA O
 xide ceramics containing prima-
D
rily aluminium oxide (Al2O3).
• CM M
 ixed ceramics containing
primarily aluminium oxide (Al2O3)
but containing components other

Milling
than oxides.
E

Drilling
F

Boring

G
Tool holding

H
Other information
Machinability

A 39
 A Choice of inserts – grades

How to select insert geometry and grade

Turning

Select the geometry and grade according to the application.

B Build up of a grade chart Machining conditions

Wear resistance
Parting and

Good
grooving

C
Average
Threading

Difficult

D
Milling

Good Average Difficult

E Machining conditions
Good conditions
• Continuous cuts
Drilling

• High speeds
• Pre-machined workpiece
F • Excellent component clamping
• Small overhangs

Average conditions
Boring

• Profiling cuts
• Moderate speeds
G • Forged or cast workpiece
• Good component clamping
Tool holding

Difficult conditions
• Interrupted cuts
• Low speeds
H • Heavy cast or forged skin on workpiece
Other information

• Poor component clamping

Machinability

A 40
 Choice of inserts – grades
A

Dedicated grades for ISO P, M and K

Turning
Dedicated grades minimize tool wear development
The workpiece material influences the wear during the B
cutting action in different ways. Therefore dedicated
grades have been developed to cope with the basic wear

Parting and
mechanisms, eg:

grooving
- Flank wear, crater wear and plastic deformation in steel
- Built-up edge and notch wear in stainless steel
C
- Flank wear and plastic deformation in cast iron.

Threading
D
Select geometry and grade depending on the type of the
workpiece material and type of application.

Milling
E

Drilling
F

Boring

G
ISO GC 4200 ISO GC 2000 ISO GC 3200
P M K
Tool holding

H
Other information
Machinability

A 41
 A Choice of inserts – shape

Selection of the insert shape

Turning

The influence of large and small point angle

B The insert shape and point angle varies Each shape also has unique limitation.
considerably from the smallest, at 35°, to For example:
the round insert. - high edge accessibility during machining
Parting and

leads to a weaker cutting edge.

grooving

Each shape has unique properties:

- some provide the highest roughing
strength
C
-o
 thers give the best profiling
accessibility.
Threading

Round 90° 80° 80° 60° 55° 35°

R S C W T D V
D
Milling

Cutting edge
Accessibility
strength
Drilling

Vibration Power
F tendency consumption
Boring

Large point angle Small point angle

G • Stronger cutting edge • Weaker cutting edge

• Higher feed rates • Increased accessibility
Tool holding

• Increased cutting forces • Decreased cutting forces

• Increased vibration • Decreased vibration

H
Other information
Machinability

A 42
 Choice of inserts – shape
A

Factors affecting choice of insert shape

Turning
Insert shape should be selected relative to the entering
angle accessibility required of the tool. The larges pos-
sible point angle should be applied to give insert strength
B
and reliability.

 = Most suitable

Parting and
grooving
 = Suitable

C
Insert shape

Threading
Roughing strength    

Light roughing/semi-
finshing      D

Finishing     

Milling
Longitudinal turning     
E
Profiling     

Facing      

Drilling
Operational versatility      
F
Limited machine power      Boring

Vibration tendencies    

Hard material G
 
Tool holding

Intermittent machining     

Large entering angle    

H
Other information

Small entering angle    

Machinability

A 43
 A Choice of inserts – shape

Number of cutting edges

Turning

Insert shape
B

ISO (first letter) R S C W T D V

Parting and
grooving

Number of edges,
4 lub 8 2 lub 4 3 lub 6 3 lub 6 2 lub 4 2 lub 4
negative inserts
C
Number of edges,
4 2 3 3 2 2
positive inserts
Threading

D Selection of the nose radius

Effect of small and large nose radius
Milling

re
E re
re
Drilling

Large nose radius

Boring

Small nose radius

• Ideal for small cutting • Heavy feed rates
G depth Rule of thumb
• Large depths of cut
• Reduces vibration The depth of cut
• Strong edge security
Tool holding

• Weak cutting edge should be no less

• Increased radial pres- than 2/3 of the nose
sures radius re.

H
Other information
Machinability

A 44
 Choice of inserts – nose radius
A

A small nose radius should be first choice

Turning
With a small nose radius, the radial cutting forces can
be kept to a minimum, while utilizing the advantages of a
larger nose radius leads to a stronger cutting edge, better B
surface texture and more even pressure on the cutting
edge.

Parting and
grooving
C
DOC

DOC

Threading
DOC

D
• T he relationship between nose radius and DOC (depth
of cut) affects vibration tendencies.
It is often an advantage to choose a nose radius which

Milling
is smaller than the DOC.

Effect of nose radius and DOC

Drilling
The radial force exerted on the workpiece However with a round insert, radial pres-
grows linearly until the nose radius of the sure will never stabilize because the
insert is less than the depth of cut where theoretical nose radius is half the insert
F
it stabilizes at the maximum value. diameter (iC).
Boring

G
Tool holding

H
Other information
Machinability

A 45
 A Choice of inserts – nose radius

High feed turning with wiper inserts

Turning

Wiper – General information

Why use a wiper
B Wiper insert • Increase feed and gain
productivity.
Rmax •U
 se normal feed rate and
Parting and

rWiper
grooving

gain surface quality.

When to use wipers
• Use wipers as a first
C
choice where it’s pos-
sible.
Limitations
Threading

Coventional insert • General limitation is

vibration.
D Rmax •V
 isually, surfaces can
rISO
look different even
though the measured
surface is great.
Milling

E
Wiper – Technical solution
•O
 ne wiper cutting edge is based on
Drilling

3-9 radii.
•C
 ontact surface between insert and
F component is longer with wipers.
• L onger contact surface makes a better
surface finish.
• L onger contact surface increases cutting
Boring

forces which makes a wiper insert more

sensitive to vibration when machining
G unstable components.
Tool holding

H
Other information

A conventional nose radius compared

Machinability

with a wiper nose radius.

A 46
 Choice of inserts – nose radius
A

Wiper – Surface finish

Turning
Traditional
insert
B

Rule of thumb

Parting and
grooving
• Two times feed with a wiper will
generate as good surface as con-
Wiper insert ventional geometries with normal
Twice the feed. C
feed, same Ra • The same feed with a wiper will
generate twice as good surface

Threading
compared with conventional
geometries.

D
Wiper insert
Same feed,
half Ra
Rt = Maximum value peak-to-valley height

Milling
Ra = Arethmetic average height of the
profile E

Drilling
Achieved surface – traditional ISO inserts and wipers

Ra F
µm
6.00

5.00 Insert geometry

Boring

4.00 Standard -PM

G
3.00 Wiper -WM
Tool holding

2.00
Wiper -WMX
1.00

0.00 H
0.20 0.35 0.50 0.65 Feed, fn mm/r
Other information
Machinability

A 47
 A Choice of inserts – speed and tool life

Cutting data parameters effect tool life

Turning

B
Use the potential of:
Parting and

- ap – to reduce number of cuts

grooving

- fn – for shorter cutting time

- vc – for best tool life
C
Threading

Cutting speed
Tool life

D
vc – large effect on tool life.
Adjust vc for best economy.
Milling

E Cutting speed vc
Drilling

Feed
Tool life

fn – less effect on tool life than vc.

F
Boring

Feed fn

Cutting depth
Tool life
Tool holding

ap – little effect on tool life.

H
Other information
Machinability

Cutting depth ap

A 48
 Choice of inserts – speeds and tool life
A

Effects of cutting speed

Turning
The single largest factor determining tool life

Too high Too low B

• Rapid flank wear • Built-up edge

Parting and
• Poor finish • Uneconomical

grooving
• Rapid cratering
• Plastic deformation
C

Threading
Effects of feed rate
D
The single largest factor determining productivity

Too high Too low

Milling
• Loss of chip control • Stringers
• Poor surface finish • Uneconomical
E
•C
 ratering, plastic defor-
mation
• High power consumption

Drilling
• Chip welding
• Chip hammering F

Boring

Effects of depth of cut

Too deep Too small G
• High power consumption • Loss of chip control
Tool holding

• Insert breakage • Vibrations

• Increased cutting forces • Excessive heat
• Uneconomical
H
Other information
Machinability

A 49
 A Choice of tools – external turning

External turning
Turning

Tool selection and how to apply

B
General guidelines
Parting and

•S
 ecure insert and tool holder clamping is
grooving

an essential factor for stability in turning.

• T ool holder types are defined by the
C entering angle, the shape and size of the
insert used.
• T he selection of tool holder system is
Threading

mainly based on the type of operation.

•A
 nother important selection is the use of
negative versus positive inserts.
D
•W
 henever possible choose modular
tools.
Milling

Definitions of key figures

Drilling

F
Boring

22° Max in copy angle

G Entering angle κr 93°
Feed directions
Tool holding

H Insert shape
Other information

Insert point angle 60°

Machinability

A 50
 Choice of tools – external turning
A

Four main application areas

Turning
Longitudinal turning/facing
B
The most common turning operation.
• Rhombic shape C-style (80°) insert is frequently used.

Parting and
• Holders with entering angle of 95° and 93° are commonly

grooving
used.
• Alternatives to the C-style insert are D-style (55°), W-style (80°)
and T-style (60°). C

Threading
Profiling
Versatility and accessibility is the determining factor.
• The effective entering angle (kr) should be considered for
satisfactory machining. D
• Most commonly used entering angle is 93° because it allows
an in-copying angles between 22-27°.
• The most frequently used insert shapes are D-style (55°),

Milling
V-style (35°) and T-style (60°) inserts.

E
Facing
The tool is fed in towards the centre.

Drilling
• Pay attention to the cutting speed which will change progres-
sively when feeding towards the centre.
• Entering angle of 75° and 95°/91° are commonly used.
F
• C-style (80°), S-style (90°), and T-style (60°) inserts are fre-
quently used. Boring

Plunging
G
A method to produce or widening shallow grooves.
• Round inserts are very suitable for plunge turning as they can
Tool holding

be used for both radial and axial feeds.

• Neutral 90° holders for round inserts are commonly used.

H
Other information
Machinability

A 51
 A Choice of tools – external turning

Large entering angle

Turning

Features / Benefits
• Cutting forces directed towards chuck.
B
• Can turn against a shoulder.
• Higher cutting forces at entrance and exit of cut.
Parting and
grooving

95° • Tendency to notch in HRSA and hard materials.

C
Threading

Small entering angle

D

Features / Benefits
Milling

• Produces a thinner chip

- Increased productivity.
E • Reduced notch wear.
• Can not turn against a shoulder.
45°
Drilling

F
Boring

G
Tool holding

H
Other information
Machinability

A 52
 Choice of tools – external turning
A

The entering angle

Turning
Important consideration in profile turning

B
In-copying Longitudinal turning Out-copying

Parting and
kr

grooving
kr
kr β
C

Threading
• T he effective entering angle (kr) should also be con-
sidered for satisfactory machining when the operation
involves profiling. D
β • T he maximum in-copying angle beta (β) is recommend-
ed for each tool type and is specified in the catalogues.

Milling
E
Axial and radial cutting forces
Large entering angle Small entering angle

Drilling
F
Ff = axial
Ff = axial

Fp = radial
Boring

Fp = radial

G
• F orces directed toward the chuck. Less • Forces are directed both axially and
tendency for vibration. radially.
Tool holding

•H
 igher cutting forces especially at en- • Reduced load on the cutting edge.
trance and exit of cut.
• F orces are directed both axially and
radially.
H
- Vibration tendencies.
Other information
Machinability

A 53
 A Choice of tools – external turning

Define the suitable clamping system

Turning

Tooling system

Longitudinal
B

Plunging
Profiling
turning

Facing
++
Parting and

=R  ecommended tool
grooving

holder system
+ = Alternative system

Rigid clamp
design ++ ++ ++
Threading

Negative inserts

D Lever
design + + + +
Milling

Wedge
E clamp + + +
design
Drilling

Screw
clamp + ++ + ++
Positive inserts

design
F

Screw
clamp + ++
Boring

design T-rail

G
Rigid clamp
++ ++ ++
Ceramic and CBN

design
Tool holding

inserts

H Top clamp
design + + + ++
Other information
Machinability

A 54
 Choice of tools – external turning
A

Insert recommendation depending on operation

Turning
Insert shape

Longitudinal
B

Plunging
Profiling
turning

Facing

Parting and
++ =

grooving
Recommended insert shape

+= Alternative shape
C
C Rhombic 80° ++ +

Threading
D Rhombic 55° + ++ +
R Round + + + ++ D

S Square + ++
+ + + +

Milling
T Triangular

W Trigon 80° + + E

V Rhombic 35° +

Drilling
K Rhombic 55° + + +
F

Modern insert clamping for turning tools

Boring

Screw clamping, G
Rigid clamping "P lever style" Screw clamping
T-rail
Tool holding

H
Other information
Machinability

A 55
 A Choice of tools - internal turning

Internal turning
Turning

Tool selection and how to apply

B
General guidelines
Parting and

• In internal turning (boring operations)

grooving

the choice of tool is very much restricted

by the component's hole diameter and
length.
C
-C
 hoose the largest possible bar diame-
ter and the smallest possible overhang.
Threading

-C
 hip evacuation is a critical factor for
successful boring.
- T he way of clamping is decisive regard-
D
ing performance and result.
Milling

E
Drilling

F
Selection factors
Tool and insert geometry Chip evacuation Tool requirements
Boring

• Entering angle • Chip size • Reduced length

• Insert shape, negative/ • Chip control • Increased diameters
G positive
• Techniques • Optimized shape
• Insert geometry
• Different tool materials
Tool holding

• Nose radius
• Clamping

H
Other information
Machinability

A 56
 Choice of tools – internal turning
A

Effect of cutting forces on internal turning

Turning
Radial and tangential cutting forces deflect the boring bar
B
Tangential cutting force, Ft
• F orces the tool down, away from the

Parting and
centre line.

grooving
• Gives a reduced clearance angle.

C
Radial cutting force, Fr
• Alters cutting depth and chip thickness.

Threading
•G
 ives out of tolerance dimension and
risk of vibration.
Fr
D
Feed force, Fa
Fa
• Directed along the feed of the tool.

Milling
Ft F
E

Selecting entering angles

Entering angle and cutting forces

Drilling
• Select an entering angle close to 90°.
F

Boring

• If possible never less than 75°, which

means a dramatic increase of the radial G
cutting force Fr.
Tool holding

- L ess force in radial direction = less

deflection.

H
Other information
Machinability

A 57
 A Choice of tools – internal turning

Four main application areas

Turning

Longitudinal turning/facing
B The most commonly used internal turning operation.
• Rhombic shape C-style (80°) insert is frequently used.
Parting and

• Boring bars with an entering angle of 95° and 93° are

grooving

commonly used.
• D-style (55°), W-style (80°) and T-style (60°) insert shapes
are also frequently used.
C

Profiling
Threading

Versatility and accessibility is the determining factor.

D • The effective entering angle (kr) should be considered.

• Bars with entering angle of 93°, allowing an in-copying angle
between 22–27°, are commonly used.
• D-style (55°), V-style (35°) and T-style (60°) inserts are
Milling

frequently used.

E
Longitudinal turning
Boring operations are performed to open up existing holes.
Drilling

• An entering angle of close to 90° is recommended.

• Use smallest possible overhang.
F • C-style (80°), S-style (90°) and T-style (60°) inserts are fre-
quently used.
Boring

Back boring
G
Back boring is a boring operation with reverse feed.
• It is used for turning shoulders less than 90°.
Tool holding

• Boring bars with 93° entering angles and D-style (55°) inserts
are commonly used.

H
Other information
Machinability

A 58
 Choice of tools – internal turning
A

Insert recommendation depending on operation

Turning
Insert shape Longitudinal Profiling Facing
turning B

++ = Recommended insert shape

Parting and
+=

grooving
Alternative shape

C Rhombic 80° + ++
C
D Rhombic 55° + ++ +

Threading
R Round + +
S Square + D

T Triangular ++ + +
+ +

Milling
W Trigon 80°

V Rhombic 35° + E

Selecting the insert basic shape

Drilling
Positive inserts generate lower cutting force and tool deflection
• Inserts with clearance angle 7° F
- First choice for small and medium holes
from 6 mm diameter.
• Inserts with clearance angle 11°
Boring

- First choice when small cutting forces

and long overhangs are required.
• F or best economy G
- Use negative inserts in stable condi-
tions and with short ovrehang.
Tool holding

11°, positive, 7°, positive, Negative,

single sided single sided double sided
inserts inserts inserts H
Other information
Machinability

A 59
 A Choice of tools – internal turning

Insert point angle

Turning

Small point angle:

- Increases accessibility Use the smallest
B angle giving accept-
- Decreases vibration able strength and
- Decreases cutting forces. economy
Parting and
grooving

Round 90° 80° 80° 60° 55° 35°

C R S C W T D V
Threading

D
Cutting edge
Accessibility
strength

Vibration tendency Power consumption

Milling

Chip area and nose radius

Cutting forces and cutting tool deflection
Drilling

F
Rule of thumb!
Choose a nose
radius which is some-
Boring

what less than the

cutting depth.
• Both small and large • The relationship between
G
chip areas can cause re (nose radius) and ap
vibration: (depth of cut) affects
vibration tendencies.
Tool holding

- Large due too high

cutting forces • Less force in radial direc-
- Small due too high tion = less deflection.
friction between the tool
H
and the workpiece.
Other information
Machinability

A 60
 Choice of tools – how to apply
A

The way of clamping the boring bar

Turning
Critical stability factors for optimized performance
B
dmm • Maximum contact between tool and tool
holder (design, dimensional tolerance).

Parting and
• Clamping length 3 to 4 times bar diam-

grooving
eter (to balance cutting forces).
• Holder strength and stability.
C
3 - 4 x dmm

Threading
D

Milling
Tool requirements for clamping E
Maximum contact between tool and tool holder

Drilling
Best choice
Coromant Capto® coupling F

Acceptable
Boring

G
Not recommended
Tool holding

Not recommended H
Other information
Machinability

A 61
 A Choice of tools - how to apply

EasyFix sleeves
Turning

For correct clamping of cylindrical bars

B
Guarantees correct centre height
Parting and
grooving

Benefits:
• Cutting edge at right position
C
• Best cutting action gives better surface finish
• Reduce set-up time
Threading

• Even insert wear.

D Silicon sealer
Milling

E Groove
Drilling

F
Boring

Spring plunger

G A spring plunger mounted in the sleeve clicks into a

groove in the bar and guarantees correct centre height.
The slot in the cylindrical sleeve is filled with a silicon
Tool holding

sealer which allows the existing coolant supply system to

be used.

H
Other information
Machinability

A 62
 Choice of tools - how to apply
A

Factors that affect vibration tendencies

Turning
Vibration tendencies grow towards the right
B

Parting and
grooving
Entering angle
C

Threading
Nose radius
0.8 – 1.2 mm

Micro and
macro geometry D

Edge design

Milling
E

Entering angle Edge design

• Choose an entering angle as close to

Drilling
• Insert wear changes the clearance
90° as possible, never less than 75°.
between the insert and the hole wall
Nose radius and this can affect the cutting action
• Choose a nose radius which is some- and lead to vibration.
F
what smaller than the cutting depth.
• Inserts with thin coatings, or uncoated
Micro and macro geometry inserts, are to be preferred as they
• Use a positive basic-shape insert, as normally give lower cutting forces.
Boring

these give lower cutting forces com-

pared to negative inserts.
G
Tool holding

H
Other information
Machinability

A 63
 A Choice of tools - how to apply

Chip evacuation
Turning

Chip evacuation is a critical factor for successful boring

B •C
 entrifugal force presses the chips to
the inside wall of the bore.
Parting and

• T he chips can damage the inside of the

grooving

bore.

- Internal coolant can help with chip

C evacuation.
-B
 oring upside down to keep chips away
from cutting edge.
Threading

Chip evacuation and chip control

Hard breaking of chips, short chips
Milling

• Power demanding and can increase the

vibration.
E
•C
 an cause excessive crater wear and
result in poor tool life and chip jamming.
Drilling

F Long chips
• Can cause chip evacuation problems.
•C
 auses little vibration tendency, but can
in automated production cause prob-
Boring

lems due to chip evacuation difficulties.

G
Tool holding

Short and spiral chips

• To be preferred. Easy to transport and
do not cause a lot of stress on the cut-
ting edge during chip breaking.
H
Other information
Machinability

A 64
 Choice of tools - how to apply
A

Recommended tool overhang

Turning
Maximum overhang for different types of bars

B
Steel bar
– up to 4 x dmm

Parting and
grooving
Carbide bar
– up to 6 x dmm

Short, dampened bar C

– up to 7 x dmm
Long, dampened bar

Threading
– up to 10 x dmm
Carbide reinforced, damp-
ened bar
– up to 14 x dmm D
Clamping
length:
Overhang: ... x dmm 14 10 7 6 4
4 x dmm

Milling
Eliminate vibrations E

Internal machining with dampened boring bars

Drilling
Rubber damper • Raise productivity in deep bores

Coolant tube • Minimize vibration

F
Oil •M
 achining performance can be main-
tained or improved
•D
 ampened boring bars are available
Boring

in diameters from 10 mm
High density mass - F or max overhang 14 x dmm (carbide
reinforced) G
Cutting head
Tool holding

Steel bar

H
Other information

Dampened bar
Machinability

A 65
 A Code keys

Code key for inserts and tool holders

Turning

Extract from ISO 1832—1991

B
INSERT Tolerances Insert thickness
Nose radius
Parting and
grooving

C
C N M G 09 03 08 - PF
1 2 3 4 5 6 7 8
Threading

1. Insert shape
5. Insert size = cutting edge length
D

2. Insert clearance angle

Milling

TOOL HOLDERS
E
External

D C L N R 16 16 H 09
Drilling

B 1 C 2 D E F G 5

F
C3 -
A
Internal
Boring

G
A 25 T S C L C R 09
H J G B 1 C 2 D 5
Tool holding

Bar diameter

S = Solid steel bar Holder style

A = Steel bar with coolant supply
H E = Carbide shank bar
Coromant Capto®
Other information

F = Dampend, carbide shank bar

coupling size
Machinability

A 66
 Code keys
A

1. Insert shape 2. Insert clearance angle

Turning
80° 55° 35° 80°
C D R S T V W
B C P N B
4. Insert type 5. Insert size = Cutting edge length

Parting and
grooving
A G
M T l mm: 06–25 07–15 06–32 09–25 06–27 11–16 06–08
C
7. Nose radius

02 rε = 0.2 First choice nose radius recommendations:

Threading
04 rε = 0.4
T-MAX P CoroTurn 107
08 rε = 0.8
12 rε = 1.2 Finishing 08 04
16 rε = 1.6 Medium 08 08
24 rε = 2.4 Roughing 12 08
D

8. Geometry — manufacturer´s option

Milling
The manufacturer may add a further two symbols to the code describing the
insert geometry e. g.
E
-PF = ISO P Finishing
-MR = ISO M Roughing

B. Clamping system

Drilling
D M P S F
Rigid clamping (RC) Top and hole clamping Hole clamping Screw clamping
Boring

D. Hand of tool E. Shank height G. Tool length

Tool length G
R = l1 in mm
Right-hand style
Tool holding

L F. Shank width H = 100 S = 250

Left-hand style K = 125 T = 300
M = 150 U = 350
P = 170 V = 400 H
N
Other information

Q = 180 W = 450
Neutral R = 200 Y = 500
Machinability

A 67
 A Troubleshooting

Troubleshooting
Turning

Chip control
B Problem Cause Solution
Long unbroken snarls winding • Feed too low for the chosen • Increase the feed.
around the tool or workpieces. geometry.
Parting and

• Select an insert geometry

with better chip breaking
grooving

capabilities.
• Use a tool with high pres-
C sure coolant.
Threading

• Depth of cut too shallow for • Increase the depth of cut or

the chosen geometry. select a geometry with bet-
ter chip breaking capability.

• Nose radius too large. • Select a smaller nose

radius.
Milling

• Unsuitable entering angle • Select a holder with as large

E entering angle as possible
(κr = 90°).
Drilling

Very short chips, often sticking
together, caused by too hard
F chip breaking. Hard chip break-
ing often causes reduced tool
life or even insert breakages
due to too high chip load on
the cutting edge.
Boring
• Feed too high for the chosen
geometry
• Choose a geometry
designed for higher feeds,
preferably a single-sided
insert.
• Reduce the feed.

• Unsuitable entering angle. • Select a holder with as small

G entering angle as possible
(κr = 45°–75°).
Tool holding

• Nose radius too small. • Select a larger nose radius.

H
Other information
Machinability

A 68
 Troubleshooting
A

Surface finish

Turning
Problem Cause Solution

The surface looks and feels
“hairy” and does not meet the
tolerance requirements
• The chips are breaking
against the component
and marking the finished
surface.
• Select a geometry which
guides the chips away. B
• Change entering angle.
• Reduce the depth of cut.

Parting and
grooving
• Select a positive tool system
with a neutral angle of
inclination.
C

• Hairy surface caused by • Select a grade with better

Threading
excessive notch wear on the resistance to oxidation wear,
cutting edge. e.g a cermet grade.
• Reduce the cutting speed.
D

• Too high feed in combination • Select a wiper insert or a

Milling
with too small nose radius larger nose radius.
generates a rough surface.
• Reduce the feed.
E

Burr formation

Burr formation at the end of
the cut when the cutting edge
is leaving the workpiece.
Drilling
• The cutting edge is not • Use inserts with sharp
sharp enough. edges:
- PVD coated inserts F
• The feed is too low for the - ground inserts at small
edge roundness. feed rates, < 0.1 mm/r. Boring

• Notch wear at depth of cut, • Use a holder with a small G

or chipping. entering angle.
Tool holding

• End the cut with a chamfer

or a radius when leaving the H
workpiece.
Other information
Machinability

A 69
 A Troubleshooting

Vibration
Turning

Problem Cause Solution

High radial cutting forces due - Unsuitable entering angle. • Select as large entering
B to: angle as possible (κr = 90°)
Parting and
grooving

Nose radius to large. • Select a smaller nose

radius.
Vibrations or chattermarks
C which are caused by the
tooling or the tool mounting.
Typical for internal machining - Unsuitable edge rounding, or • Select a grade with a thin
with boring bars. negative chamfer. coating, or an uncoated
grade.
Threading

- Excessive flank wear on cut- • Select a more wear resistant

D ting edge. grade or reduce speed.
Milling

High tangential cutting forces - Insert geometry creating high • Select a positive insert
E due to: cutting forces. geometry.
Drilling

- Chip-breaking is too hard • Reduce the feed or select a

giving high cutting forces. geometry for higher feeds.

- Varying or too low cutting • Increase the depth of cut

forces due to small depth slightly to make the insert
of cut. cut.
Boring

G
- Tool incorrectly positioned. • Check the centre hight.
Tool holding

H
Other information


Machinability

A 70
 A

Turning
Problem Cause Solution
- Instability in the tool is due to • Reduce the overhang
long overhang. B
• Use the largest bar
diameter.
• Use a Silent Tool or a car-

Parting and
bide bar.

grooving
C

Threading
- Unstable clamping offers • Extend the clamping length D
insufficient rigidity. of the boring bar.
• Use EasyFix for cylindrical
bars.

Milling
E

Drilling
F

Boring

G
Tool holding

H
Other information
Machinability

A 71