Sandvik Titanium Machining Guide PDF

APPLICATION GUIDE
Titanium
Ti-6Al-4V
Ti-5553
Ti-5Al-2.5Sn
Ti-8Al-1Mo-1V
Ti-10V-2Fe-3AI
More information
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Contents
1 Introduction 2 4 Drilling 98
Material 3 Main considerations 100
Industry segments 6 Programme overview 104
Process planning 8 Short hole drilling 105
Machine considerations 9 Deep hole drilling 112
2 Turning 17 5 Boring 113

Main considerations 17 Main considerations 114
External turning 21 Programme overview 115
Internal turning 32
Parting & grooving 36
6 Tooling system considerations 120
Small part machining 41
High pressure coolant 43
Component feature solutions 46 7 Component solutions examples 124
Geometry recommentations 53
Cutting data recommendations 54 8 Formulas and definitions 130
3 Milling 56
Main considerations 57
Grades 62
Programming guidelines 64
Face milling 70
Shoulder milling 72
Profile milling 76
Slot milling 80
Plunge milling 82
Thread milling 83
High speed machining 84
Dedicated methods 85
Component feature solutions 89
Cutting data recommendations 96
1. Introduction
1. Introduction
This application guide will help you towards the most productive
and problem-free machining in titanium.
It provides information about which techniques to apply and how to

avoid costly mistakes when working with titanium components.
Also included is information on machining principles, recommen-
dations and trouble-shooting advice for the most common opera-
tions and applications in the titanium machining area.
2
1. Introduction
Material
Titanium sets complex machining demands. It has metallurgical
characteristics and material properties that affect the cutting action
more severely than other metals such as cast iron and stainless
steel.
However, by combining a well-planned process with dedicated

application knowledge and tools/set-ups optimized for titanium,
gains can be made to take advantage of the great properties that
this material has to offer.
Titanium and its alloys are used extensively in the following areas:
• Aerospace engine
• Aerospace frame
• Aerospace landing gear
• Small part machining
• Medical implants
• Automotive, gearbox, turbo
• Connecting
Machining properties
Feature Influence on cutting tool
Retains strength at relatively high temperatures High forces and heat generation
Thin chip thickness, narrow contact area on rake Concentrated cutting forces, lower than average
face feed
Poor thermal conductivity High hot hardness required
Speed/feed sensitive
Cyclic chip formation – variable forces Prone to vibration/chatter
Chemically reactive with cutting materials Crater wear
High level of carbide content Flank wear
3
1. Introduction
Titanium alloys cross reference
Composition (approx %) Tensile Specific

strength Hardness cutting
Condition Designation Al Sn Mo V Zr Cr others N mm-2 HP force kc/MPa
Ti-5Al-2.5Sn 5 2.5 x.xx 790 300-400 1200
Ti-5Al-2.5SN ELl 5 2.5 690
α and near
Ti-8Al-1Mo-1V 8 1 1 900
α alloys
Ti-6Al-2Sn-4Zr-2Mo 6 2 2 4 900
Ti-3Al-2.5V 3 2.5 620
Ti-6Al-4V 6 4 900 310-350 1700
Ti-6Al-6V-2Sn 6 2 6 1030
Ti-6Al-2Sn-4Zr-6Mo 6 2 6 4 1170
Ti-5Al-2Sn-4Mo-27r-4Cr (Ti-17) 5 2 4 2 4 1125
Ti-7Al-4Mo 7 4 1030
Ti-6Al-32Sn-27r-2Mo-2Cr- 6 2 2 2 2 0.25 1280
0.25Si
Ti-8Mn 8 860
Ti-13V-11Cr-3Al 3 13 11 1170 275-400 2400
Ti-11.5Mo-6Zr-4.5Sn (β III) 4.5 11.5 6 700
β and near Ti-3Al-8V-6Cr-4Zr-4Mo (β C) 3 4 8 4 6 900
β alloys Ti-10V-2Fe-3Al 3 10 2 1170
Ti-15V-3Al-3Cr-3Sn 3 3 15 3 1000
Ti-5553 5 5 5 3 1.3 1160
Machinability comparison of different titanium types

The cutting data in this guide focuses on speeds for Ti6Al4V.
The same strategy and feeds should be used for other grades of
titanium but the speed should be altered depending upon the level
of machinability.
4
1. Introduction
Alloying elements
Titanium alloys fall into three classes depending on the structures
and alloying types present. These additions are reflected in the
designation codes used to describe each alloy.
Alpha alloys – additions of Al, O and/or N preferentially stabilise the

α phase.
Beta alloys – additions of Mb, Fe, V Cr and/or Mn stabilise the β

phase.
Mixed α+β alloys, in which a mixture of both classes is present.
Mixed α+β alloys account for the majority of titanium alloys em-
ployed today. Ti-6Al-4V, first developed in 1954, remains the most
common general purpose grade in use, not only for aerospace but
also for general purpose applications.
These chemical additions have a direct influence on the physical

properties of the alloys, their chemical and thermal behaviour and
their machinability.
5
1. Introduction
Industry segments
Typical components
Aerospace
6
1. Introduction
Medical
Small part machining
7
1. Introduction
Process planning
Before machining any titanium component, it is especially important
to plan and optimize the process. This plan will indicate the most
suitable cutting tools, together with opportunities to benefit from
specific application knowledge.
A basic analysis should look like this:
nning process
Optimized production pla
5
4
3
2
1
Program CAM and

Tool selection, simulation
Tool concept cutting data
Machining selection
Analysis of strategy
conditions
8
1. Introduction
Machine considerations
When investing in original equipment the decisions made will define
machining efficiency for the next 10 years. New developments
and technologies offer an opportunity to improve over traditional
methods.
Configuration
Multifunctional
The component will dictate if both turning and rotating spindle
operations are required.
Aerospace structural parts generally do not require turning but

engine and landing gear do. The options to mill and turn on the
same machine now cover all machine types.
• 5-axis machining centres with rotating table for turning

• B-axis or Multi-Task machines
• Turning centres with driven tools
• Vertical lathes with rotating spindle and 90º head for 3- and
4-axis milling
9
1. Introduction
Multi-functional machines will greatly improve machine utilization.

The best option is generally determined by the length and diameter
of the component.
Coromant Capto® can be used without compromising milling,

drilling, or turning applications.
10
1. Introduction
Number of axis
Many titanium components require 5 machine axis, which are less
stable than 3- or 4-axis machines. However with reduced setup
savings it is just a matter of adapting best programming techniques
(limit radial engagement) if 5 axis are required, so that roughing
and finishing can be done in the same setup.
5-axis machines can be grouped into 3 categories.

• Trunnion table – vertical fixed spindle with 4th and 5th axis in the
workpiece table. Provides the most stable milling operations and
also the best dynamic speed for simultaneous 5-axis milling – i.e.
very good for components like blisk/impellor. The limitation is
component size, so it is best suited to components of 1 m and
smaller.
• 90º head – the 4th and 5th axis are in the 90º head. Configura-
tion allows larger machine beds and larger components. Best
suited to large applications with no turning
• B-axis – 4th axis with workpiece rotation and 5th axis in spindle.
Ideal for turn-mill (up to dia 0.8 m) and mill-turn applications
(0.8 up to 2 m)
11
1. Introduction
Spindle motor
Power
Full slot end milling will draw the biggest power. This is diameter
dependent.
- dia 100 mm (4 inch), ap = 100 mm (4 inch): 38 kW
- dia 66 mm (2.5 inch), ap = 57 mm (2.2 inch): 16 kW
Optimized programming (reduced radial engagement) prevents such

high power requirements. 30KW is suitable for typical applications.
Torque
Torque requirement is directly related to the diameter of the tool,
face milling and slotting are the major considerations. Face milling
is not normally a large percentage of the overall machining time
and a smaller face mill can often be used.
If large diameter side and face tools are to be used, a geared

motor should be considered.
Rpm
A large proportion of machining time is spent on semi-finishing and
finishing.
High speed machining (high rpm, low radial immersion) for semi-
finishing and finishing offers very large machining time reductions.
Cutting speeds up to 200 m/min (656.1 ft/min) are used. For a
10 mm (0.394 inch) end mill, this requires 6365 rpm. Ensure high
enough rpms for the required tool diameter.
12
1. Introduction
Interface
Machine interface selection is key to metal cutting efficiency but
often is not considered enough during the investment stage.
It has to be quick to change and rigid to transmit the power and

torque for rotating applications or resist the cutting forces for
turning applications.
If the cutting forces are greater than the interface capability, the
process will be unstable and reduce metal cutting efficiency and
machine utilization (vibration, breakdowns).
The requirements need to be considered for each application. For

multifunctional machines, turning (static) and rotating requirements
need to be combined.
Clamping force comparison
Clamping Clamping
force – N force – lb
90.000 20.000
80.000 18.000
16.000
70.000
14.000
60.000
12.000
50.000
10.000
40.000
8.000
30.000
6.000
20.000
4.000
10.000 2.000
0 0
Big Plus Big Plus HSK 63 HSK 100 C6 C8 C10
CAT 40 CAT 50
Sources: HSK Handbook, copyright 1999.

Big Daishowa (Big plus spindle system.)
13
1. Introduction
Rotating spindle
Bending stiffness is the main consideration, as the cutting forces
try to ‘lever’ the interface coupling apart. Long tools and high
cutting forces, with long-edge cutters for example, make titanium
machining one of the most demanding applications for a spindle
interface.
Factors providing good bending stiffness resistance are:

• Flange contact diameter – this explains the evolution from the
traditional steep taper to Big Plus, HSK and Coromant Capto,
which all have face and taper contact to improve bending
stiffness
• Clamping force – the harder the coupling is held the greater the
forces required to lever apart. HSK and Coromant Capto utilize
segment clamping to be able to apply a greater clamping force
than a pull stud can withstand
The cross sectional area (CSA) of the male coupling is another

factor. Coromant Capto has a stronger CSA allowing much greater
clamping force.
Bending Stability Bending Stability

1.5
Deflection (mm/m)
Deflection (mm/m)
1.5
1.0 1.0
0.5 0.5
Bending moment Bending moment
(Nm) (Nm)
0 0
0 1000 2000 0 2000 4000
C6- 45kN C10- 80kN
C6- 22kN C10- 50kN
HSK-A 63- 22kN HSK-A 100- 50kN
7/24 taper, size 40-15kN 7/24 taper, size 50-25kN
Sources: © WZL/Fraunhofer IPT
14
1. Introduction
Static spindle – multifunctional

Although longer turning tools (mainly boring bars) require good
coupling bending stiffness, torque is also a major consideration.
The greater the distance, or radius, the cutting edge is from the
coupling center line, the greater the torque the coupling has to
withstand.
This is an important consideration especially for multi-functional

machines which use the same spindle for rotating and static
applications. If the machine is used for just rotating spindle
applications, then the traditional steep taper or HSK coupling is
normally adequate to withstand the cutting forces generated.
15
1. Introduction
The fundamental difference between Coromant Capto® and other

tooling systems is that it was developed to cover static and rotat-
ing applications. For this reason the drive key was replaced by the
tapered polygon. The polygon has been used in ship crank shafts
for many years due to the high torque transmission required.
Torque Stability Torque Stability

12 12
Deflection
(mm/m)
Deflection
(mm/m)
10 10
5 Torsional moment 5 Torsional

(Nm) moment
(Nm)
0 0
0 500 1000 0 2500 5000
C8- 46kN C10- 50kN
HSK-A 63- 22kN HSK-A 100- 50kN
7/24 taper, size 40-15kN 7/24 taper, size 50-25kN
Turning interface
A machine with automatic tool change (ATC) will provide good
machine utilization. This is readily available on vertical lathes
(VTLs) with a RAM but is only now becoming an option on a few
turning centers with a revolver.
For turning centers without ATC, manual quick change tooling

provides the next best option to reduce tool change and set up
time as well as best stability and high pressure coolant (HPC)
application.
16
2. Turning
2. Turning
Main considerations
Titanium turning can be divided into the three stages of first stage
machining (FSM), intermediate stage machining (ISM) and last
stage machining (LSM). Each has its own machining techniques,
challenges and specific application considerations.
Cutting data Qualities required from

Application areas recommendations cutting tool material
ap 3-10 mm
(0.118-0.394 inch) • Toughness
• Heavy roughing fn 0.3-0.8 mm • Crater wear
FSM
• Removal of skin (0.012-0.031 inch) resistance
vc 25 m/min • Hot hardness
(82 ft/min)
ap 0.5-4 mm
(0.02-0.157 inch)
• Roughing/medium • Hot hardness
ISM • Clean materials fn 0.2-0.5 mm
(0.008-0.02 inch) • Crater wear
• Profiling resistance
vc 40-80 m/min
(131.2-262.5 ft/min)
ap 0.25-0.5 mm
(0.01-0.02 inch)
• Surface integrity • Hot hardness
LSM fn 0.1-0.4 mm
• Semi-finishing/ (0.004-0.016 inch) • Crater wear
finishing resistance
vc 80-120 m/min
(262.5-393.7 ft/min)
17
2. Turning
Effect of entering angle

When machining titanium alloys, productivity and performance is
affected by approach angle (κr), feed rate (fn) and chip thickness
(hex).
The main wear patterns of crater wear and plastic deformation are
not influenced by approach angle and remain constant. The speed
of wear growth and overall performance changes drastically depend-
ing on the heat generated.
Heat can be controlled by a balance of speed, chip thickness and

depth of cut.
Changing insert shape and entering angle can affect insert wear by
up to a factor of 8.
Effect of entering angle on tool wear mechanism
Radial forces
Low High
95º 75º 45º 45º Round

CNMG120408-SM SNMG120408-SM SNMG120408-SM CNMX1204A2-SM RCMT1204MO-SM
95º 75º
45º
45º 45º
18
2. Turning
First stage machining (FSM)

Up to 10 mm (0.394 inch) depth of cut
FSM of titanium is a simple process involving heavy roughing.
• Forged titanium components with uneven skin

• Machined in annealed or heat-treated condition at foundry or
basic component shape
• Uncoated grades are optimum
• High depths of cut, low speeds
• Usually simple workpiece shapes, machined with standard
turning tools
• Critical parts have a test ring removed for material analysis
Intermediate stage machining (ISM)

0.5 to 4 mm (0.02 to 0.157 inch) depth of cut
At this stage, the titanium is in the final solution treated-condition.
• Profiling at varying depths of cut

• Material without skin
• Moderate tolerances
• To 1 mm (0.039 inch) of finished profile
• Pocketing and profiling due to complex component shape
• Often special tool holders and inserts required (especially for
grooving)
• Thin-walled components
• Coated grades can be used
19
2. Turning
Last stage machining (LSM)

0.2 to 0.5 mm (0.008 to 0.020 inch) depth of cut
LSM represents the least amount of material removal from the

component.
• The critical production stage

• Highest demands on surface quality
• Last cut to final shape subjected to very strong restrictions on
surface quality
• Tools, tool paths and cutting data sometimes certified for critical
parts by end user
• B-axis turning is used to avoid mismatch and blend areas on the
component
Best
productivity
FSM
- to shoulder
Depth of
cut
ISM
- pocketing
LSM
Thin walls
20
2. Turning
External turning
Machine requirements
• The power of the machine is not normally a restriction
Tool selection
• Square inserts with large nose radius are the optimum choice
due to constant approach angle and larger depth of cut capability
• Round inserts (large iC)
• Insert size: iC19
Optimum geometry
• -QM for improved safety and longer chips
• -SMR for improved chip breaking
• -SM to reduce cutting forces
• -HM for heavy roughing
Optimum grade
• H13A (uncoated)
Square insert for larger
depth of cut
Tool holding
• For best stability choose Coromant Capto size C8 and C10 tool
holders
21
2. Turning
• Lower machine tool power reqiurement than for FSM.
• Machine tool flexible enough to manage complex component
shapes, with high stability and accessibility
• High pressure coolant (HPC) capability aids productivity
Tool selection
Round inserts are the optimum choice, providing strength and many
benefits for titanium, including:
• Reduced tool wear

• Moderate/high cutting speed
• High strength
• High feed capability
• Smaller depths of cut, closer to finished size
• Good accessibility for profiling and pocketing
To reduce cutting edge engagement and vibration, maximum depth

of cut should be no greater than 25% of the insert diameter
Optimum geometry
• -SMR is the first choice due to secure edge line
• -SM is a back-up choice to reduce cutting forces
Round inserts for
smaller depth of cut
Optimum grade and higher feed capa-
• H13A (uncoated) bility
• GC1115 (PVD-coated) for optimum balance between toughness
and wear resistance
Tool holding
• For best stability choose Coromant Capto
22
2. Turning
Programming recommendations
• Reduce feed as depth of cut increases
• The larger the difference between component corner radius and
insert diameter, the less feed needs to be reduced
• Use 50% feed rolling into radius compared to parallel cuts, as a
starting point
• Trochoidal turning is the first choice method
Trochoidal turning
This method separates the part into manageable machining
segments. It should be used for all profiling requirements
• Roll into cut at reduced feed on entry

• Increase feed to max fn for linear cuts
• Alternate direction of passes when using CoroCut -RO and
S-RCMX (round) inserts, to best utilize the cutting edge
50% fn max 50% fn max

fn max
Programmed radius = insert diameter
Ramping
• An alternative programming method if trochoidal turning is not
the optimum solution, regarding CAD, CAM, NC control system
• Program a varying depth of cut into the operation
• Potential notch wear is spread over whole cutting edge
• Gives longer tool life and more predictable wear
23
2. Turning
• A high value machine with quick tool changing and HPC capability
is essential
Tool selection
• A ground insert edge increases tool life
• Select insert and geometry to suit component stability
For thin wall components, to reduce radial forces:

• Choose entering angle kr 45º, radius no bigger than 3 x ap
• Positive geometry with small edge rounding, e.g. -SGF
• Lower feed range – 0.15 mm/rev (0.006 inch/rev)
For rigid components, giving best productivity:

• Large radius or round inserts (grade H13A)
• CoroCut® RO, 6 mm (0.236 inch) for productivity and surface
integrity
24
2. Turning
Optimum geometry
• -SGF for highest surface quality demands, equal to previous
geometry -NGP
• -SF for best chip control when surface finish is not the primary
consideration
• CoroCut -RO
Optimum grade
• H13A (uncoated)
• GC1105 (PVD, sharp edge) for reduced cutting forces and high
cutting speed
• CD10 (PCD) for longer tool life at high cutting speeds
Tool holding
• For best stability choose Coromant Capto®
25
2. Turning
Optimized insert geometries

for titanium turning
The ISO S insert geometries are designed to handle depths of cut
from 0.2 to 10 mm (0.008 to 0.394 inch) with excellent chip con-
trol and low tool pressure.
Inserts: Double-sided, T-Max® P

Insert styles: S, C, D, T, V, W
Nose radii: 0.4 to 1.6 mm (0.016 to 0.063 inch)
Insert grades: H13A, GC1105, GC1115, GC1125, S05F
-SMR for secure and reliable production
Applications
• Medium to light roughing
• Continuous, interrupted and demanding cuts
• Forged and cast skin
Features and benefits

–SMR
• Security
ith
ing w
rough • Highest edge line toughness
Light
• Chip control
• High feed rate capacity
-SM for secure production in long continuous cuts
Applications
• First choice geometry
• Semi-finish to medium turning

• Reliable production
• Sharp edge line
–SM
ing with • Chip control
finish
Semi
• Long length of cut, SCL (spiral cutting length)
26
2. Turning
Easy to choose ISO geometries
-SMR
S
Depth of cut
-SM
-SGF -SM First choice
-SF -SMR High feed, interruptions
-SF Chip breaking
-SGF Lowest tool pressure
Feed rate
-SF when chip breaking is needed
Applications
• Finish to semi-finish machining
• When chip control is needed

• Chip-breaking geometry
• Process security
ith -SF • Sharp edge line
ing w
Finish
• Low tool pressure
• Long length of cut, SCL (Spiral Cutting Length)
-SGF for highest surface quality demands
Applications
• Finish to semi-finish turning with highest accuracy and lowest tool
pressure

• Periphery ground with sharpest edge line
• Extreme accuracy
with –
SGF • Lowest tool pressure
ing
Finish
• Chip control
• Highest quality surface integrity
27
2. Turning
CoroTurn® TR
Designed with T-rails in the tip seat and corresponding slots on
the insert for added stability and guaranteed precision for profile
turning.
• The combination of tool holder and insert provides a good source

of stability for demanding profile turning operations
• Insert shapes V (35°) and D (55°) for profile turning
• Geometries for finishing (-F) and medium (-M) turning
• V-style inserts are used for finishing only
• Tools available with high pressure coolant
28
2. Turning
Polycrystalline diamond (PCD)

PCD is a composite of diamond particles sintered together with a
metallic binder. PCD tools can be used for extremely long finishing
cuts in titanium.
• Cutting edge temperature must be kept low

• High pressure coolant will increase tool life by up to 40%
Tests show that PCD grade CD10 has extremely long tool life in
finishing operations. Compared to grade H13A, it offers longer tool
life at over twice the cutting speed capability. Tool life is increased
with the application of HPC.
Tests also show that despite high cutting speeds of up to

225 m/min (738.2 ft/min) CD10 retains high surface integrity,
similar to –SGF.
Comparison of uncoated grade H13A with PCD grade CD10, in a

finishing operation
0.2
vb/mm
0.18
0.16
0.14
0.12
0.1
0.08
0.06
0.04
0.02
0
0 2.5 5 15 30 45 60 75 90 105 120 135 150 165 180 min
CNGG 120408 -SGF H13A (vc 120 fn 0.15)

N123H1-0400-RS CD10 (vc 225)
N123H1-0400-RS CD10 (vc 225 HPC)
ap 0.25 mm (0.820 inch) fn 0.2 mm/r (0.7 inch/r)

PCD tool life with NPC (5 bar) and HPC (70 bar)
29
2. Turning
Primary considerations for critical components

• Cutting speed, feed and flank wear should be controlled/limited
for finishing cuts
• Tool breakage when finishing could embed foreign material in the
component
• Tool blends can be areas of stress
Predictive machining
To ensure that the chosen insert style and grade can make one
pass, we provide spiral cutting length (SCL) information.
• For a given diameter and length of cut the SCL can be calculated
for a given feed rate
• Correct speed can then be applied to guarantee making the pass
with acceptable wear
• Generates good surface integrity and dimension and preventing
any need to re-cut
Dm1 × π lm
SCL (m) = ×
1000 fn
Dm1 × π lm
SCL (inch) = ×
12 fn
SCL (m)
For titanium, the best surface results are achieved with:

Insert: CoroCut® RO in uncoated grade H13A
Cutting data: up to 120 m/min (394 ft/min)
30
2. Turning
Surface integrity
The cutting process can affect the integrity of the component,
leading to distortion of thin parts or reduced fatigue life on critical
rotating parts (disks/shafts).
Cutting forces and high cutting temperatures lead to alterations of

the micro-structure which can cause changes in micro-hardness,
plastic deformation and residual stresses in the component sub-
surface.
Key factors affecting severity of surface change

• Cutting parameters: changing feed gives little effect; change in
cutting speed has a negative effect on the surface.
• Grade-geometry effect on wear: the trailing edge of the insert
is the critical point as it transmits heat to the component and
generates the finished diameter. Wear at this point increases
temperature and forces, resulting in more spring passes and
component deflection
Best practice for finishing

Finish with carbide (3 passes) use SCL to ensure cutting data gives
cutting length required.
1) Semi finish – 0.5 mm (0.02 inch)

2a) Finish measure: same insert style and
geometry as finish cut – 0.25 mm (0.01 inch)
2b) Measure component to gauge last cut,
size to correct offset of tools
3) Finish cut to size
31
2. Turning
Internal turning
• Rigid interface and stable machine to cope with bending forces
from the boring bar
Tool selection
• Use entering angle close to 90° (lead angle 0°) but never less
than 75° (lead angle 15°) to reduce bar deflection and vibration.
• Insert size: 12 (iC 1/2) Square insert for larger
depth of cut
Optimum geometry
• -QM for improved safety and longer chips
• -SMR for improved chip breaking
Optimum grade
• H13A (uncoated)
Tool holding
• Use the largest possible bar size and smallest overhang for
maximum stability
• The optimum stability solution for clamping the boring bar is a
Coromant Capto® integrated tool
32
2. Turning
• Machine tool with HPC capability improves chip evacuation
Tool selection
• 55º insert with a 93º entering angle
• Insert size: 12 (iC 1/2)
Optimum geometry Square insert for larger

• -SM for smoother cutting edge depth of cut
Optimum grade
• H13A
• GC1105 for interrupted cuts
Tool holding
maximum stability
• Anti-vibration tools include tool dampening technology for the
complete system, from machine interface to cutting edge
33
2. Turning
• Machine with HPC capability is essential to achieve satisfactory
chip evacuation
Tool selection
• Use a positive basic shape insert with positive geometry to
minimize deflection
• 55º ground insert with a 93º entering angle
• Insert size: 12 (iC 1/2)
Square insert for larger
Optimum geometry depth of cut
• -SGF for highest surface quality demands
Optimum grade
• H13A
Tool holding
maximum stability
• Anti-vibration tools include tool dampening technology for the
complete system, from machine interface to cutting edge
34
2. Turning
Silent Tools®
• Dampened tools are the best performing tools of their kind
• They provide a smooth surface finish with close tolerance, even
where extremely slender tool assemblies are required
• Serration lock coupling gives access to full range of cutting
heads with HPC capability
• Up to 250 mm (9.842 inch) diameter, 14 × D length is available
CoroTurn® SL70
• One standard assortment of blades and adaptors for profiling
and pocketing in complex components without the need for
special tools
• The oval coupling increases tool reach for machining in turbine
disks and other limited-accessibility components
• Cutting blades designed to fit typical profiling and pocketing
features
• Available with RCMT round- and CoroCut inserts and HPC
35
2. Turning
Parting and grooving

Parting and grooving is a turning category covering a wide range of
applications, requiring dedicated tools. It involves both intermediate
and last stage machining.
Typical component types

• Thin wall
• Rigid wall
• Large cross section
• Slender cross section
Main considerations
To perform successful parting and grooving, the following points
should be considered.
Vibration
• Choose an insert with small corner radius
• Choose an insert with sharp cutting edges
• Aim for the shortest possible overhang
• Reduce the insert width
• Use dampened tools wherever possible
36
2. Turning
Accessibility
• Select the correct tool for the component, i.e. 0°, 45°, 90°
• The SL70 oval coupling is ideal for complex components
• Combine special tool adaptors with standard cutting blades
• Double edge- and single-edge inserts are available
Coolant
• Use high pressure coolant (HPC) to improve chip breaking
• Ensure effective evacuation from the groove to avoid
re-cutting of chips
• Small, spiral chips are the optimum chip form
Programming
• Ensure constant stock: 0.2-0.5 mm (0.008-0.02 inch) when
finishing
• When parting a large component: stop 0.5 mm
(0.02 inch) from the end of the component
• When parting a small component <10 mm (0.394 inch) diameter:
reduce feed at 2 mm (0.079 inch) diameter
• Micro stops: do not retract tool out of the component
37
2. Turning
Tool selection Stable
RCMT
trochoidal
Wide grooving
Feature is wider than it is CoroCut -TF CoroCut -GM
deep
Small width Large width
CoroCut -RO DNMG - left/right
Unstable
Stable
Narrow grooving
Feature is width of one
insert
CoroCut 3 CoroCut -TF
CoroCut XS CoroCut GF
Unstable
38
2. Turning
Stable
Profiling
Creating conical or curved CoroCut -RO RCMT
features on a cylindrical
workpiece. Small width Large width
CoroCut -RO CoroCut -RO
Unstable
Stable
Deep grooving
Feature is deeper than it is
wide
CoroCut single edge -TF
Q-Cut -SF WCMX
Dampened blade -GF Dampened blade -GF

Divide operation into steps Divide operation into steps
Unstable
39
2. Turning
Stable
Parting off
A shearing operation to CoroCut 3 CoroCut -CM
separate the finished part
from bar stock Small width Large width
CoroCut XS CoroCut -GF
Unstable
40
2. Turning
Small part machining

When it comes to machining of small titanium components, the
primary tooling options are CoroMill® 325 for thread whirling and
QS holders with high pressure coolant (QS HP). Both tooling op-
tions are optimized for sliding head machines.
QS holders with high pressure coolant (QS HP)

Combining the quick change capability of the QS holding system
with high pressure coolant – a first for sliding head machines.
QS HP fits directly on the tool post to provide problem-free

production and improved component quality in the most demand-
ing, long-chipping materials.
QS HP is available for the following applications

• General turning – CoroTurn® 107
• Parting & grooving – CoroCut® 1-2 and 3
• Turning, parting & grooving and threading – CoroCut® XS
41
2. Turning
CoroMill® 325
Ideal for threading long, slender components, medical bone screws
and implants.
• Thread whirling inserts and holders create special thread forms

in titanium, quickly and at high tolerances
• Threading is from rough stock at high speeds without the need
for a dedicated thread whirling machine
Directions for use

• Mount the whirling ring onto the spindle unit
• Whirling rings are designed with a differential-pitch insert layout
to avoid vibration.
• The sliding head spindle unit is tilted to the helix angle of the
thread
Standard and special inserts

• Standard inserts for HA and HB threads fit all thread whirling
rings
• Standard inserts follow thread standard ISO 5835-1991 for
medical screws.
42
2. Turning
High pressure coolant (HPC)

High pressure coolant (70 to 80 bars) is a standard option for all
new machines. To maximize machining efficiency in titanium it is a
pre-requisite.
CoroTurn® HP is the standard high pressure coolant tooling for

turning
• A precise, high velocity jet provides chip control
• Accurate targeting enables improved cooling and higher cutting
speeds
• CoroTurn HP utilizes 1 mm (0.04 inch) nozzles to provide a
precise jet to break the chip
• Normally the maximum number of nozzles required is
4-20 litres/minute
• Hydraulic wedge lifts the chip

• Reduces temperature
• Improves chip control
Coromant Capto® nor-

mal coolant inlet
Pre-defined target
areas on the insert
face
High precision jet nozzles
43
2. Turning
CoroTurn® HP provides benefits even at low pressures

(8-10 bars)
• Fixed coolant nozzles take away the need for manual adjustment
• The shorter contact length between chip and rake face is
beneficial
• Higher cutting speeds achievable due to reduced crater wear
Main considerations
• Filtration is required when using HP tools, this stops material
becoming stuck in the coolant nozzles
• Ensure sufficient pump pressure to achieve the desired effect
• Ensure the correct cooling system is used for the machine
SNMG120416 -SMR H13A RCMT1204MO -SM H13A

fn=0.4 mm/r, ap=4 mm, κr 450 fn=0.4 mm/r, ap=2.5 mm
40
Tool life, min
60
Tool life, min
35
50
30
25 40
20 30
15
20
10
10
5
Cutting speed m/min (ft/min) Cutting speed m/min (ft/min)
0 0
50 55 60 65 70 75 80 50 60 70 80 90 100
(164) (180) (197) (213) (229) (246) (262) (164) (196) (229) (262) (295) (328)
HPC 70 bar UHPC 200 bar

RC 5 bar HPC 70 bar
RC 5 bar
44
2. Turning
Ultra high pressure coolant (80-1000 bars)

The Jetbreak Coromant Capto coupling is a standard option
for fewer machine tool makers and has dedicated clamping
units and cutting units.
• UHPC coolant is supplied externally into the Coromant

Capto coupling, bypassing the clamping mechanism
• Coolant is directed through 4 coolant jets to different
parts of the insert
• UHPC blanks are prepared with four sealing seats,
final design will determine if one or more will be drilled
through for coolant supply
• Coolant nozzles are interchangeable, allowing different sizes to
be used depending on the application
• A high pressure pump is required
• 200 bars (2900 psi) is the maximum recommendation for
titanium turning – UHPC achieves up to 1000 bars (14500 psi)
• UHPC should not be applied in finishing as deflected chips can
damage the surface.
CNMX1204M0-SM CNMG120408-SM H13A

40 Vc=75 (m/min), fn=0.25 mm/r, ap=1.5 mm
Tool life/min
35
30
35
25
Tool life/min
30
20
25
15 20
15
10
10
5
5
0 0
UHPC
UHPC UHPC
UHPC HPC
HPC RC
RC UHPC
UHPC UHPC
UHPC HPC
HPC RC
200 bar
200 bar 70
70bar
bar 70
70bar
bar 5 bar
5 bar 200
200 bar 120bar
120 bar 70bar
70 bar bar
5 bar
Toolholder
Vc = 60 (m/min)
Vc = 75 (m/min)
45
2. Turning
Component feature solutions
FSM – 26 HRC
Removal of skin
κr 75º for larger
depth of cut (ap)
Cutting speed Depth of cut, Feed, mm/r Metal removal

Insert Geometry Grade m/min (ft/min) mm (inch) (inch/r) Tool life, min* rate, cm3/min SCL, m
S-SNMM 190616 SR H13A 20 (65.6) 7 (0.276) 0.45 (1.476) 35 44.1 700
*Ti-6Al-4V
FSM – 26 HRC
Clean material
Cutting speed, Depth of cut, Feed, mm/r Metal removal

Insert Geometry Grade m/min (ft/min) mm (inch) (inch/r) (inch/r) Tool life, min* rate, cm3/min SCL, m
SNMG 190616 SM H13A 25 (82) 7 (0.276) 0.45 (1.476) 60 79 1500
SNMG 190619 SMR H13A 25 (82) 7 (0.276) 0.45 (1.476) 60 79 1500
* Ti-6Al-4V
1 2 3
FSM – 26 HRC 1) Groove 2 mm (0.079 inch) past

outside dia. of the test ring
Removal of test ring
2) Stop groove 2 mm (0.079 inch)
short of breaking through
3) Axial groove until ring drops into

"nest"
46
2. Turning
ISM – 46 HRC Max. ramping angle

Roughing with high 40° for DSDNN
25° for DSSNL/R
depth of cut
Cutting speed, Metal

m/min Depth of cut, Feed, mm/r Coolant removal rate,
Insert Geometry Grade (ft/min) mm (inch) (inch/r) bar (psi) Tool life, min* cm2/min SCL, m
SNMR 190616 SM H13A 40 (131) 7 (0.276)
SNMR 120408 SM H13A 60 (197) 7 (0.276) 0.35 (0.013)
SNMG 120416 SMR H13A 60 (197) 4 (0.157) 0.4 (0.016) 5 (72) 17 96 1050
SNMG 120416 SMR H13A 60 (197) 4 (0.157) 0.4 (0.016) 70 (1015) 33 96 2016
SNMG 120416 SMR H13A 75 (246) 4 (0.157) 0.4 (0.016) 70 (1015) 11 96 850
*Ti-6Al-4V
Carbide
Cutting speed, Metal

m/min (ft/ Depth of cut, Feed, mm/r Coolant removal rate,
Insert Geometry Grade min) mm (inch) (inch/r) bar (psi) Tool life, min* cm2/min SCL, m
CNMX 1204A1 SM H13A 60 (197) 1.50 (0.060) 0.35 (0.014) 5 (72)
CNMX 1204A2 SM H13A 60 (197) 2.50 (0.098) 0.35 (0.014) 5 (72) 30 52 1884
CNMX 1204A2** SM H13A 75 (246) 2.50 (0.098) 0.35 (0.014) 70 (1015) 31 66 2325
*Ti-6Al-4V
**Special tool with directed coolant (CNMX)
47
2. Turning
ISM – 46 HRC
Profiling and pocket-
ing
CoroCut RCMT/S-RCMX
vc 67m/min (220 ft/min) vc 67 m/min 220 ft/min)
la 9.5/6 mm ap 1.5 mm (0.059 in)
(0.374/0.236 in) fn 0.15 mm/r (0.006 in/r)
fn 0.07 mm/r (0.003 in/r)
Carbide RCMT 1204M0-SM H13A

vc 50 m/min (164 ft/min)
ap 3 mm (0.118 inch)
fn 0.4 mm/r (0.016 in/r)
(G1)
fn 0.2 mm/r
(0.008 in/r)
(G2)
3
Q 60 cm /min
3
(3.661 in /min)
Cutting Feed,
speed, Depth of mm/r Tool life, Metal removal
Insert Geometry Grade m/min cut, mm (inch/r) min* rate, cm2/min SCL, m
RCMT 10T3M0 SM H13A 50 (164) 1.50 0.35 5 26.25 250
(0.059) (0.014)
RCMT 1204M0 SM H13A 50 (164) 2.00 0.50 5 50 250
(0.079) (0.020)
*Ti-6Al-4V
48
2. Turning
ISM – 46 HRC
Profiling and
pocketing, CoroCut.
Use trochoidal turning method
Cutting Depth of Feed,

speed, cut, mm mm/r Tool life, Metal removal SCL,
Insert Geometry Grade m/min (inch) (in/r) min* rate, cm2/min m
N123L2-0800 RO H13A 50 (164) 1.20 0.50 6 33 300
(0.047) (0.020)
N123J2-0600 RO H13A 50 (164) 1.00 0.40 6 22.5 300
(0.039) (0.016)
N123H2-0400 RO H13A 50 (164) 0.60 0.30 6 10.5 300
(0.024) (0.012)
*Ti-6Al-4V
49
2. Turning
Blade grooves on
disc/spool.
N123K2-0600-0004-TF N123K2-0600-0004-TF LG123L1-0400-0020-RS

H13A H13A GC1105
vc 50 m/min (164 ft/min) vc 50 m/min (164 ft/min) vc 50 m/min (164 ft/min)

fn 0.2 mm/r (0.008 in/r) ap 0.5 mm (0.020 inch) ap 0.5 mm (0.020 inch)
fn 0.25 mm/r (0.010 fn 0.25 mm/r (0.010
inch/r) inch/r)
Grooves on stator
vanes.
CoroCut 90° insert CoroCut 90° insert

GC1115 GC1115
vc 30 m/min (98 ft/min) vc 30 m/min (98 ft/min)

la 2 mm (0.079 inch) ap 0.25 mm (0.010 inch)
fn 0.1 mm/r (0.004 fn 0.15 mm/r (0.006
inch/r) inch/r)
50
2. Turning
ISM – 46 HRC Operation 1a Operation 1b

Rings
Cutting speed, Depth of cut, mm

Operation Insert Geometry Grade m/min (ft/min) (inch) Feed, mm/r (inch/r)
1a CNMG 120412 SM GC1105 50 (164) 1.0 (0.039) 0.20 (0.008)
1b N123G2-0300-0004 GF GC1105 50 (164) - 0.08 (0.003)
Operation 1c Operation 1d
Cutting speed,
Operation Insert Geometry Grade m/min (ft/min) Depth of cut, mm Feed, mm/r (inch/r)
1c DNMG 150612 SM GC1105 50 (164) 1.0 (0.039) 0.20 (0.008)
1d DNMG 150612 SM GC1105 50 (164) 0.25 (0.010) 0.20 (0.008)
Operation 1e Operation 1f
Cutting speed,
Operation Insert Geometry Grade m/min (ft/min) Feed, mm/r (inch/r)
1e N123G2-0300-0004 GF GC1105 50 (164) 0.08/0.12
1f N123G2-0300-0004 GF GC1105 50 (164) 0.08/0.12
51
2. Turning
ISM – 46 HRC
Thin walls/unstable.
Cutting speed, Depth of cut, Tool life, Metal removal SCL,

Insert Geometry Grade m/min mm Feed, mm/r min* rate, cm2/min m
CNGG 120408 SGF H13A 50 (164) 1.50 (0.059) 0.20 (0.008) 5 15 250
CNMG 120408 SM GC1105 50 (164) 1.00 (0.039) 0.20 (0.008) 5 10 250
Internal machining.
Bar type selection DNMG 150608-SM 1105

vc 50 m/min, ap 2 mm, fn 0.15 mm/r
Steel dampened
boring bars
Steel boring DNMG 150608-SM 1105

bars vc 50 m/min, ap 2 mm, fn 0.15 mm/r
Steel boring RNGN 120400 T01020 6060

bars vc 200 m/min, ap 2 mm, fn 0.15 mm/r
Length to dia.
ratio 1Ø 2Ø 3Ø 4Ø 5Ø 6Ø 7Ø 8Ø 9Ø 10 Ø
For overhangs up to 14 x dmm, use Silent Tools carbide reinforced boring bars.
52
2. Turning
Geometry recommendations
Recommendation for tool geometry
Geometry recommendation
Application Feed range, Edge Geometry General

Grooving
area mm/r rounding requirements turning
Double Single
CoroCut Q-Cut
sided sided
Direct pressed - SMR SM

FSM 0.3-0.8 Medium S-SNMM-SR
primary land
QM
SM UM TF 5E
0.25-0.40
(0.25 for κr Direct pressed
ISM Small
90º, 0.40 for positive geometry 4P
SMR RO
κr 45
SM (Xcel) GS/RS
SGF AL GF 4G
Ground positive
LSM 0.1-0.2 Small
geometry CGT RO 4P
UM
GS/RS
Round insert geometries

Geometry recommendation
Machining stage Feed range mm/r Edge rounding
FSM 0.3-0.5 Neg land RCMX H13A
ISM 0.2-0.4 Small neg land RCMT-SM H13A
0.1-0.3 None RCGX-AL H10

LSM
0.2-0.4 Small neg land RCMT-SM H13A
53
2. Turning
Cutting data recommendations

Uncoated Cutting
Machining grade (first Coated speed, Feed, Depth of
stage Insert style choice) grade m/min mm/r cut, mm Comments
S/CNMG 190616 SR H13A GC2015 30-60 0.3-0.4 < 10

Use SNMG – 45° approach to
reduce chip thickness where
FSM
possible – max n umber of
RNMG 190600 SR H13A GC1115 30-60 0.3-0.4 <6 edges.
S/CNMG 190616-SMR H13A GC1125 30-60 0.3-0.8 < 10
Normally component dictates

CNMX-SM H13A GC1115 40-60 0.25-0.35 < 2.7
insert style – use 45° approach
for best tool life.
S/CNMG 120412-SM H13A GC1115 30-60 0.2-0.4 <5

ISM
RCMT 1606M0-SM H13A <4 Round inserts give the h

ighest
50-70 0.3-0.4
RCMT 1204M0-SM H13A GC1115 <3 productivity where component
allows their use.
S/CNMG 120412-SMR H13A GC1115 30-60 0.2-0.5 <3
CNGG 120408 SGF H13A 80-120 0.1-0.2 0.25-1.0 NGP/AL micro geometry opti-
mised for Titanium fi nishing.
CCGX 120408-AL H10 80-120 0.1-0.2 0.25-1.0

LSM
Round inserts give the best

RCMT 1204MO-SM H13A 80-120 0.2-0.4 0.25-1.0 productivity and surface fi nish
where components allow their
use.
RCGX 10T3M0-AL H13A 80-120 0.2-0.3 0.25-1.0
Grooving
Uncoated Cutting
Machining grade (first Coated speed, m/ Feed, Depth of
stage Insert style choice) grade min mm/r cut, mm Comments
H13A GC1105 50-70 0.1-0.2 - For rough grooving o

perations
TF 5E
ISM
Max
H13A GC1105 50-70 0.2-0.5 For rough profiling operations
0.25 x dia
RO 4P
H13A GC1105 80-100 0.05-0.15 - For finish grooving o

perations.
GF 4G
LSM
H13A GC1105 80-120 0.1-0.4 - For finish profiling operations.

RO 4P
54
3. Milling
3. Milling
Titanium requires specific considerations due to its high strength
to weight ratio which results in higher cutting temperatures. It is
also chemically reactive which can result in adhesion, welding and
smearing when machining. The combination of mechanical, thermal
and chemical loads will create a typical wear pattern known as
edge chipping.
To be successful in machining titanium, optimized tools are neces-

sary. However, to achieve an optimized process these must be
combined with application 'know how' to deliver a robust machining
process.
Typical cutting parameters
Application Cutting data

areas recommendations Depth of cut Wear types
Roughing vc 40-60 m/min > 3 mm
(131.2-196.8 ft/min) (> 0.118 inch)
Semi-finishing vc 60-80 m/min 1-3 mm

(196.8-262.5 ft/min) (0.039-0.118 inch)
Finishing vc 80-120 m/min 0.5-1 mm

(262.5-393.7 ft/min) (0.02-0.039 inch)
56
3. Milling
Main considerations
Horizontal or vertical machine

Vertical machine tools are predominately used in the first stages
of machining a component. For components with many different
features it is advisable to use a horizontal machine tool to aid
evacuation of chips, preventing chip re-cutting and giving a more
predictable tool life.
All machine tool configurations benefit from secure coolant delivery

with through-spindle coolant preferred.
The component features and process plan define the machine tool
configuration requirement which lead from 3 axis through to full 5
axis simultaneous motion machine tools.
Component fixturing and stability

At each stage of the manufacturing process the demands on stabil-
ity increase. The component has to be fixtured securely to minimize
movement and vibration.
As the component reaches the final finishing processes the tool

gauge lengths increase, leading to extended tool overhang. It is
here that the use of modular tooling such as Coromant Capto and
tuned adaptors should be considered.
To deliver a secure manufacturing process, it is critical that all fac-

tors are optimized to ensure part quality.
57
3. Milling
Spindle options
The process plan for the component will dictate the ideal spindle
choice for the machining stage. If roughing the component then a
spindle which offers high torque and power at a low rpm range is
required.
When at the semi-finishing/finishing stages a spindle which offers

higher rpm is required due to the smaller diameter of cutting tool
and lower radial engagement.
These Spindle configurations are usually to the equivalent of ISO

50 or larger.
T
T Nm
Nm PPkW
kW
3 Starts Increases until max power is reached,

max power
2
then flattens out
1
Reduces as spindle
4 speed increases
0
P n rpm
T
58
3. Milling
Maximum chip thickness

Maximum chip thickness is one of the most important parameters
for achieving a productive and reliable milling process.
• A thin chip with a hex value that is too low is among the most
common causes of poor performance, resulting in low productiv-
ity. This can negatively affect tool life and chip formation.
• A value that is too high will overload the cutting edge, which can
lead to breakage.
Chip thinning allows for increased feed

Feed per tooth can be increased in the three following situations
due to the chip thinning effect, when:
• Using straight edge cutters with entering angles lower than 90°
• Using round inserts or large radius inserts, at smaller depths of
cut, ap
• Peripheral milling at a small radial engagement, ae/Dc
1. Straight edge insert, ae > 50% of Dc

For straight edge inserts, chip thickness, hex is equal to fz when
entering angle is 90°. As entering angle, kr decreases, fz can be
increased.
Example:
If the maximum chip thickness, hex is 0.1 and the entering angle, kr is 45°,
the feed recommendation, fz is 1.4 × 0.1 = 0.14 mm/tooth
(0.006 inch/tooth)
Entering angle Modification fz mm/tooth (inch/tooth):

kr factor hex mm (inch)
min. start max.
0.10 0.15 0.20
(0.004 (0.006) (0.008)
90º 1.0 0.10 0.15 0.20
(0.004) (0.006) (0.008)
75º 1.0 0.10 0.16 0.21
(0.004) (0.006) (0.008)
65º 1.1 0.11 0.17 0.22
(0.004) (0.007) (0.009)
45º 1.4 0.14 0.21 0.28
(0.006) (0.008) (0.011)
10º 5.8 0.58 0.86 1.15
(0.023) (0.033) (0.045)
59
3. Milling
2. Round and radius insert cutters

• Best performance is achieved when the entering angle, kr
<60°
remains under 60°. For larger depths of cut, it is better to use
<25% iC
square inserts with a constant kr of 45°
• The chip thickness, hex varies with round inserts, and depends on
the entering angle and radial engagement coskr =
(0.5 iC - ap)
0.5 iC
hex × iC
fz =
2 × √ ap × iC − ap²
Example: CoroMill® 300 insert
Max. chip thickness, Feed per tooth, fz mm (inch)

hex mm (inch)
ap mm (inch)
iC Min. Start Max 1 1.5 2 2.5 3 3.5 4
0.1 0.15 0.2 0.23 0.19 0.17
8
(0.004) (0.006) (0.008) (0.009) (0.007) (0.007)
0.1 0.2 0.25 0.33 0.28 0.25 0.23
10
(0.004) (0.008) (0.010) (0.013) (0.011) (0.010) (0.009)
0.1 0.2 0.25 0.36 0.30 0.27 0.25 0.23
12
(0.004) (0.008) (0.010) (0.014) (0.012) (0.011) (0.010) (0.009)
0.1 0.2 0.25 0.41 0.34 0.30 0.28 0.26 0.24 0.23
16
(0.004) (0.008) (0.010) (0.016) (0.013) (0.012) (0.011) (0.010) (0.009) (0.009)
60
3. Milling
3. Peripheral milling
• The hex value varies depending on the cutter diameter and work-
ing engagement, the radial immersion of a cutter, ae/Dc
• Feed can be increased by the modification value in the table
below depending on the ratio, ae/Dc
Width of cut diameter ratio Modification factor fz mm/tooth (inch/tooth):

ae/Dc hex (mm)
min. start max.
0.1 0.15 0.2
50-100% 1.0 0.10 (0.004) 0.15 (0.006) 0.20 (0.008)
25% 1.16 0.12 (0.005) 0.17 (0.007) 0.23 (0.009)
20% 1.25 0.13 (0.005) 0.19 (0.007) 0.25 (0.010)
15% 1.4 0.14 (0.006) 0.21 (0.008) 0.28 (0.011)
10% 1.66 0.17 (0.007) 0.25 (0.010) 0.33 (0.013)
5% 2.3 0.23 (0.009) 0.34 (0.013) 0.46 (0.018555)
Chip formation through cutter position
Exit from cut

• Thick chip on exit causes uneven and short tool life
• A sudden change in load from compressive to tensile causes
carbide to chip on point leaving insert
The process should ensure lowest possible chip thickness on exit

from cut.
61
3. Milling
Grades
Sandvik Coromant grades are designed to cope with the demands
of titanium milling, where the thermal, chemical and mechanical
loads on the cutting edges come close to the limits of every known
cutting tool material.
The titanium milling grade chain
Stable and constant

conditions
Unstable and difficult

conditions
ae = radial depth of cut
62
3. Milling
Grade S30T
For best tool life and productivity in:
• Good stability
• Predictable cutting conditions
• Small/moderate vibration
• Moderate/high cutting speeds
Grade S40T
For highest security and longest tool life in:
• Difficult/unpredictable cutting conditions
• Poor stability with moderate/severe vibration
• Moderate cutting speeds
Grade GC2040
• For applications where temperature load is high within the
S40 area
• Complement to S40T in unstable and difficult conditions
• When cutting temperature is excessive (high cutting
speeds, poor coolant flow)
Grade GC1010
• An optimizer in the S20 area
• For very stable conditions/minimal vibration
• Ideal for high speed machining and finishing at high surface
speeds
63
3. Milling
Programming guidelines
Entering the component

When the cutter is programmed to enter straight into the workpiece,
thick chips will be produced at the exit until the cutter is fully en-
gaged. This will dramatically reduce tool life
The main way to solve this problem is:
Roll into cut Thick chip on exit of

cut until cutter is fully
Program a roll into cut in a clockwise motion. By rolling into cut, the engaged.
chip thickness on exit is always zero, allowing for higher feed and
longer tool life.
Keep cutter constantly engaged

Sharp changes of direction in a cut will cause the same problem as
occurs when entering straight into the workpiece.
Rolling around all corners should always be applied as a key step to

provide a robust, optimized process. Program around interruptions
and holes when possible.
Keep cutter constantly engaged.
64
3. Milling
In face milling, sharp changes of cutter direction gener-

ate thick chips on exit.
In peripheral milling, roll around external corners.
Arc of engagement into cut

Programme around holes
and interruptions.
Large (max.) arc of engagement
• Long time in cut
• High radial forces
• More heat generated
• CVD coated grades
Small arc of engagement

• Short time in cut and less heat = > higher vc
• Thinner chip = > higher fz
• Higher vc and fz can be applied
• Sharp edges
• PVD coated grades
Optimal
• ae = 70% Dc
Highest metal removal – ae and fz
• ae < 25 % Dc
Allows chip thinning and higher fz
65
3. Milling
Insert wear depending on entry
Material: titanium Ti6AI4V
Grade S30T S40T GC2040
Straight
2 passes 6 passes 6 passes
Roll-in
12 passes 12 passes 6 passes
Results
Insert wear, diameter 50 mm (1.969 inch)
vc 80 m/min (260 ft/min)
fz 0.23 mm (0.009 inch)
ae 38 mm (1.5 inch)
ap 3 mm (0.118 inch)
66
3. Milling
Entry into workpiece
Ramp into cut radially Rolling into cut circular interpolation
Cutter path in cut
Face milling boss Internal corners pocketing
67
3. Milling
Milling in corners
Considerations
• Machining into corners requires careful consideration of the suit- The problem
able arc of cutter engagement, and also of the appropriate feed
rate
• When feeding the cutter into internal corners, the radial arc of
engagement will increase and place extra demands on the cut-
ting edge
• Often, the process becomes unstable, creating vibration and an Corner radius = 50% × Dc
insecure process Taditional corner milling
• Wobbling cutting forces often create undercutting of the corner.
There is also a risk for frittering the tool edges, or total tool break
down Solution No 1
Solution – limit the arc of engagement
• Using a programmed radius (circular milling) to reduce the arc of

engagement and a radial cut will reduce the vibration tendencies, Corner radius = 75% × Dc
which will allow higher depths of cut and feed rates
• Machine a bigger corner radius than stated in the drawing. This Mill a bigger component
radius
can sometimes be favorable, as it allows the use of a bigger cut-
ter diameter in roughing, which maintains high productivity
• Alternately use a smaller Dc cutter to mill the desired corner Solution No 2
radius
Roughing
• A programmed radius of 50% Dc is optimal
Corner radius =
Finishing 100% × Dc
• For finishing, it is not always possible to have such a large radius;
however, the cutter diameter should be no larger than 1.5 × com- Use a smaller cutter
ponent radius (e.g. corner radius 10 mm = max 15 mm)
68
3. Milling
Programming
Centre line or periphery feed

• A machine is designed for either centre line feed, vf (without
radius compensation) or periphery feed, vfm (with radius compen-
sation)
• If the machine requires a centre line feed, and periphery feed is
programmed instead (on machines without radius compensation),
the fz value will become too high, with the subsequent risk of
insert breakdown
Centre line feed programming

• The NC codes generated will program the centre of the cutter
rather than the periphery
• For straight line cutting (G1), the feed at the wall of the com-
ponent, vfm is the same as the programmed feed, vf while the
periphery feed around a radius (G2) will be higher than the tool
centre feed
• Therefore the table feed, vf needs to be reduced to maintain the
feed per tooth, fz and keep constant hex
Centre line, vf or periphery feed, vfm
69
3. Milling
Face milling
Face milling is a common milling operation and can be performed
using a range of different tools.
• Forged titanium components with uneven skin

• Machined in annealed or heat-treated condition
• Coated grades are optimum
• Traditional or high feed milling techniques can be applied
• For finish face milling solid carbide is recommended when sur-
face integrity is critical.
CoroMill® 300 CoroMill® 200 CoroMill® 210

• First choice for roughing and semi • First choice for difficult roughing and • First choice for long overhang
finishing semi finishing • Good choice for roughing and semi
• High feed possibilities • High feed possibilities finishing in aerospace
• Many insert sizes • Many insert sizes • High feed and small depth of cut
• Small diameters • Large diameters • Large to small diameters
• Large diameters
Optimum geometry / grades Optimum geometry / grades Optimum geometry / grades

E-SL S30T Light: S30T First choice: S30T
(S40T, GC2040) PL/ML (S40T, GC2040) E-PM/MM (GC1010, S40T,
GC2040)
Medium: S30T Alternative choice: S30T
PM/MM (S40T, GC2040) M-PM/MM (GC1010, S40T),
(GC2040)
Heavy: S40T
PM/MM (GC2040)
Cutting data see page 96-97
70
3. Milling

• First choice for 45° face mills • Good choice for face roughing and semi • First choice for face milling when small
• First choice for finish face milling finishing diameters are required
• Good choice for large depth of cut • Flexible for face and shoulder milling • Flexible for face and shoulder milling
• Many insert sizes: 11,17 and 18 • Many shank lengths
• Small to large diameters

Light: S30T Light: E-PL/ML S30T GC1030
E-PL (GC1010, S40T) (GC1010, S40T,
GC2040)
Medium, light: S30T Medium light: S30T
M-PL (GC1010, S40T) M-PL/ML (GC1010, S40T,
GC2040)
Heavy: S30T Medium: S30T
K-MM, M-MM (S40T, GC2040) M-PM/MM (GC1010, S40T,
(C2040)
Application checklist and hints
• Program the cutter to roll into cut and reduce the feed to obtain a
smooth entry
• Apply down milling for favourable chip formation i.e. thick to thin
chip
• Use tool path programming to avoid entries and exits
71
3. Milling
Shoulder milling
Shoulder milling is used when there is a requirement for two faces
at 90º.
• Forged titanium components with uneven skin or in pre-machined

condition
• Machined in annealed or heat-treated condition
• Coated grades are optimal
• Maximum chip thickness can be applied
• Pockets, slots and peripheral faces are common features
CoroMill® 390 CoroMill® 690 CoroMill® Plura

• First choice in ISO S • First choice in ISO S • First choice for long overhang
• Large radius options • Large radius options • Good choice for roughing and semi finish-
• Ramping capability • HPC capability ing in aerospace
• Dampened options • High feed and small depth of cut
• Turn milling capability • Large to small diameters

Light: S30T (GC1010, Light: S30T (S40T, First choice: S30T
E-PL/ML S40T, GC2040) E-SL GC2040) E-PM/MM (GC1010, S40T,
GC2040)
Medium light: S30T (GC1010, Alternative choice: S30T
M-PL/ML S40T, GC2040) M-PM/MM (GC1010, S40T,
GC2040)
Medium: S30T (GC1010,
M-PM/MM S40T, GC2040)
72
3. Milling
CoroMill® 790 CoroMill® 316 Finishing long edge cutter

• First choice in ISO S, finishing • First choice for shoulder milling when • Highly productive choice
• Large radius options small diameters are required • Long cutting edge for large ap
• High speed machining • Flexible for both face and shoulder • Good surface finish, no mismatch
milling
• Many shank lengths

Light: GC1010 GC1030 LDHT (side insert) GC1030
H-PL LEHT (end insert) GC1030
• Down milling is always the first choice and is especially important

for shoulder milling due to the 90º entering angle
• Machining should be performed to direct the cutting forces to the
support points of the fixture. Up milling can therefore be a favour-
able option in some cases
• Selection of cutter pitch is dependent on the stability of the
entire system, including: machine tool, workpiece, material and
clamping
• In ISO 40 machines and smaller, coarse-pitch cutters are recom-
mended due to limited stability
73
3. Milling
Application checklist and hints (continued)
• Coarse pitch cutters are recommended for machining

components mounted high up on a cube fixture
• The positioning of the cutter on the workpiece is very important
and should receive extra attention
• When Dc/ae >10, the feed fz should be adjusted in accordance
with the hex value to achieve a good result and avoid edge break-
down
• If the shoulder depth is smaller than 75% of the cutting edge
length, the quality of the vertical surface does not normally
require extra finishing
• Choose a tougher carbide insert than for face milling
• If CoroMill® long edge cutters are used, the conditions are
demanding, therefore an even tougher grade may be required
• The deeper the cut, the more important it is to choose lower
cutting speed to avoid vibration
• When vibration occurs, decrease vc and increase fz check against
the recommended hex value
• Ensure that enough machine power is available for the chosen
cutting data
74
3. Milling
Tool holding
• Pay special attention to power requirements when taking large
cuts, particularly with long edge cutters
• The larger the cutting depth, the more important the size and sta-
bility of the coupling, as the radial forces are considerable when
using shoulder face mills, particularly long edge milling cutters
• The Coromant Capto® coupling provides optimum stability and
the smallest deflection for all cutters – particularly important for
long or extended tooling
75
3. Milling
Profile milling
Profile milling covers multi-axis milling of convex and concave
shapes in 2- and 3-dimensions.
• Perform roughing and finishing in separate machines, using dedi-

cated cutting tools
• Perform finishing in a 4/5 axis machine tool with advanced
software and programming techniques, to improve geometrical
accuracy and surface quality

• First choice for roughing and semi • First choice for difficult roughing and • First choice for semi finishing to finishing
finishing semi finishing • First choice for radii
• Many insert sizes • Many insert sizes • Many insert sizes radii 5, 6, 8, 10, 12,5,
• Small diameters • Large diameters 16, 20 and 25 mm
• Large diameters

E-SL S30T Light: S30T M - inserts for GC1025
(S40T, GC2040) PL/ML (S40T, GC2040) higher security (GC1030)
Medium: S30T E - inserts with GC1025
PM/MM (S40T, GC2040) sharper edges and (GC1030)
higher precision
Heavy: S40T
PM/MM (GC2040)
76
3. Milling
CoroMill® Plura CoroMill® 316

• First choice in ISO S when solid carbide • First choice when small diameters are
is required required
• Flexible for all other milling
Optimum geometry / grades Optimum geometry / grades

Roughing to finishing with variable flute GC1030
depth: R216.34-xxx50-BCxxP R216.24-
xxx50xBCxxP R216.34-xxx50-AKxxP
R216.24-xxx50xAKxxP
Grade selection depending on application.
Finishing with:
Finishing cutter R215.36-xxx50-ACxxL
GC1620
Finish profiling with CoroMill® Plura solid carbide end mills:

• Work with radial engagement (ae) below 40% of cutter diameter to
reduce chip thickness
• Maximize depth of cut to reduce number of passes
• Utilize the available edge
• Control radial engagement (ae) where radial depth of cut is below
20% of cutter diameter, to reduce toughness demand and allow
optimized cutting data
• Smaller radial cuts (ae) reduce cutting tool deflection
• Use a tool with high bending stiffness to keep high tolerance
level and geometrical accuracy
• Use down milling to reduce heat and prolong tool life
77
3. Milling
Profiling with solid carbide can be split into 2 groups, each with
specific cutter requirements:
2D profiling
• Long-edge reach for producing profile on pocket or exterior
• Correct radius to suit the demand at the bottom of the pocket
• ‘Necked’ cutters provide access in pockets over 2 × Dc
• High-helix multi-flute cutter designs should be used
3D profiling
• Ball nose end mills used for profiling curved and twisted surfaces
• For short tools and 3-axis milling, use standard ball nose end
mills
• For longer overhangs and 5-axis milling, use conical ball nose end
mills for rigidity
78
3. Milling
Helix angle
• The angle of the cutting edge relative to the tool centreline
• Determines length of cutting edge engagement for given cutting
depth, influences performance and chip flow
• Larger helix angle gives longer cutting edge and tool life with
lower radial forces
Finishing – use high helix angle

Roughing – use low helix angle due to higher tool strength
30° 45° 60°
Helix angle
79
3. Milling
Slot milling
Deep slots are long but not often wide, such as in titanium engine
mounts, landing gears and brackets. These components require
effective roughing operations with minimum rest milling before the
finishing operation.
• Tool selection is determined by width and depth of the slot, and

to some extent, length
• Machine type and frequency of operation determine whether an
end mill, long edge cutter or side and face mill cutter should be
used
CoroMill® 690,
CoroMill® 331 CoroMill® 327 CoroMill® 390 long edge
• First choice for deep slots • Good choice for small and narrow slots • Good choice for medium deep slots
• Flexible • Internal slots • Coarse pitch for slots
• Chamfering and threadmilling possible • Large chip rooms for chip evacuation
• Small diameters

E-SL S30T GM GC1025 Light: S30T
(S40T, GC2040) E-SL (S40T, GC2040)
H-WL GC1030
80
3. Milling
CoroMill® 390 CoroMill® Plura CoroMill® 316

• Good choice for small and wide slots • First choice in ISO S when solid carbide • First choice when small diameters are
• Many insert sizes: 11,17 and 18 is required required
• Small to large diameters • Flexible for all milling


Light: S30T Roughing to finishing with variable flute GC1030
E-PL/ML (GC1010, S40T, depth: R216.34-xxx50-BCxxP R216.24-
GC2040) xxx50xBCxxP R216.34-xxx50-AKxxP
R216.24-xxx50xAKxxP
Grade selection depending on application.
Medium light: S30T Finishing with:

M-PL/ML (GC1010, S40T, Finishing cutterR215.36-xxx50-ACxxL 1620
GC2040)
Medium: S30T
M-PM/MM (GC1010, S40T,
GC2040)
• Choose cutter size, pitch and position so that at least one edge
is in cut at all times
• Check chip thickness to achieve the optimum feed per tooth
• Reduce feed on entry due to thick chip on exit
• Choose side and face milling for best stability and productivity
when the slot is deep and narrow.
81
3. Milling
Plunge milling
Cutting is performed at the end of the tool instead of the periph-
ery, giving an advantageous change of cutting forces from radial to
axial. Plunge milling is generally an alternative method when side
milling is not possible, due to vibration tendencies.
CoroMill® 210 215A CoroMill® 390

• First choice for long overhang • First choice for heavy plunging • Good choice for face roughing and semi
• Good choice for roughing and semi • Large diameters finishing
finishing in aerospace • Flexible for both face and shoulder
• High feed and small depth of cut milling
• Large to small diameters • Many insert sizes 11,17 and 18

• Small to large diameters

First choice: S30T Light: S30T
E-PM/MM (GC1010, S40T, E-PL/ML (GC1010, S40T,
GC2040) GC2040)
Alternativ choice: S30T Medium light: S30T
M-PM/MM (GC1010, S40T, M-PL/ML (GC1010, S40T,
GC2040) GC2040)
Medium: S30T
M-PM/MM (GC1010, S40T,
GC2040)
CoroMill® 316
• First choice when small diameters are
required
• Flexible for all milling
Optimum geometry / grades
GC1030
82
3. Milling
Thread milling
Many holes in titanium components require threads. The key is to
maintain high levels of accuracy and productivity and selecting the
appropriate threading method is a key factor.
• Always engage and retract the thread milling cutter in a smooth

tool path
• Climb milling is the preferred choice
• The relationship between the threading diameter and the cutting
diameter should be no less than 1.5
• A smaller cutting diameter helps to achieve high quality threads

and minimize profile deviation.
• Cutter diameter should be no greater than 70% of the threading
diameter.
• A machine tool capable of simultaneous movement in the x, y
and z-axis direction is required
83
3. Milling
High speed machining (HSM)

Here, the cutting engagement arc/time is a low percentage of the
cutting revolutions. Solid carbide end mills are used extensively for
high speed machining, with the following advantages:
• High productivity in demanding titanium materials

• Long radial cutting edges enable large axial depths of cut in rela-
tion to cutter diameter
HSM uses high rpm and axial cutting depths (ap) with small radial
engagement (ae) and feed per tooth (fz).
High axial cutting depth ap = 1 to 2 × dia

Low radial cutting depth ae = 4 to 20% dia
Low chip thickness fz = 0.05 to 0.1 mm
(0.02-0.004 inch)
Cutting speed selected for vc = 120-225 m/min
specific ae (393.7-738.2 ft/min)
This is possible due to:

Factor Effect Benefit
Thin chip thickness Low cutting force/deflection Deeper axial cuts
Small arc of engagement Reduced temperature at cut- Higher speeds
ting zone
Utilize
Max ap
Control ae
Requirements
• High spindle speed: machine tool spindle has to provide speeds high enough for small
diameter end mills.
• No extra demands on rigidity
84
3. Milling
Dedicated methods
Circular ramping (3 axis)

Circular ramping is used to open up a cavity/pocket/non-round hole
with a milling tool
Application
• Rough hole making over 30 mm (1.181 inch) diameter
• Lower powered machines
• Components with curved surfaces
• Intermittent entry/exit, thin walls
• For producing blind holes when flat bottom is required
Advantages
• One tool covers range of hole diameters, shapes and sizes
• High metal removal rates, reduced burr formation
• Suitable for all machine types and configurations
• Improved roundness of hole compared to boring/drilling
• Minimized vibration problems
Process
• Enter drilled hole in a circular path with max. radial depth at 30%
of cutter diameter
• Feed tool axially and enter hole while performing a circular move-
ment
• Anti-clockwise motion ensures down milling is achieved
• Largest possible radius should be used in corners
85
3. Milling
Plunge milling
Here, the end of the cutter (axial cutting edge) is used instead of
the side (radial cutting edge). This method offers an ideal solution
for difficult materials like titanium.
Application
• Demanding conditions such as instability, long tool length
• In tool overhangs over 4 × Dc
• For semi-finishing of corners
• When machine power/torque is limited
• Horizontal machines facilitate chip evacuation
Process
• Feed tool in axial direction
• Use end of tool to cut (instead of periphery)
• Gradually increase plunge depth to reduce vibration
• Maximum sideways movement is 0.75 × cutter diameter
• Start at bottom and work upwards in cavities
• Drill and plunge in narrow slots to aid chip evacuation
Advantages
• Several indexable insert end mills and round insert cutters are
good plunging tools
• Low power consumption/noise
86
3. Milling
Slicing
Productive and secure method of roughing and semi-roughing using
small depth of cut (ap) and small radial depth of cut (ae). Slicing can
be divided into two application areas.
Trochoidal milling – primarily for machining slots

Corner milling – for semi-roughing corners
Trochoidal milling
A 2D roughing method in a confined space or slot, ideal for difficult
materials like titanium.
Application
• Rough milling of confined cavities, pockets and grooves
ap ≤2 × Dc
• Ideal for slotting when vibration is a problem
ae = small
vf = high
Process
vc = up to 10 ×
• Requires specialized programming and machine tool capabilities conventional
• Program tool to roll in- and out of cut with low radial pitch methods
• Maximum radial cut should be no more than 20% of cutter diam-
eter
Advantages
• Controlled arc of engagement gives low cutting forces enabling
high axial depths of cut
• Whole cutting edge length utilized so heat and wear are uniform
and spread evenly, giving longer tool life than traditional slot mill-
ing
• Multi-edge tools enable high table feeds and secure tool life
87
3. Milling
Corner milling
This method uses multiple passes to take away material from
corners left from a previous operation where a larger tool could not
reach.
Application
• Aerospace frame structural parts
• Mould bases and pressing dies
• Stable machine tool and centre feed reduction control is
essential
• Solid carbide tool required
Process
• No roll in- or out of cut required
• Multiple passes successively remove material, giving consistent,
low radial engagement and low cutting forces
• Tool centre feed (vf) needs to be reduced relative to vfm
• Decrease feed for each pass as ratio between cutter path dia-
meter Dvf and Dm constantly increases towards the finished radius
Advantages
• High speed – short engagement time
• High axial cut – low cutting forces
• High feed – reduced chip thickness
88
3. Milling
Component feature solutions

In the aeospace industry, some of the most common
features are pockets in structural parts.
The most common, optimized methods for machining

a cavity/pocket are shown below.
1. Drilling and circular interpolation/milling

• The basic choice for pockets
• First choice for aerospace-frame structural parts
• High material removal for non-round holes
• Requires stable machine
• Requires careful programming
2. Drilling and plunge milling

• Problem solver in long overhangs
• Simple programming, suitable for older/multi-spin-
dle machines
• Low material removal rate
3. Circular ramping
• Fewer tools needed, no drills
• Flexible, produces wide range of cavity sizes
• Suitable for all machines and configurations
• Less productive for large cavities
89
3. Milling
Solution for standard features

These seven pockets are generic sizes which can be used as
a reference for your specific titanium component.
For cost effective solutions in each pocket, please contact your

local Sandvik Coromant representative.
100 × 100 mm
(3.937-3.937 inch
Radius 6 mm
(0.236 inch) 63 × 63 mm
100 × 100 mm
(2.480-2.480 inch)
(3.937-3.937 inch Depth 100 mm
(3.937 inch) Radius 6 mm
Radius 6 mm
(0.236 inch)
(0.236 inch)
Depth 40 mm
Depth 40 mm
(1.575 inch)
(1.575 inch)
110 × 63 mm
(4.331-2.480 inch)
Radius 6 mm
(0.236 inch)
Depth 40 mm 110 × 63 mm
(1.575 inch) (4.331-2.480 inch)
40 × 40 mm
Radius 6 mm (1.575-1.575 inch)
(0.236 inch)
Radius 6 mm
Depth 100 mm (0.236 inch)
(3.937 inch) 150 × 33 mm Depth 40 mm
(5.905-1.299 inch) (1.575 inch)
Radius 6 mm
(0.236 inch)
Depth 50 mm
(1.968 inch)
90
3. Milling
Thin walls (finishing)

Thin walls are divided into three groups of different height/thick-
ness ratio, with each requiring specific machining methods to
ensure success.
Thicker walls H:T <15:1

Thin walls H:T <30:1
Very thin walls H:T <30:1
Thin walls deflect under pressure so separate machining passes

are required to minimize friction and vibration.
91
3. Milling
1. Finishing thicker walls
H:T <15:1
Stability: relatively stable
• Machine each side of the wall in overlapping passes

• Leave clearance on the faces for finishing passes
92
3. Milling
2. Finishing thin walls
H:T <30:1
Stability: less stable and prone to deflection
• Choose step-support milling, with passes on alternate sides of

the wall
• Overlapping passes provide material support to add stability
• Finishing clearance on faces should be between 0.2 and 1 mm
(0.008-0.04 inch)
93
3. Milling
3. Finishing very thin walls
H:T >30:1
Stability: very unstable
• Machine passes on alternating sides of the wall

• Approach the wall thickness in stages
• The material support of thicker sections is crucial as thinner sec-
tions are being machined
• Move passes down the wall in a step formation moving outwards
94
3. Milling
Thin base
The base of a component is regarded as thin when the floor of the
pocket <1/30 of the pocket width, max 2.5 mm (0.098 inch).
When the base is unsupported, tools and machining strategy

should be carefully selected.
Example
Material Ti6Al4V
Blank 215 × 200 × 60
(8.465 × 7.874 × 2.362 inch)
Issue: unsupported base when machining second side
Side 1
Step 1: open up blank using indexable insert drill, dia 40 mm
(1.575 inch)
Step 2: rough mill (helical) with long-edge milling cutter, dia 32 mm
(1.26 inch)
Step 3: finish with end mill, where max ae = 30% of tool dia
Side 2
Step 4 & 5: repeat step 1, 2 (above) leaving extra 4 mm (0.157
inch) thickness to the base, to give added stability for subsequent
machining
Step 6: modify finishing operation to ae max 60%
Result
Increasing max-ae from 30% to 60% of cutter diameter reduces
surface quality but does not lead to additional vibration tendencies
or deflection.
95
3. Milling
Cutting data recommendations, Ti6A14V

CoroMill® 390
fz mm/tooth (inch/tooth) vc m/min (ft/min)
Insert Insert
geometry size Starting value min-max Grades Rec. min-max
GC1010 70 (229.7) 50-80 (164.0-262.5)
11 0.08 (0.003) 0.05-0.12 (0.002-0.005)
E-PL/ML S30T 60 (196.8) 40-70 (131.2-229.7)
17 0.08 (0.003) 0.05-0.15 (0.002-0.006)
Light S40T 50 (164.0) 30-60 (98.4-196.8)
18 0.10 (0.004) 0.05-0.19 (0.002-0.007)
GC2040 40 (131.2) 30-50 (98.4-164.0)
GC1010 70 (229.7) 50-80 (164.0-262.5)
11
M-PL/ML 0.10 (0.004) 0.05-0.15 (0.002- 0.006) S30T 60 (196.8) 40-70 (131.2-229.7)
17
Medium light 0.10 (0.004) 0.05-0.15 (0.002- 0.006) S40T 50 (164.0) 30-60 (98.4-196.8)
18
GC2040 40 (131.2) 30-50 (98.4-164.0)
GC1010 70 (229.7) 50-80 (164.0-262.5)
11 0.12 (0.005) 0.08-0.15 (0.003-0.006)
M-PM/MM S30T 60 (196.8) 40-70 (131.2-229.7)
17 0.15 (0.006) 0.08-0.20 (0.003-0.008)
Medium S40T 50 (164.0) 30-60 (98.4-196.8)
18 0.20 (0.008) 0.08-0.30 (0.003-0.012)
GC2040 40 (131.2) 30-50 (98.4-164.0)
CoroMill® 790
H-PL 12
0.15 (0.006) 0.03-0.20 (0.001-0.008) GC1010 200 (656.2) 150-250 (492.1-820.2)
Light 16
CoroMill® 690
S30T 60 (196.8) 40-70 (131.2-229.7)
E-SL
10 0.10 (0.004) 0.05-0.15 (0.002-0.006) S40T 50 (164.0) 30-60 (98.4-196.8)
Light
GC2040 40 (131.2) 30-50 (98.4-164.0)
S30T 60 (196.8) 40-70 (131.2-229.7)
E-SL
14 0.12 (0.005) 0.07-0.17 (0.003-0.007) S40T 50 (164.0) 30-60 (98.4-196.8)
Light
GC2040 40 (131.2) 30-50 (98.4-164.0)
CoroMill® 331
04 0.05 (0.164) 0.02-0.15 (0.066-0.492)
05 0.05 (0.164) 0.02-0.15 (0.066-0.492)
H-PL/ML S30T 60 (196.8) 40-70 (131.2-229.7)
08 0.06 (0.20) 0.03-0.15 (0.098-0.492)
Light GC2040 40 (131.2) 30-50 (98.4-164.0)
11 0.06 (0.20) 0.03-0.15 (0.098-0.492)
14 0.06 (0.20) 0.03-0.15 (0.098-0.492)
04 0.07 (0.230) 0.04-0.18 (0.131-0.591)
05 0.07 (0.230) 0.04-0.18 (0.131-0.591)
H-PM/MM S30T 50 (164.0) 30-60 (98.4-196.8)
08 0.09 (0.295) 0.05-0.20 (0.164-0.656)
Medium light GC2040 40 (131.2) 30-50 (98.4 -164.0)
11 0.09 (0.295) 0.05-0.20 (0.164-0.656)
14 0.09 (0.295) 0.05-0.20 (0.164-0.656)
CoroMill® 245
GC1010 60 (196.8) 40-70 (131.2-229.7)
E-PL
12 0.15 (0.006) 0.07-0.20 (0.003-0.008) S30T 50 (164.0) 30-60 (98.4-196.8)
Light
S40T 40 (131.2) 30-50 (98.4-164.0)
GC1010 60 (196.8) 40-70 (131.2-229.7)
M-PL
12 0.17 (0.007) 0.08-0.21 (0.003-0.008) S30T 50 (164.0) 30-60 (98.4-196.8)
Medium light
S40T 40 (131.2) 30-50 (98.4-164.0)
S30T 50 (164.0) 30-60 (98.4-196.8)
K-MM 12 0.23 (0.009) 0.10-0.28 (0.004-0.001)
S40T 40 (131.2) 25-50 (82.0-164.0)
M-MM 18 0.25 (0.010) 0.10-0.30 (0.004-0.012)
GC2040 40 (131.2) 25-50 (82.0-164.0)
CoroMill® 210 high feed
GC1010 60 (196.8) 40-70 (131.2-229.7)
E-PM/MM 09 0.8 (0.031) 0.5-1.2 (0.02-0.047) S30T 50 (164.0) 30-60 (98.4-196.8)
First choice 14 1.0 (0.04) 0.5-1.5 (0.02-0.059) S40T 40 (131.2) 30-50 (98.4-164.0)
GC2040 40 (131.2) 30-50 (98.4-164.0)
GC1010 60 (196.8) 40-70 (131.2-229.7)
09 0.8 (0.031) 0.5-1.2 (0.02-0.047) S30T 50 (164.0) 30-60 (98.4-196.8)
M-PM/MM
14 1.0 (0.04) 0.5-1.5 (0.02-0.059) S40T 40 (131.2) 30-50 (98.4-164.0)
GC2040 40 (131.2) 30-50 (98.4-164.0)
CoroMill® 210 for plunge

GC1010 60 (196.8) 40-70 (131.2-229.7)
E-PM/MM 09 0.15 (0.006) 0.1-0.2 (0.004-0.008) S30T 50 (164.0) 30-60 (98.4-196.8)
First choice 14 0.20 (0.008) 0.1-0.25 (0.004-0.01) S40T 40 (131.2) 30-50 (98.4-164.0)
GC2040 40 (131.2) 30-50 (98.4-164.0)
GC1010 60 (196.8) 40-70 (131.2-229.7)
09 0.15 (0.006) 0.1-0.2 (0.004-0.008) S30T 50 (164.0) 30-60 (98.4-196.8)
M-PM/MM
14 0.20 (0.008) 0.1-0.25 (0.004-0.01) S40T 40 (131.2) 30-50 (98.4-164.0)
GC2040 40 (131.2) 30-50 (98.4-164.0)
96
3. Milling
CoroMill® 300
fz mm/tooth (inch/tooth) vc m/min (ft/min)
Insert Insert
geometry size Starting value min-max Grades Rec. min-max
08 0.12 (0.005) 0.05-0.15 (0.002-0.006)
10 0.15 (0.006) 0.05-0.18 (0.002-0.007) GC1010 70 (229.7) 50-80 (164.0-262.5)
E-PL/ML 12 0.15 (0.006) 0.05-0.20 (0.002-0.008) S30T 60 (196.8) 40-70 (131.2-229.7)
Light 16 0.18 (0.007) 0.05-0.25 (0.002-0.01) S40T 50 (164.0) 30-60 (98.4-196.8)
20 0.2 (0.008) 0.05-0.25 (0.002-0.01) GC2040 40 (131.2) 30-50 (98.4-164.0)
25.4 0.23 (0.009) 0.05-0.28 (0.002-0.011)
08 0.13 (0.005) 0.05-0.21 (0.002-0.008)
GC1010 70 (229.7) 50-80 (164.0-262.5)
10 0.18 (0.007) 0.05-0.25 (0.002-0.01)
E-PM/MM S30T 60 (196.8) 40-70 (131.2-229.7)
12 0.18 (0.007) 0.05-0.25 (0.002-0.01)
Medium light S40T 50 (164.0) 30-60 (98.4-196.8)
16 0.2 (0.008) 0.05-0.30 (0.002-0.012)
GC2040 40 (131.2) 30-50 (98.4-164.0)
20 0.25 (0.01) 0.05-0.40 (0.002-0.016)
08 0.13 (0.006) 0.07-0.20 (0.003-0.008)
10 0.15 (0.006) 0.07-0.25 (0.003-0.01) GC1010 70 (229.7) 50-80 (164.0-262.5)
M-PM/MM 12 0.15 (0.006) 0.07-0.25 (0.003-0.01) S30T 60 (196.8) 40-70 (131.2-229.7)
Light 16 0.18 (0.007) 0.07-0.25 (0.003-0.01) S40T 50 (164.0) 30-60 (98.4-196.8)
20 0.2 (0.008) 0.07-0.30 (0.003-0.012) GC2040 40 (131.2) 30-50 (98.4-164.0)
25.4 0.23 (0.009) 0.07-0.33 (0.003-0.012)
08 0.15 (0.006) 0.07-0.25 (0.003-0.01)
10 0.2 (0.008) 0.07-0.30 (0.003-0.012) GC1010 70 (229.7) 50-80 (164.0-262.5)
M-PH/MH 12 0.2 (0.008) 0.07-0.30 (0.003-0.012) S30T 60 (196.8) 40-70 (131.2-229.7)
Medium light 16 0.25 (0.01) 0.07-0.40 (0.003-0.016) S40T 50 (164.0) 30-60 (98.4-196.8)
20 0.35 (0.014) 0.07-0.55 (0.003-0.022) GC2040 40 (131.2) 30-50 (98.4-164.0)
25.4 0.4 (0.016) 0.07-0.60 (0.003-0.022)
CoroMill® 200
10 0.12 (0.005) 0.07-0.17 (0.003-0.007)
S30T 60 (196.8) 40-70 (131.2-229.7)
PL/ML 12 0,12 (0.005) 0.07-0.17 (0.003-0.007)
S40T 50 (164.0) 30-60 (98.4-196.8)
Light 16 0.12 (0.005) 0.07-0.17 (0.003-0.007)
GC2040 40 (131.2) 30-50 (98.4-164.0)
20 0.12 (0.005) 0.07-0.17 (0.003-0.007)
10 0.17 (0.007) 0.10-0.28 (0.004-0.011)
S30T 60 (196.8) 40-70 (131.2-229.7)
PM/MM 12 0.17 (0.007) 0.10-0.28 (0.004-0.011)
S40T 50 (164.0) 30-60 (98.4-196.8)
Medium 16 0.17 (0.007) 0.10-0.28 (0.004-0.011)
GC2040 40 (131.2) 30-50 (98.4-164.0)
20 0.17 (0.007) 0.10-0.28 (0.004-0.011)
10 0.28 (0.011) 0.10-0.42 (0.004-0.017) S30T
PM/MM 12 0.28 (0.011) 0.10-0.42 (0.004-0.017) S40T 50 (164.0) 30-60 (98.4-196.8)
Heavy 16 0.28 (0.011) 0.10-0.42 (0.004-0.017) GC2040 40 (131.2) 30-50 (98.4164.0)
20 0.28 (0.011) 0.10-0.42 (0.004-0.017)
CoroMill® 316 (in stable conditions)
Cutting speed Large Small Feed Large Small
engagement engagement Profile engagement engagement Profile
ae ≤ 1.0 × Dc ae ≤ 0.3 × Dc ae ≤ 1.0 × Dc ae ≤ 0.3 × Dc
ae ≤ 0.005 × Dc ae ≤ 0.005 × Dc
ap ≤ 0.5 × Dc ap ≤ 0.5 × Dc ap ≤ 0.5 × Dc ap ≤ 0.5 × Dc
vc m/min vc m/min vc m/min Dc mm fz mm fz mm fz mm
ISO CMC HB (ft/min) (ft/min) (ft/min) (inch) (inch) (inch) (inch)
01.1 125 190 (625) 280 (920) 630 (2065 10 0.045 0.07 0.12
01.2 150 170 (560) 255 (835) 580 (1905) (0.375) (0.0018) (0.0028) (0.0047)
01.4 210 150 (490) 225 (740) 510 (1675)
12 0.055 0.085 0.14
P 02.1 175 165 (540) 245 (805) 555 (1820)
(0.500) (0.0022) (0.0033) (0.0055)
02.2 300 100 (330) 150 (490) 340 (1115)
03.11 200 170 (560) 250 (820) 570 (1870) 16 0.065 0.11 0.16
03.22 380 80 (260) 120 (395) 280 (920) (0.625) (0.0026) (0.0043) (0.0063)
05.11 200 70 (230) 110 (360) 240 (785) 20 0.08 0.13 0.18
M 05.21 200 55 (180) 85 (280) 190 (625) (0.750) (0.0031) (0.0051) (0.0071)
05.51 230 45 (150) 70 (230) 155 (510)
07.1 130 120 (395) 180 (590) 395 (1295)
08.1 180 130 (425) 190 (625) 420 (1380)
K 08.2 245 110 (360) 160 (525) 360 (1180)
09.2 250 105 (345) 155 (510) 350 (1150)
N 30.22 90 1000 (3280) 1100 (3610) 1300 (4265)
20.22 350 25 (80) 35 (115) 80 (260)
S 23.22 350 40 (130) 80 (260) 150 (490)
97
4. Drilling
4. Drilling
Many different tools and application methods are now available for
successful drilling in titanium and there are many possibilities for
achieving optimum performance and productivity.
However, as titanium is a challenging and expensive material to

drill, careful planning, testing and selection of application method is
required.
L/Dc
15 × Dc CoroDrill® Delta-C
CoroDrill® 805
10 × Dc
CoroDrill® 880 large
T-Max U Trepanner
Coromant Delta
5 × Dc
CoroDrill® 880
Dc mm
(inch)
0.3 10 20 30 40 50 60 70 80 90 100 110 120 130

(0.012)
(0.393) (0.787) (1.181) (1.575) (1.968) (2.362) (2.756) (3.149) (3.543) (3.937) (4.331) (4.724) (5.118)
98
4. Drilling
Drilling definitions
Drilling tools and applications are divided into two distinct areas.
Short hole drilling

The application area in holes up to 10 × drill diameter. No special
drill supports or equipment are required to machine the hole.
Deep hole drilling

The machining of holes with a relatively large depth-to-diameter
ratio, which may reach up to 150:1. The area is defined by holes
deeper than 10 × drill diameter and requires a special drilling
technique.
Basic drilling principles still apply in this area but satisfactory chip
breaking and evacuation without damage to tool/workpiece is
essential.
Typical component features

A successful machining outcome is dependent on an assessment
of the component design and the selection of an appropriate
strategy and consideration of the following typical features.
• Straight short (<10 × Dc) and deep (>10 × Dc) holes

• Bottom or through holes
• Step and chamfer holes
• Pockets and slots
99
4. Drilling
Main considerations
Coolant recommendations
• Always apply coolant to ensure a stable process
• Prefer internal coolant
• High pressure coolant (HPC) improves chip formation and
evacuation
• Emulsion EP additives, 9-12% oil is recommended
• Volume is more important than pressure, but pressure helps to
deliver the volume requirement
High pressure coolant (HPC)

• Always recommended for titanium drilling
• Use when chip formation is poor
• Use when chip jamming occurs
Machining example: chip formation

Tool CoroDrill 880
Dia 25 mm (0.984 inch) 5 × D
vc m/min (ft/min) 80 (262.5)
fn mm/rev (inch/rev) 0.12 (0.005)
10 bar pressure
Hole could not be completed without HPC at the given cutting data
Chip formation
Tool CoroDrill 846
Dia 8 mm (0.315 inch) 5 × D
vc m/min (ft/min) 45 (147.6 foot)
fn mm/rev (inch/rev) 0.14 (0.006)
65 bar pressure
HPC ensures better chip formation and is beneficial for titanium

drilling
100
4. Drilling
Entering non-flat surfaces

When entering an uneven, non-flat surface there is a risk of drill
deflection. This can be avoided by reducing feed on entry, using the
following guidelines (for indexable-insert drills)
• A Convex surface – no feed reduction necessary

• B Concave surface – reduce feed to 1/3 of recommendation
• C Inclined surface – reduce feed to 3/4-1/3 of recommendation
when entering angle is 2-89°
• D Curved surface – reduce feed to 1/9 (or 1/3 of recommenda-
tion for concave surface)
A B C D
Convex surface Concave surface Inclined surface Curved surface
101
4. Drilling
Stability
A good level of stability is important when drilling titanium, and
consideration should be given to:
• Machine and fixtures

• Fragile components
• Unsupported brackets
• Long tool overhangs
Effects of cutting data selection
Feed rate (fn)

• Controls chip formation
• Contributes to hole quality, primarily surface finish fn
• Increases feed = higher feed force
• Contributes to mechanical and thermal stress
Speed (vc)
Has the largest influence on tool life
Speed (too low):

• Built-up edge
• Poor chip breaking/evacuation
• Unproductive vc
Speed (too high):

• Rapid flank wear
• Poor hole quality
• Poor tolerances
• Peripheral wear
• Plastic deformation
102
4. Drilling
Chip control
Poor chip control damages the drill, resulting in poor hole quality
• When good chip control (completely helical chips) is not being

achieved, increase the feed rate.
• If increased feed does not work, or when CoroDrill® Delta-C is
being used, introduce an interrupted drill cycle which periodically
retracts the drill approximately 0.3 mm (0.012 inch) from the
hole bottom, before continuing.
Excellent chip form Acceptable chip form Chip jamming

CoroDrill Delta-C CoroDrill Delta-C CoroDrill Delta-C
103
4. Drilling
Programme overview
The choice of drill for best performance in titanium drilling is
influenced by safety, reliability and batch size.
Drills are separated into the following areas:

Solid carbide drills <20 mm (0.787 inch)
Indexable-insert drills 12.7-58 mm (0.449-2.283 inch)
Deep hole drills 15.6-183.9 mm (0.614-7.240 inch)
First choice recommendations

Short hole Short hole Short hole Deep hole
3 - 12 mm 12 - 63 mm 65 - 125 mm 25 - 65 mm
(0.118 - 0.472 inch) (0.0472 - 2.480 inch) (2.559 - 4.921 inch) (0.984 - 2.559 inch)
CoroDrill® Delta C 846 CoroDrill® 880 CoroDrill® 880 - large CoroDrill® 805
104
4. Drilling
Short hole drilling
CoroDrill® Delta-C (846)

• All round drill family for most materials
• Modern, coated solid carbide
• Recommended for titanium machining in
geometry 846 and grade GC1220
• Diameters ranging from 3 to 12 mm
(0.118 to 0.472 inch) with recommended
grade and geometry
Drilled depths:
Short option 2-3 × Dc
Long option 4-5 × Dc
Hole tolerance IT8-9-10
Surface finish Ra 1-2 µm
Coolant recommendations
• Internal coolant supply is recommended
• Coolant pressure at minimum 10 bars, preferably higher
• 65 bars has been successfully tested
Cutting data recommendations –titanium alloys

CoroDrill Delta-C 846 grade GC1220
Drill diameter Cutting speed vc Feed fn
mm (inch) m/min (ft/min) mm/rev (inch/rev)
3.00 - 6.00 20 - 60 0.06 - 0.12
(0.118 - 0.236) (65.6-196.8) (0.002 - 0.005)
6.01 - 10.00 20 - 60 0.08 - 0.20
(0.236 - 0.393) (65.6-196.8) (0.003 - 0.007)
10.01 - 12.00 20 - 60 0.14 - 0.28
(0.397 - 0.472) (65.6-196.8) (0.005 - 0.011)
105
4. Drilling
CoroDrill® 880
• Diameters: 12-63 mm
(0.472-2.480 inch)
• Lengths: 2, 3, 4 and 5 × diameter as
standard
• More lengths available on request
• Coromant Capto® coupling and cylindrical
shank
Titanium recommendations
Geometry
-LM
Grades, diameters 12.00-16.49 mm

GC1044 central insert grade
GC4044 peripheral insert grade
GC1044
Grades, diameters 16.50-63.00 mm
GC1044 central insert grade
H13A peripheral insert grade
If uncoated is a demand H13A GC4044

Use H13A on both inserts (size 02-09)
106
4. Drilling
CoroDrill® 880 applications
CoroDrill® 880 cutting data recommendations – titanium alloys

Geometry -LM Feed rate (fn)
ISO S Drill diameter Insert size Cutting speed Drill length Drill length Drill length
Titanium mm m/min 2-3 x Dc 4 x Dc 5 x Dc
(inch) (feet/min) mm (inch) mm (inch) mm (inch)
12.00 - 13.99 01 40 - 135 0.06 - 0.14 0,04 - 0.12 0.04 - 0.10
(0.472 - 0.550) (131 - 442) (0.002 - 0.005) (0.001 - 0.004) (0.001 - 0.003)
14.00 - 16.49 02 40 - 135 0.06 - 0.14 0.06 - 0.12 0.06 - 0.09
(0.551 - 0.649) (131 - 442) (0.002 - 0.005) (0.002 - 0.004) (0.002 - 0.003
GC4044
16.50 - 19.99 03 40 - 135 0.08 - 0.16 0.08 - 0.14 0.08 - 0.11
(0.649 - 0.787) (131 - 442) (0.003 - 0.006) (0.003 - 0.005) (0.003 - 0.004)
20.00 - 23.99 04 40 - 135 0.08 - 0.16 0.08 - 0.14 0.08 - 0.11
(0.787 - 0.944) (131 - 442) (0.003 - 0.006) (0.003 - 0.005) (0.003 - 0.004)
24.00 - 29.99 05 40 - 135 0.12 - 0.18 0.10 - 0.16 0.12 - 0.12
(0.944 - 1.180) (131 - 442) (0.004 - 0.007) (0.003 - 0.006) (0.004 - 0.004)
30.00 - 35.99 06 40 - 135 0.12 - 0.18 0.12 - 0.18 0.12 - 0.12
(1.181 - 1.416) (131 - 442) (0.004 - 0.007) (0.004 - 0.007) (0.004 - 0.004)
36.00 - 43.99 07 40 - 135 0.12 - 0.18 0.12 - 0.18 0.12 - 0.12
H13A
(1.417 - 1.731) (131 - 442) (0.004 - 0.007) (0.004 - 0.007) (0.004 - 0.004)
44.00 - 52.99 08 40 - 135 0.12 - 0.18 0.12 - 0.18 ---
(1.732 - 2.086) (131 - 442) (0.004 - 0.007) (0.004 - 0.007)
53.00 - 63.50 09 40 - 135 0.14 - 0.20 0.14 - 0.20 ---
(2.086 - 2.499) (131 - 442) (0.005 - 0.007) (0.005 - 0.007)
107
4. Drilling
CoroDrill® 880 larger drills

Cartridge solution
• Standard CoroDrill® 880 inserts
• Insert sizes 06-09
One central insert

• Geometry -LM and grade GC1044 for titanium
Three peripheral inserts

• Geometry -LM and grade H13A for titanium
Cutting data
(Cutting data is optimized in horizontal machine)
Recommended start values (dia 80 mm)

vc = 45 m/min (147.6 ft/min)
fn = 0.14 mm/rev (0.006 inch/rev)
Power
When drilling a Ø 80 mm (3.15 inch) hole in titanium at
vc = 45 m/min (147.6 ft/min),
fn = 0.14 mm/rev (0.006 inch/rev),
the approximate power consumption is 4.6 kW.
Torque
When drilling a diameter 80 mm (3.15 inch) hole in titanium at
vc = 45 m/min (147.6 ft/min),
fn = 0.14 mm/rev (0.006 inch/rev)
the approximate torque required is 240 Nm.
108
4. Drilling
CoroDrill® 805
• The indexable drill for deeper holes
• For productive and secure drilling of deeper holes, using
horizontal machines
Same inserts and support pads as CoroDrill® 800
First choice geometry and grade for titanium machining:

• GC1025 for inserts
• PM1 (or H13A as special) for support pads
Cutting data
• Use the same cutting speed as for CoroDrill® 800
• Feed should be reduced to 75% of recommendation for
CoroDrill 800, due to reduced room for chip evacuation
Coolant
• Emulsion with minimum 10% oil and EP additives
• Flow rate and pressure as for indexable short hole drills
at same diameter
Intermediate insert
Central insert
Support pads
Peripheral insert
109
4. Drilling
CoroDrill 805 – length/diameter ratio

Diameter range 25.00-65.00 mm
(0.984-2.559 inch)
Hole depth 13-7 × Dia
Hole tolerance IT 10
Surface finish Ra 2 µm
Length/diameter ratio
Length × Dc
14
12
10
0
Dc mm 25- 27- 30- 40- 52- 57- 64-
(inch) 26.99 29.99 39.99 51.99 56.99 63.99 65.00
CoroDrill® 805 cutting data recommendations

Inserts Drill diameter
Geometry/grade Support pads Cutting speed mm (inch)
P I C Grade m/min 25.00 - 43.00 43.01 - 65.00
(feet/min) (0.984 - 1.692) (1.693 - 2.559)
-G1025 -G1025 -G1025 PM1 30 - 60 0.07 - 0.23 0.15 - 0.25
(98 - 196) (0.003 - 0.009) (0.006 - 0.01)
P=peripheral, I=intermediate, C=central Feed mm/rev (inch/rev)
110
4. Drilling
Power requirement 8 400
Power kW
n (rpm)
Power requirement recommendations for 7 350
titanium (Ti-6AI-4V) are calculated for an un- 6 300
used tool. A tool with normal wear requires 5 250

10-30% more power, depending on drill 4 200
diameter. 3 150
2 100
Material: Ti-6AI-4V, 330HB 1
rpm
50
Cutting data: vc = 45 m/min (148 ft /min) Power requirement
0 0
fn = 0.14 mm/rev (0.006 inch/rev) 40 63 80
Drill diameter (mm)
100
Torque requirement
400 400
The approximate torque requirement for
Torque Nm
n (rpm)
350 350
titanium. 300 300
250 250
Material: Ti-6AI-4V, 330HB 200 200
Cutting data: vc = 45 m/min (147.6 ft/min) 150 150
fn = 0.14 mm/rev (0.006 inch/rev) 100 100
rpm
50 50
Torque requirement
0 0
40 63 80 100
Drill diameter (mm)
Cutting fluid flow requirement 350
Cutting fluid flow requirement for a given 300

Flow required - litres/min
coolant hole diameter (mm), with 2 coolant 250 1.5
holes. 2
200 2.5
3
150 3.5
4
4.5
100
5
5.5
50
6
0
10 20 30 40 50 60 70 80
Pressure bar
111
4. Drilling
Deep hole drilling

The Single Tube System (STS) T-MAX adjustable solid drill head is
the preferred deep hole drilling system for titanium machining.
It is the best choice for extremely deep bores and for materials with
poor chip forming qualities, such as titanium.
T-MAX adjustable solid drill head

• Good hole straightness in long workpieces
• Setting possibilities on the diameter
• High penetration rate
• Diameter range 65-130 mm (2.6-5.118 inch)
• Available with support pads for process security
CoroDrill® 800
The most productive choice for diameter range 25-65 mm
(0.984-2.6 inch). For holes up to 150 × Dc
• Unique support pad design

• Lowest cost per hole
• Consistent performance within a wide application area
• Available as standard
CoroDrill® 805
See short hole drills.
112
5. Boring
5. Boring
Boring is the method used to improve the quality and/or enlarge

an existing hole. Several flexible boring systems are available from
Sandvik Coromant in a wide diameter range for roughing, fine boring
and reaming.
There are two main types of boring:
Roughing
• Machining of an existing hole to prepare for a finishing operation,
where the focus is on metal removal.
• Hole tolerances equal to, or greater than IT9
Finishing
• Machining of an existing hole for close hole tolerance and quality
surface finish
• Small cutting depths <0.5 mm (0.020 inch)
• Hole tolerance IT6-IT8
The required hole quality affects the type of operation and the
choice of boring tool.
Roughing Finishing
113
5. Boring
Main considerations
Chip control
Chip control is always critical in boring applications and successful
evacuation from the hole without damage to the tool or surface is
essential
Tool holding
The reduction and elimination of vibration is essential in boring
applications. The tool must have high bending stiffness and torque
transmission and the following issues should be taken into con-
sideration:
• Use Coromant Capto® adaptors or Hydro-Grip® chucks for best

stability and hole quality
• Choose the shortest possible adaptor for the operation
• Use Silent Tools® dampened adaptors for long overhangs (>4×D)
• Use a tapered adaptor (if possible) to increase static stiffness
and reduce tool deflection
• For long overhangs, ensure rigid tool clamping with flange contact
to spindle
Assembly
Boring tools often need to be assembled from several items to suit
an application
• Slides/cartridges
• Boring adaptors
• Reductions/extensions
• Basic holders
Cutting data
• Chip evacuation and tool vibration influence the selection of cut-
ting data.
• Follow the insert- and grade-recommendations for general turning
• Reduce cutting speed when machining long overhangs
114
5. Boring
Programme overview
CoroBore® 825
• Basic option for finishing
• High precision surfaces
• Always first choice for fine boring
• Slide diameter for increased diameter range and back
boring
• Precision adjustment for close tolerances
Diameter range: 19-315 mm (0.748-12.402 inch)

Diameter range (dampened): 19-315 mm (0.748-12.402 inch)
Hole depth: to 4 × D
Hole depth (dampened): to 6 × D5m
Diameter adjustment 0.002 mm
Maximum adjustment 15 mm (0.591 inch)
Typical applications
Medium- to large diameter precision holes 19-981.6 mm
(0.748-38.646 inch) with high quality surface when used as a con-
ventional tool and with CoroBore® XL
• Conventional boring, back boring
• Deeper holes and long overhangs
• External machining
• Adjust from small- to large diameter to avoid backlash
115
5. Boring
CoroBore® 826
• Fits CoroBore® 825 adaptors for diameter range 150-300 mm
(5.905-11.811 inch)
• User-friendly adjustment capability for fine hole tolerances
• Each diameter increment adjustment felt with a click
• Each increment adjusts diameter by 0.002 mm
• High quality surface and productivity with CoroTurn® 107 wiper
inserts
• Maximum adjustment: 1 mm (0.039 inch)
• Adjust from small- to large diameter to avoid backlash
CoroBore® 820
• The first choice for rough boring
• Insert slides can be adjusted to cover many diameters with one
tool
• Productive multi-edge boring
Diameter range: 35-306 mm (1.378-12.047 inch)

Boring depth: to 4 × D
Hole tolerance: to IT9
• Medium- to large diameter holes
• Maximum productivity
• Triple-edge step-/single-edge boring
• Medium- to high power machine tools
116
5. Boring
Reamer™ 830
• The high feed, multi-edge reaming tool
• Complement to CoroDrill® 880 for high precision holes at high
feeds
• Exchangeable heads with high precision front clamping
• Coolant to each cutting edge for effective chip evacuation
• Through holes with high quality surface finish 10-31.75 mm
(0.394-1.25 inch)
• Long-series production
• High feeds
Hole depth: 45-106 mm (1.772-4.173 inch)
117
5. Boring
CoroBore® XL
CoroBore XL is a complete solution of fine and rough boring tools
for larger hole diameters, with new bridges and holders for added
security:
• Rigid and reliable performance in larger bores

• User friendly tool assembly
• New axially-adjustable roughing cartridges
Assortment
CoroBore® 825 XL
• Fine boring for diameter range
298-1275 mm (11.73-50.20 inch)
CoroBore® 826 XL
• Fine boring for diameter range
298-1260 mm (11.73-49.61 inch)
CoroBore® 820 XL
• Rough boring for diameter range
298-780 mm (11.73-30.71 inch)
• Semi-finishing for diameter range
298-1260 mm (11.73-49.61 inch)
Maximum cutting speed starting values

• Rough boring: 200 m/min (656.2 ft /min)
• Finish boring: 240 m/min (787.4 ft /min)
Maximum depth of cut:

• 0.5 mm (0.020 inch)
In a finishing operation, note the position of the cartridge/head to

avoid damaging the workpiece when retracting the tool.
118
6. Tooling system considerations

Modular versus solid
Coromant Capto modular system can be used with all machine
interfaces (CAT, BT, ISO, HSK, Big Plus) to build assemblies. In this
respect it is possible to have a common tooling platform regardless
of the machine interfaces utilized. This supports the opportunity to
select the right interface for the machine and be able to keep to a
common platform.
Many machines have coolant pressures of 70-100 bar as standard.

This is sufficient to incorporate high pressure coolant (HPC) which
makes a noticeable difference to performance and is a prerequisite
for titanium machining.
Modular tooling is essential for HPC machining, to ensure quick

tool changes, minimize machine stoppages and to secure coolant
connection and supply from machine to cutting edge.
120
For larger spindle sizes (#50 and HSK100) longer gauge lengths
are often required and this is to the benefit of cost effective modu-
lar system.
For smaller spindle sizes (#40 and HSK63) it is often best to keep
the gauge length as short as possible and solid tool holding is
beneficial.
It is good to look at each assembly individually and mix and match

solid and modular depending upon the length requirement. Being
able to combine standard items to build up an almost unlimited
number of assemblies provides great flexibility to production.
When using integrated milling tools it is best to use ‘oversize cut-
ters’ to provide optimum clearance and stability.
Coupling Milling
size cutter dia
C3 32 35
C4 40 44
C5 50 54
C6 63 66
C8 80 84
121
Round tool holding

Aerospace titanium components utilize a high amount of solid
carbide round tools due to the small corner radii and complex com-
ponent details.
High speed machining is used for semi-finishing and finishing with

high axial cutting depth (2 × Dc) and low radial depth (5% Dc).
Running at the optimum cutting speeds is dependent upon a con-

trolled chip thickness.
Run out is critical for optimizing metal cutting efficiency. Hydraulic

or shrink fit should be used for best clamping and run out charac-
teristics.
Weldon or ER might be cheaper alternatives however they will

reduce production efficiency.
2 remaining challenges for tool holding for solid carbide specific to

titanium and aerospace machining are:
Accessibility
Complex component geometry ensures that 5-axis machining is
widely used. Typical component features requiring good accessibil-
ity are frame/structural parts with small corner radii and deep walls
and engine blisk and impellors
The combination of the small cutter radius, long gauge length and
accessibility means that the optimum shape is a 5 degree conical.
The ‘Coromant Capto conical modular’ range of shrink fit and
exchangeable head EH coupling provides a dedicated alternative to
conical solid carbide end mills.
The benefits are significantly lower cutter costs as well as being

able to use standard rather than special cutters.
122
Tool pull out – Plura with iLock shrink fit

Axial forces created when machining titanium materials with a solid
carbide end mill can be very high. This is due to the high helix angle
required combined with high axial depth of cut and radial engage-
ment. In some situations the tool can pull out from the chuck even
though the chucks have an extremely high clamping force.
Tool pull out is catastrophic for expensive aero-

space components. Process security is essential
which can affect metal cutting efficiency compared
to the potential.
Weldon chucks are often used to prevent pull out

but with poor run out which again limits efficiency
and tool costs.
The iLock system

iLock provides security against pull out with high precision, allow-
ing for optimized metal cutting efficiency for heavy duty cutting. It
prevents the tool from being pulled out of the holder in extreme
machining conditions.
Higher axial depths of cut can be used whilst maintaining the same
time in cut. The production time required reduces which increases-
production efficiency and also reduces tool usage by two to three
times.
123
7. Component solutions
Aerospace landing gear – main fitting

A common landing gear component increasingly produced in
titanium alloys, such as Ti-5553.
Main challenges:
• Deep hole machining
• Profile milling
• Internal turning
Deep hole machining

• T-MAX 424.10
• Close diameter tolerance
• High surface finish
• Dia: 65-130 mm (2.560-5.118 inch)
124
Profile milling
• CoroMill® 216
• Contouring, copy milling
• Max depth: 44 mm (1.732 inch)
• Available with grade S30T, optimized for
titanium
Internal turning
• Silent Tools® boring bars
• Dia: up to 250 mm
(9.842 inch)
• Length: up to 14 × D
125
Aerospace wing – pylon bracket

A component found in the wing of modern aircraft, which can be of
open or closed design.
Main challenges
• Roughing 3D pocket
• Finishing 3D pocket
• Deep slotting
Slotting
• Side and face cutters provide best
stability
• CoroMill® 331: adjustable cartridges with
grades S30T and S40T for titanium.
126
Roughing 3D pocket: closed angle

• Slicing method: CoroMill® Plura bull nose end mill
• Plunging method: CoroMill® 390
Finishing 3D pocket: closed angle

• Conical bull nose end mill: high
quality surface
127
Aerospace engine - impellor

The impellor is found in the APU. The machining of the turbo foils is
a similar process for both impellor and blisk.
Operation
A
Point milling – roughing slot
M
• Generates a 3D-profile with successive
levels of passes
• Tool contacts the material at a point on
the corner radius of the tool
• Contact point varies depending on the
desired surface
Tool selection
CoroMill® 316
• Axial depth of cut limited to half diameter
of tool
• Bull nose exchangeable insert offers
balance of productivity and economy
128
R K Operation
A
Flank milling – finishing blade profile
• Higher axial depth of cut produces profile
in fewer passes
• Only flank and corner radius used to pro-
duce fillet radius
Tool selection
Conical ball nose end mill
• This method with high axial depth is the
fastest method where component, CAM
software and tool allow
• Tool is designed specifically for this op-
eration, offering stability and reach
129
8. Formulas and definitions

Turning, METRIC
Cutting speed, m/min
π × Dm × n
vc =
1000
Spindle speed, r/min

vc × 1000
n=
π × Dm
Designation/
defination
Machining time, min

Symbol
Unit
lm
Tc =
fn × n
Dm Machined diameter mm
fn Feed per revolution mm/r
ap Cutting depth mm
vc Cutting speed m/min
Metal removal rate, cm3/min
n Spindle speed rpm
Q = vc × ap × fn Pc Net power kW
Q Metal removal rate cm3/min
hm Average chip thickness mm
hex Maximum chip thickness mm
Tc Period of engagement min
Net power, kW
lm Machined length mm
v × ap × fn × kc N/mm2
Pc = c kc Specific cutting force
60 × 103 kr Entering angle degree
130
Turning - INCH
Cutting speed, ft/min
π × Dm × n
vc =
12
Spindle speed, rpm

vc × 12
n=
π × Dm
Designation/
Machining time, min

definition
Symbol
Unit
lm
Tc =
fn × n
Dm Machined diameter inch
fn Feed per revolution inch/r
ap Cutting depth inch
vc Cutting speed ft/min
Metal removal rate, inch3/min
n Spindle speed rpm
Q = vc × ap × fn × 12 Pc Net power HP
Q Metal removal rate inch3/min
hm Average chip thickness inch
hex Maximum chip thickness inch
Tc Period of engagement min
Net power, HP
lm Machined length mm
v × ap × fn × kc
Pc = c kc Specific cutting force N/inch2
33 × 103 ψr Lead angle degree
131
Milling - METRIC
Table feed, mm/min
vf = fz × n × zc

π × Dcap × n
vc =
1000
Spindle speed, r/min

vc × 1000 Designation/
n= definition
π × Dcap
Symbol
Unit
Feed per tooth, mm
ae Working engagement mm
vf
fz = ap Cutting depth mm
n × zc
Dcap C
utting diameter at cutting
depth ap mm
Feed per revolution, mm/rev Dm Machined diameter

(component diameter) mm
v
fn = f fz Feed per tooth mm
n
n Spindle speed rpm
Metal removal rate, cm3/min vc Cutting speed m/min
ap × ae × vf vf Table feed mm/min
Q=
1000 zc Number of effective teeth pcs
hex Maximum chip thickness mm
Net power, kW hm Average chip thickness mm
ae × ap × vf × kc kc Specific cutting force N/mm2

Pc = Pc Net power kW
60 × 106
Mc Torque Nm
Torque, Nm Q Metal removal rate cm3/min
Pc × 30 × 103 kr Entering angle degree

Mc =
π×n
132
Milling - INCH
Table feed, inch/min
vf = fz × n × zc

π × Dcap × n
vc =
12
Spindle speed, rpm
Designation/
vc × 12
n=
definition
π × Dcap
Symbol
Unit
Feed per tooth, mm
ae Working engagement inch
vf
fz = ap Cutting depth inch
n × zc
Dcap C
utting diameter at cutting
depth ap inch
Feed per revolution, inch/rev Dm Machined diameter

(component diameter) inch
v
fn = f fz Feed per tooth inch
n
fn Feed per revolution inch
n Spindle speed rpm
Metal removal rate, inch3/min vc Cutting speed ft/min
vf Table feed inch/min
Q = ap × ae × vf
zc Number of effective teeth pcs
hex Maximum chip thickness inch
Net power, HP hm Average chip thickness inch
ae × ap × vf × kc kc Specific cutting force N/ inch2

Pc = Pc Net power HP
396 × 103
Mc Torque lbf ft
Torque, lbf ft Q Metal removal rate inch3/min
Pc × 16501 ψr Lead angle degree

Mc =
π×n
133
Drilling - METRIC
Penetration rate, mm/min
vf = fn × n

π × Dc × n
vc =
1000
Designation/
Spindle speed, r/min definition
Symbol
vc × 1000
Unit
n=
π × Dc
Dc Drill diameter mm
Feed force, N
n Spindle speed rpm
D
Ff ≈ 0.5×kc × c fn × sin kr vc Cutting speed m/min
2
vf Penetration rate mm/min
Ff Feed force N
Metal removal rate, cm3/min kc Specific cutting force N/mm2

Mc Torque Nm
v × Dc × fn
Q= c Pc Net power kW
4
Q Metal removal rate cm3/min
kr Entering angle degree
Net power, kW
vc × Dc × fn × kc
Pc =
240 × 103
Torque, Nm
Pc × 30 × 103
Mc =
π×n
134
Drilling - INCH
Penetration rate, inch/min
vf = fn × n

π × Dc × n
vc =
12
Designation/
Spindle speed, rpm
definition
Symbol
vc × 12
Unit
n=
π × Dc
Dc Drill diameter inch
fn Feed per revolution inch/r
Feed force, N
n Spindle speed rpm
D
Ff ≈ 0.5×kc × c fn × sin kr vc Cutting speed ft/min
2
vf Penetration rate inch/min
Ff Feed force N
Metal removal rate, inch3/min kc Specific cutting force lbs/inch2

Mc Torque lbf ft
Q = vc × Dc × fn × 3 Pc Net power HP
Q Metal removal rate inch3/min
ψr Lead angle degree
Net power, HP
vc × Dc × fn × kc
Pc =
132 × 103
Torque, lbf ft
Pc × 16501
Mc =
π×n
135
136
Head office:
AB Sandvik Coromant
SE-811 81 Sandviken, Sweden
www.sandvik.coromant.com
E-mail: info.coromant@sandvik.com
C-2920:35-ENG/01 Printed on recycleable paper.

Printed in Sweden, AB Sandvikens Tryckeri. © AB Sandvik Coromant 2011.12

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APPLICATION GUIDE

2 Turning 17 5 Boring 113

It provides information about which techniques to apply and how to

However, by combining a well-planned process with dedicated

Titanium alloys cross reference

Composition (approx %) Tensile Specific

Machinability comparison of different titanium types

Alpha alloys – additions of Al, O and/or N preferentially stabilise the

Beta alloys – additions of Mb, Fe, V Cr and/or Mn stabilise the β

Mixed α+β alloys, in which a mixture of both classes is present.

These chemical additions have a direct influence on the physical

Small part machining

A basic analysis should look like this:

Program CAM and

Aerospace structural parts generally do not require turning but

• 5-axis machining centres with rotating table for turning

Multi-functional machines will greatly improve machine utilization.

Coromant Capto® can be used without compromising milling,

5-axis machines can be grouped into 3 categories.

Optimized programming (reduced radial engagement) prevents such

If large diameter side and face tools are to be used, a geared

It has to be quick to change and rigid to transmit the power and

The requirements need to be considered for each application. For

Clamping force comparison

Sources: HSK Handbook, copyright 1999.

Factors providing good bending stiffness resistance are:

The cross sectional area (CSA) of the male coupling is another

Bending Stability Bending Stability

Sources: © WZL/Fraunhofer IPT

Static spindle – multifunctional

This is an important consideration especially for multi-functional

The fundamental difference between Coromant Capto® and other

Torque Stability Torque Stability

5 Torsional moment 5 Torsional

For turning centers without ATC, manual quick change tooling

Cutting data Qualities required from

Effect of entering angle

Heat can be controlled by a balance of speed, chip thickness and

Effect of entering angle on tool wear mechanism

95º 75º 45º 45º Round

First stage machining (FSM)

FSM of titanium is a simple process involving heavy roughing.

• Forged titanium components with uneven skin

Intermediate stage machining (ISM)

At this stage, the titanium is in the final solution treated-condition.

• Profiling at varying depths of cut

Last stage machining (LSM)

LSM represents the least amount of material removal from the

• The critical production stage

Intermediate stage machining (ISM)

• Reduced tool wear

To reduce cutting edge engagement and vibration, maximum depth

• Roll into cut at reduced feed on entry

50% fn max 50% fn max

Programmed radius = insert diameter

Last stage machining (LSM)

For thin wall components, to reduce radial forces:

For rigid components, giving best productivity:

Optimized insert geometries

Inserts: Double-sided, T-Max® P

-SMR for secure and reliable production

Features and benefits

-SM for secure production in long continuous cuts