Workpiece Materials Web PDF

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

Workpiece material
2
Carbon steel -
Free cutting steel
Carbon steel
Alloy
Machinability
steel Austenitic
SS
Titanium
Alloys Nickel based
alloys
Cobalt based
alloys Special
high temp
alloys
General construction steel
Chemical, petrochemical, medical, gas

and paper industry
Energy production, aviation and space travel
COPYRIGHT © 2008, Seco Tools AB 2/82

Workpiece material
3
Chemical
composition Thermal
conductivity
Mechanical
properties Inclusions
Non-alloy steel and cast steel

Low-alloy steel and cast steel
P
High-alloy steeland cast steel
SS and cast steel (fer/mar)
Workpiece Self-hardening
M
origination
Stainless steel (austenitic)
Grey cast iron

K Ductile cast iron Material
Nodular cast iron (ferritic/perlitic) structure
Non-ferrous metals
N
Aluminium and aluminium alloys
Super alloys
S
Titanium and titanium based alloys
Hard cast iron

H
Hardened steel

Machinability
4
Environment
Cutting forces
Surface integrity 3120
3100
800 800
3080
600
400
600
Fy
400
3060
200 200
0 0 3040
-200
-400
-200
-400
3020 Fx
-600
-800
-600
-800
3000 Fz
0 50 100 150 200 250 2980
0 2 4 6 8 10
Tool wear
Chip formation
f
vc

Machinability
5
Machining method
Cutting material Cutting geometry
Cutting conditions
vc f
Workpiece material
Chemical Thermal
composition conductivity
Toolholders
Mechanical
properties Inclusions
Machinability
Workpiece Work
raw material hardening
Material
structure
Human factor
Machine
Clamping Cooling

Machinability
6
Material to be machined The process

steel – SS – GCI – etc. roughing - 1/2 rough - finishing
Cutting speed Cutting depth Feed

Vc ap f
Carbide grade Geometry
The correct insert

The cutting process
7

The cutting process
8
Cutting forces
The cutting force can be divided
into:
Axial force component
Radial force component
Tangential force component
Radial force
The tangential force determines Axial force
the cutting force.
The combination of tangential and

radial force is the main cause of Tangential force
any vibration and workpiece
deformation.

The cutting process
9
Hard materials
Fc = Kc11 * b * h 1-mc
Superalloys
Kc11 = specific cutting force
b = chip width
Non-ferrous materials h = chip thickness
Cast iron
Stainless steel
Steel
0 1 000 2 000 3 000 4 000 5 000 6 000 7 000

(Typical example )
kc11 (N/mm²)

Workpiece materials
10
Materials with high ductility
DO Low carbon steel and aluminium,

Group 16.
LO
Soft
D1 Continuous chips, difficult to
machine.
L1
Decrease ductility to increase
machinability.
Materials with low ductility
DO Gray cast iron, Gr.12.

LO
Hard
Discontinuous chips.
Increase ductility to increase
machinability.

Workpiece materials
11
High hardness materials
Tool steel, Group 6

Hardened Steel, Group 7
Superalloys, Group 21
Cast iron, Group 15
Low hardness materials
Aluminum, Group 16
Low carbon steel, Group 1
diameter
Materials that work harden (proportional to penetration)
Stainless steel, Groups 8, 9, 10 & 11

Superalloys, Groups 20, 21

Workpiece materials
“Difficult”
Large cutting forces (Tensile strength)
to machine
Ha
rd
en
ed
Ni a
lloy
st
sup
ee
era
l
lloy
Ti a H
lloy igh
al l
oy
Ca
ste
el
st
Sta
inle
ir o
Duc ss s
n
tile tee
iron l Una
lloy
Cast ed s
alu al teel
loy Alumin
ium
“Easy”
to machine
Long chips (Ductility (%))

The cutting process
13
Temperature
• Heat conductivity of tool material

and workpiece material.
• Cutting speed.
• Geometry of cutting edge.
This temperature (gradient)

Largely determines the wear
factor and tool life.

Thermal conductivity
14
Materials with high thermal conductivity
• Copper, Group 18
• Aluminium, Group 16
• Low carbon steel, Group 1
Materials with low thermal conductivity
• Titanium, Group 22
• Superalloys, Groups 20, 21

Surface integrity
15
Surface integrity is the general term used to describe the properties and
the condition of a machined workpiece with regard to the surface and sub-
surface.
800 800
Residual tension MPa
600 600
400 Tension 400
200 200
0 0
-200 -200
Compression
-400 -400
-600 -600
-800 -800
0 50 100 150 200 250
Depth under the surface (µm)
(Typical example )
- Surface finish: Rt,Ra…

- Residual tension: Pressure or tensile forces
- Self-hardening: Retention of austenite/hard martensite
- Heat affected zone (HAZ): Lower hardness

Surface integrity
16
Workpiece material
Tool
Self-
hardening
Work-
piece
material
Tool
Self-
hardening

Surface integrity
17

Surface stresses
18
Tension Compression
Crack Crack
Influencing factors are the cutting speed, cutting edge wear, cutting
edge angle and cutting method (radial turning or classical), the cutting
depth, the feed and the nose radius.
Great influence on fatigue properties

Surface stresses
19
(Typical example )
Depth from surface

Machinability rating
20
Material Machinability Rating

9S20 cold rolled steel 100
Ductile cast iron 35
Stainless steel 440 50
Aluminium 2024-T 150
9S20 is assigned a rating of 100

and other materials are compared to this standard.

21
Non-alloy steeland cast steel. < 600 N/mm2

Low-alloy steel and cast steel < 900 N/mm2
P
High-alloy steeland cast steel > 900 N/mm2
Stainless steel and cast steel (fer/mar) < 750 N/mm2
M Stainless steel (austenitic) > 750 N/mm2
Grey cast iron

K Ductile cast iron
Nodular cast iron (ferritic/perlitic)
Non-Ferrous metals
N
Aluminium and aluminium based alloys
Superalloys
S
Titanium and titanium based alloys
Hard cast iron > 60 Shore

H
Hardened steel > 45 HRC

22
Aluminium & alloys
Grey cast iron
Steel
Stainless steel
Machinability
Super alloys
and titanium

23
Workpiece materials
– applications – cutting materials
Change in
properties
Class Sub- Material to be machined Application Cuttting Cutting
colour groups conditions material
Steel, steel castings Finish turning and boring; high cutting speeds, small chip section,
P01 accuracy of dimensions and fine finish vibration-free operation.
Steel, steel castings Turning, copying, threading and milling, high cutting
P10 speeds, small or medium chip sections.
Increasing cutting speed

Steel, steel castings
Resistance to wear
Turning, copying, milling, medium cutting
Increasing feed
P20 Malleable cast iron with long
P speeds and chip sections
Toughness
chips
Steel Steel, steel castings Turning, milling, planing, medium or low cutting speeds, medium
P30 Malleable cast iron with long or large chip sections, and machining in unfavorable conditions.
chips
Steel, steel castings with sand Turning, planing, slotting, low cutting speeds, large chip section
P40 inclusion and cavities with the possibility of large cutting angles for machining in
unfavorable conditions.
Steel, steel castings of medium For operations demanding very tough carbide; turning, planing,
P50 or low tensile strength, with slotting, low cutting speeds, large chip sections with the possibility
sand inclusion and cavities of large cutting angles for machining in unfavorable conditions.
Areas of application for the various cutting materials

1. Influence on cutting conditions.
2. Influence on properties of cutting materials.

24
(Typical example )
MN 2006 Turning page 31

25
Group Number Family Name

1 to 6 Mild and alloy steels
7 Hardened Steel
8 to 11 Stainless steels
11 to 15 Cast irons
16 to 19 Non-ferrous alloys
20 to 21 Superalloys /High temperature alloys
22 Titanium alloys
Rule of thumb: Within a family of workpiece material groups, machining difficulty increases as the group
number increases.

26
Mild and Alloy Steels
Groups 1 through 7
0.028 to 2.0% carbon
Small amounts of other
metals
Nickel
Chromium
Manganese

27
Group 1: Mild and Alloy Steels
Properties Carbon content < 0.28%

Tough, cheap, and impact resistant
Easily worked
Soft and gummy
Machining 50 to 100% machinability rating

Stringy, continuous chips
Watch for BUE
Easy to machine at high cutting speeds
High speed: MTCVD (AL2O3)
Med. speed: CVD (TiC, TiN)
Low speed: PVD (TiCN)
Uses Hub caps, stampings, wheels

28
Group 3: Ordinary Carbon Steels
Properties Carbon content: 0.28 to 0.50%

Harder and stronger
Tough, cheap, and impact resistant
Easily worked, soft and gummy

Machining 45 to 65% machinability rating
Stringy, continuous chips
Watch for BUE
Moderately difficult to machine
Med. speed: CVD (TiC, TiN)
Uses • I-beams, auto frames, axle housings

29
Group 6: Tool Steels

Properties Carbon content: 0.50 to 2.0%
Small amounts of nickel, molybdenum, chromium, and/or
vanadium.
Very high hardness.
Tougher and stronger.
Machining 35 to 65% machinability rating.

Difficult to machine.
Watch insert flank wear.
Reduce cutting speed.
Medium speed: CVD (TiC, TiN)
If RC > 45, use CBN
Uses • Tool steel, springs, bearings, dies, punches

30
Stainless Steels
Groups 8 through 11.
At least 10.5% chromium.
Less than 1.2% carbon.
Properties which increase from
Group 8 to 9 to 10 to 11.
Corrosion resistance.
Hardness.
Temperature resistance.

31
Stainless Steels
Alloyed steel with maximum 1.2% carbon

and at least 10.5% chromium.
Cr2O3
Chromium Oxygen

Stainless Steels
32
Stainless steel structures
Ferritic Martensitic Austenitic Duplex
The microstructure and alloy elements are the determining factors.

They determine properties such as heat resistance,
corrosion resistance, oxidation resistance.
And also the machinability!!
Ferritic stainess steel (400 series, e.g. 405, 430, 442)
(low carbon steel + Cr).
Martensitic stainless steel (400 series, e.g. 403, 416, 422)
(ferritic stainless steel + C).
Precipitation hardened stainless steel (PH-steel, e.g. 15-5PH, 17-4PH, PH13-8Mo))
(martensitic stainless steel + Cu, Al, Nb).
Austenitic stainless steel (300 series, e.g. 301, 304, 316)
(ferritic stainless steel + Ni).
Duplex stainless steel (200 series)
(austenitic stainless steel - Ni + Mn, N).
Stainless Steels
33
Influence of material structure
120
100
80
Machinability (%)
60
40
20
0
Ferritic SS Martensitic SS Austensitic SS Duplex SS PH SS
(Typical example )

Stainless Steels
34
Mo Cr N Ni C Ti Mn S Ca Pb
☺ ☺
Machinability
☺ ☺
☺ ☺
Carbon
Nickel
Nitrogen
Molybdenum
Chromium
Manganese
Titanium
Lead
Sulphur/phosphor
Calcium
– Build up edge problems.
– Hard, very homogenous surfaces (scales).
– Poor surface finish.
– Burring.
– Poor chip formation and difficult chip removal.
35
Stainless Steels
The PRE factor is a criterion for the corrosion resistance
The resistance of the stainless steel to pitting is indicated by the PRE factor
(Pitting Resistance Equivalent).
PRE factor = % Cr + 3.3 x % Mo + 30 x % N

PRE factor = % Cr + % Ni (when no Mo or N)
The PRE factor determines heavily the machinability

Stainless Steels
36
Martensitic
Martensitic - austenitic
Duplex
Cutting speed V30 (m/min)
Austenitic
Reference cutting speed

- 30 minutes tool life
- b/h = 10
- flat insert
- untreated cutting edge
- uncoated P20
(Typical example ) PRE value

Stainless Steels
37
Low thermal conductivity
The heat which needs to be

removed in the chip and the
workpiece is concentrated in
the insert in stainless steel.
(plastic deformation)

Stainless Steels
38
Self-hardening (surface hardening)
If the tension in the stainless

steel exceeds the elongation
limit, stainless steel will
show self-hardening.
Hardness
This is the case

in the shearing zone.
This is made worse through

formation of Cr2O3 (quickly
and always).
(Typical example )
Distance from the surface

Cutting speed zones
39
Technically optimum Total Friction

Wear
Diffusion
Oxidation
Cutting Build up edge
Temperature / cutting speed

Cutting speed zones
40
Cutting build up edge

Tendance for build up edge
1 2 3
± 60 m/min ± 100 m/min Cutting speed

Cutting speed zones
41
Cutting speed zone 1
Low productivity zone 40 - 60 (m/min)
• Use TiN or TiCN – coated (PVD) tough inserts or uncoated tough

inserts (P25-P40, K20).
• Use cooling to keep the temperature down.
• Use small chip sections (sharp inserts).
• High tool life is possible.
• Long finishing times – Low productivity and high costs.
• Reliability questionable.

Cutting speed zones
42
Build up edge wear zone 60 - 100 (m/min)
Chip
Burs on chip
Burs on workpiece
Build up edge
Great build up edge in this area.

Avoid cutting speed zone 2.

Cutting speed zones
43
Roughing – High productivity zone 100 - 300 (m/min)
• Use tough coated inserts (P25C) or wear resistant uncoated inserts

(P15) or cermet.
• Use inserts with big positive rake (approx. 200).
• Aim for large chip sections (f > 0.15 (mm/t), ap > 1 (mm)).
• Do not use cooling except if there could be problems with chip removal.

Cutting speed zones
44
Finishing – High productivity zone 120 - 350 [m/min]
• Cutting speeds approx. 25% higher than in roughing.
• Use cermet, P15 (uncoated), PVD coated micrograin grades.
• Feed f = 0.05 - 0.15 (mm/t) and ap > 0.5 (mm).
• If f < 0.05 (mm/t) en ap < 0.5 (mm) use uncoated K20.
• Use abundant coolant to keep the temperature low.
• In contour milling with small radial cutting depths, apply a cutting depth
factor and do not use coolant.

Stainless Steels
45
Machining in stainless steel requires five times as many cutting

edges as the same process in classical steel.
Be careful with other problems such as interrupted cuts and casting

scales.
Also pay attention to:

– Austenitic structure
number of workpieces
Threading (following)
– Duplex structure
– Nitrogen reinforced structure
– Precipitation hardened SS
– Pre-processing
Avoid false economies

Turning (previous)
Insert wear

Stainless steel turning
46
Chip formation
Burring
Sticky chipping
Build up edge (wear)

47
Chip formation
AISI 304 Ck 45
AISI 304 Ca
48
Machine
Select maximum stability and capacity.
Avoid worn machines for accurate work.

49
Toolholder
Select the largest possible shank

section.
Select a strong insert clamping system.
Minimize the projection length.

Select sound seating.

50
Working method
Select varying cutting depths for Roughing with entering angle of

heavy and lengthy roughing 75° or 45°.
processes. Then finish with 90°.

51
Working method
For heavy roughing, use variable cutting depths.

52
Rough workpiece
First chamfer if possible. In

burnished pieces, always
begin by removing
burnished residue.
53
Inserts
Select strong inserts with sharp

geometries (entering angle).
Select large nose radius.
Select internal positive single sided

inserts and external double sided
negative inserts.

54
Cutting conditions
Use large cutting depths.
Use large feeds.
Change inserts regularly (not too much

wear).

Stainless steel milling
55
Some advice
1. Smooth cutting process is important (smooth cutting geometry, large rake angle, sharp yet
reinforced cutting edges (small T phase/honing)).
2. Good chip removal.
3. Cutting under the hard surface layer.
4. Use down-milling.
5. Limit heat development
1. cooling (at the right place).
2. thick chip (0.08 mm min hm) to gain sufficient mass for maximum heat removal.
6. Average chip thickness (very important)

1. cutter positioning (10% D on exit side of workpiece).
2. feed = > T - phase/honing.
7. Cutting depth at least 1 mm and no finishing passes (unless absolutely essential) (friction).
8. Maximum carbide mass (to remove heat).

56
Some advice – feed and cutting depth

• average chip thickness (hm) is very important and critical for tool life (verify with cutting edge
geometry - M/ME).
• Inco / SS (+ feed / + tool life) (titanium, if short tool life, reduce feed).
• if inserts with T-phase are used, the feed must be greater than this phase.
• avoid feed = 0 (helical interpolation milling instead of drilling).
• small cutting depths shorten the tool life.
• minimum cutting depth 1 mm.
• the smaller the cutting depth, the higher the cutting speed required (correct cutting temperature)
(cutting speed factor in contour milling).

57
Some advice – cutting speed

High cutting speed method
15 to 20 minutes tool life.
Low cutting speed method
45 to 60 minutes tool life.
High pressure cooling >50 bar
Higher cutting speed.
Low tool life - 45 to 100 minutes.
Use high cutting speed if possible. High cutting speed method Low cutting speed method
Most stainless steels are easily machined, except PH-SS and cooling is not necessary
most of the time.
Good chip evacuation (removal of chips from the workpiece).
1. Low cutting speed (low temperature) Vc= 30 - 60 m/min.

2. Build-up in cutting edge zone.
3. High cutting speed (high temperature) Vc= 100 - 300 m/min.

58
Group 8: Stainless Steels
Properties Little or no alloying elements other than carbon and

chromium.
Good corrosion and temperature resistance.

Easy to machine.
Soft, continuous chips.
Watch for BUE (built-up edge).
Use positive rake tools.
Cobalt enriched zone.
MTCVD coatings.
Uses • Cookware, surgical tools, pump components.

59
Group 9: Stainless Steels
Properties May contain nickel, molybdenum, sulphur, and

vanadium.
Increased hardness.
Increased corrosion and temperature resistance.

More difficult to machine.
Stringy, brittle chips.
Watch for notching at DOC line.
Use positive rake tools
MTCVD coating.
Uses • Piping pumps, process equipment.

60
Group 10 and 11: Stainless Steels
Properties May contain nitrogen and titanium.

Excellent corrosion and temperature resistance.
Very high hardness.

Very difficult to machine.
Watch for surface work hardening.
Flank wear and edge chipping are typical failure
modes.
Use positive rake tools.
MTCVD coatings.
CBN and ceramics.
Uses Piping, pumps, process equipment in demanding
conditions.

61
Cast Irons
Groups 12 through 15
Greater than 2.0% carbon
Tend to be abrasive to
machine
May also contain:
Magnesium
Silicon
Sulphur
Phosphorus
Brake drums

62
Group 12: Cast Irons
Properties Carbon in form of flakes.

Abrasive
Low to medium hardness.
Strong and cheap to produce.
Moderately difficult to machine.
Machine at high cutting speeds.
High speeds: AL2O3.
Medium speeds: CVD (TiC, TiCN, AL2O3).
Low speeds: PVD (TiAIN) and CVD (TiC).
Uses Engine blocks, inexpensive castings.

63
Groups 13 & 14: Cast Irons
Properties Cerium and magnesium cause carbon to form spheroids.

Harder and more abrasive.
More ductile, less brittle.
Machining Discontinuous chips.

High speed: AL2O3; CBN; ceramic (SiN).
Medium speed: CVD (TiC, TiCN, AL2O3).
Low speed: PVD (TiAIN) and CVD (TiC).
Uses Crankshafts, structural parts, pulleys, brakes.

64
Group 15: Cast Irons

Properties Silicon causes carbon to form spheroids.
Called “ductile cast iron”.
Excellent tensile strength.
Good wear resistance.
Cheaper and lighter than steel.
High cutting forces.
Analogous to interrupted-cut.
Negative rake for strength.
High speed: AL2O3; CBN; ceramic (SiN).
Medium speed: CVD (TiC, TiCN, AL2O3).
Low speed: PVD (TiAIN) and CVD (TiC).
Uses Gears, truck springs, turbo-compressor housings,
crankshafts.

65
Non-Ferrous Alloys

Less than 50% iron.
Most metals are soft
(except for tungsten
carbide).
Machinability varies over a
wide range.
Aluminium piston

66
Aluminium
Low density.
High strength.
Good thermal conductivity.
Good corrosion resistance.
– 1xxx 99% Al
– 2xxx + Cu
– 3xxx + Mn
– 4xxx + Si
– 5xxx + Mg
– 6xxx + Mg, Si
– 7xxx + Zn
– 8xxx + Other elements

67
Aluminium
Some advice
General
Carbide grade or PCD.
Polished rake surface.
Positive rake angle.
Coarse pitch cutter.
Large chip evacuation grooves.
Cutting speed
600 to 2000 (max) m/min with carbide inserts.
1500 - 6000 m/min with PCD inserts.
Feed
0.15 to 0.50 mm/rev.

68
Aluminium
Some advice
Build-up of cutting edge
Adjust cutting speed / use coolant / very positive geometry.
Chip control and evacuation

Open pitch cutter when milling.
Wash chips away with coolant.
Burring
Use micro-sharp cutting edges.
Abrasive wear
Carbide grade or PCD.
Finishing
With coolant, not for roughing.
Close pitch cutters

For large table feed, but needs power.

69
Group 16: Aluminum (<16% Si)
Properties Properties enhanced by alloying with silicon, copper,

and magnesium.
High strength to weight ratio and corrosion
resistance.
Excellent tensile strength.
Cheaper and lighter than steel.
Group 16 includes silver, brass, and gold.
Stringy, continuous chips.
Watch for BUE.
Free machining; run at high cutting speeds.
Use positive rake tooling.
Uses Auto body panels, wheels, aerospace applications.

70
Group 17: Aluminum (>16% Si)
Properties Alloyed to enhance strength.

Increased hardness.
Very abrasive.
Group 17 includes aluminum-bronze, cupro-nickel,
and magnesium-bronze.

Non-free machining.
Machine at slower cutting speeds.
Uses Engine blocks.

71
Group 18: Difficult Non-Ferrous
Properties Group 18 includes difficult to machine alloys of

copper, babbit, and bronze.
Good strength.
High ductility and toughness.
Very abrasive.
Watch for BUE.
Tends to tear.
Uses Bushings, bearings, valve seats.

72
Group 19: Super Hard Alloys
Properties Group 19 includes tungsten carbide.

Very high hardness.
Very high strength.
Abrasive
Machine at very slow cutting speeds.
Uses Dies, punches, and wear parts.

73
Superalloys/High Temperature Alloys

High strength.
Maintain properties at
elevated temperatures.
Very difficult to machine.

74
Nickel, iron and cobalt alloys, the most important properties

being:
Exceptional strength.
Corrosion resistance at high temperatures.

75

.
Superalloys
Nickel based Cobalt based Iron based
Inconel 600 Nickel-iron based MAR-M 509 A-286

Waspoloy X40 Discaloy
René N4 Inconel 718 Haynes 188 Haynes 556
MAR-M-247 Inconel 706 FSX-414
Hastelloy X

76
Titanium Alloys
Titanium
Alpha alloy Alpha-Beta alloy Beta alloy
HCP Mix BCC
• High strength/weight ratio.

• High strength/creep resistance up to 500°C.
• Excellent corrosion resistance.

77
Superalloys and Titanium Alloys

Machinability of superalloys
More heat generation upon machining (structure) and low thermal conductivity.
This means higher cutting temperatures.
Increasing strength at higher temperatures (basic property) (cutting temperature).
This means higher cutting forces.
Difficult chip control (greater toughness).
Carbide precipitates (due to heat treatment).
Work-hardening (hard layer).
Machinability of titanium alloys
Low thermal conductivity. This means higher cutting temperatures.

Small Young’s modulus (workpiece deformation, tolerances, vibrations).
Chemically very reactive (oxidation) (ignition and combustion during machining).

78
Superalloys and Titanium Alloys

General recommendations
Machine in softest possible state.
Positive rakes.
Sharp cutting edges.
Strong basic geometry (nose radius).
Stable working conditions.
Avoid workpiece deformation.
Use small entering angles.
Single-pass cutting or varying cutting depth.

79
Group 20: Superalloys

Properties Hardness < 35RC.
Group 20 includes nickel, cobalt, and iron alloys.
Very high hardness.
Very abrasive.

Machine at very slow cutting speeds.
Work hardens rapidly.
Notching at DOC line.
High cutting forces and temperatures.
Watch for BUE.
Uses Prosthetics, heat exchangers, aviation, maritime,

plumbing.

80
Group 21: Superalloys
Properties Hardness > 35RC.

Group 21 includes nickel, cobalt, iron alloys,
Inconel®600, Hastelloy®X, Monel®400.
Extremely high hardness.
Very abrasive.
Similar issues as Group 20 but to a greater degree.

Machine at extremely slow cutting speeds.
Work hardens rapidly.
Notching at DOC line.
High cutting forces and temperatures.
Watch for BUE.
Uses Jet engines.

81
Group 22: Refractory Metals

Properties Group 22 includes titanium, niobium, tantalum,
molybdenum, and tungsten.
High temperature resistance.
Poor oxidation resistance in air.
High thermal conductivity.
Flex readily.
Sometimes flammable.
May react with tool materials.
Low coefficient of thermal expansion.
Machine at very low cutting speeds.
Watch for BUE.
Uses Aircraft frames, nuclear plants.

82
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1

Duplex SS 42CrMo4 Ca-treated 316L

COPYRIGHT © 2008, Seco Tools AB Workpiece materials 1/82

General construction steel

Chemical, petrochemical, medical, gas

COPYRIGHT © 2008, Seco Tools AB 2/82

Non-alloy steel and cast steel

Grey cast iron

Hard cast iron

COPYRIGHT © 2008, Seco Tools AB 3/82

COPYRIGHT © 2008, Seco Tools AB 4/82

COPYRIGHT © 2008, Seco Tools AB 5/82

Material to be machined The process

Cutting speed Cutting depth Feed

Carbide grade Geometry

The correct insert

COPYRIGHT © 2008, Seco Tools AB 6/82

COPYRIGHT © 2008, Seco Tools AB 7/82

 The combination of tangential and

COPYRIGHT © 2008, Seco Tools AB 8/82

0 1 000 2 000 3 000 4 000 5 000 6 000 7 000

COPYRIGHT © 2008, Seco Tools AB 9/82

Materials with high ductility

DO  Low carbon steel and aluminium,

DO  Gray cast iron, Gr.12.

COPYRIGHT © 2008, Seco Tools AB 10/82

High hardness materials

 Tool steel, Group 6

Low hardness materials

 Stainless steel, Groups 8, 9, 10 & 11

COPYRIGHT © 2008, Seco Tools AB 11/82

Long chips (Ductility (%))

COPYRIGHT © 2008, Seco Tools AB 12/82

• Heat conductivity of tool material

• Geometry of cutting edge.

This temperature (gradient)

COPYRIGHT © 2008, Seco Tools AB 13/82

Materials with high thermal conductivity

• Low carbon steel, Group 1

Materials with low thermal conductivity

• Superalloys, Groups 20, 21

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- Surface finish: Rt,Ra…

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Great influence on fatigue properties

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Material Machinability Rating

9S20 is assigned a rating of 100

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Non-alloy steeland cast steel. < 600 N/mm2

M Stainless steel (austenitic) > 750 N/mm2

Grey cast iron

Hard cast iron > 60 Shore

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Aluminium & alloys

Grey cast iron

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Increasing cutting speed

Areas of application for the various cutting materials

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The combination of tangential and

DO Low carbon steel and aluminium,

DO Gray cast iron, Gr.12.

Tool steel, Group 6

Stainless steel, Groups 8, 9, 10 & 11

Properties Carbon content < 0.28%

Machining 50 to 100% machinability rating

Uses Hub caps, stampings, wheels

Properties Carbon content: 0.28 to 0.50%

Machining 35 to 65% machinability rating.