Training Handbook en HQ

Training
Handbook
METAL CUTTING TECHNOLOGY
Metal Cutting Technology training handbook
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Content
Turning Drilling
Theory A4 Theory E4
Selection procedure A 12 Selection procedure E 15
System overview A 16 System overview E 20
Choice of inserts A 22 How to apply E 26
Choice of tools Hole quality and tolerances E 38
- External A 49 Troubleshooting E 43
- Internal A 54
Code keys A 64
Boring
Troubleshooting A 68
Theory F4
Selection procedure F8
Parting & Grooving
System overview F 13
Theory B4 Choice of tools F 16
Selection procedure B7 How to apply F 22
System overview B 11 Troubleshooting F 27
Parting & grooving - how to apply B 16
- Parting of B 22
Tool holding
- General grooving B 26
- Circlip grooving B 28 History and background G4
- Face grooving B 29 Why modular tooling G8
- Proiling B 32 Turning centers G 16
- Turning B 34 Machining centers G 25
- Undercutting B 36 Multi-task machines G 30
Troubleshooting B 37 Chucks G 35
Threading Machinability
Theory C4 Workpiece materials H4
Selection procedure C9 Manufacture of cemented carbide H 18
System overview C 13 The cutting edge H 29
How to apply C 19 Cutting tool materials H 40
Troubleshooting C 24 Tool wear & maintenance H 52
Tapping C 28
Other information
Milling
Machining economy H 63
Theory D4 ISO 13399 - The industry standard H 78
Selection procedure D9 Formulas and deinitions H 81
System overview D 13 E-learning H 92
Choice of insert – how to apply D 24
Choice of tools – how to apply D 29
Troubleshooting D 36
Turning
Turning generates cylindrical and rounded forms with a

single-point tool. In most cases the tool is stationary with
the workpiece rotating.
• Theory A4
• Selection procedure A 12
• System overview A 16
• Choice of inserts – how to apply A 22
• Choice of tools – how to apply

- External A 49
- Internal A 54
• Code keys A 64
• Troubleshooting A 68
A3
A Theory
General turning operations

Turning
Turning is the combination of two movements – rotation

of the workpiece and feed movement of the tool.
B The feed movement of the tool can be along the axis of
the workpiece, which means the diameter of the part will
be turned down to a smaller size. Alternatively, the tool
Parting and
can be fed towards the center (facing of) at the end of

grooving
the part.
Often feeds are combinations of these two directions,
C resulting in tapered or radius surfaces.
Threading
D
Milling
Turning and facing as axial and radial tool movements.
E
Drilling
F Three common turning operations:

- Longitudinal turning
- Facing
Boring
- Proiling
G
Tool holding
H
Other information
Machinability
A4
Theory
A
Deinitions of terms
Turning
Spindle speed
The spindle speed rpm (revolution per minute) is B

n (rpm)
the rotation of the chuck and workpiece.
Parting and
grooving
C
Cutting speed
Threading
The cutting speed is the surface speed, m/min
(ft/min), at which the tool moves along the work-
vc m/min piece in feet (meters) per minute. D
(ft/min)
Milling
Deinition of cutting speed
of the diameter, pi (π) and the spindle speed (n)

The deinition of cutting speed (vc) as the result E
in the revolutions per minute (rpm). The circum-

ference (C) is the distance the cutting edge
Drilling
moves in a revolution.
F
vc = cutting speed, m/min (ft/min)
Dm = machined diameter, mm (inch)
C = Circumference, π x Dm mm (inch)
n = spindle speed, (rpm)
π (pi) = 3.14
Boring
G
Tool holding
Metric Inch
π × Dm × n π × Dm × n H
vc = m/min vc = ft/min
Other information
1000 12
Machinability
A5
A Theory
Calculation of the circumference (C)

• Circumference = π x diameter
Turning
• π (pi) = 3.14
B
Parting and
Example:
grooving
Dm2 = 100 mm (3.937 inch)

C = 3.14 x 100
C
= 314 mm
C = 3.14 x 3.937
= 12.362 inch
Threading
Dm1 = 50 mm (1.969 inch)

C = 3.14 x 50
D = 157 mm
C = 3.14 x 1.969
= 6.183 inch
Milling
Example of cutting speed calculation

E The cutting speed difers depending on the workpiece diameter.
Given:
Spindle speed, n = 2000 rpm
Drilling
Diameter, Dm1 = 50 mm (1.969 inch)
F Diameter, Dm2 = 80 mm (3.150 inch)

Boring
Metric Inch
G π × Dm × n π × Dm × n
vc = m/min vc = ft/min
1000 12
Tool holding
3.14 × 50 × 2000 314 3.14 × 1.969 × 2000 1030

vc1 = = vc1 = =
1000 m/min 12 ft/min
H 3.14 × 80 × 2000 3.14 × 3.150 × 2000
vc2 = = 502 vc2 = = 1649
Other information
1000 m/min 12 ft/min

Machinability
A6
Theory
A
Deinitions of terms
Turning
Spindle speed
The workpiece rotates in the lathe, with a
certain spindle speed (n), at a certain B
number of revolutions per minute (rpm).
Parting and
grooving
Surface/cutting speed
The cutting speed (vc) in m/min (ft/min) at
which the periphery of the cut workpiece C
diameter passes the cutting edge.
Threading
Feed
The cutting feed (fn) in mm/r (inch/r) is the
movement of the tool in relation to the
n = spindle speed (rpm) revolving workpiece. This is a key value D
in determining the quality of the surface
vc = cutting speed m/min (ft/min) being machined and for ensuring that the
fn = cutting feed mm/r (inch/r) chip formation is within the scope of the
tool geometry. This value inluences, not
Milling
ap = depth of cut mm (inch) only how thick the chip is, but also how the
KAPR = entering angle chip forms against the insert geometry.
E
PSIR = lead angle
Depth of cut
The cutting depth (ap) in mm (inch) is half
Drilling
of the diference between the un-cut and
cut diameter of the workpiece. The cutting
depth is always measured at right angles F
to the feed direction of the tool.
Entering angle = 95°
Lead angle = -5°
Entering angle KAPR, lead angle PSIR
Boring
The cutting edge approach to the work-

piece is expressed through the entering
angle (KAPR), which is the angle between G
the cutting edge and the direction of feed.
It can also be expressed as the lead angle
Tool holding
(PSIR), the angle between the cutting edge

and the workpiece plane. The entering
angle is important in the basic selection of
the correct turning tool for an operation. H
Other information
Machinability
A7
A Theory
Calculating cutting data

Turning
Cutting speed
Example of how to calculate the spindle speed (n) from cutting speed (vc).
B
Parting and
grooving
Given:
Cutting speed, vc = 400 m/min (1312 ft/min)
C Diameter Dm = 100 mm (3.937 inch)
Threading
Metric Inch
π × Dm π × Dm
vc × 1000 vc × 12
D n= r/min n= r/min
400 ×1000 1312 × 12

n= = 1274 r/min n= = 1274 r/min
3.14 × 100 3.14 × 3.937
Milling
E Inclination and rake angles

Drilling
λ
F
γ
Boring
Rake angle Inclination angle

G
The rake angle gamma (GAMO) is a The inclination angle lamda (LAMS) is the
measurement of the edge in relation to angle the insert is mounted in the tool
Tool holding
the cut. The rake angle of the insert itself holder. When mounted in the tool holder,
is usually positive and the clearance face the insert geometry and inclination in the
is in the form of a radius, chamfer or land tool holder will determine the resulting
and afects tool strength, power consump- cutting angle with which the cutting edge
H tion, inishing ability of the tool, vibration cuts.
Other information
tendency and chip formation.

Machinability
A8
Theory
A
Cutting depth and chip formation
Turning
B
Parting and
grooving
C
Threading
The cutting depth (ap) is the length the Chip formation varies with depth of cut,
edge goes into the workpiece. entering (lead) angle, feed, material and
D
insert geometry.
Milling
Feed rate and the efective cutting edge length E
Drilling
F
Boring
Feed rate Cutting edge length G

The feed rate (fn) is the The efective cutting edge length (LE) relates to cutting
distance the edge moves depth and entering (lead) angle.
Tool holding
along the cut per revolu-

tion.
H
Other information
Machinability
A9
A Theory
Insert shape selection, entering angle (lead angle) and

chip thickness
Turning
The entering angle KAPR (lead angle The chip thickness is reduced and the
B PSIR), of the tool and the nose radius RE width increases with a smaller entering
of the insert efect the chip formation, in angle or larger lead angle.
that the chip cross-section changes.
The direction of chip low is also changed.
Parting and
grooving
C
Entering angle KAPR (Lead angle PSIR)
• Is deined by the holder tip seat in combi-
nation with insert shape selected.
Threading
Maximum chip thickness hex

D
• Reduces relative to the feed rate as
the entering angle reduces (lead angle
increases).
KAPR = 45°
Milling
PSIR = 45°
hex ≈ fn x 0.71
E
Possible entering (lead) angle positions for insert shapes
CNMG DNMG WNMG

Drilling
F Entering angle KAPR: Entering angle KAPR: Entering angle KAPR:

95° 107.5°, 93°, 62.5° 95°
Lead angle PSIR: Lead angle PSIR: Lead angle PSIR:
-5° -17.5°, -3°, 27.5° -5°
Boring
SNMG RCMT TNMG

G
Entering angle KAPR: Entering angle KAPR: Entering angle KAPR:
Tool holding
45°, 75° Variable 93°, 91°, 60°

Lead angle PSIR: Lead angle PSIR: Lead angle PSIR:
45°, 15° Variable -3°, -1°, 30°
H
VNMG
Other information
Machinability
Entering angle KAPR: Lead angle PSIR:

117.5°, 107.5°, 72.5° -27.5°, -17.5°, 17.5°
A 10
Theory
A
The efect of entering angle (lead angle) on chip thickness
Turning
Maximum chip thickness hex reduces relative to the feed rate as the entering
angle reduces (lead angle increases).
B
Parting and
grooving
KAPR KAPR KAPR KAPR
Entering angle KAPR 95° 75° 60° 45° 90° min C

Lead angle PSIR -5° 15° 30° 45° 0° max
Chip thickness
Threading
compared to feed, 1 0.96 0.87 0.71 Variable
mm (inch)
Contact length la, D

mm (inch) at ap 2 (.079) 2.08 (.082) 2.3 (.091) 2.82 (.111) Variable
2 mm (.079 inch)
Milling
Calculating power consumption
The net power (Pc) required for metal E
cutting is mainly of interest when n = spindle speed (rpm)
roughing, where it is essential to ensure
vc = cutting speed m/min (ft/min)
that the machine has suicient power for
fn = cutting feed mm/rev (inch/rev)
Drilling
the operation and is measured in kW and
HP. The eiciency factor of the machine is
ap = depth of cut mm (inch)
also of great importance.
F
kc = speciic cutting force N/mm2 (lbs/in2)
For information about the kc value, see
page H 16. Pc = net power kW (HP)
kW = kilowatts
Boring
HP = horsepower
G
vc × ap × fn × kc
Tool holding
Pc = kW
60 × 103
vc × ap × fn × kc H
Pc = HP
Other information
33 × 103
Machinability
A 11
A Selection procedure
Selection procedure
Turning
B Production planning process

Parting and
grooving
Dimension and type of

operation
C 1 Component
Workpiece material and

Threading
quantity
2 Machine Machine parameters

Milling
E Type of turning tool:

- External/internal
- Longitudinal
3 Choice of tool - Facing
- Proiling
Drilling
Cutting data, tool path,

etc.
4 How to apply
Boring
G
Tool holding
5 Troubleshooting
H Remedies and solutions
Other information
Machinability
A 12
Selection procedure
A
1. Component and the workpiece material
Turning
Parameters to be considered
Component B
• Analyze the dimensions and quality demands of the
surface to be machined
Parting and
• Type of operation (longitudinal, facing and proiling)
grooving
• External, internal
• Roughing, medium or inishing
• Tool paths C
• Number of passes
• Tolerances.
Threading
Material D
P Steel
• Machinability
M Stainless steel • Cast or pre-machined
K Cast iron • Chip breaking
Milling
• Hardness
N Non-ferrous • Alloy elements.
S Heat resistant super alloys E
and titanium
H Hardened steel
Drilling
2. Machine parameters
Condition of the machine F
Some important machine considerations:
• Stability, power and torque, especially for
larger diameters
Boring
• Component clamping
• Tool position
• Tool changing times/number of tools in turret
G
• Spindle speed (rpm) limitations, bar feed magazine
• Sub spindle, or tail stock available?
Tool holding
• Use all possible support

• Easy to program
• Cutting luid pressure.
H
Other information
Machinability
A 13
3. Choice of tools
Turning
General application - Turning with rhombic inserts
B Advantages Disadvantages
• Operational versatility • Can cause vibration when
turning slender compo-
• Large entering angle
nents.
Parting and
grooving
• For turning and facing

• Good roughing strength.
C
Threading
Turning with wiper inserts

Advantages Disadvantages
• Increase feed and gain • In back turning and
D productivity proiling the wiper edge
is not efective.
• Use normal feed rate and
gain surface quality
Milling
• Productivity booster.
E
Coromant unique Turning concepts
Advantages
• Increased cutting data in
Drilling
proiling
F • Increased ability to hold

tolerance.
Boring
Advantages
• Multiple edge solution
G
• Chip control and predictable tool life.
Tool holding
Advantages
• Turning in all directions
H • Eicient and productive turning.
Other information
Machinability
A 14
Selection procedure
A
4. How to apply
Turning
Important application considerations
The tool path has a signiicant impact on
B
the machining process.
It inluences:
Parting and
- Chip control
grooving
- Insert wear
- Surface quality
- Tool life.
C
In practice, the tool holder, insert geometry,
grade, workpiece material and tool path
inluences the cycle time and productivity
Threading
considerably.
Milling
5. Troubleshooting
Some areas to consider
E
Insert clearance angle
• Use positive inserts for lower cutting
forces in general and for internal turning.
Drilling
Chip breaking
Negative style Positive style • Optimize the chip breaking by changing
F
the depth of cut, the feed or the insert
geometry.
Nose radius
Boring
• The depth of cut should be no less then

the nose radius (RE).
G
Insert wear
• Make sure that the lank wear does not
Tool holding
exceed the general recommendation of

0.5 mm (.020 inch).
ap RE H
Other information
Machinability
A 15
A System overview
External Turning - negative inserts

Turning
1. Longitudinal turning
B 2. Proiling
3. Facing
Parting and
grooving
1 2
Threading
D
Milling
Overview of tool holders

Drilling
F
Boring
G • Negative insert • Negative insert • Negative/positive • Negative inserts

• Rigid clamping • Lever clamping inserts • Lever clamping
system system • All clamping system
Tool holding
• Modular/shank • Modular/shank systems • Precision coolant

tools. tools. • Cutting heads • Modular/shank
• Modular/shank tools.
tools.
H
Other information
Machinability
A 16
System overview
A
External Turning - positive inserts
Turning
1. Longitudinal turning
2. Proiling B
3. Facing
Parting and
grooving
C
1
Threading
2
3
D
Milling
E
Drilling
F
Boring
• Positive insert • Positive insert • Negative/positive • Positive insert G

• Screw clamping • Screw clamping insert • Screw clamping
system system • All clamping system
Tool holding
• Modular/shank • iLock™ interface systems • Modular/shank

tools • Modular/shank • Cutting heads tools.
• Precision coolant. tools. • Modular/shank
tools.
H
Other information
Machinability
A 17
A System overview
Internal turning, negative/positive inserts

Turning
B
Parting and
grooving
C
Threading
Positive inserts Negative inserts
D
Overview of internal tool holders
Milling
E
• Negative/positive inserts • Negative insert • Negative insert
• Dampened boring bars • Rigid clamping system • Lever clamping system
• Boring bars • Modular/boring bars. • Modular/boring bars.
Drilling
F
Boring
G • Negative/positive insert • Positive insert • Dampened boring bars

• All clamping systems • Screw clamping system • Boring bars.
• Cutting heads • Cutting heads
Tool holding
• Dampened modular/ • Modular/boring bars.

boring bars • Precision coolant.
• Precision coolant.
H
Other information
Machinability
A 18
System overview
A
Tools for small part machining
Turning
1. External turning
2. External turning B
(Sliding head machines)
3. Internal turning
Parting and
1
grooving
2 (Exchangeable inserts)
4. Internal turning
5. Internal turning C
(Carbide rods)
5
Threading
4 3
D
External tools
Milling
E
• Positive insert • Quick change tools • Positive insert
Drilling
• Screw clamping system • Positive insert • Screw clamping system.
• Shank tools • Screw clamping system.
• Precision coolant. F
Internal tools
Boring
G
Tool holding
• Positive insert • Positive insert • Positive insert

• Screw clamping system • Screw clamping system. • Carbide rods
• Precision coolant. • Machine adapted bars. H
Other information
Machinability
A 19
A System overview
Overview of insert clamping systems

Turning
Clamping of negative basic-shape inserts

B
Parting and
grooving
C
Rigid clamping system Lever clamping system
Threading
Clamping of positive basic-shape inserts
D
Milling
E Screw clamping system

Drilling
Screw clamping system

Boring
Clamping of positive iLock™ inserts

G
Tool holding
iLock™
H
Other information
Screw clamping system

5°/7°
Machinability
A 20
System overview
A
Modern insert clamping for turning tools
Turning
Rigid clamping
• Negative inserts B
• Excellent clamping
Parting and
• Easy indexing.
grooving
C
Lever clamping
Threading
• Negative inserts
• Free chip low D
• Easy indexing.
Milling
E
Screw clamping
• Positive inserts
Drilling
• Secure clamping of the
insert
F
• Free chip low.
Boring
Screw clamping system, iLock™ G
• Positive inserts
Tool holding
• Very secure clamping

• High accuracy.
H
Other information
Machinability
A 21
A Choice of inserts
Choice of inserts
Turning
• Basic factors A 23
Parting and
grooving
• Insert geometries A 31
C
• Insert grades A 38
Threading
• Insert shape, size, nose radius A 41
• Cutting data efect on tool life A 47

D
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
A 22
Choice of inserts – basic factors
A
The complex world of metal cutting
Turning
Getting metal cutting processes right means knowing the workpiece material, then
choosing the correct insert geometry and grade to suit the speciic application.
B
Parting and
grooving
Workpiece material
• The interaction between
an optimized insert
geometry and grade for a C
certain workpiece mate-
rial is the key to success-
ful machining.
Threading
• These three main basic
factors must be carefully
considered and adapted D
for the machining opera-
tion in question.
• The knowledge and
Milling
understanding of how
to work with and employ
these factors is of vital E
importance.
Grade Geometry
Drilling
F
The machining starts at the cutting edge
Typical chip breaking sequences with high speed imaging

Boring
G
Tool holding
H
Other information
Machinability
A 23
A Choice of inserts – basic factors
Six material groups

Turning
In the metal cutting industry there is an Workpiece materials are divided into
incredibly broad range of component 6 major groups in accordance with the
B designs made from diferent materials. ISO-standard, where each group has
Each material has its own unique unique properties regarding machinability.
characteristics inluenced by the alloying
elements, heat treatment, hardness, etc.
Parting and
This strongly inluences the selection of

grooving
cutting tool geometry, grade and cutting

data.
C
Threading
Workpiece material groups
Steel • ISO P – Steel is the largest material

D P group in the metal cutting area, ranging
from unalloyed to high-alloyed material
including steel castings and ferritic and
martensitic stainless steels. The
machinability is normally good, but difers
Milling
a lot depending on material hardness,

carbon content, etc.
E
Drilling
F
Stainless steel • ISO M – Stainless steels are materials
M alloyed with a minimum of 12%
chromium; other alloys are, e.g., nickel
and molybdenum. Diferent conditions
Boring
such as ferritic, martensitic, austenitic

and austenitic-ferritic (duplex), makes this
G
an extensive material group. Common for
all these types are that they expose
cutting edges to a great deal of heat,
Tool holding
notch wear and built-up edge.
H
Other information

Machinability
A 24
A
 • ISO K – Cast iron is, contrary to steel, a

Cast iron short-chipping type of material. Gray cast
K
Turning
iron (GCI) and malleable cast irons (MCI)
are quite easy to machine, while nodular
cast iron (NCI), compacted graphite iron B
(CGI) and austempered cast iron (ADI) are
more diicult. All cast irons contain silicon
carbide (SiC) which is very abrasive to the
Parting and
grooving
cutting edge.
Aluminum • ISO N – Non-ferrous metals are softer

N types of metals such as aluminum,
Threading
copper, brass, etc. Aluminum with a
silicon content (Si) of 13% is very abra-
sive. Generally high cutting speeds and
long tool life can be expected for inserts D
with sharp edges.
Milling
E
Heat resistant • ISO S – Heat Resistant Super Alloys
S alloys include a great number of high-alloyed
iron, nickel, cobalt and titanium-based
Drilling
materials. They are sticky, create built-up
edge, workharden and generate heat,
very similar to the ISO M-area, but they
are much more diicult to cut, leading to F
shorter tool life for the cutting edges.
Boring
Hardened • ISO H – This group covers steels with a G

H steel hardness between 45-65 HRc and also
chilled cast iron around 400-600 HB.
The hardness makes them all diicult to
Tool holding
machine. The materials generate heat

during cutting and are very abrasive to
the cutting edge.
H
Other information
Machinability
A 25
Cutting forces
Turning
Another expression of the diferences in the six material groups is through the force
(FT) needed to shear of a speciic chip cross-section in certain conditions.
B This value, the speciic cutting force value (kc), is indicated for various types of
workpiece materials and used in the calculation of how much power is needed for
an operation.
Parting and
kc1 = speciic cutting force for average chip thickness 1 mm (.039 inch).
grooving
C
P Steel
Threading
• P materials have a kc1 variation of:

1500-3100 N/mm2
(217,500-449,500 lbs/inch2)
Milling
E M Stainless steel
Drilling
F
• M materials have a kc1 variation of:
1800-2850 N/mm2
(261,000-413,250 lbs/inch2)
Boring
K Cast iron
G
Tool holding
H • K materials have a kc1 variation of:

790-1350 N/mm2.

Other information
(114,550-195,750 lbs/inch2)
Machinability
A 26
A

N Aluminum
Turning
B
Parting and
grooving
• N materials have a kc1 variation of:
350-1350 N/mm2
C
(50,750-195,750 lbs/inch2)
Threading
S Heat resistant super alloys
D
Milling
• S materials have a kc1 variation of:
2400-3100 N/mm2 E
(348,000-449,500 lbs/inch2) for HRSA
1300-1400 N/mm2
(188,500-203,000 lbs/inch2) for titanium
Drilling
alloys
F
Hardened steel
H
Boring
• H materials have a kc1 variation of:

Tool holding
2550 – 4870 N/mm2

(369,750-706,150 lbs/inch2)
H
Other information
Machinability
A 27
Chip formation
Turning
There are three patterns for a chip to break after it has been cut.
B
Self-breaking Against the tool Against the workpiece
Parting and
grooving
C
Threading
D
Milling
E
Self-breaking, where the Chips breaking against the Chips breaking against the
material, in combina- tool, where the chip curves workpiece, where the chip
tion with how the chip is around until it makes snaps when making con-
Drilling
curved, leads to the chips contact with the clearance tact with the surface that
being parted as they come face of the insert or tool has just been machined.
of the insert. holder, and the resulting This type of chip breaking
F
strain snaps it. Although is usually not suitable in
often accepted, this applications where a good
method can in some cases surface inish is needed,
lead to chip hammering, because of possible
Boring
where the chip damages damage caused to the

the insert. component.
G
Tool holding

Other information
Machinability
A 28
A
Chip formation varies with diferent parameters
Turning
Chip formation varies with depth of cut, feed, material and tool geometry.
B
Self-breaking Against the tool Against the workpiece
Parting and
grooving
ap
ap
KAPR C
Threading
D
Insert rake angle

The rake angle (γ) gamma (GAMO) is a measurement of the edge in rela-
Milling
tion to the cut. This can be either negative or positive tools. Based on E
this, there are negative and positive inserts, where the clearance angles
are either zero or several degrees plus. This determines how the insert
can be tilted in the tool holder, giving rise to a negative or positive cutting
action.
Drilling
F
Positive cutting action Negative cutting action

Boring
γ γ G
Tool holding

Other information
Machinability
A 29
 Insert rake angle

Turning
There is a distinction in cutting edge geometry between negative and positive insert
geometry:
B - A negative insert has a wedge angle of 90° seen in a cross-section of the basic shape
of the cutting edge.
- A positive insert has an wedge angle of less than 90°.
The negative insert has to be inclined negatively in the tool holder so as to provide a
Parting and
grooving
clearance angle tangential to the workpiece while the positive insert has this clearance
built in.
C
Negative style
• Double/single sided Note: The clearance
• Edge strength angle is the angle
Threading
• Zero clearance between the front

face of the insert and
• External/internal machining the vertical axis of the
• Heavy cutting conditions. workpiece.
D
Positive style
• Single sided
Milling
• Low cutting forces

• Side clearance
E • Internal/external machining
• Slender shafts, small bores.
Drilling
Insert geometries
F
Metal cutting is very much the science of removing chips from the workpiece material in
the right way. Chips have to be shaped and broken of into lengths that are manageable
in the machine.
Boring
• In milling and drilling a lot of parameters inluence the

G chip formation compared to turning.
• Turning is a single-cut operation with a stationary tool
and a rotating workpiece.
Tool holding
• The insert rake angle, geometry and feed play an

important role in the chip formation process.
• Removing heat from the cutting zone through the chip
(80%) is a key issue.
H
Other information
Machinability
A 30
Choice of inserts – geometries
A
The design of a modern insert
Turning
Deinitions of terms and geometry design
B
Nose radius edge Main cutting edge
design design
Parting and
grooving
0.25 mm
(.010")
20° C
5°
Macro geometry with • Cutting edge rein-
Threading
chip breaker forcement 0.25 mm
(.010")
Geometry for small • Rake angle 20°
cutting depths • Primary land 5° D
0.2 mm (.008")
Milling
E
The reinforcement of the cutting edge
The Edge Roundness (ER) treatment gives the cutting
edge the inal micro-geometry.
Drilling
• ER-treatment is done before coating, and F
gives the inal shape of the cutting edge
(micro-geometry).
• The relationship between W/H is what
Boring
makes inserts suitable for diferent

applications.
G
Tool holding
H
Other information
Machinability
A 31
A Choice of inserts – geometries
The working area of an insert geometry

Turning
A chip breaking diagram for an insert

geometry is deined by acceptable chip
B breaking for feed and depth of cut.
Cutting depth,
Parting and
ap mm (inch) • Cutting depth (ap) and feed (fn) must be

grooving
adapted to the chipbreaking area of the

geometry to get acceptable chip control.
C • Chip breaking which is too hard can lead
to insert breakage.
• Chips which are too long can lead to
Threading
disturbances in the machining process

and bad surface inish.
D
Feed, fn mm/r (inch/r)
Milling
Three main methods in Turning

E R = Roughing Roughing
M = Medium machining • Maximum metal removal rate and/or
severe conditions
F = Finishing
Drilling
• Large cutting depth and feed rate

Cutting depth, combinations
ap mm (inch)
F • High cutting forces.
Medium machining
• Most applications – general purpose
Boring
• Medium operations to light roughing

G • Wide range of cutting depth and feed
rate combinations.
Tool holding
Finishing
• Small cutting depths and low feed rates
H • Low cutting forces.
Other information
Machinability
A 32
A
Chip breaking areas
Turning
Turning of low alloy steel
Roughing – R
Cutting depth, High depth of cut and feed rate combina- B
ap mm (inch)
tions. Operations requiring the highest
CNMG 120408 (CNMG 432) edge security.
Parting and
grooving
(.236) 6.0
Medium – M
Medium operations to light roughing.
(.157) 4.0 Wide range of depth of cut and feed rate C
combinations.
(.079) 2.0
Threading
Finishing – F
Operations at light depths of cut and low
feed rates.
0.1 0.4 0.8 Operations requiring low cutting forces. D
(.004) (.016) (.031)
Milling
Chip breaking diagram
E
Roughing of steel Chip breaking area:
CMC 02.1
P R
ap = 5.0 (1.0 - 7.5 ) mm
fn = 0.5 (0.25 - 0.7) mm/r
Drilling
ap = .197 (.039 - .295) inch
Cutting depth, CNMM 120412-PR fn = .020 (.010 - .028) inch/r
ap mm (inch) (CNMM 432-PR) F
The area marked
in red indicates the
area which gives
Boring
(.236) 6.0 acceptable chip

breaking.
(.118) 3.0 G
(.059) 1.5
Tool holding
(.039) 1.0
(.020) 0.5
H

0.1 0.2 0.3 0.4 0.5 0.6 0.7
Other information
(.004) (.008) (.012) (.016) (.020) (.024) (.028)

Machinability
A 33
 Medium machining of Chip breaking area:

steel CMC 02.1 PM
Turning
ap = 3.0 (0.5 - 5.5) mm

fn = 0.3 (0.15 - 0.5) mm/r
B ap = .118 (.020 - .217) inch
fn = .012 (.006 - .020) inch/r
CNMG 120408-PM
Cutting depth,
ap mm (inch)
(CNMG 432-PM)
Parting and
grooving
(.236) 6.0
C
(.118) 3.0
Threading
(.059) 1.5
(.039) 1.0
D
(.020) 0.5
0.1 0.2 0.3 0.4 0.5 Feed, fn mm/r (inch/r)

Milling
(.004) (.008) (.012) (.016) (.020)
E
Finishing of steel Chip breaking area:
CMC 02.1
P F
ap = 0.4 (0.25 - 1.5) mm
fn = 0.15 (0.07 - 0.3) mm/r
Drilling
ap = .016 (.010 - .059) inch

Cutting depth, fn = .006 (.003 - .012) inch/r
CNMG 120404-PF
ap mm (inch)
F (CNMG 434-PF)
(.059) 1.5
Boring
(.049) 1.25
G (.039) 1.0
(.030) 0.75
Tool holding
(.020) 0.5
(.010) 0.25
H
0.1 0.15 0.2 0.25 0.3 0.35 Feed, fn mm/r (inch/r)
Other information
(.004) (.006) (.008) (.010) (.012) (.014)

Machinability
A 34
A
Selection of inserts
Turning
Considerations when selecting inserts
It is important to select the correct insert
size, insert shape, geometry and insert B
nose radius to achieve good chip control.
• Select the largest possible point angle on
Parting and
grooving
the insert for strength and economy.
L • Select the largest possible nose radius

for insert strength. C
RE • Select a smaller nose radius if there is a
tendency for vibration.
L= cutting edge length (insert size)
Threading
RE = nose radius
D
Dedicated inserts for the ISO P, M, K and S area
The diferent micro and macro-geometries are adapted to the various
Milling
requirements in the applications.
Workpiece
Finishing Medium Roughing E
material
0.07 mm 0.2 mm 0.32 mm

(.003") (.008") (.013")
Drilling
F
0.29 mm 0.32 mm
(.012") (.013") Boring
0.1 mm 0.25 mm
(.004") (.010") G
Tool holding
H
Other information
Machinability
A 35
Geometry description
Turning
Every insert has a working area with optimized chip control.

A geometry description and application information are also
B available.
Geometry working Geometry Application

Parting and
area description
grooving
-PM CNMG 432-PM -PM – for medium turning

(CNMG 12 04 08-PM) with broad capability for steel.
C ap = 0.5 – 5.5 mm Feed (fn): 0.1 – 0.65 mm/r (.004 – .026 inch/r).
fn = 0.15 – 0.5 mm/r Depth of cut (ap): 0.4 – 8.6 mm (.016 – .339 inch).
ap = .020 – .217 inch Operations: turning, facing and proiling.
Threading
fn = .006 – .020 inch/r Advantages: all-purpose, reliable, with problem-

ap inch (mm) free machining.
0.25 mm (.010 in.)
(.236) 6.0 Components: axles, shafts, hubs, gears, etc.
D (.197) 5.0 Limitations: depth of cut and feed, risk of over-
(.157) 4.0 loading the cutting edge.
0.20 mm (.008 in.)
(.118) 3.0 General recommendations: Combine with a
(.079) 2.0 wear resistant grade for best productivity.
(.039) 1.0
Possible optimization: geometry WMX.
Milling
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 fn mm (inch)
(.004) (.008) (.012) (.016) (.020) (.024) (.028) (.031) (.035)
From universal to optimized turning inserts

Drilling
Universal inserts
F • Universal geometry
• Optimizing with grades
• Performance compromised.
Boring
Application area
G
Optimized inserts
Tool holding
• Dedicated geometries and

grades
• Optimized performance
H according to workpiece
Other information
material and machinability.

Machinability
Application area
A 36
A
Inserts for general turning
Turning
The choice of diferent insert concepts
Negative, double/single-sided inserts • A negative insert has a

wedge angle of 90° seen in B
a cross-section of the basic
Plain inserts shape of the cutting edge.
Parting and
• Available as double/single-
grooving
sided inserts with P-hole or
plain.
Double Single Without With hole Concept C

sided sided hole multi-edge
Threading
Positive, single-sided inserts • A positive insert has a wedge
angle less than 90°.
• Available with 7° or 11° clear- D
ance angle.
• The positive iLock™ inserts
have a clearance angle of 5°
or 7°.
Milling
Positive Positive Positive Concept Concept
11° 7° iLock™ iLock™
clamping clamping
E
Chip forming at high pressure and temperatures
Drilling
The choice of cutting material and grade is critical for success
F
The ideal cutting tool material should:
- be hard to resist lank wear and
deformation
Boring
- be tough to resist bulk breakage

- not chemically interact with the G
workpiece material
Tool holding
- be chemically stable to resist oxidation

and difusion
Temperatures given in
Celsius - have good resistance to sudden thermal
changes.
H
Other information
Machinability
A 37
A Choice of inserts – grades
The main range of cutting tool materials

Turning
The most common cutting tool materials are divided into the following
main groups:
B
- Uncoated cemented carbide (HW) • CN Nitride ceramics containing
primarily silicon nitride (Si3N4).
- Coated cemented carbides (HC)
Parting and
grooving
• CC Ceramics as above, but coated.

- Cermets (HT, HC)
- Cubic boron nitrides (BN)
• HT Uncoated cermet containing
C primarily titanium carbides (TiC) - Polycrystalline diamonds (DP, HC)
or titanium nitrides (TiN) or both.
• DP Polycrystalline diamonds.
• HC Cermet as above, but coated.
• HC Polycrystalline diamonds, but
Threading
- Ceramics (CA, CM, CN, CC) coated.

• CA Oxide ceramics containing primarily
D aluminum oxide (Al2O3).
• CM Mixed ceramics containing
primarily aluminum oxide (Al2O3)
but containing components other
Milling
than oxides.
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
A 38
Choice of inserts – grades
A
How to select insert geometry and grade
Turning
Select the geometry and grade according to the application.
Build up of a grade chart Machining conditions B
Wear resistance
Parting and
grooving
Good
C
Average
Threading
Diicult
Good Average Diicult
Milling
Machining conditions
E
Good conditions
• Continuous cuts
• High speeds
• Pre-machined workpiece
Drilling
• Excellent component clamping
• Small overhangs.
F
Average conditions
• Proiling cuts
Boring
• Moderate speeds
• Forged or cast workpiece
• Good component clamping. G
Diicult conditions
Tool holding
• Interrupted cuts
• Low speeds
• Heavy cast or forged skin on workpiece
• Poor component clamping. H
Other information
Machinability
A 39
A Choice of inserts – grades
Dedicated grades
Turning
Dedicated grades minimize tool wear development
B The workpiece material inluences the wear during the

cutting action in diferent ways. Therefore dedicated
grades have been developed to cope with the basic wear
Parting and
mechanisms, e.g.:
grooving
- Flank wear, crater wear and plastic deformation

- Built-up edge and notch wear.
C
Threading
D ISO ISO ISO

Steel Stainless steel Cast iron
P M K
Milling
E
ISO ISO Heat resistant and super ISO
Non-ferrous Hardened steel
N S alloys H
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
A 40
Choice of inserts – shape
A
Selection of the insert shape

The inluence of large and small point angle
Turning
The insert shape and point angle varies Each shape also has unique limitations. B
considerably from the smallest, at 35°, to For example:
the round insert. - high edge accessibility during machining
Parting and
leads to a weaker cutting edge.
grooving
Each shape has unique properties:
- some provide the highest roughing
strength.
C
- others give the best proiling accessibility.
Threading
Round 90° 80° 80° 60° 55° 35°
R S C W T D V
D
Milling
E
Cutting
edge Accessibility
strength
Drilling
Power con-
Vibration sumption
tendency F
Boring
Large point angle Small point angle

• Stronger cutting edge • Weaker cutting edge G
• Higher feed rates • Increased accessibility
Tool holding
• Increased cutting forces • Decreased cutting forces

• Increased vibration. • Decreased vibration.
H
Other information
Machinability
A 41
A Choice of inserts – shape
Factors afecting choice of insert shape

Turning
Insert shape should be selected relative to the entering (lead)

angle accessibility required of the tool. The largest possible point
B angle should be applied to give insert strength and reliability.
Parting and
grooving
Insert shape
C
Roughing strength ++ ++ ++ + +
Threading
Light roughing/semi-
inishing + ++ + ++ ++
D Finishing + + ++ ++ ++
Longitudinal turning ++ + + ++ +
Milling
Proiling + + ++ ++
E
Facing + ++ ++ + + +
+ + ++ +
Drilling
Operational versatility + ++
F Limited machine power + + ++ ++ ++
Vibration tendencies + ++ ++ ++
Boring
Hard material ++ ++
G
Intermittent machining ++ ++ + + +
Tool holding
++ = Most suitable + = Suitable

H
Other information
Machinability
A 42
Choice of inserts – shape
A
Number of cutting edges
Turning
Insert shape
B
ISO (irst letter) R S C W T D V
Parting and
grooving
Number of edges,
8* 8 4 6 6 4 4
negative inserts
C
Number of edges,
4* 4 2 3 3 2 2
positive inserts
Threading
*Depending on ap
Selection of the Corner radius D
Efect of small and large nose radius
Milling
RE
RE E
RE
Drilling
F
Boring
Small corner radius Large corner radius

Rule of thumb
• Ideal for small cutting • Heavy feed rates
The depth of cut
depth G
• Large depths of cut should be no less then
• Reduces vibration the nose radius (RE).
• Strong edge security
Tool holding
• Weak cutting edge.

• Increased radial
pressures.
H
Other information
Machinability
A 43
A Choice of inserts – nose radius
A small nose radius should be irst choice

Turning
With a small nose radius, the radial cutting forces can be kept to a minimum, while
utilizing the advantages of a larger nose radius leads to a stronger cutting edge, better
B surface texture and more even pressure on the cutting edge.
Parting and
grooving
DOC
C
DOC
DOC
Threading
D
• The relationship between nose radius and DOC (depth of cut) afects vibration tendencies.
It is often an advantage to choose a nose radius which is smaller than the DOC.
Milling
E Efect of nose radius and DOC

The radial force exerted on the workpiece However with a round insert, radial
grows linearly until the nose radius of the pressure will never stabilize because the
insert is less than the depth of cut where it theoretical nose radius is half the insert
Drilling
stabilizes at the maximum value. diameter (IC).
Fr
Boring
G
Tool holding
H
Other information
Machinability
A 44
Choice of inserts – nose radius
A
High feed turning with wiper inserts
Turning
Wiper – General information
Why use a wiper
• Increase feed and gain B
productivity
Wiper insert • Use normal feed rate and
Parting and
gain surface quality.
grooving
Rmax When to use wipers
rWiper
• Use wipers as a irst
choice where it’s C
possible.
Limitations
Threading
Conventional insert • General limitation is
vibration
Rmax • Visually, surfaces can D
rISO look diferent even
though the measured
surface is great.
Milling
E
Wiper – Technical solution
• One wiper cutting edge is based on
Drilling
3-9 radii.
• Contact surface between insert and
component is longer with wipers. F
• Longer contact surface makes a better
surface inish.
• Longer contact surface increases cutting
Boring
forces which makes a wiper insert more

sensitive to vibration when machining
unstable components. G
Tool holding
H
Other information
A conventional nose radius compared with a wiper

Machinability
nose radius.
A 45
A Choice of inserts – nose radius
Wiper – Surface inish

Turning
Traditional
B insert
Rule of thumb
Parting and
grooving
• Two times feed with a wiper will

generate as good surface as con-
Wiper insert ventional geometries with normal
C Twice the feed.
feed, same Ra • The same feed with a wiper will
generate twice as good surface
Threading
compared with conventional

geometries.
D
Wiper insert
Same feed,
half Ra
Rt = Maximum value peak-to-valley height
Milling
Ra = Arithmetic average height of the

E proile
Drilling
Achieved surface – traditional ISO inserts and wipers
F Ra
(µm)
(236) 6.00
(197) Insert geometry

Boring
5.00
(157) 4.00 Standard -PM

G
(118) 3.00 Wiper -WM
Tool holding
(79) 2.00
Wiper -WMX
(39) 1.00
H (0) 0.00
0.20 0.35 0.50 0.65 Feed, fn mm/r (inch/r)
Other information
(.008) (.014) (.020) (.026)

Machinability
A 46
Choice of inserts – speed and tool life
A
Cutting data parameters afect tool life
Turning
Use the potential of: B
- ap – to reduce number of cuts
Parting and
- fn – for shorter cutting time
grooving
- vc – for best tool life
Threading
Tool life
Cutting speed D
vc – large efect on tool life.
Adjust vc for best economy
Milling
Cutting speed vc E
Drilling
Feed
Tool life
fn – less efect on tool life than vc

F
Boring
Feed fn
Cutting depth
Tool life
Tool holding
ap – little efect on tool life
H
Other information
Machinability
Cutting depth ap
A 47
A Choice of inserts – speeds and tool life
Efects of cutting speed

Turning
The single largest factor determining tool life
B Too high Too low

• Rapid lank wear • Built-up edge
Parting and
• Poor inish • Uneconomical.

grooving
• Rapid cratering
• Plastic deformation.
C
Threading
Efects of feed rate

D
The single largest factor determining productivity
Too high Too low

Milling
• Loss of chip control • Stringers

• Poor surface inish • Uneconomical.
E
• Cratering, plastic
deformation
• High power consumption
Drilling
• Chip welding
F • Chip hammering.
Boring
Efects of depth of cut

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

• Increased cutting forces. • Excessive heat
• Uneconomical.
H
Other information
Machinability
A 48
Choice of tools – external turning
A
External turning
Turning
Tool selection and how to apply
B
Parting and
grooving
C
Threading
D
Milling
General guidelines
E
• Secure insert and tool holder clamping is an essential
factor for stability in turning.
• Tool holder types are deined by the entering (lead)
Drilling
angle, the shape and size of the insert used.
• The selection of tool holder system is mainly based on F
the type of operation.
• Another important selection is the use of negative
versus positive inserts.
Boring
• Whenever possible choose modular tools.
G
Tool holding
H
Other information
Machinability
A 49
A Choice of tools – external turning
Four main application areas

Turning
Longitudinal turning/facing
B
The most common turning operation
• Rhombic shape C-style (80°) insert is frequently used.
Parting and
• Holders with entering angles of 95° and 93° (lead angles of –5°
and –3°) are commonly used.
grooving
• Alternatives to the C-style insert are D-style (55°), W-style (80°)

and T-style (60°).
C
Proiling
Threading
Versatility and accessibility is the determining factor

• The efective entering angle KAPR (lead angle PSIR) should be
D considered for satisfactory machining.
• Most commonly used entering angle = 93° (lead angle is –3°)
because it allows an in-copying angle between 22°-27°.
• The most frequently used insert shapes are D-style (55°) and
V-style (35°) inserts.
Milling
E
Facing
The tool is fed in towards the center
• Pay attention to the cutting speed which will change pro-
Drilling
gressively when feeding towards the centre.

• Entering angles of 75° and 95°/91° (Lead angles of 15° and
F –5°/–1°) are commonly used.
• C-style (80°) and S-style (90°), inserts are frequently used.
Boring
Pocketing
G
A method to produce or widen shallow grooves
• Round inserts are very suitable for plunge turning as they can
be used for both radial and axial feeds.
Tool holding
• Neutral 90° holders for round inserts are commonly used.
H
Other information
Machinability
A 50
A
Large entering angle (small lead angle)
Turning
Features / Beneits
• Cutting forces directed towards chuck B
• Can turn against a shoulder
Parting and
• Higher cutting forces at entrance and exit of cut
grooving
• Tendency to notch in HRSA and hard materials.
Threading
Small entering angle (large lead angle)
D
Features / Beneits
• Produces a thinner chip
Milling
- Increased productivity
• Reduced notch wear E
• Cannot turn against a shoulder.
45º
(45º)
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
A 51
A Choice of tools – external turning
The entering and copying angle

Turning
Important consideration in proile turning
B • In proile turning, the cut can vary with regard

to cutting depth, chip thickness and speed.
Out- Longitu- In-
• The largest suitable nose angle on the insert Copying dinal Copying
Parting and
grooving
should be selected for strength and cost

eiciency, but the insert nose angle also has
to be considered in relation to accessibility for
C proper clearance between material and cutting
edge.
• The most common nose angles used are 55°
Threading
and 35°.
• The entering/lead and insert nose angle are
both important factors for accessibility. The
D work piece proile has to be analyzed in order
to select the most suitable copying angle.
• A free cutting angle of at least 2° between the
workpiece and the insert has to be maintained.
Milling
E
Axial and radial cutting forces
Large entering angle Small entering angle
Drilling
(small lead angle) (large lead angle)
F
Ff = axial
Ff = axial
Fp = radial
Boring
Fp = radial
G • Forces directed toward the chuck. Less • Forces are directed both axially and radially.
tendency for vibration.
• Reduced load on the cutting edge.
Tool holding
• Higher cutting forces especially at

• Forces are directed both axially and radially
entrance and exit of cut.
- Vibration tendencies.
H
Other information
Machinability
A 52
A
Insert recommendation depending on operation
Turning
Insert shape
Longitudinal
Pocketing
B
Proiling
turning
Facing
Parting and
++ = Recommended
grooving
+ = Alternative
C
Rhombic 80° ++ +
Threading
Rhombic 55° + ++ +
Round + + + ++ D
Square + ++
+ + +
Milling
Triangular
Trigon 80° + + E
Rhombic 35° +
Drilling
Selecting the insert clearance angle F
Wedge Screw Concept

Boring
Lever Rigid clamping

clamping clamping clamping
G
Tool holding
H
Other information
Machinability
A 53
A Choice of tools - internal turning
Internal turning
Turning
Tool selection and how to apply

B
General guidelines
Parting and
• In internal turning (boring operations) the

grooving
choice of tool is very much restricted

by the component’s hole diameter and
length.
C
- Choose the largest possible bar
diameter and the smallest possible
overhang
Threading
- Chip evacuation is a critical factor for

successful boring
D
- The clamping method has a decisive
efect on the performance and result
- Applying coolant can improve chip
evacuation.
Milling
E
Drilling
F
Selection factors
Tool and insert geometry Chip evacuation Tool requirements
• Entering (lead) angle
Boring
• Chip size • Reduced length

• Insert shape, negative/ • Chip control • Increased diameters
G positive
• Techniques • Optimized shape
• Insert geometry
• Coolant. • Diferent tool materials
Tool holding
• Nose radius
• Clamping
• Corner radius.
• Dampened solutions.
H
Other information
Machinability
A 54
Choice of tools – internal turning
A
Efect of cutting forces on internal turning
Turning
Radial and tangential cutting forces delect the boring bar
B
Tangential cutting force, Ft
• Forces the tool down, away from the
Parting and
center line
grooving
• Gives a reduced clearance angle.
C
Radial cutting force, Fr
• Alters cutting depth and chip thickness
Threading
Fr • Gives out of tolerance dimension and
risk of vibration.
Fa D
Feed force, Fa
• Directed along the feed of the tool.
Ft F
Milling
E
Selecting entering (lead) angles
Drilling
Entering (lead) angle and cutting forces
F
• Select an entering angle close to 90°
(lead angle close to 0°). Boring
• If possible, do not choose an entering

angle less than 75° (lead angle not more G
than 15°), since this leads to a dramatic
increase of the radial cutting force Fr.
Tool holding
- Less force in radial direction = less

delection.
H
Other information
Machinability
A 55
A Choice of tools – internal turning
Four main application areas

Turning
Longitudinal turning/facing
B The most commonly used internal turning operation.
• Rhombic shape C-style 80° insert is frequently used.
• Boring bars with an entering (lead) angle of 95° (-5°) and 93° (-3°)
Parting and
are commonly used.

grooving
• D-style 55°, W-style 80° and T-style 60° insert shapes are also
frequently used.
C
Proiling
Threading
Versatility and accessibility is the determining factor.

• The efective entering angle, KAPR (lead angle, PSIR) should be
D considered.
• Bars with entering (lead) angle of 93° (–3°), allowing an in-copy-
ing angle between 22–27°, are commonly used.
• D-style 55° and V-style 35° inserts are frequently used.
Milling
E
Longitudinal turning
Boring operations are performed to open up existing holes.
• An entering (lead) angle of close to 90° (0°) is recommended.
Drilling
• Use smallest possible overhang.

• C-style 80°, S-style 90° and T-style 60° inserts are frequently
F used.
Boring
Back boring
G
Back boring is a boring operation with reverse feed.
• It is used for turning shoulders less than 90°.
Tool holding
• Boring bars with 93° (–3°) entering (lead) angles and D-style 55°
inserts are commonly used.
H
Other information
Machinability
A 56
Choice of tools – internal turning
A
Selecting the insert clearance angle
Turning
Positive inserts generate lower cutting force and tool delection
B
• Inserts with clearance angle 7°
- First choice for small and medium holes
from 6 mm (.236 inch) diameter.
Parting and
grooving
• For best economy
- Use negative inserts in stable condi-
tions and with short overhang. C
Threading
D
7°, positive, single
Negative, double
sided inserts
sided inserts
Milling
Insert recommendation depending on operation
E
Insert shape Longitudinal Proiling Facing
turning
++ = Recommended
Drilling
+ = Alternative
F
Rhombic 80° + ++
Rhombic 55° + ++ +
Boring
Round + +
G
Square +
Tool holding
Triangular ++ +
Trigon 80° + + H
Other information
Rhombic 35° +
Machinability
A 57
A Choice of tools – internal turning
Insert point angle

Turning
Large point angle: Small point angle:

- Stronger cutting edge - Increases accessibility Use the smallest angle
B - Higher feed rates - Decreases vibration giving acceptable
- Increases cutting forces - Decreases cutting forces strength and economy.
- Increases vibration
Parting and
grooving
C Round 90° 80° 80° 60° 55° 35°

R S C W T D V
Threading
Cutting edge
Accessibility
strength
Milling
Vibration tendency Power consumption
Chip area and corner radius

Cutting forces and cutting tool delection
Drilling
F
Rule of thumb!
Choose a nose radius
which is somewhat less
Boring
than the cutting depth.
G • Both small and large chip • The relationship between

areas can cause vibration: RE (nose radius) and ap
- Large due too high (depth of cut) afects
Tool holding
cutting forces vibration tendencies.

- Small due too high • Less force in radial direc-
friction between the tool tion = less delection.
and the workpiece.
H
Other information
Machinability
A 58
Choice of tools – how to apply
A
Clamping the boring bar
Turning
Critical stability factors for optimized performance
B
• Maximum contact between tool and tool
holder (design, dimensional tolerance).
Parting and
• Clamping length 3 to 4 times bar dia-
grooving
meter (to balance cutting forces).
• Holder strength and stability.
C
Threading
D
Milling
Tool requirements for clamping E
Maximum contact between tool and tool holder
Drilling
Recommended
F
Coromant Capto® coupling
Boring
Acceptable
Not recommended
Tool holding
H
Not recommended
Other information
Machinability
A 59
A Choice of tools - how to apply
EasyFix sleeves
Turning
For correct clamping of cylindrical bars
B Guarantees correct center height

Parting and
Beneits:
grooving
• Cutting edge in right position
C • Best cutting action gives better surface inish

• Reduced setup time
• Even insert wear.
Threading
D Silicon sealer
Milling
E Groove
Drilling
F
Boring
Spring plunger
G A spring plunger mounted in the sleeve clicks into a

groove in the bar and guarantees correct center height.
The slot in the cylindrical sleeve is illed with a silicon
Tool holding
sealer which allows the existing coolant supply system to

be used.
H
Other information
Machinability
A 60
Choice of tools - how to apply
A
Factors that afect vibration tendencies
Turning
Vibration tendencies grow towards the right
B
Parting and
grooving
Entering angle
C
Threading
Lead angle
Corner radius D
Micro and macro geometry
Milling
Edge design
E
Depth of cut (DOC)
Drilling
Lead (entering) angle Edge design
• Choose an entering angle as close to 90° • Insert wear changes the clearance F
(lead angle as close to 0°) as possible, between the insert and the hole wall. This
never less than 75° (more than 15° for can afect the cutting action and lead to
lead angle). vibration.
Boring
Corner radius • Inserts with thin coatings, or uncoated

• Choose a corner radius which is some- inserts, are to be preferred as they
what smaller than the cutting depth. normally give lower cutting forces. G
Micro and macro geometry Depth of cut (DOC)
Tool holding
• Use a positive basic-shape insert, as • Choose a corner radius which is some-

these give lower cutting forces com- what smaller than the cutting depth.
pared to negative inserts.
H
Other information
Machinability
A 61
A Choice of tools - how to apply
Chip evacuation
Turning
Chip evacuation is a critical factor for successful boring
B • Centrifugal force presses the chips to the

inside wall of the bore.
• The chips can damage the inside of the
Parting and
grooving
bore.
- Internal coolant can help with chip

C evacuation.
- Boring upside down helps to keep
chips away from the cutting edge.
Threading
Chip evacuation and chip control

Milling
Short and spiral chips

• Preferred. Easy to transport and do not
E cause a lot of stress on the cutting edge
during chip breaking.
Drilling
F Long chips
• Can cause chip evacuation problems.
• Causes little vibration tendency, but can
in automated production cause problems
Boring
due to chip evacuation diiculties.
Hard breaking of chips, short chips

Tool holding
• Power demanding and can increase the

vibration.
• Can cause excessive crater wear and
H result in poor tool life and chip jamming.
Other information
Machinability
A 62
Choice of tools - how to apply
A
Recommended tool overhang
Turning
Maximum overhang for diferent types of bars
B
Steel bar
– up to 4 x DMM
Parting and
grooving
Carbide bar
– up to 6 x DMM
C
Short, dampened bar
– up to 7 x DMM
Threading
Long, dampened bar
– up to 10 x DMM
D
Carbide reinforced, dampened bar
– up to 14 x DMM
Clamping
Overhang: ... x DMM
Milling
14 10 7 6 4 length:
4 x DMM
E
Eliminate vibrations
Internal machining with dampened boring bars
Drilling
• Increase productivity in deep bores. Rubber damper
• Minimize vibration. Coolant tube F

Oil
• Machining performance can be maintained
or improved.
Boring
• Dampened boring bars are available in

diameters from 10 mm (.394 inch).
High density mass
• For max overhang 14 x DMM (carbide G
reinforced).
Cutting head
Tool holding
Steel bar
H
Other information
Dampened bar
Machinability
A 63
A Code keys
Code key for inserts and toolholders - METRIC

Turning
Extract from ISO 1832:1991

B
INSERT Tolerances Insert thickness
Nose radius
Parting and
grooving
C
C N M G 12 04 08 - PM
1 2 3 4 5 6 7 8
Threading
1. Insert shape
5. Insert size = cutting edge length
D
2. Insert clearance angle

Milling
TOOL HOLDERS
E
External
D C L N R 25 25 M 12
Drilling
B 1 C 2 D E F G 5
F
C4
A
Internal
Boring
G
A 25 T D C L N R 12
H J G B 1 C 2 D 5
Tool holding
Bar diameter
S = Solid steel bar Holder style

A = Steel bar with coolant supply
H Coromant Capto® E = Carbide shank bar
F = Dampened, carbide shank bar
Other information
coupling size
Machinability
A 64
Code keys
A
1. Insert shape 2. Insert clearance angle
Turning
80° 55° 35° 80°
C D R S T V W
B C P N B
4. Insert type 5. Insert size = Cutting edge length
Parting and
grooving
A G
M T l mm: 06–25 07–15 06–32 09–25 06–27 11–16 06–08
C
7. Nose radius
02 RE = 0.2 First choice nose radius recommendations:
Threading
04 RE = 0.4 T-MAX P CoroTurn 107
08 RE = 0.8
RE 12 RE = 1.2 Finishing 08 04
16 RE = 1.6 Medium 08 08
24 RE = 2.4 Roughing 12 08
D
8. Geometry — manufacturer’s option
Milling
The manufacturer may add a further two symbols to the code describing the
insert geometry e. g.
-PF = ISO P Finishing E
-MR = ISO M Roughing
B. Clamping system
Drilling
D M P S F
Rigid clamping (RC) Top and hole clamping Hole clamping Screw clamping
Boring
D. Hand of tool E. Shank height G. Tool length
Tool length G
R = l1 in mm
Right-hand style
Tool holding
L F. Shank width H = 100 S = 250

Left-hand style K = 125 T = 300
M = 150 U = 350
P = 170 V = 400 H
N
Q = 180 W = 450
Other information
Neutral R = 200 Y = 500

Machinability
A 65
A Code keys
Code key for inserts and toolholders - INCH

Turning
Extract from ANSI/ISO standards

B
INSERT Tolerances Insert thickness
Nose radius
Parting and
grooving
C
C N M G 4 3 2 - PM
1 2 3 4 5 6 7 8
Threading
1. Insert shape
5. Insert size
D
2. Insert clearance angle

Milling
TOOL HOLDERS
E
External
D C L N R 16 4 D
Drilling
B 1 C 2 D E 5 F
F
C4
A
Internal
Boring
G
A 16 T D C L N R 4
H J G B 1 C 2 D 5
Tool holding
Bar diameter
S = Solid steel bar Holder lead angle

A = Steel bar with coolant supply
H Coromant Capto® E = Carbide shank bar
F = Dampened, carbide shank bar
Other information
coupling size
Machinability
A 66
Code keys
A
1. Insert shape 2. Insert clearance angle
Turning
80° 55° 35° 80°
C D R S T V W
B C P N B
4. Insert type 5. Insert size
Parting and
grooving
A G Inscribed circle is indicated in 1/8"
S T W
M T
C
7. Nose radius
0 RE = .008 First choice nose radius recommendations:
Threading
1 RE = 1/64
T-MAX P CoroTurn 107
2 RE = 1/32
RE 3 RE = 3/64 Finishing 2 1
4 RE = 1/16 Medium 2 2
6 RE = 3/32 Roughing 3 2
D
8. Geometry — manufacturer’s option
Milling
The manufacturer may add a further two symbols to the code describing the
insert geometry e. g.
-PF = ISO P Finishing E
-MR = ISO M Roughing
B. Clamping system
Drilling
C D M,W P S F
Top clamping Rigid clamping (RC) Top and hole clamping Hole clamping Screw clamping
Boring
D. Hand of tool E. Shank or bar size G. Tool length
Shanks: External, l1 in inch Internal, l1 in inch G

R height and
width A = 4.0
Right-hand style B = 4.5
Tool holding
C = 5.0
L D = 6.0
Left-hand style M= 6.0
Bars: M = 4.0
R= 8.0
S= 10.0 H
N
T= 12.0
Other information
Neutral U= 14.0
Machinability
A 67
A Troubleshooting
Troubleshooting
Turning
Chip control
B Problem Cause Solution
Long unbroken snarls winding • Feed too low for the chosen • Increase the feed.
around the tool or workpieces. geometry. • Select an insert geometry
Parting and
with better chip breaking

grooving
capabilities.
• Use a tool with high precision
coolant.
C
Threading
• Depth of cut too shallow for • Increase the depth of cut or

the chosen geometry. select a geometry with better
chip breaking capability.
• Nose radius too large. • Select a smaller nose radius.

Milling
• Unsuitable entering (lead) • Select a holder with as large

E angle. entering angle (small lead
angle) as possible KAPR =90°
(PSIR =0°).
Drilling
Very short chips, often • Feed too high for the chosen • Choose a geometry
sticking together, caused by geometry. designed for higher feeds,
F too hard chip breaking. Hard preferably a single-sided
chip breaking often causes insert.
reduced tool life or even insert • Reduce the feed.
breakages due to too high
chip load on the cutting edge.
Boring
• Unsuitable entering (lead) • Select a holder with as small

G angle. entering angle (large lead
angle) as possible KAPR
=45°–75° (PSIR=45°–15°).
Tool holding
• Nose radius too small. • Select a larger nose radius.

H
Other information

Machinability
A 68
Troubleshooting
A
Surface inish
Turning
Problem Cause Solution
The surface looks and feels • The chips are breaking • Select a geometry which
“hairy” and does not meet the against the component and guides the chips away. B
tolerance requirements. marking the inished surface. • Change entering (lead) angle.
• Reduce the depth of cut.
Parting and
• Select a positive tool system
grooving
with a neutral angle of inclina-
tion.
• Hairy surface caused by • Select a grade with better
Threading
excessive notch wear on the resistance to oxidation wear,
cutting edge. e.g., a cermet grade.
• Reduce the cutting speed.
D
• Too high feed in combination • Select a wiper insert or a
Milling
with too small nose radius larger nose radius.
generates a rough surface. • Reduce the feed.
E
Burr formation
Drilling
Burr formation at the end of • The cutting edge is not sharp • Use inserts with sharp edges:
the cut when the cutting edge enough. - PVD coated inserts.
is leaving the workpiece. • The feed is too low for the - ground inserts at small feed F
edge roundness. rates, < 0.1 mm/r (.004 inch/r).
Boring
• Notch wear at depth of cut, • Use a holder with a small G

or chipping. entering angle (large lead
angle).
Tool holding
• End the cut with a chamfer

or a radius when leaving the H
workpiece.
Other information

Machinability
A 69
A Troubleshooting
Vibration
Turning

High radial cutting forces due • Unsuitable entering/lead • Select as large as possible
B to: angle. entering angle (KAPR = 90°)
or as small as possible lead
angle (PSIR = 0°).
Parting and
grooving
• Nose radius too large. • Select a smaller nose radius.

Vibrations or chatter marks
C which are caused by the
tooling or the tool mounting.
Typical for internal machining • Unsuitable edge rounding, or • Select a more positive
with boring bars. negative chamfer. geometry or a grade with a
thin coating, or an uncoated
Threading
grade.
• Excessive lank wear on • Select a more wear resistant

D cutting edge. grade or reduce speed.
Milling
High tangential cutting forces • Insert geometry creating • Select a positive insert
E due to: high cutting forces. geometry.
Drilling
• Chip-breaking is too hard • Reduce the feed or select a

giving high cutting forces. geometry for higher feeds.
• Varying or too low cutting • Increase the depth of cut

forces due to small depth slightly to make the insert
Boring
of cut. cut.
G
• Tool incorrectly positioned. • Check the center height.
Tool holding

Other information
Machinability
A 70
Troubleshooting
A
Turning
• Instability in the tool due to • Reduce the overhang.
long overhang. • Use the largest bar diameter. B
• Use a Silent Tool or a carbide
bar.
Parting and
grooving
C
Threading
• Unstable clamping ofers • Extend the clamping length D
insuicient rigidity. of the boring bar.
• Use EasyFix for cylindrical
bars.
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
A 71
Parting & Grooving
Parting and grooving is a category of turning. It has a

wide range of machining applications requiring dedicated
tools.
These tools can be used, to some extent, for general
turning.
• Theory B4
• Selection procedure B7
• System overview B 11
• Parting & grooving – how to apply B 16
• Troubleshooting B 37
B3
A
Theory
Parting & grooving theory

Parting of
Turning
B
Chip evacuation is essential
Chip evacuation is a critical factor in parting operations. There is
little opportunity to break chips in the conined space as the tool
Parting and
grooving
moves deeper. The cutting edge is designed largely to form the

chip so it can be evacuated smoothly. Consequences of poor
chip evacuation are chip obstruction, which leads to poor surface
C
quality, and chip jamming, leading to tool breakdown.
Threading
D • Chip evacuation is a critical factor in parting

operations.
• Chip breaking is diicult in the conined slots
created as tools cut deep into the workpiece.
Milling
• Typical chips are clock-spring shaped,

narrower than the groove.
E
• The insert geometry shrinks the chip width.
Drilling
F
Parting of – deinition of terms
Boring
n
n = spindle speed (rpm)
G vc = cutting speed m/min (ft/min)
fnx = radial cutting feed mm/r (inch/r)
Tool holding
OH = overhang recommended
H
Other information
Machinability
B4
Theory
A
Cutting speed value
Turning
When parting of to center, the cutting speed will gradually
be reduced to zero when the machine has reached its rpm
limit. B
Parting and
grooving
• Cutting speed declines to zero at the
C
center.
Threading
D
100 – 0% of vc
Milling
Feed reduction towards center E
Cutting speed decreases toward the part center line, causing unbalance.
Feed rate must be reduced to maintain cutting force balance during the
part-of. The feed rate should be reduced to the minimum recommended or
Drilling
about 0.05 mm/rev (.002"/rev) at 2 mm (.079") before reaching centerline.
• Start cut with recommended feed

Boring
rate, reference insert box
• Reduce feed to 0.05 mm/rev (.002"), 2 mm
(.079") before centerline G
• Feed reduction reduces vibration and
Tool holding
increases tool life

• Feed reduction also reduces pip size.
2 mm H
Other information
(.079 inch)
Machinability
B5
A Theory
Grooving– deinition of terms

Turning
The tool movement in directions X and Z is called feed rate (fn), or

fnx/fnz, mm/r (inch/r). When feeding towards center (fnx), the rpm will
B increase until it reaches the rpm limit of the machine spindle. When
this limitation is passed, the cutting speed (vc) will decrease until it
reaches 0 m/min (ft/min) at the component center.
Parting and
grooving
C n = spindle speed (rpm)

n
fnz = axial cutting feed mm/r (inch/r)
Threading

ar = depth of groove mm (inch)
D (outer dia. to center or bottom of
groove)
ap = depth of cut in turning
Milling
E
Face grooving– deinition of terms
The feed has a great inluence on chip formation, chip breaking, and
thickness, and also inluences how chips form in the insert geometry.
In sideways turning or proiling (fnz), the depth of the cut (ap) will also
Drilling
inluence chip formation. The groove diameter for the irst cut must be
F within the range speciied on the used tool holder.

Boring

G fnz = axial cutting feed mm/r (inch/r)
n
Tool holding
ar = depth of groove mm (inch)

DAXIN = minimum irst groove diameter
(2 on this illustration)
H
DAXX = maximum irst groove
Other information
diameter (1 on this illustration)

Machinability
2
B6
Selection procedure
A
Tool selection procedure
Turning
Production planning process B
<.01 mm (.0004")
Parting and
grooving
Dimension and quality
of the groove or face
C
1 Component
Workpiece material,
Threading
chip evacuation
Machine parameters
Milling
2 Machine
E
Type of tool:
- Spring-clamp
3 Choice of tool - Screw-clamp
Drilling
- Insert type
Cutting data, method,

cutting luid, etc
4 How to apply
Boring
G
Tool holding
5 Troubleshooting Remedies and solutions

H
Other information
Machinability
B7

Turning
B
Component
• Analyze the dimensions
Parting and
and quality demands of

grooving
the groove or face to be

machined
C • Type of operation: parting,
grooving
• Cutting depth
Threading
• Cutting width
• Corner radius.
D
Material
Milling
P M K • Machinability
E • Chip breaking
N S H • Hardness
• Alloy elements.
Drilling
F 2. Machine parameters
Some important machine considerations:
• Stability, power and torque especially for
Boring
larger diameters
• Component clamping
G
• Turret interface
• Tool changing times/number of tools in
Tool holding
turret
• Chip evacuation
H • Cutting luid and coolant.

Other information
Machinability
B8
Selection procedure
A
3. Choice of tools
Turning
Example of diferent machining methods
B
Multiple grooving
• Multiple grooving is the best method for
Parting and
grooving
rough grooving when the depth is bigger
than the width.
• Make a “fork”. This will improve chip low C
and increase tool life.
Threading
D
Plunge turning
• Plunge turning is the best choice when
Milling
machining steel and stainless steel and
when the width of the groove is larger
than the depth. E
• Good chip control.
Drilling
F
Ramping
• Ramping avoids vibration and minimizes
Boring
radial forces.
• Round inserts are the strongest inserts
available. G
• Double the number of cuts/passes.
Tool holding
• First choice in heat resistant super alloys

(HRSA). Reduces notch wear.
H
Other information
Machinability
B9
4. How to apply
Turning
Application considerations
B • Center height is important, ±0.1 mm
(±.004 inch).
• Recommended feed rate 0.05 mm
Parting and
grooving
(.002 inch) / rev approximately 2 mm

2 mm (.079 inch) before center.
(.079 inch)
Max ±0.1 mm • Use shortest possible overhang, OH mm
C
(±.004 inch) (inch).
• Largest height dimension on blade for
bending stifness.
Threading
• Use coolant to improve chip low.
D
Milling
5. Troubleshooting
Drilling
Some areas to consider Insert wear and tool life

• Check the wear pattern and if necessary
F adjust cutting data accordingly.
To improve chip formation & tool wear

• Use recommended chip former.
Boring
• Use neutral front angle.

• Check center height.
G
• Use cutting luid.
Tool holding
H
Other information
Machinability
B 10
System overview
A
System overview
Turning
External parting and grooving
B
1. Parting-of solid bars and tubes 4. Shallow to deep grooving
2. Turning and recessing 5. Face grooving
Parting and
3. Undercutting 6. Proiling
grooving
4 C
Threading
6 D
1
4
Milling
3 4
2 E
Drilling
Internal grooving F
1. Grooving and pre-parting

2. Face grooving
Boring
3. Proiling
1 G
3
Tool holding
1 H
Other information
2
Machinability
B 11
A System overview
Diferent systems
Turning
Insert type
B
CoroCut CoroCut Circlip
Application CoroCut2 CoroCut1 CoroCut3 QD QF 266
Parting and
grooving
Parting
(Cut of)
Medium Deep Shallow Deep
C
Grooving
Threading
Face groov-
ing
D
Turning
Milling
Proiling
E
Undercutting
Drilling
F Circlip
grooving
First choice Second choice

Boring
G
Tool holding
H
Other information
Machinability
B 12
System overview
A
External parting and grooving
Turning
Diferent systems
B
External parting – diameter ranges
Deep parting – Ø < 160 mm (6.299”)
Parting and
grooving
Medium parting – Ø < 40 mm (1.575”)
C
Shallow parting – Ø < 12 mm (.472”)
Threading
Grooving – depth ranges D
Deep grooving – depth < 100 mm (3.937”)
Milling
Medium grooving – depth < 50 mm (2.000”)
E
Shallow grooving – depth < 6 mm (.236”)
Shallow grooving – depth < 3.7 mm (.146”)
Drilling
F
Face grooving – diameter ranges

Boring
G
Large diameters > 34 mm (1.338")
Tool holding
Small diameters > 0.2 mm (.0078")
Small diameters > 6 mm (.236")

H
Medium to large diameters > 16 mm (.629")
Other information
Machinability
B 13
A System overview
Internal parting and grooving

Turning
Diferent systems
B
Internal grooving – min hole diameter
Parting and
grooving
C
Threading
≥4.2 ≥10 ≥12 ≥25

(≥.165) (≥.394) (≥.472) (≥.984)
D
Milling
E Min. hole
4.2 10 12 25 diameter,
(.165) (.394) (.472) (.984) mm (inch)
Drilling
F Face grooving – hole diameter range

Boring
Ø6.2 Ø12 Ø23

(Ø.244) (Ø.472) (Ø.906)
G
Tool holding
First cut
diameter,
mm
6.2 – 18 12 – 30 23 – ∞ (inch)
H
(.244 – .709) (.472 – 1.181) (.906 – ∞)
Other information
Machinability
B 14
System overview
A
Inserts
Turning
Geometry overview
B
Application
Parting and
grooving
Parting
Grooving Turning Proiling C
Machining (Cut of)
condition
Threading
Finishing CF GF TF
D
Medium CM GM TM RM AM
Milling
Roughing CR
E
RO
Drilling
Optimizer CS RS
F
GE RE
Boring
G
Tool holding
H
Other information
Machinability
B 15
A
Turning Parting and grooving – how to apply
B
Parting & grooving and how
to apply
Parting and
grooving
• Parting and grooving and how to apply B 17

C
• Parting of and how to apply B 22

Threading
• General grooving and how to apply B 26
D • Circlip grooving and how to apply B 28
• Face grooving and how to apply B 29

Milling
• Proiling and how to apply B 32

E
• Turning and how to apply B 34
• Undercutting and how to apply B 36

Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
B 16
Parting and grooving – how to apply
A
Tool overhang and workpiece delection
Turning
The tool overhang should always be minimized for
improved stability. In parting and grooving operations
consideration must be given to the depth of cut and the B
width of the groove, which means that stability must often
be compromised to meet the demands of accessibility.
Parting and
grooving
C
Best stability
Threading
• Overhang (OH) should be as small as
possible
• Largest seat size should be used
D
Milling
E
Internal machining
Shank type:
Drilling
• Steel bars ≤3 x DMM
• Dampened steel bars ≤5 x DMM F
• Carbide bars ≤5 x DMM
• Carbide reinforced dampened bars, up to
Boring
7 x DMM.
G
Tool holding
Inserts:
• Use smallest possible width
H
• Use light cutting geometries.
Other information
Machinability
B 17
A Parting and grooving – how to apply
Tool holder selection parameters

Turning
System considerations
B
Parting and
grooving
C
Threading
Deep parting
D Shallow parting Medium parting

Milling
Deep parting Medium parting Shallow parting
E • First choice are spring- • First choice for medium • Use the 3-edge insert for
clamp blades with single- parting are holders with economic parting in mass
edge inserts. 2-edge inserts. production.
Drilling
F General tool holder considerations

Tool block with spring-clamp tool blade for tool overhang
adjustment.
Boring
G • Shortest possible overhang, OH mm (inch)

• Maximum tool holder shank
Tool holding
• Largest height dimension

• Maximum blade width.
H
Other information
Machinability
B 18
A
Spring-clamp design blades
Turning
Features/Beneits
• Quicker insert change B

• Cut of larger diameter
• Adjustability
Parting and
grooving
• Deep grooving
• Double ended
• Radial feed only
C
Threading
Screw-clamp and spring-lock design holders
D
Features/Beneits
• Smaller diameters
• Shallow grooving
Milling
• Radial & axial feed
• Increased rigidity
E
• Single ended
Drilling
Screw-clamp design holders for 3-edge inserts F
Features/Beneits
Boring
• Extremely small insert widths

- grooving down to 0.5 mm (.020")
- parting down to 1 mm (.039"). G
• Cutting depths up to 6 mm (.236").
• One holder for all insert widths.
Tool holding
• Very tight insert indexing tolerance.

• The productivity choice, 3 cutting edges.
H
Other information
Machinability
B 19
A Parting and grooving – how to apply
Parting-of bars
Turning
Use as narrow an insert as possible:

- To save material
B - Minimize cutting force
- Minimize environmental pollution.
Parting and
grooving
C
Threading
D
Material savings
Milling
E
Drilling
Positioning of the tool

F
Use maximum deviation of ±0.1 mm
Max ±0.1 mm (±.004 inch)
(±.004 inch) from center line.
Too high cutting edge

Boring
• Clearance will decrease.

• Cutting edge will rub (break).
G
Too low cutting edge
Tool holding
• Tool will leave material in center (PIP).
H
Other information

Machinability
B 20
A
 Positioning of the tool
Turning
90º mounting of tool holder
• Perpendicular surface
• Reduce vibrations. B
Parting and
grooving
Hand of insert C
Three types of insert with diferent
Hand of insert entering angles:
Threading
- Right hand (R)
- Neutral (N)
- Left hand (L).
D
Right hand (R)
Milling
Insert geometry E
Neutral entering angle
• Increases strength
• Higher feed/productivity
Drilling
• Better surface inish
• Straighter cut
F
• Pip stays on part falling of.
Small/large corner radius

Boring
Small corner radius G

• Smaller pip
• Better chip control
Tool holding
• Lower feed rate.
Large corner radius

• Increased feed rate H
• Longer tool life.
Other information
Machinability
B 21
A Parting of – how to apply
Parting of
Turning
Pip reduction by using diferent front angles
B • Choose left or right hand front angle to

control the pip or burr.
• When the front angle is:
- increased, the pip/burr is decreased
Parting and
grooving
- decreased, the chip control and tool life

are improved.
• Centrifugal force will always push away
C the parted of component
- Tool will leave material in center (pip).
R
Threading
Example of front angles on

D 1-, 2- and 3-edge inserts: Note!
KAPR = 95°, 98°, 100°, 102°, 105°, A front-angled insert will give reduced
110° chip control due to the direction of the
(PSIR = 5°, 8°, 10°, 12°, 15°, 20°) chip low. (A neutral insert directs the
chip straight out of the groove).
Milling
Parting-of tubes
Drilling
Use insert with the smallest possible width (CW) to

F save material, minimize cutting force and environmental
impact.
Boring
G
Parting-of thin walled tubes
Tool holding
Make sure that the lowest possible cutting forces are

generated. Use inserts with the smallest possible width
and sharpest cutting edges.
H
Other information
Machinability
B 22
A
Tool selection - Review
Turning
General Consider:
recommendations:
B
• Neutral inserts • Cutting depth
• Smallest possible • Insert width
Parting and
insert width
grooving
• Front angle
• Largest possible tool
• Corner radius.
holder.
C
Threading
D
Use cutting luid
Cutting luid has an important function since the space is often
restricted and obstructed by the chips. It is therefore important
Milling
that precision coolant always us used in large amounts and
directed at the cutting edge throughout the whole operation.
E
Drilling
F
Boring
Apply: Result:
G
• Use large amounts • Positive efect on chip
formation
Tool holding
• Directly at the cutting

edge • Prevents chip jamming
• Precision coolant. • Adds tool life.
H
Other information
Machinability
B 23
A Parting of – how to apply
Practical hints
Turning
Max ±0.1 mm
(±.004 inch) • Center height is important,
±0.1 mm (±.004 inch).
B
• If subspindle is used, pull
away the component
Parting and
approximately 2 mm
grooving
ø2 mm (.079 inch) before center.

(ø.079inch)
• Recommended feed rate
C 0.05 (.002 inch) / per rev
approximately 2 mm
(.079 inch) before center –
also for tube parting.
Threading
D
2 mm
(.079 inch)
fn 0.05 mm (.002 inch) / rev

Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
B 24
Parting of – how to apply
A
Recommendations for boring bar solutions
Turning
Recommended overhang
B
DMM
Parting and
Carbide reinforced
grooving
dampened bars
LBX <7 x DMM C
DMM
Threading
Dampened steel bars
Carbide bars
D
LBX ≤5 x DMM
DMM
Milling
E
Solid steel bars
LBX ≤3 x DMM
Drilling
F
EasyFix sleeves Boring
Use EasyFix clamping sleeves G

for accurate machining with less
vibration and precise height.
Tool holding
H
Other information
Machinability
B 25
A Grooving – how to apply
General grooving
Turning
• Single cut grooving is the most

economic and productive method to
B produce grooves.
• If the depth of the groove is bigger than
the width, multiple grooving is the best
Parting and
method for rough grooving.

grooving
• A screw-clamp or spring-lock design

holder should be selected for grooving
C operations.
Threading
D
Milling
E
Single cut grooving
• Economic and productive method to

Drilling
produce grooves.
• Finishing geometry has width tolerance
F
of ±0.02 mm (±.0008 inch) and works well
in low feeds.
• Wiper inserts give extremely high quality
surface on the side of the groove.
Boring
G
Tool holding
H
Other information
Machinability
B 26
Grooving – how to apply
A
Multiple grooving
Turning
• The best method for rough grooving
when depth is bigger than width.
• Use the insert width to produce full B
grooves and then remove the rings.
Parting and
grooving
C
Threading
D
Practical hints
When producing high quality grooves, there is often a
need for chamfered corners.
Milling
E
A • One way is to use the corners on the
insert, for example, of a inishing grooving
insert, to chamfer; see illustration A.
Drilling
F
Boring
B • A better way to make grooves with

chamfer in mass production is to order G
a Tailor Made insert with the exact
chamfer form; see illustration B.
Tool holding
H
Other information
Machinability
B 27
A Circlip grooving – how to apply
Circlip grooving
Turning
Circlips on shafts and axle components are

very common.
B • Circlip grooving can be performed with
three-edge inserts or two-edge grooving
inserts.
Parting and
grooving
• For internal grooving there is also a wide

choice of inserts and boring bars.
C
Threading
Systems to choose from

3-edge inserts 2-edge inserts • For best economy, use 3-edge inserts in
D
widths 1.00 - 3.18 mm (.039 - .125 inch).
• Or 2-edge inserts in widths 1.50 - 6.00 mm
(.059 - .236 inch).
Milling
E Carbide rod inserts • Internal inserts are available for min. hole
Internal inserts
diameter 10 mm (.394 inch) and with circlip
widths 1.10 - 4.15 mm (.043 - .163 inch).
• Min hole diameter for carbide rod inserts is
Drilling
4.2 mm (.165 inch) and circlip widths

are 0.78 - 2.00 mm (.031 - .079 inch).
F
Milling is an alternative for non-rotating

Boring
Internal Internal/external
components
G • The circlip widths for diameters
9.7 – 34.7 mm (.382 - 1.366 inch) cutters
are 0.70 - 5.15 mm (.028 - .203 inch).
Tool holding
• The circlip widths for diameters

39 – 80 mm (1.535 - 2.480 inch) cutters are
1.10 - 5.15 mm (.043 - .203 inch).
Cutter diameter Cutter diameter
H 9.7 – 34.7 mm 39 – 80 mm
(.382 - 1.366 inch)
Other information
(1.535 - 2.480 inch)

Machinability
B 28
Face grooving – how to apply
A
Face grooving
Turning
Making grooves axially on the faces on a
component requires tools dedicated to the
application. B
• The correct curve on the tool is dependent
on the radius of the workpiece.
Parting and
grooving
• The inner and outer diameters of the
groove need to be taken into account in
order to select the tool.
C
Threading
D
Tools for face grooving
Milling
E
Drilling
F
• Curved tool for face • Curved tool for face • Exchangable cutting
grooving, shank 0º style. grooving, shank 90º style. blades make it possible to
Boring
make a special tool from

standard tools.
G
Tool holding
H
Other information
Machinability
B 29
A Face grooving – how to apply
Choice of R and L tools depending on rotation

Turning
• Tool is fed axially towards

the end surface of the
B part.
• Tool must be adapted to
the bending radius of the
Parting and
grooving
groove.
• Machine largest diameter
C and work inwards for best
chip control.
Left hand (L) tool

Threading
Right hand (R) tool

Milling
E Choice of A and B curve, right or left hand tool

Choose the correct tool – A or B curve, right or left hand
style – depending on machine setup and workpiece rotation.
Drilling
F
Clockwise Spindle
rotation
Boring
G
Tool holding
Counter-Clockwise
Spindle rotation
H
www.tool-builder.com
Other information
Machinability
B 30
Face grooving – how to apply
A
First cut consederation
Turning
1 If the insert support rubs workpiece inside dia:
- maybe the dia. range is wrong
- tool is not parallel to axis B
- check center height
- lower the tool below center line.
Parting and
grooving
1
2
2 If the insert support rubs workpiece outside dia: C
- maybe the dia. range is wrong
- tool is not parallel to axis
Threading
- check center height
- lift the tool above center line.
D
Roughing and inishing a face groove
Milling
Roughing Finishing
E
2
1
Drilling
First cut (1) always starts Machine the irst cut (1) within the given diameter range.
F
on the largest diameter
Cut two (2) inishes the diameter. Always start outside
and works inwards. The
and turn inwards.
irst cut ofers chip control
Boring
but less chip breaking. Finally, cut three (3) inishes the inner diameter to the
correct dimensions.
Cuts two (2) and three (3)
should be 0.5–0.8 x width G
of the insert. Chip breaking
will now be acceptable and
Tool holding
the feed can be increased

slightly.
H
Other information
Machinability
B 31
A Proiling – how to apply
Proiling
Turning
When machining components with

complex shapes, proiling inserts ofer
B great opportunities for rationalization.
• Modern parting and grooving tool
systems can also perform turning.
Parting and
grooving
• A screw-clamp tool holder should be

selected for turning and proiling
C operations in view of achieving maximum
stablility.
• A neutral tool holder is suitable for both
Threading
opening up or completing a recess.

• The round shape inserts have dedicated
geometries for these operations.
D
Milling
E
Drilling
F
Boring
G Ramping
Tool holding
H • Use round inserts for outstanding chip control and good

surface inish.
Other information
• In unstable setups, use ramping to avoid vibrations.

Machinability
B 32
Turning – how to apply
A
Proile turning
Turning
Insert radius < component radius
• Large area of insert creates high cutting force so B
Recommended feed should be reduced.
• If possible, use an insert radius that is smaller than
Parting and
grooving
the component radius.
• If you must have the same insert radius as the com-
ponent radius, use micro-stops to make the chip
C
short and avoid vibrations.
Threading
D
Insert radius ≥ component radius is not

recommended
Milling
E
Drilling
fn1 = parallel cuts – max. chip thickness 0.15–0.40 mm (.006 - .016 inch).
F
fn2 = radius plunging – 50% max. chip thickness.
Boring
G
Tool holding
H
Other information
Machinability
B 33
A Turning – how to apply
Turning
Turning
The most common applications for wide

grooves or turning between shoulders
B are multiple grooving, plunge turning or
ramping. All three methods are roughing
operations and have to be followed by
Parting and
a separate inishing operation. A rule of

grooving
thumb is that if the width of the groove is

smaller than the depth – multiple grooving
C should be used and vice versa for plunge
turning. However, for slender components,
the ramping method may be used.
Threading
• Use holders with smallest possible over-

hang, screw or spring-lock clamping and
Milling
insert with rail shape if possible.

• Use a stable, modular tooling system if
E possible.
• Reinforced blade will increase stability.
Drilling
F Roughing
Boring
G
Tool holding
1. Radially infeed to required depth +0.2 mm (+.008 inch) (max 0.75 x insert width).
2. Retract radially 0.2 mm (.008 inch).
3. Turn axially to opposite shoulder position.
H
4. Retract radially 0.5 mm (.020 inch).
Other information
Machinability
B 34
Turning – how to apply
A
Finishing
Turning
As the insert contours around the radius, most of the move-
ment is in the Z direction. This produces an extremely thin
chip along the front cutting edge which can result in rubbing B
and hence vibration.
Parting and
grooving
C
Threading
• The axial and radial cutting depth should
be 0.5–1.0 mm (.020–.039 inch).
D
Milling
Axial turning
Surface inish E
• This wiper efect generates high quality
surface inish.
• You get the best wiper efect when you
Drilling
Ra max “ind” the right combination between feed
(fn) and blade delection.
F
• Ra value below 0.5 µm (20 Ra) will be
generated with high bearing. Boring
G
Tool holding
H
Other information
Machinability
B 35
A Undercutting – how to apply
Undercutting
Turning
• When a clearance is needed.
B • These applications require dedicated inserts with round

cutting edges that are sharp and accurate.
• The tolerance of these inserts is low ±0.02 mm
Parting and
(±.0008 inch).
grooving
C
Threading
D Tools for undercutting

Angled Angled 20° Angled 45°
7° ,45° and 70°
Milling
E
Drilling
F
• Holder for external under- • Holder for internal under- • Holder for external under-
cutting. Insert with two cutting. Insert with two cutting. Insert with one
cutting edges. cutting edges. cutting edge.
Boring
G
Tool holding
H
Other information
Machinability
B 36
Troubleshooting
A
Troubleshooting
Turning
Tool wear
B
Problem
Parting and
grooving
Plastic
Crater Built-up
Flank wear deforma- Chipping Fracture
wear edge C
tion
Solution
Threading
More positive
geometry ++
D
Tougher grade ++
Milling
More wear
resistant grade ++ + + E
Increase cutting
+
Drilling
speed
F
Decrease
cutting speed + + ++ Boring
Reduce feed
rate ++ + + G
Tool holding
Choose stronger
geometry + ++
H
+ + = Best possible remedy + = Possible remedy
Other information
Machinability
B 37
A Troubleshooting
Problem Solution
Bad surface
Turning
• Use a short and stable tool. • Check speed/feed

B • Take away the chips, use guidelines.
geometry with good chip • Use wiper geometry.
control. • Check tool setup.
Parting and
• Use tools with precision

grooving
coolant.
Bad surface on aluminum

Threading
• Select the sharpest • Select a special soluble oil

geometry. for the material.
• Use geometry with good • Use tools with precision
D chip control. coolant.
Milling
E Bad chip breaking

• Change geometry.
• Select a higher feed.
• Use dwelling (pecking).
Drilling
• Use tools with precision

coolant.
F
Boring
G
Tool holding
H
Other information
Machinability
B 38
Troubleshooting
A
Problem Solution
Turning
Vibration
• Use a stable setup. • Change geometry.
• Check speed/feed guide- • Check tool condition. B
lines. • Check tool set-up (center
• Use shorter tool and compo- height).
Parting and
nent overhang.
grooving
C
Poor tool life
Threading
• Check center height. • Check condition of blade. If
• Check angle between tool blade is old, the insert could
and component. be unstable in the tip seat.
• Use tools with precision D
coolant.
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
B 39
F2
Threading
Thread turning is the process of an indexable insert tool
making a number of passes along the section of a work-
piece requiring a screw thread.
By dividing the full cutting depth of the thread into a
series of small cuts, the sensitive thread-proile point of
the cutting edge is not overloaded.
• Theory C4
• Selection procedure C9
• System overview C 13
• How to apply C 19
• Troubleshooting C 24
• Tapping C 28
C3
A Theory
Threading theory
Turning
The threading methods

B The prime functions of a thread are:
- to form a mechanical coupling
Parting and
- to transmit motion by converting rotational movement into linear and vice-versa

grooving
- to obtain a mechanical advantage; using a small force to create a larger one.
C
Threading
Diferent ways of making threads

D
Molding Metal cutting Rolling
Milling
Metal cutting threading methods

Drilling
F Thread turning Tapping Thread milling

Boring
Thread whirling Grinding

Tool holding
H
Other information
Machinability
C4
Theory
A
Deinitions of terms
Turning
B
ap = total depth of thread mm (inch)
Parting and
grooving
nap = number of passes
Threading
P = pitch, mm or threads
D
β = angle of the thread
per inch (TPI.)
d1 = minor diameter external
Milling
D1 = minor diameter internal
d2 = pitch diameter external E
D2 = pitch diameter internal
d = major diameter external
ϕ = helix angle of the thread
Drilling
D = major diameter internal
Boring
G
Tool holding
H
Other information

Machinability
C5
A Theory
 Deinitions of terms
Turning
1. Root
• The bottom surface joining the two
B adjacent lanks of the thread.
2. Flank
• The side of a thread surface connecting
Parting and
the crest and the root.

grooving
3. Crest
• The top surface joining the two lanks.
C
Threading
• The helix angle (ϕ) is dependent on and

Helix angle
D
related to the diameter and pitch (P) of
the thread.
• By changing the shim, the lank clearance
• The angle of inclination is lambda (λ).

Milling
of the insert is adjusted.
E The most common angle of inclination is

1° which is the standard shim in the tool
holder.
Drilling
Cutting forces in and out of the thread

Boring
• The highest axial cutting force in the

G threading operation occurs during the
entrance and exit of the cutting tool.
Tool holding
• Aggressive cutting data can lead to

movement of insecurely clamped inserts.
H
Other information
Machinability
C6
Theory
A
Inclining the insert for clearance
Turning
Selecting shims for inclination
The inclination angle can be set using shims under the
insert in the tool holder. The choice of which shim to use B
can be made by referring to a chart in the catalog.
As standard, all tool holders are delivered with the shim
Parting and
set at 1°.
grooving
C
Tangent of inclination angle
Threading
Note! that some pull threading operations require a shim with
negative inclination angle.
D
Standard shim = 1°
tan λ =
π × d2
P *ns
Milling
* ns = number of starts
E
Pitch, mm Threads/inch
Drilling
F
Boring
G
Tool holding
H
Other information
Workpiece mm
Machinability
diameter inch
C7
A Theory
Selecting shims for inclination

Turning
The diameter and pitch inluence the inclination angles.
B Example of how to use the diagram.

1. The workpiece diameter is 40 mm 2. The workpiece diameter is 102 mm
(1.575") with a thread pitch of 6 mm (4") with a thread of 5 threads per inch.
Parting and
(.236"). From the diagram we can see From the diagram we can see that the
grooving
that the required shim must have an required shim must have an inclination
inclination angle of 3º (standard shim angle of 1º (standard shim can be used).
C can not be used).
Threading
Pitch, mm Threads/inch
1
Milling
E
Drilling
F
Workpiece mm
diameter inch
Boring
Marking of threading inserts and shims

How to read and understand markings.
G
Angle of shim
Tool holding
inclination
Thread
proile
H
Pitch
Other information
Internal (O)
Machinability
External, no marking Carbide grade
C8
Selection procedure
A
Turning
Production planning process
B
Parting and
grooving
Dimension and
quality of the
thread
C
1 Component
Workpiece mate-
rial, thread proile
Threading
and quantity
Machine parameters
2
Milling
Machine
E
Type of tool:
- Multi-point
3 - Full proile
Drilling
Choice of tool
- V-proile
Cutting data,
infeed etc.
4
Boring
How to apply
G
Tool holding
Troubleshooting Remedies and

5 solutions
H
Other information
Machinability
C9

Turning
Component
B
• Analyze the dimensions and quality
demands of the thread to be machined
Parting and
• Type of operation (external or internal)

grooving
• Right- or left-hand thread
C • Type of proile (metric, UN, etc.)

• Pitch size
• Number of thread starts
Threading
• Tolerance (proile, position).
Material
P M K
Milling
• Machinability
E N S H • Chip breaking
• Hardness
• Alloy elements.
Drilling
F 2. Machine parameters
Condition of the machine and setup
• Spindle interface
Boring
• Machine stability
G • Available spindle speed

• Coolant supply
Tool holding
• Clamping of the workpiece

• Power and torque
• Available programming cycles
H
• Tool reach and clearance
Other information
• Tool overhang.
Machinability
C 10
Selection procedure
A
3. Choice of tools
Turning
Diferent ways to make threads
Multi-point inserts
B
A full proile (topping) insert with several Advantages
teeth reduces the number of required • Reduced number of
Parting and
in-feeds and generates high productivity, infeeds
grooving
e.g. a multi-point insert with two teeth • Very high productivity.
reduces the number of in-feeds to half.
The tool pressure increases proportion- Disadvantages C
ally with the number of teeth, requiring • Requires stable setups
stable setups and shortened overhangs. • Needs suicient room
Suicient room behind the thread is also behind the thread.
Threading
needed.
D
Full proile inserts
The thread is cut by the insert with good Advantages
Milling
control over the geometrical properties • Better control over the
as the distance between the root and thread form
the crest is controlled. • Less deburring. E
The insert can only cut one pitch.
Disadvantages
As the insert is generating both the root
and the crest, the tool pressure increases, • Each insert can only cut
Drilling
putting high requirements on setup and one pitch.
overhang.
F
V-proile inserts
The insert can accommodate a range Advantages
Boring
of pitches thus reducing stock. The • Flexibility, the same insert

root and lanks are being formed by the can be used for several
insert. G
pitches.
The crest is controlled in a prior turning
Tool holding
operation, resulting in high tolerances. Disadvantages

• Can result in burr forma-
In setups prone to vibrations, a non- tion that needs to be
topping insert can often prove to be a taken away.
solution due to the reduction of cutting H
pressure.
Other information
Machinability
C 11
4. How to apply
Turning

B The infeed method can have a signiicant impact on
the thread machining process.
Parting and
It inluences:
grooving
- chip control
- insert wear
C - thread quality
- tool life.
Threading
In practice, the machine tool, insert geometry, work-

piece material and thread pitch inluence the choice
of infeed method.
D
5. Troubleshooting
Milling
If you run into trouble with insert tool life, chip control
or poor thread quality. Please consider the following
E aspects.
Infeed type
• Optimize infeed method, number and depth of
passes.
Drilling
Insert inclination
F • Ensure there is suicient and even clearance
(insert – inclination shims).
Insert geometry
• Make sure the right insert geometry is used
Boring
(A, F, or C geometries).
λ
Insert grade
G • Select the correct grade based on the material and
toughness demands.
Tool holding
Cutting data
• If necessary change cutting speed and number of
passes.
H
Other information
Machinability
C 12
System overview
A
System overview
Turning
External thread turning
1. Small part thread turning B
2. Conventional thread turning
Parting and
3. Oil pipe thread turning
grooving
C
Threading
3
TP* 0.5 – 8 mm D
10 – 5 TPI* 2
32 – 3 TPI 1
TP 0.2 – 2 mm
Milling
Internal thread turning 10 – 5 TPI E
Min hole: 60.3 mm
(2.374")
TP 0.5 – 8 mm
32 – 3 TPI
4
Drilling
Min hole: 12 mm
TP 0.5 – 2.5 mm (.472")
32 – 10 TPI
Min hole: 10 mm 3 F
TP 0.5 – 3 mm (.394")
56 – 16 TPI
Min hole: 4 mm 2
(.157")
Boring
G
1. Solid carbide thread turning tools
Tool holding
2. Exchangeable cutting head

thread turning tools
3. Conventional threading
4. Oil pipe threading H
Other information
*TPI = Threads per inch

*TP = Thread pitch
Machinability
C 13
A System overview
External thread turning assortment

Turning
Choose from an extensive program
B Inserts
Parting and
grooving
C
Threading
Thread pitch (TP)

D 0.2 2.0 5.0 8.0 mm
32 10 3 TPI
Milling
E • Four insert dimension

(L) / sizes (IC):
11, 16, 22, 27 mm
(1/4, 3/8, 1/2, 5/8 inch) 11 16 22 27
Drilling
(1/4) (3/8) (1/2) (5/8)
Tool holders
Boring
• Coromant Capto® cutting units

G • QS-holders
• Shank tools
Tool holding
• Exchangable cutting heads

• Cartridges.
H
Other information
Machinability
C 14
System overview
A
Internal thread turning assortment
Turning
Choose from an extensive program and several systems
Bars for oil pipe

Solid carbide tool for Conventional bars
Parting and
threading
grooving
thread turning
Exchangeable head
Conventional bars
adaptor
C
≥60 mm
Threading
≥25 mm
≥4 mm ≥10 mm ≥12 mm (≥2.362")
(≥.472") (≥.984")
(≥.157") (≥.394")
Milling
4 10 12 25 60
(.157) (.394) (.472) (.984) (2.362)
E
Min. hole diameter, mm (inch)
Drilling
For high precision, internal thread turning of small holes F
Solid carbide threading Exchangeable head inserts Boring
G
Tool holding
H
Other information
Machinability
C 15
A System overview
Thread forms
Turning
Application Insert/thread form Thread type Code
B
ISO metric MM
General use
American UN UN
Parting and
grooving
Whitworth, NPT
WH, NT
Pipe thread British Standard (BSPT), NPTF
PT, NF
American National Pipe Threads
C
Food and ire Round DIN405 RN
Threading
MJ MJ
Aerospace
UNJ NJ
D RD
API Round
Oil and gas V38, 40,
API ”V” form 60°
50
Milling
Oil and gas Buttress, VAM BU
E Trapezoidal TR
Motion
ACME AC
General use
Stub ACME SA
Drilling
General usage Aerospace

• Good balance between load bearing • High precision and minimized risk for
capacity and volume of material. stress concentration and breakage.
F
Pipe Threads Oil & Gas
• Ability to bear loads. • Extreme load bearing and leak proof
requirements, with limitations of thin wall
• Able to form leak-proof connections
Boring
thickness of pipe.
(threads are often conical).
Motion
Food & Fire
G • Symmetrical form.
• Same as for pipe threads but round, for
easy cleaning for food. • Large contact surface.
Tool holding
• Easily repeated connecting/disconnecting • Sturdy form.

for ire.
H
Other information
Machinability
C 16
System overview
A
Insert types
Turning
Three diferent types of thread turning inserts
B
Full proile inserts
• For high productivity in threading.
Parting and
grooving
C
V-proile inserts - 60º and 55º
• For threading with minimum tool
Threading
inventory.
D
Multi-point inserts
• For highly productive, economic thread
Milling
turning in mass production.
Three diferent geometries
Drilling
A-geometry F-geometry C-geometry
First choice in most opera- Sharp geometry. Chip breaking geometry.
F
tions.
Boring
G
Tool holding
Good chip forming in a Gives clean cuts in sticky Optimized geometry for
wide range of materials. and work hardening low carbon, low alloy and
materials. easily machined stainless
steel. H
Other information
Machinability
C 17
A System overview
Threading solutions
Turning
• Ultra-rigid threading with ixed position

inserts.
B
• The insert locates in the correct position
with guidance of the rail.
Parting and
• The screw forces the insert on the rail

grooving
back to a radial stop at one contact face

in the insert seat. (The red contact faces).
C • A secure insert interface ensures better
tool life and thread quality.
Threading
A variety of tool holder solutions

Milling
E
Coromant Capto®
Quick change coupling Boring bar external coupling Drop head
Drilling
F
Boring
G
Tool holding
H
Other information
Coromant Capto® Shank tool

Exchangable cutting
internal coupling
Machinability
head
C 18
How to apply
A
How to apply
Three diferent types of infeed
Turning
The infeed method can have a signiicant In practice, the machine tool, insert B
impact on the thread machining process. geometry, workpiece material and
It inluences: thread pitch inluence the choice of
Parting and
- chip control infeed method.
grooving
- insert wear
- thread quality
- tool life. C
Modiied lank infeed
Threading
• Most newer CNC machines can be programmed for
modiied lank.
D
• Used with C-geometry as the chip breaker will not function
with radial infeed.
• Axially directed cutting forces reduce the risk of vibrations.
Milling
• Controlled chip direction.
• Used for all insert geometries. E
• C-geometry, designed only for modiied lank infeed.
Drilling
Radial infeed
• Used by all manual machines and most canned CNC F
programs.
• First choice for work hardening materials and suitable for
ine pitches.
Boring
G
Incremental infeed
Tool holding
• Normally used with very large proiles and pitches, long

work threading cycles where tool life needs to match the
length of the thread.
• Requires special programming. H
Other information
Machinability
C 19
A How to apply
Modiied lank infeed

Turning
• Most CNC machines have a programmed cycle using this

infeed.
B • Chip is similar to that in conventional turning - easier to form
and guide.
• Axially directed cutting forces reduce the risk of vibrations.
Parting and
grooving
• Chip is thicker, but has contact with only one side of the insert.
• Less heat is transferred to the insert.
C
• First choice for most threading operations.
Infeed direction
Threading
Chip low Chip low
D
Milling
Feed direction
Feed direction
E
• Better chip control
• Better surfaces
C-geometry
Drilling
insert • For C-geometry insert, modiied lank infeed

is the only suitable infeed.
F
Radial infeed
• Most commonly used method - and only method possible
on older non-CNC lathes.
Boring
• Makes a stif “V” chip.

G • Even insert wear.
• Insert tip exposed to high temperatures, which restricts
Tool holding
depth of infeed.
• Suitable for ine pitches.
• Vibration possible and poor chip control in coarse pitches.
H
• First choice for work hardening materials.
Other information
Machinability
C 20
How to apply
A
Incremental infeed
Turning
• Recommended for large proiles.
• Even insert wear and longest tool life in very
coarse threads. B
• Chips are directed both ways, making control
diicult.
Parting and
grooving
C
Programming methods
Threading
Ways of improving the machining result
D
Decreasing depth per pass (Constant chip area)
Allows for constant chip area. • The deepest pass is the irst
This is the most common pass
method in CNC programs.
Milling
• Follows recommendation on
infeed tables in catalog
• More “balanced” chip area E
• Last pass actually around
0.07 mm (.0028").
Drilling
F
Constant depth per pass

Each pass is of an equal • Much more demanding on
Boring
depth, regardless of the the insert

number of passes.
• Ofers best chip control G
• Should not be used for
pitches larger than TP 1.5
Tool holding
mm or 16 TPI.
H
Other information
Machinability
C 21
A How to apply
Thread turning with full proile inserts

Turning
Use extra stock/material for topping the thread

For topping inserts, 0.03 – 0.07 mm (.001 – .003") material should be left from prior
B turning operations to allow for proper forming of the crest.
Parting and
• The blank does not need to be turned to the exact diameter

grooving
prior to the threading.

• Add extra stock/material on the workpiece diameter,
C 0.06 – 0.14 mm (.002 – .006") for topping the inish diameter of
the thread.
Threading
Infeed values recommendations

Number of infeeds and total depth of thread.
D
ISO metric and inch, external
No. of Pitch, mm Reduce cutting speed
infeeds ➝
0.5 0.75 1.0 1.25 1.5 1.75 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0
(nap)
Radial infeed per pass, mm
Milling
1 0.11 0.17 0.19 0.20 0.22 0.22 0.25 0.27 0.28 0.34 0.34 0.37 0.41 0.43 0.46
2 0.09 0.15 0.16 0.17 0.21 0.21 o.24 0.24 0.26 0.31 0.32 0.34 0.39 0.40 0.43
3 0.07 0.11 0.13 0.14 0.17 0.17 0.18 0.20 0.21 0.25 0.25 0.28 0.32 0.32 0.35
4 0.07 0.07 0.11 0.11 0.14 0.14 0.16 0.17 0.18 0.21 0.22 0.24 0.27 0.27 0.30
E 5 0.34 0.50 0.08 0.10 0.12 0.12 0.14 0.15 0.16 0.18 0.19 0.22 0.24 0.24 0.27
6 0.67 0.08 0.08 0.10 0.12 0.13 0.14 0.17 0.17 0.20 0.22 0.22 0.24
7 0.80 0.94 0.10 0.11 0.12 0.13 0.15 0.16 0.18 0.20 0.20 0.22
8 0.08 0.08 0.11 0.12 0.14 0.15 0.17 0.19 0.19 0.21
9 1.14 1.28 0.11 0.12 0.14 0.14 0.16 0.18 0.18 0.20
10 0.08 0.11 0.12 0.13 0.15 0.17 0.17 0.19
Drilling
11 1.58 0.10 0.11 0.12 0.14 0.16 0.16 0.18

12 0.08 0.08 0.12 0.13 0.15 0.15 0.16
13 1.89 2.20 0.11 0.12 0.12 0.13 0.15
F 14
14
0.08
2.50
0.10
2.80
0.10
3.12
0.13
0.12
0.14
0.12
16 0.10 0.10
3.41 3.72
No. of Pitch, TPI

infeeds
Boring
(nap) 32 28 24 20 18 16 14 13 12 11 10 9 8 7 6 5 4.5 4
Radial infeed per pass,
1 .007 .006 .007 .007 .008 .007 .007 .008 .009 .008 .008 .008 .009 .010 .009 .012 .011 .013
2 .006 .005 .006 .007 .007 .007 .007 .007 .008 .008 .008 .008 .008 .009 .009 .011 .011 .012
G 3 .005 .005 .006 .006 .007 .007 .007 .007 .008 .008 .008 .008 .008 .009 .009 .011 .011 .012
4 .003 .004 .005 .006 .006 .006 .006 .007 .007 .007 .007 .007 .008 .009 .009 .011 .010 .012
5 .003 .003 .005 .005 .006 .006 .006 .007 .007 .008 .007 .007 .008 .008 .010 .010 .011
6 .003 .003 .005 .005 .006 .006 .006 .006 .007 .007 .008 .008 .010 .010 .011
Tool holding
7 .003 .005 .005 .005 .006 .006 .006 .007 .008 .008 .010 .010 .011
8 .003 .003 .003 .005 .006 .006 .006 .007 .008 .009 .009 .010
9 .003 .005 .005 .006 .007 .007 .009 .009 .010
10 .003 .005 .005 .006 .007 .008 .008 .010
11 .003 .005 .005 .007 .008 .008 .009
12 .003 .003 .006 .007 .008 .008
H 13 .005 .006 .007 .008
14 .004 .004 .007 .007
Other information
14 .006 .006
Machinability
16 .004 .004
3.72 3.72
C 22
How to apply
A
Positioning of the tool
Turning
Max ± 0.1 mm (±.004 inch) Use maximum deviation of ±0.1 mm (±.004") from
centerline.
Too high cutting edge B
• Clearance will decrease.
Parting and
• Cutting edge will rub (break).
grooving
Too low cutting edge
• The thread proile can be incorrect. C
Threading
Method of thread turning
Right and left hand threads and inserts
D
External Internal
Right hand threads Left hand threads Right hand threads Left hand threads
Milling
E
Right hand Left hand

Right hand Left hand tool/insert tool/insert
Drilling
tool/insert tool/insert
F

Boring
G
Left hand Right hand
Tool holding
Left hand Right hand

tool/insert tool/insert Left hand Right hand
tool/insert tool/insert H
Other information
Negative shims must be used in a pull threading application.

Machinability
C 23
A Troubleshooting
Thread turning application hints

Turning
Some vital factors to consider to achieve success
B • Check the workpiece diameter for • It is recommended that the tool should
correct working allowance before start a minimum distance of 3 times
thread-turning, add 0.14 mm (.006") the thread pitch before engaging the
as crest allowance. workpiece.
Parting and
grooving
• Position the tool accurately in the • Precision coolant can improve tool life
machine. and chip control.
C • Check the setting of the cutting edge • A quick change system allows for quick
in relation to pitch diameter. and easy setup.
• Make sure the correct insert geometry • For best productivity and tool life, irst
Threading
is used (A, F, or C). choice - multi-point insert, second

choice - full proile single point insert,
• Ensure there is suicient and even
third choice - V-proile insert.
D clearance (insert-inclination shims) to
achieve correct lank clearance by
selecting the appropriate shim.
• If threads are rejected, check entire
Milling
setup, including machine tool.

• Check the available CNC program for
E thread turning.
• Optimize infeed method, number and
size of passes.
Drilling
• Ensure the correct cutting speed for

the demands of the application.
F • In case of pitch error on component
thread, check to see if machine pitch
is correct.
Boring
G
Tool holding
H
Other information

Machinability
C 24
Troubleshooting
A
Troubleshooting
Problem
Turning
Cause Solution
Plastic deformation
B
1. Excessive temperature in 1. Reduce the cutting speed,
cutting zone. increase the number of
2. Inadequate supply of infeeds.
Parting and
grooving
coolant. Reduce the largest infeed
A B 3. Wrong grade. depth, check the diameter
before threading.
(A) Starts as plastic 2. Improve coolant supply.
deformation, 3. Choose a grade with better C
(B) which leads to edge resistance to plastic defor-
chipping. mation.
Threading
Built-up edge (BUE) D
1. Often occurs in stainless 1. Increase cutting speed.
steel and low carbon steel 2. Choose an insert with good
materials. toughness, preferably PVD
2. Unsuitable grade or cutting
Milling
coated.
A edge temperature too low.
B
BUE (A) and edge chipping E
(B) often occur in combina-
tion. Accumulated BUE is then
ripped away together with
small amounts of insert mate-
Drilling
rial, which leads to chipping.
F
Insert breakage
1. Wrong turned diameter prior 1. Turn to correct diameter
to threading. before threading opera-
Boring
2. Infeed series too tough. tion, 0.03 – 0.07 mm (.001

3. Wrong grade. – .003") radially larger than
4. Poor chip control. max. diameter for thread. G
5. Center height incorrect. 2. Increase number of infeeds.
Reduce size of the largest
infeeds.
Tool holding
3. Choose a tougher grade.

4. Change to C-geometry and
use modiied lank infeed.
5. Correct center height.
H
Other information

Machinability
C 25
A Troubleshooting
 Problem Cause Solution
Rapid lank wear

Turning
1. Highly abrasive material. 1. Wrong grade. Choose a

B 2. Cutting speed too high. more wear resistant grade.
3. Infeed depths too shallow. 2. Reduce cutting speed.
4. Insert is above center line. 3. Reduce number of infeeds.
4. Correct center height.
Parting and
grooving
C Abnormal lank wear

1. Incorrect method for lank 1. Change method of lank
infeed. infeed for F-geometry and
Threading
2. Insert inclination angle does A-geometry; 3 - 5° from

not agree with the lead lank, for C-geometry; 1°
angle of the thread. from lank.
2. Change shim to obtain
D Poor surface on one lank of correct angle of inclination.
thread.
Milling
Vibration
E 1. Incorrect clamping of the 1. Use soft jaws.
workpiece.
2. Incorrect setup of the tool. 2. When using tail stock,
3. Incorrect cutting data. optimize centering hole of
4. Incorrect center height. component and check pres-
Drilling
sure of tail stock/face drive.
Minimize overhang of tool.

F
Check that the clamping
sleeve for bars is not worn.
Use 570-3 anti-vibration

Boring
bars.
3. Increase cutting speed; if

G this does not help, lower the
speed dramatically and try
F-geometry.
Tool holding
4. Adjust center height.
H
Other information

Machinability
C 26
Troubleshooting
A
 Problem Cause Solution
Poor surface inish
Turning
1. Cutting speed too low. 1. Increase cutting speed.
2. The insert is above the 2. Adjust center height. B
center height. 3. Use C-geometry and
3. Uncontrolled chips. modiied lank infeed.
Parting and
grooving
Poor chip control C
1. Incorrect method of infeed. 1. Modiied lank infeed 3 - 5°.
2. Incorrect thread geometry. 2. Use C-geometry with
modiied lank infeed 1°.
Threading
Shallow proile D
1. Wrong center height. 1. Adjust center height.
2. Insert breakage. 2. Change cutting edge.
Excessive wear.
Milling
Incorrect thread proile
E
1. Unsuitable thread proile 1. Correct tool, shim and
(angle of thread and nose insert combination.
radius) external inserts used 2. Adjust center height.
for internal operation or vice 3. Adjust to 90°.
Drilling
versa. 4. Correct the machine.
2. Wrong center height.
3. Holder not 90° to center line.
4. Pitch error in machine. F
Boring
Excessive edge pressure

1. Work hardening material 1. Reduce the number of G
in combination with infeed infeeds.
depths which are too Change to F-geometry.
shallow for the geometry. 2. Change to a tougher grade.
Tool holding
2. Excessive pressure on 3. Use modiied lank infeed.

cutting edge can cause
chipping.
3. Proile with too small thread
proile angle. H
Other information
Machinability
C 27
A
Turning
B
Parting and
grooving
Tapping
C
• Theory C 29
Threading
• Tapping process C 30
D • Hole size and tolerances C 33
• Coolant C 34
Milling
• Tool holding C 35
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
C 28
Theory A
Tapping theory
Turning
Deinitions of terms
B
1. Rake angle
2. Relief (clearence)
Parting and
grooving
3. Chamfer angle
4. Chamfer (length)
5. Spiral point angle C
6. Spiral angle
Threading
7. Pitch
8. Outer diameter
Long chamfer
Milling
• High torque
• Best surface quality E
• Thin chips
• Low pressure at the chamfer
Drilling
• Longer tool life
• Most common for spiral point tap.
F
Boring
Medium chamfer Short chamfer

Cutting tap Cutting tap
G
Tool holding
Forming tap Forming tap
H
Other information
Machinability
C 29
A Theory
Diferent standards
Turning
B - ISO
- ANSI
Parting and
grooving
ISO and ANSI have quite short OAL (overall length) and are rather similar.
Except for the shank diameter which is in inch for ANSI and metric for ISO.
C
- DIN
Threading
- DIN/ANSI
DIN is a long version and metric.
D DIN ANSI is a mix of both, with shank diameter from ANSI and OAL from DIN.
Milling
Tapping process
E
Diferent types of tapping processes
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
C 30
Tapping process A
Geometries for diferent types of holes
Turning
Spiral point tap for through holes Spiral lute tap for blind holes
B
Parting and
grooving
C
Threading
• The strongest tap style • The most common tap style
• Suited for tough conditions • Drives the chips up along the shank
D
• Pushes the chips forward through • Tap for blind holes.
the hole
• Tap for through hole.
Milling
E
Straight lute tap for all holes Forming tap - a chip free tap solution
Drilling
F
Boring
• For short chipped material like cast iron • A chip-free tap solution
• Often used in automotive industry, e.g. • For soft steel, stainless steel and
pumps and valves aluminum
G
• Can be used for all types of holes and • Can be used for all types of holes and
Tool holding
depths. depths
• Increases the strength of the thread in
some materials, e.g. aluminum.
H
Other information
Machinability
C 31
A Tapping process
Forming and tapping processes

Turning
B Forming tap Cutting tap

The thread is formed by The tap cuts the material.
deforming the material.
Chips are generated.
Parting and
No chips are generated.

grooving
C
Threading
D
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
C 32
Hole size and tolerances A
Hole size and tolerances
Turning
B
Parting and
grooving
C
Threading
Basic calculation of hole size, cutting taps
D = TD - TP D
D = Hole diameter (mm, inch)
TD = Nominal thread diameter (mm, inch)
Milling
TP = Thread pitch (mm, inch)
Hole size for M10 x 1.5 cutting tap = 8.5 mm (8.5 = 10 - (1.5) E
Hole size for 1/4" - 20 cutting tap = .2008" (.2008" = 1/4 - (20).
Drilling
Basic calculation of hole size, forming taps F
D = TD - (TP/2)
D = Hole diameter (mm, inch)
Boring
TD = Nominal thread diameter (mm, inch)

TP = Thread pitch (mm, inch) G
Drill size for M10 x 1.5 forming tap = Hole size for 1/4" - 20 cutting
tap = .2008" (.2008" = 1/4 - (20) mm (9.3 = 10 - (1.5/2))
Tool holding
Drill size for 1/4" - 20 forming tap = .2264" (.2264" = 1/4 - (20/2)).
H
Other information
Machinability
C 33
A Coolant
Coolant
Turning
Important for successful performance

B
Coolant supply is essential in tapping and
inluences
Parting and
grooving
• Chip evacuation
• Thread quality
C • Tool life.
Threading
D
Coolant supply
Internal or external External coolant supply Diferent cutting luid/
coolant supply emulsion
Milling
E Three mail alternativ

• Mineral oil based
• Synthetic coolant
Drilling
• Straight oil.
F Two more options

• Always to be preferred to • The most common
improve chip evacuation, coolant method • Vegetable oil based
especially in long
• Can be used when chip • Semi synthetic.
chipping materials and
Boring
formation is good
when threading deeper
holes (2-3 x D) • To improve chip evacua- Always be aware of
G tion, at least one
• To be preferred for hole • Type of cutting luid used
coolant nozzle (two if drill
depths above 3 times in the machine
is stationary) should be
Tool holding
the diameter.
directed closely to the • Oil content.
tool axis.
H
Other information
Machinability
C 34
Tool holding A
Tool holding for tapping
Turning
Overview
Floating rubber collet chuck Beneits and B

recommendations
Allows a certain amount of play to enable a proper path.
Often used in manual and small tuning machines. • Rubber collets cover a
Parting and
grooving
wide clamping range
• Tension and compression
to eliminate feed error.
C
Threading
D
Coromant Capto®
Milling
Rigid ER collet chuck Beneits and
recommendations
With this approach there is no tension/compression play. E
That means motion of the spindle and axis movement • Rigid tapping is often
has to be precisely synchronized. This requires a more faster
sophisticated CNC controller.
• Tooling cost is lower (rigid
Drilling
holders cost less than
tension/compression
holders) F
• More compact and
reliable than tension/
compression holders
Boring
• Can result in a more

accurate thread.
G
Rigid tapping with ER collet chuck
Tool holding
Note! Increased forces on the tap results in reduced tool life.

Does not reverse quick enough at high speeds, say 6000 rpm.
H
Other information
Machinability
C 35
A Tool holding
Quick change tapping chuck

Turning
First choice for standard tapping operations. All-round, lower volume production.
Mainly for older, non-stable machines.
B
Beneits and recommendations
• Easy tap holding with quick change
Parting and
grooving
• Tension and compression to eliminate feed error

• Adaptors with or without clutch.
C
Threading
D
Milling
E
Coromant Capto® HSK solid holder Weldon solid holder
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
C 36
Tool holding A
Synchronous feed tap chucks
Turning
Rigid tap holder with micro loat compensation for elimination of oversized
threading. First choice for CNC machine tools and synchronized tapping
operations. B
Beneits and recommendations
Parting and
grooving
• High volume production / high precision
• Reduces thrust force on tap lanks
• Limited actual compensation provides accurate depths C
• Designed for internal high pressure coolant.
Threading
D
Milling
E
Coromant Capto® Weldon shank holder MAS-BT solid holder
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
C 37
D2
Milling
Milling is performed with a rotating, multi-edge cutting

tool which performs programmed feed movements
against a workpiece in almost any direction.
Milling is mostly applied to generate lat faces, but with
the development of machines and software there are
increasing demands to produce other forms and surfaces.
• Theory D4
• Selection procedure D9
• System overview D 13
• Choice of inserts – how to apply D 24
• Choice of tools – how to apply D 29
• Troubleshooting D 36
D3
A Theory
Milling theory
Deinitions of terms
Turning
B Spindle speed, cutting speed and cutter diameter

Parting and
grooving
n = Spindle speed, rpm

(revolutions per minute)
C vc = Cutting speed m/min (ft/min)
ve = Efective cutting speed m/min
(ft/min)
Threading
DC = Cutter diameter mm (inch)

DCX = Maximum cutting diameter
D mm (inch)
Milling
E
Drilling
Spindle speed (n) in rpm is the number of revolutions the milling tool
on the spindle makes per minute.
F Cutting speed (vc) in m/min (ft/min) indicates the surface speed at
which the cutting edge machines the workpiece.
Speciied cutter diameter (DCX), having an efective cutting depth to
diameter (DC), which is the basis for the cutting speed vc or ve.
Boring
G
Tool holding

Other information
Machinability
D4
Theory
A
Turning
Feed, number of teeth and spindle speed
B
fz = Feed per tooth mm/tooth
(inch/tooth)
Parting and
vf = Table feed mm/min (inch/min)
grooving
zn = Number of cutter teeth (pcs)
zc = Efective number of teeth (pcs) C
[in engagement]
fn = Feed per revolution mm/rev
(inch/rev) [fz x zc]
Threading
n = Spindle speed (rpm)
Milling
vf = fz × zc × n mm/min (inch/min)
Drilling
Feed per tooth, fz mm/tooth (inch/tooth), is a value in milling for calculating
the table feed. The feed per tooth value is calculated from the recommended
maximum chip thickness value.
F
Feed per minute, vf mm/min (inch/min), also known as the table feed, machine
feed or feed speed is the feed of the tool in relation to the workpiece in
distance per time-unit related to feed per tooth and number of teeth in the
cutter.
Boring
The number of available cutter teeth in the tool (zn) varies considerably and
is used to determine the table feed while the efective number of teeth (zc) is G
the number of efective teeth in cut.
Feed per revolution (fn) in mm/rev (inch/rev) is a value used speciically for
Tool holding
feed calculations and often to determine the inishing capability of a cutter.

Other information
Machinability
D5
A Theory
Deinitions of terms
Turning
Depth of cut
B ae = Radial depth of cut mm (inch)

[working engagement]
ap = Axial depth of cut mm (inch)
Parting and
grooving
Axial depth of cut, ap mm (inch), is what the the diameter of the cutter. It is the distance
C tool removes in metal on the face of the across the surface being machined or, if
workpiece. This is the distance the tool is the tool diameter is smaller, that is covered
set below the unmachined surface. by the tool.
Threading
Radial cutting width, ae mm (inch), is the

width of the component engaged in cut by
D
Net power, torque and speciic cutting force
ap = Axial depth of cut mm (inch)

ae = Radial depth of cut mm (inch)
Milling
[working engagement]
vf = Table feed mm/min (inch/min)
E
kc = Speciic cutting force N/mm2
(lbs/inch2)
Pc = Net power kW (Hp)
Drilling
The net power (Pc) is the power the Mc = Torque Nm (lbf ft)
machine must be able to provide to the
cutting edges in order to drive the cutting Metric
F
action. The eiciency of the machine must
ap × ae × vf × kc
be taken into consideration when selecting Pc = kW
cutting data. 60 × 106
Boring
The torque (Mc) is the torque value Inch

produced by the tool during cutting ap × ae × vf × kc
action, which the machine must be able Pc = Hp
G 396 × 103
to provide.
The speciic cutting force value (kc1) is a Metric
Tool holding
material constant, expressed in N/mm2

π×n
Pc × 30 × 103
(lbs/inch2). The values can be found in our Mc = Nm
main ordering catalog and technical guide.
Inch
H
π×n
Pc × 16501
Other information
Mc = lbf ft
Machinability
D6
Theory
A
Climb or conventional milling
Turning
Climb milling – preferred method
Using climb milling (also • In climb milling, the insert
referred to as down milling), starts its cut with a large
B
the burnishing efect is chip thickness.
avoided, resulting in less
Parting and
heat and minimal work-
grooving
hardening tendency.
Conventional milling
Threading
The feed direction of the • In conventional milling
workpiece is opposite to (also referred to as up
that of the cutter rotation milling) the chip thick-
at the area of cut. ness starts at zero and D
increases to the end of
the cut.
Milling
Always use climb milling for best E
cutting conditions.
Cutter diameter and position
Drilling
The selection of milling cutter diameter The position of the cutter in relation to the
is usually made on the basis of the workpiece engagement, and the contact F
workpiece width with the availability of which the cutter teeth have, are vital
the machine power also being taken factors for a successful operation.
into account.
Boring
• Cutter diameter should be 20 – 40% larger than the

G
width of cut.
• 2/3 rule (i.e., 150 mm (5.906 inch) cutter)
Tool holding
- 2/3 in cut, 100 mm (3.937 inch)

- 1/3 out of cut, 50 mm (1.969 inch).
• By moving the milling cutter of the center, a more
constant and favorable direction of cutting forces will H
be obtained.
Other information
Machinability
D7
A Theory
Chip formation through cutter position

Turning
The cutting edge in a radial direction engages with the

workpiece in three diferent phases:
B
1. Entrance into cut
2. Arc of engagement in cut
Parting and
grooving
3. Exit from cut. ae = 75% x DC
C DC = Cutter diameter
ae = working engagement
The centerline of the cutter is well inside the workpiece

Threading
width, ae >75% of DC.

• Most favorable cutting conditions and optimized use of
D the cutter diameter.
• The initial impact at the entry of cut is taken up further
along the cutting edge, away from the sensitive tip.
ae • The insert leaves the cut gradually.
Milling
E The centerline of the cutter is well outside the workpiece

width, ae <25% of DC.
• The angle of entry is positive
• The impact at the entry is taken up by the outermost tip
Drilling
of the insert and the load is gradually taken up by the the

tool.
F ae
The centerline of the cutter is in line with the workpiece

Boring
edge, ae = 50% of DC.

• Not recommended.
G
• The shock loads at the cutting edge are very high at
entry.
Tool holding
ae
= Recommended cutter position.

H
= Not recommended cutter position.
Other information
Machinability
D8
Selection procedure
A
Selection procedure
Turning
Production planning process B
Parting and
grooving
Type of operation and
method
C
1 Component
Threading
Workpiece material and
quantity
Machine
Milling
2 Machine parameters
3 Choice of tool Select type of cutter
Drilling
F
4 How to apply
Boring
Cutting data, method etc.
G
Tool holding
5 Troubleshooting Remedies and solutions
H
Other information
Machinability
D9

Turning
B Geometric shape
• Flat surface
Parting and
• Deep cavities
grooving
• Thin walls/bases
• Slots.
C
Threading
P M K Material Tolerances
N S H • Machinability • Dimensional accuracy
D
• Cast or pre-machined • Surface inish
• Chip forming • Part distortion
• Hardness • Surface integrity.
Milling
• Alloy elements.
E
Drilling
Condition of the machine and setup

F
Machine Tool holding
• Available power • Long overhang
• Age/condition – stability • Poor holding
Boring
• Horizontal/vertical • Axial/radial runout.

G • Spindle type and size
• Number of axes/
coniguration
Tool holding
• Workpiece clamping.
H
Other information
Machinability
D 10
Selection procedure
A
3. Choice of tools
Turning
Diferent ways to optimize milling
Cutters with round inserts B
• Robust milling cutters • Round inserts require
Parting and
grooving
more stable machines.
• Very lexible for face
milling and proiling
• High performance C
multi-purpose cutters.
Threading
45° face mill
D
• General choice for face • Max cutting depth 6-10
milling mm (.236-.394 inch).
Milling
• Balanced radial and axial
cutting forces
E
• Smooth entry into cut.
Drilling
90° square shoulder face mill
Advantages Disadvantages F
• Great versatility • Feed per tooth is relatively

low while fz = hex.
• Large depth of cut
Boring
• Low axial cutting forces

(thin workpieces)
G
• Light-cutting inserts with
true four edges.
Tool holding
H
Other information
Machinability
D 11
4. How to apply
Turning

Number of cutting Stability
B edges/pitch
• Choose largest possible
• Selecting the right spindle size or outer
number of edges or pitch diameter.
Parting and
grooving
is very important.
• It afects both produc- Chip formation through
tivity and stability. cutter positioning
C
• Always use climb milling
Insert geometry
• Move the cutter of the
• Select between a geo- center
Threading
metry for Light, Medium • Use a cutter with a dia-

or Heavy machining. meter 20–50% larger
than the cut.
D
Milling
5. Troubleshooting
Drilling
F Insert wear and tool life Unsatisfactory surface

inish
• Check the wear pattern
and if necessary adjust • Check spindle runout
the cutting data • Use wiper inserts
Boring
accordingly. • Decrease feed per tooth.
G Vibration
• Weak ixture
Tool holding
• Long tool overhang

• Weak workpiece
• Size of spindle taper.
H
Other information
Machinability
D 12
System overview
A
System overview
Face milling
Turning
Cutters for general use B
Face and square shoulder milling
Parting and
cutter for light face milling operations
grooving
Face milling cutter with round
inserts for tough conditions
C
General purpose face milling cutter
with 45° entering (lead) angle
Threading
D
Milling
E
Dedicated cutters
Drilling
High feed face milling Face milling cutters for cast iron machining
K F
Boring
G
Heavy duty face milling
Face milling cutters for aluminum machining

Tool holding
H
Other information

Machinability
D 13
A Systems overview
Shoulder milling
Turning
Cutters for general use

Face and shoulder milling for light
B shoulder milling operations
Face and shoulder milling

cutter for heavy machining
Parting and
grooving
C
Threading
Side and face milling cutter used

for shoulder milling operation
D
Dedicated end mills and long edge cutters

Milling
End mill with exchangeable,

E solid carbide head
Indexable insert
end mill
Drilling
Long edge milling cutter

Solid carbide end mill
Boring
G
Deep shoulder milling Edging with square shoulder milling cutters
Tool holding

Other information
Machinability
D 14
System overview
A
 Proiling
Turning
Cutters for general use – roughing
B
Round insert
Parting and
Round insert end mill
grooving
cutter
Threading
D
Cutters for general use – inishing

End mill with
Milling
exchangeable,
solid carbide head
Solid carbide ball
nose end mill E
Drilling
F
Boring
Other methods
Turn milling Blade milling G
Tool holding
H
Other information

Machinability
D 15
A System overview
Groove milling
Turning
Cutters for general use – radial groove milling

B
Parting and
Cutters for grooving and Side and face mill

grooving
parting of for groove milling
Internal grooving and slotting

Threading
D
Cutters for general use – axial slot milling
Indexable insert end mill

Milling
End mill with exchangeable,

solid carbide head
E Long edge milling
cutter
Drilling
F
Boring
Thread milling and shallow grooving

G
Tool holding
Indexable insert
cutter
Indexable insert
H end mill
Other information
Machinability
D 16
System overview
A
Overview of milling operations
Turning
Modern milling is a very universal machining Tooling developments have also con-
method. During the past few years, hand- tributed to the new possibilities, along
in-hand with machine tool developments, with the gains in productivity, reliablity B
milling has evolved into a method that and quality consistency that have been
machines a very broad range of conigura- made in indexable insert and solid carbide
tions. The choice of methods in multi- technology.
Parting and
axis machinery makes milling a strong
grooving
contender for producing holes, cavities,
surfaces that used to be turned, threads,
etc. C
Face milling High-feed milling Shoulder milling Groove milling
Threading
D
Milling
Parting of Chamfering Proile milling Turn milling
Drilling
Plunge milling Trochoidal milling Circular milling Linear ramping F
Boring
Helical interpolation Thread milling

Tool holding
H
Other information
Machinability
D 17
A System overview
Milling methods
Turning
Milling machines may be manually operated, mechanically

automated, or digitally automated via computer numerical
B control (CNC).
Parting and
grooving
Conventional milling methods

C
Vertical milling machines
In conventional 3-axis machines, milling
most frequently entails the generation of
Threading
lat faces, shoulders and slots.

Surfaces and forms, other than those
D described below, are increasing steadily as
the number of ive-axis machining centers
and multi-task machines grows.
Milling
E
Drilling
Face milling High-feed milling Shoulder milling Groove milling

F
Boring
G
Parting of Chamfering Plunge milling
Tool holding
H
Other information
Machinability
D 18
System overview
A
Advanced milling methods
Turning
Modern 4 to 5 axis machines
Today, machines are developing in all directions. Turning centers now have
milling capability through driven tools, and machining centers have turning B
capability via turnmill or mill-turn machines. CAM developments mean that
5-axis machines are increasing.
Parting and
grooving
The results of these trends C
and the development of
methods put new demands
Threading
and opportunities on the
tooling, such as:
• Increased lexibility
D
• Fewer machines/setups to
complete a component
• Reduced stability
Milling
• Longer tool lengths
• Lower depth of cut. E
Drilling
Proile milling Turn milling Trochoidal milling Circular milling
F
Boring
G
Linear ramping Helical interpolation Thread milling
Tool holding
H
Other information
Machinability
D 19
A System overview
Positioning of cutters for face milling

Turning
Type of milling
B cutter
Parting and
grooving
C
Considerations Round inserts 10-25° 45° 90°
Machine/spindle
Threading
size ISO 40, 50 ISO 40, 50 ISO 40, 50 ISO 30, 40, 50
D Stability
High High Medium Low
requirement
Roughing Very good Good Very good Acceptable

Milling
Finishing Acceptable Acceptable Very good Good

E
Cutting depth ap Medium Small Medium Large

Drilling
Versatility Very good Good Good Very good

F
Productivity Very good Very good Very good Good

Boring
G
Tool holding
H
Other information
Machinability
D 20
System overview
A
Positioning of cutters for shoulder milling
Turning
Type of milling
cutter B
Parting and
grooving
90° 90° 90° 90° C
Considerations
Machine/spindle
Threading
size ISO 40, 50 ISO 30, 40, 50 ISO 40, 50 ISO 30, 40, 50
Stability D
High High Medium Low
requirement
Roughing Very good Good Acceptable Good
Milling
Finishing Acceptable Acceptable Very good Good E
Cutting depth ap Large Medium Small Large
Drilling
Material All All Aluminum Aluminum
F
Versatility Very good Very good Acceptable Good Boring
G
Tool holding
H
Other information
Machinability
D 21
A System overview
Positioning of cutters for proile milling

Turning
Type of milling
B cutter
Parting and
grooving
C Ball nose Ball nose Ball nose

Considerations Round inserts
indexable exchangable solid carbide
Machine/spindle
Threading
size ISO 40, 50 ISO 40, 50 ISO 30, 40 ISO 30, 40
Stability
D requirement
High Medium Medium Low
Roughing Very good Good Acceptable Acceptable

Milling
Finishing Acceptable Acceptable Very good Very good

E
Cutting depth ap Medium Medium Small Small

Drilling
Versatility Very good Very good Very good Very good

F
Productivity Very good Good Good Good

Boring
G
Tool holding
H
Other information
Machinability
D 22
System overview
A
Positioning of cutters for slots and grooves
Turning
Type of milling cutter
B
Parting and
grooving
Groove
C
Considerations Grooving Long edge
Side and face
Machine/spindle size ISO 50 ISO 40, 50 ISO 40, 50
Threading
Groove open Open Open Open
Groove closed Closed Closed Closed D
Cutting width Small Small Large
Cutting depth ap Medium-Large Small Medium-Large
Milling
Versatility Limited Good Good
E
Type of milling cutter
Drilling
F
Considerations Indexable insert Exchangable- Solid carbide end

end mill head end mill mill
Boring
Machine/spindle size ISO 30, 40, 50 ISO 30, 40, 50 ISO 30, 40, 50
G
Groove open Open Open Open
Tool holding
Groove closed Closed Closed Closed
Cutting width Medium Small Small
Cutting depth ap Medium Small Large H

Other information
Versatility Very good Very good Very good

Machinability
D 23
A Choice of inserts – how to apply
Choice of inserts and how to apply

Turning
B
Parting and
grooving
Modern milling inserts for

face milling operations.
C
Threading
The design of a modern milling insert

Milling
E Deinitions of terms and geometry design

Corner design Main cutting edge design
0.13
Drilling
(.005) 0.13
(.005)
• Cutting edge reinforce- • Cutting edge reinforce-

ment 0.13 mm (.005 inch) ment 0.13 mm (.005 inch)
Boring
• Rake angle 30° • Rake angle 30°

• Primary land 11°. • Primary land 17°.
G
Tool holding
Corner reinforcement Main cutting edge

design
H
Other information
Chip former
Machinability
D 24
Choice of inserts – how to apply
A
Making the tool choice in milling
Turning
First choice
Low Operation stability High
B
Cutter pitch
L M H
Parting and
grooving
Coarse pitch (-L) Close pitch (-M) Extra close pitch (-H) C
Threading
D
Light (-L) Medium (-M) Heavy (-H)
Machining conditions/
Wear resistant Grades Toughness
Milling
E
Good conditions Average conditions Diicult conditions
Drilling
Type of application
ap Depth of cut, F
mm (inch) Heavy milling
• Operation for maximum stock removal and/or severe
H conditions.
• Larger depth of cut and feed rate.
Boring
• Operations requiring highest edge security.
Medium milling G
• Most applications – general purpose milling.
M
• Medium operations to light roughing.
Tool holding
• Medium depth of cut and feed rate.
Light milling
• Operations at small depth of cut and low feed rates.
L • Operations requiring low cutting forces. H
Other information
fn
Machinability
Feed, mm/tooth (inch/tooth)
D 25
A Choice of inserts – how to apply
Selecting the insert geometry

Turning
B
Parting and
grooving

C
• Extra positive • General purpose • Reinforced cutting edge
geometry
• Light machining • Heavy machining
• Medium feed rates
Threading
• Low cutting forces • Highest edge security

• Medium operations to
• Low feed rates. • High feed rates.
light roughing.
D
Milling
Achieving good surface inish in milling

E
Surface
roughness • Use wiper inserts for
higher productivity and
improved surface inish
Drilling
One wiper
Standard insert insert • Limit the feed to 60% of
F the parallel land
• Mount the wiper inserts
correctly
fn
fn1 = ≤0.6 x bs2
• Set the wiper inserts
fn1 = ≤0.8 x bs1 (fn1
Boring
Feed, mm/tooth
= ≤.031 x bs1) (fn1 = ≤.024 x bs2) (inch/tooth) below other inserts.
G
bs1 bs2
Tool holding
0.05 mm

(.002 inch)
H bs, mm 2.0 8.2

(inch) (.079) (.323)
Other information
Machinability
D 26
A
How to select insert grade
Turning
Select the geometry and grade according to the application.
Build-up of a grade chart Machining conditions B
Good
Parting and
grooving
Average
C
Diicult
Threading
Good Average Diicult
D
Deine machining conditions
Milling
E
Drilling
F

Boring
• Cutting depth 25% of • Cutting depth 50% of • Cutting depth 50% of

max ap or less max ap or more max ap or more
G
• Overhang under two • Overhang two to three • Overhang over three
times cutter diameter times cutter diameter times cutter diameter
Tool holding
• Continuous cuts • Interrupted cuts • Interrupted cuts

• Wet or dry machining. • Wet or dry machining. • Wet or dry machining.
H
Other information

Machinability
D 27
A Choice of inserts – to apply
Dedicated grades for ISO P, M and K

Turning
Dedicated grades minimize tool wear development

B
The workpiece material inluences the wear during the cutting
action in diferent ways. Therefore dedicated grades have been
developed to cope with the basic wear mechanisms, e.g.:
Parting and
grooving
- Flank wear, crater wear and plastic deformation in steel

- Built-up edge and notch wear in stainless steel
C
- Flank wear and plastic deformation in cast iron.
Threading
D
Select geometry and grade depending on the type of
workpiece material and type of application.
Milling
E
Drilling
F
Boring
G
ISO P10-P50 ISO M10-M40 ISO K10-K40
P M
Tool holding
H
Other information
Machinability
D 28
A
Choice of cutter and how to apply
Turning
B
Parting and
grooving
C
High performace face milling
Threading
cutters for small to medium
cutting depths.
Making the tool choice in milling
Milling
First choice
Low Operation stability High E
Cutter pitch
L M H
Drilling
F
Coarse pitch (-L) Close pitch (-M) Extra close pitch (-H)
Boring
G
Tool holding
Machining conditions/
Wear resistant Grades Toughness
H
Other information

Machinability
D 29
A Choice of tools – how to apply
Selecting cutter pitches

Turning
First choice
B Low Operation stability High

Cutter pitch
Parting and
grooving
L M H
Threading
Coarse pitch (-L) Close pitch (-M) Extra close pitch (-H)
• Reduced number of • General purpose • High number of inserts for

D inserts maximum productivity
• Suitable for mixed
• Limited stability production • Stable conditions
• Long overhang • Small to medium • Short chipping materials
machines
Milling
• Small machines/limited • Heat resistant materials.

horsepower • Usually irst choice.
E • Deep, full slotting
operations
• Diferential pitch.
Drilling
F Limited Stable
stability conditions
First choice
Boring
G
Long
overhang K S
Tool holding
Cast iron Heat resistant

(CMC 08) alloys
Limited (CMC 20)
H horsepower
Other information
Machinability
D 30
A
Diferential pitch
Turning
In general, the coarser the cutter pitch, Diferential pitch cutters have uneven
the least chance of harmonic vibration. tooth spacing, which impacts the vibration
Sometimes, replacing a 16-tooth cutter amplitude of each tooth. Reducing the risk B
with a 12-tooth tool ends chatter of vibration.
altogether. A diferential-pitched cutter
may be required in more diicult cases
Parting and
grooving
to eliminate troublesome harmonics.
Threading
Normal pitch
D
Diferential pitch
Milling
Diferential pitch reduces the risk of vibration.
Cutting forces and entering angle
Drilling
Round insert F
90° entering angle 45° entering angle cutters 10° entering angle
Boring
G
Tool holding
KAPR
H
Other information
Machinability
D 31
Axial and radial cutting forces

Turning
Efect of entering angle (90º)
B • Thin-walled components
• Axially weak ixtured components
Parting and
• Square shoulder
grooving
• hex = fz (In case ae > 50% x DC).
C
Efect of entering angle (45º)
• General purpose 1st choice
Threading
• Reduced vibration on long tool overhang

• Chip thinning efect allows increased productivity
D
• fz = 1.41 x hex (Compensating for entering angle).
Milling
E Efect of entering angle (Variable)

On round inserts, the chip load and entering angle vary
with the depth of cut.
• Strongest cutting edge with multiple indexes

Drilling
• General purpose cutter

F • Increased chip thinning efect for heat resistant
alloys
KAPR
• hex = depends on ap.
Boring
G 10° entering angle

• High-feed milling cutters
Tool holding
• A thin chip is generated, allows very high feeds

per tooth
• Axial cutting force is directed towards the spindle
and stabilize it.
H
Other information
Machinability
D 32
A
Feed compensation for diferent entering angles
Turning
B
Parting and
grooving
90° = (fz or hex) × 1.0 45° = (fz or hex) × 1.41
Threading
√ iC
ap D
Round = depends on ap Formula for 10° = (fz or hex) x 5.76
compensation
in turning
Milling
E
Formulas for cutters with round inserts
Max. cutting diameter at a speciic
Drilling
depth (inch).
√
Dcap = DC + iC2 – (iC – 2 × ap)2 F
Facemilling round insert (ap<iC/2) (inch).

Boring
hex × iC
fz =
2 × √ ap × iC – ap 2
G
Tool holding
Side milling (ae<Dcap/2) and round insert

(ap<iC/2) (inch).
hex × iC × Dcap
fz = H
4 × √ ap × iC – ap 2 × √ Dcap × ae – ae 2
Other information
Machinability
D 33
Calculating cutting data

Turning
Example in face milling

Given: Need:
B
• Cutting speed, vc = • Spindle speed, n (rpm)
4 mm
225 m/min (738 ft/min) • Table feed, vf (.157")
Parting and
• Feed per tooth, fz = (mm/min (inch/min)

grooving
0.21 mm (.0082 inch) • Metal removal rate, Q

• Number of cutter teeth, zn = 5 cm3/min (inch3/min)
• Cutter diameter, DC = • Power consumption kW (Hp)
C 125 mm (4.921 inch)
• Cutting depth, ap = 85 mm
4 mm (.157 inch) (3.346")
• Working engagement, ae =
Threading
85 mm (3.346 inch)
D Spindle speed
Given: vc = 225 m/min (738 ft/min)
Metric Inch
π × DC
vc × 12
π × DC
Milling
vc × 1000
n= (rpm) n= (rpm)
E
225 × 1000 738 × 12
n= = 575 rpm n= = 575 rpm
3.14 × 125 3.14 × 4.921
Table feed
Drilling
Given: n = 575 rpm

F Metric Inch
vf = n × fz × zn (mm/min) vf = n × fz × zn (inch/min)
Boring
vf = 575 × 0.21 × 5 = 600 mm/min vf = 575 × .0082 × 5 = 23.6 inch/min
G
Metal removal rate
Given vf = 600 mm/min (23.6 inch/min)
Tool holding
Metric Inch
ap × ae × vf
Q= (cm3/min) Q = ap × ae × vf (inch3/min)
1000
H
4 × 85 × 600
Other information
Q= = 204 cm3/min Q = .157 × 3.346 × 23.6 = 12.4 inch3/min

Machinability
1000
D 34
A
Net power consumption
Turning
Given: Material CMC 02.1
Metric Inch
B
ae × ap × vf × kc ae × ap × vf × kc
Pc = (kW) Pc = (Hp)
60 × 106 396 × 103
Parting and
grooving
C
Milling with large engagement
Specific Hardness
cutting force Brinell CT530
kc 1
Max chip thickness,
Threading
CMC 0.1 – 0.15 – 0.2
ISO No. Material N/mm2 HB mc Cutting speed vc, m/min
Steel
P
Unalloyed
01.1 C = 0.10 – 0.25% 1500 125 0.25 430–390–50
01.2 C = 0.25 – 0.55% 1600 150 0.25 385–350–15
01.3 C = 0.55 – 0.80% 1700 170 0.25 365–330–00
01.4 1800 210 0.25 315–290–60
01.5 2000 300 0.25 235–210–95 D
Low alloyed (alloying elements 5%)
02.1 Non-hardened 1700 175 0.25 300–275–45
02.2 Hardened and tempered 1900 300 0.25 195–180–60
High alloyed (alloying elements > 5%)
03.11 Annealed 1950 200 0.25 230–205–85
03.13 Hardened tool steel 2150 200 0.25 190–170–55
03.21 2900 300 0.25 165–150–35
03.22 3100 380 0.25 105–95–85
Milling
Castings
06.1 Unalloyed 1400 150 0.25 305–280–50
06.2 Low alloyed (alloying elements 5%) 1600 200 0.25 245–220–00
06.3 High alloyed (alloying elements > 5%) 1950 200 0.25 180–160–45
E
85 × 4 × 600 × 1700 3.346 × .157 × 23.6 × 246500
Pc = = 5.8 kW Pc = = 7.7 Hp
60 × 106 396 × 103
Drilling
F
The calculation above is approximate and valid for an maximum
chip thickness (hex) of 0.1 mm (.0039 inch) .
For a more accurate value of power consumption (Pc) the kc
value should be calculated accordingly.
Boring
Metric
γo
γo
hm = Average chip thickness G
kc = kc1 × hm -mc ×
( )
1 –
100
(N/mm2) = Insert rake angle
mc = Chip thickness compensation
Tool holding
factor
Inch kc = Speciic cutting force
γo kc1 = Speciic cutting force for average
kc = kc1 × hm-mc × 1 –
100 ( ) (lbs/inch2) chip thickness 0.1 mm (.0039 inch). H
Other information
Machinability
D 35
A Troubleshooting
Application hints for milling

Turning
Power capacity
• Check power capability and machine rigidity,
B making sure that the machine can handle the
cutter diameter required.
Stability of work piece
Parting and
• Condition and considerations of component

grooving
clamping.
Overhang
C • Machine with the shortest possible tool
overhang on the spindle.
Select correct cutter pitch
Threading
• Use the correct cutter pitch for the operation

to ensure that there are not too many inserts
engaged in cut, as this may cause vibration.
D
Cutting engagement
• Ensure there is suicient insert engagement
with narrow workpieces or when milling over
voids.
Milling
Choice of insert geometry

• Use positive geometry indexable inserts
E
whenever possible for smooth cutting action
and lowest power consumption.
Drilling
Use correct feed

F • Ensure that the right feed per insert is used to
achieve the right cutting action by use of the
recommended maximum chip thickness.
Up to 0.50 mm (.020 inch)
Boring
Cutting direction
G • Use climb (down) milling whenever possible.
Component consideration
• Work piece material and coniguration. Also
Tool holding
quality demands on the surface to be machined.
H
Other information

Machinability
D 36
Troubleshooting
A
 ISO
P
P10-P50 Choice of insert grade
• Select grade depending on the type of work-
Turning
piece material and type of application.
B
Dampened milling tools
• For longer overhang of more than 4 times
Parting and
grooving
the tool diameter, vibration tendencies can
become more apparent, and dampened cutters
can improve the productivity radically.
C
KAPR
Entering angle
Threading
• Select the most suitable entering angle.
D
Cutter diameter
• Select the right diameter in relation to the
workpiece width.
Milling
Cutter position
• Position the milling cutter correctly.
E
Cutter entrance and exit

• It can be seen that by rolling into cut, the chip
thickness on exit is always zero, allowing higher
Drilling
feed and longer tool life.
F
Coolant
• Only use coolant if considered necessary.
Milling is generally performed better without.
Boring
G
Maintenance
• Follow tool maintenance recommendations
Tool holding
and monitor tool wear.
H
Other information
Machinability
D 37
F2
Boring
Boring operations involving rotating tools are applied to
machine holes that have been made through methods
such as pre-machining, casting, forging, extrusion,
lame-cutting, etc.
• Theory F4
• Selection procedure F8
• System overview F 13
• Choice of tool F 16
• How to apply F 22
• Troubleshooting F 27
F3
A Theory
Boring theory
The boring process
Turning
B
• Typically, boring operations are per-formed
in machining centers and horizontal boring
machines.
Parting and
grooving
• The rotating tool is fed axially through the

hole.
C • Most holes are through-holes, often in
prismatic components such as housings
and casings.
Threading
D Three diferent basic boring methods

Boring with a Boring with a Milling, helical
stationary tool rotating tool interpolation
Milling
E
Drilling
F • To be used only for • For unsymmetrical • Very lexible solution

symmetrical components components machined in where one milling cutter
in a turning lathe. a machining center. can be used for diferent
diameters.
• Proiling can be carried • Flexible tool solutions
Boring
out with standard boring with adjustable diameters. • Saves space in the tool
bars. magazine.
• Highly productive in
G • Very lexible tool solutions roughing operations. • Good solution when chip
with interchangeable breaking is a problem.
• High quality hole tolerance
cutting heads.
and surface inish.
Tool holding
• High quality demands of

the machine (for inishing).
H
Other information
Machinability
F4
Theory
A
Deinitions of terms
Turning
Deinitions of cutting data terms
n = spindle speed (rpm) B
ap = radial depth of cut mm (inch)
Parting and
= feed per revolution mm/r
grooving
fn
(inch/r)
DC = boring diameter mm (inch)
C
vf = penetration rate mm/min
(inch/min)
DC
fz = feed per tooth mm/rev (inch/rev)
Cutting speed
Threading
zc = efective number of teeth that
The boring tool rotates at a certain number machine the inal surface
of revolutions (n) per minute generating a
certain diameter (DC). This gives a speciic
D
cutting speed (vc) measured in m/min Metric
(ft/min) at the cutting edge.
π × DC × n (m/min)
vc =
Milling
1000
Inch E
π × DC × n
Feed
The axial tool movement is called feed rate vc = (ft/min)
12
(fn) and is measured in mm/rev (inch/revolu-
tion). The feed rate is obtained by multi-
Drilling
plying the feed per tooth, mm/rev (inch/rev),
by the number of efective teeth (zc). The
feed rate is the key value in determining vf = fn × n mm/min (inch/min) F
the quality of the surface being machined
and for ensuring that the chip formation is
within the scope of the insert geometry.
Boring
fn = zc × fz mm/r (inch/r)
G
Tool holding
Penetration rate Cutting depth

The penetration rate (vf) is the speed of The cutting depth (ap) is the diference
the axial movement and is strongly related between the uncut and the cut hole radius. H
to productivity.
Other information
Machinability
F5
A Theory
Calculating torque and power consumption

Turning
B n = spindle speed (rpm)

Pc kW (Hp) = feed per revolution mm/r
Parting and
fn
grooving
(inch/r)
DC = boring diameter mm (inch)
C = speciic cutting force N/mm2
Mc Nm (lbf ft) kc
(lbs/inch2)
Pc = power consumption kW (Hp)
Threading
Mc = torque Nm (lbf ft)

KAPR = tool cutting edge angle
Torque
D
The torque (Mc) is the torque value pro-
duced by the boring tool during cutting
action, which the machine must be able
to provide.
Milling
Metric
E
Net power Pc × 30 × 103
π×n
Mc = (Nm)
The net power (Pc) is the power the
machine must be able to provide to the
Drilling
cutting edges in order to drive the cutting

action. The mechanical and electrical Inch
eiciency of the machine must be taken
π×n
F into consideration when selecting cutting Pc × 16501
Mc = (lbf ft)
data.
Boring
Net power, kW
Speciic cutting force

( )
G vc × ap × fn × kc ap
Pc = 1 –
DC
Cutting force/area for a given chip 60 × 103
thickness in tangential direction.
Tool holding
The kc value indicates the machinability

Net power, HP
of a certain material and is expressed in
( )
N/mm2 (lbs/inch2).
H vc × ap × fn × kc ap
Pc = 1 –
132 × 103 DC
Other information
Machinability
F6
Theory
A
Hole making methods
Turning
Productive boring
Productive boring involves 2-3 cutting edges and is used
for roughing operations of hole tolerances of IT9 or larger, B
where metal removal rate is the 1st priority. In multi edge
boring all slides are set to the same diameter and height.
Parting and
The feed rate is given by multiplying the feed for each insert
grooving
by the number of inserts (fn = fz x z). This is the basic set up
for most boring applications.
C
Threading
Step boring
In Step boring the slides are set to diferent axial heights

D
and diameters. Step boring is used where large radial depth
of cuts are required or when boring in soft material (long
chipping material). The width of the chip is divided into two
small easy to handle chips by this method. The feed rate and
Milling
surface inish result is the same as if only using one insert
(fn = fz).
E
Single-edge boring
Drilling
Single-edge rough boring is used where chip control is
demanding (long chipping material) and/or when machine F
tool power is limited. Only one slide is used. The slide
surfaces are protected by covers when not in use. When
inish boring an adjustable single-edge tool is used for
closer hole tolerances, (fn = fz).
Boring
Reaming
Tool holding
Reaming is a light inishing operation performed with a

multi-edge reamer at high feeds.
H
Other information
Machinability
F7

Turning
Production planning process

B
Parting and
grooving
Hole dimension
and quality
C
1 Component
Workpiece material,
Threading
shape and quantity
2 Machine Machine parameters

Milling
3 Choice of tool
Drilling
Type of tool
Cutting data,
How to apply
Boring
4 coolant, etc.
G
Tool holding
Remedies and
5 Troubleshooting
solutions
H
Other information
Machinability
F8
Selection procedure
A
Turning
Parameters to be considered Component
B
• Identify the type of operation and note
characteristics regarding the hole to
be machined, limitations, material and
Parting and
machine.
grooving
• Clamping, clamping forces and cutting
forces. Is the component sensitive to
vibrations? C
• Select the tool that covers the boring

diameter range and depth for the opera-
Threading
tion, surface inish and tolerance.
Material
P M K
Milling
• Machinability
N S H • Chip breaking
E
• Hardness
• Alloy elements.
Drilling
F
Condition of the machine
• Spindle interface
• Machine stability
Boring
• The spindle speed

• Coolant supply G
• Coolant pressure
Tool holding
• Clamping of the workpiece

• Horizontal or vertical spindle
• Power and torque
H
• Tool magazine.
Other information
Machinability
F9
3. Choice of tools
Turning
Bending stifness and torque transmission are the

foremost important factors when choosing a tool holder
B for boring operations. Choose the tool according to your
speciic needs:
Parting and
grooving
C
Threading
• Tools for various materials, applications • Small and large diameter tools.
and conditions.
Milling
• For vibration free machining at long

• Accurate adjustment mechanisms and overhangs – use dampened tools.
E high precision coolant for inishing.
• Reduce tool assembly weight for ease of
• Optimize productivity with multiple handling and less momentum.
cutting edge tools.
Drilling
Engineered solutions
Boring
• Often a combination of multiple opera-

tions in one tool.
G
• The operations can be completed during
one feed motion.
Tool holding
H
Other information
Machinability
F 10
Selection procedure
A
4. How to apply
Turning
Tool holding
B
• Always use the strongest coupling and
aim for the shortest tool overhang.
Parting and
grooving
• For best stability and hole quality use
Coromant Capto®, dampened tools and
tapered shanks.
C
Tool considerations
• Consider entering (lead) angle, insert
Threading
geometry and grade.
Chip evacuation and cutting luid D

• Chip formation and evacuation are im-
portant factors in boring and afect hole
quality and hole tolerance.
Milling
Cutting speed, Cutting data
vc m/min (ft/min) E
• Correct cutting speed and feed rate is
essential for high productivity, tool life
and hole quality.
Drilling
• Keep in mind the torque and power of
the machine.
F
Feed, mm/r (inch/r)

Boring
G
Tool holding
H
Other information
Machinability
F 11
5. Troubleshooting
Turning

Insert wear and tool life
B
• Correct geometry, grade and cutting
data is essential in boring operations.
Parting and
grooving
Chip evacuation
• Check the chip breaking and cutting luid
C
supply.
Hole quality and tolerances

Threading
• Check clamping of boring tool/work-

piece, feed rate, machine conditions and
D chip evacuation.
Cutting data
• Correct cutting speed, feed rate and
Milling
cutting depth is essential for high

productivity, tool life and to avoid
E vibrations.
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
F 12
System overview
A
System overview
Rough boring tools
Turning
Rough boring operations are performed to open up an existing hole to
prepare for inishing. B
Dampened adapter with two
Parting and
Large diameter tool with two Tool with one insert and tool
inserts
grooving
inserts with two inserts
Threading
Tool with three inserts
D
Milling
Fine boring tools E
Fine boring operations are performed to inalize hole within tolerance

and surface inish limits.
Drilling
Single-edge tool with
dampened adapter
Single-edge tool with
F
modular adapter
Single-edge tools
Boring
Multi-edge reamer
G
Fine boring head for

Tool holding
ine boring bars
H
Other information
Machinability
F 13
A System overview
Rough boring
Turning
0 2 4 6 8 10 12 14 16 18 20 22 50 Ø inch
B 0 50 100 150 200 250 300 350 400 340 500 550 1260 Ø mm
Rough boring tools with two inserts Ø23-170 mm (0.908-6.893")

Parting and
grooving
Rough boring tools with three inserts Ø36-306 mm (1.4-12")
C
Rough dampened boring tools with two inserts Ø25-150 mm (1-6")
Threading
Large diameter rough boring tools with two inserts Ø150-1260 mm (6-50")
D
Large diameter rough boring tools with two inserts (lightweight). Ø148-300 mm
(5.82-11.81")
Milling
Large diameter rough boring tools with two inserts (dampened). Ø148-300 mm
(5.82-11.81")
E
Fine boring – small diameter

Drilling
0 0.4 0.6 0.8 1.0 1.2 1.4 6 12 24 36 61 Ø inch
F 0 10 15 20 25 30 35 150 300 600 800 1275 Ø mm
Fine boring heads with solid carbide bar Ø1-8.2 mm (0.04-0.320")

Boring
G Fine boring heads with indexable boring bar Ø6-20 mm (0.24-0.79")

Tool holding
Fine Boring Head with indexable bar or grooving bar Ø8-32 mm (0.31-1.26")
H Multi-edge reamer Ø3.97-31.75 mm (.156 - 1.25")

Other information
Machinability
F 14
System overview
A
Fine boring – medium diameters
Turning
0 0.4 0.6 0.8 1.0 1.2 1.4 6 12 24 36 61 Ø inch
0 10 15 20 25 30 35 150 300 600 800 1275 Ø mm B
Fine boring with exchangeable heads Ø19-36 mm (0.75-1.42")
Parting and
grooving
Fine boring with cylindrical shank Ø19-36 mm (0.75-1.42")
C
Fine boring with Coromant Capto (modular) Ø19-167 mm (0.75-6.58")
Threading
Fine boring with Coromant Capto (dampened) Ø23-167 mm (0.91-6.58")
D
Fine boring with Coromant Capto (lightweight)
Ø69-167 mm (2.716-6.575")
Milling
E
Fine boring – large diameters
Drilling
0 0.4 0.6 0.8 1.0 1.2 1.4 6 12 24 36 61 Ø inch
0 10 15 20 25 30 35 150 300 600 800 1275 Ø mm F
Fine boring Ø150-1275mm (5.9-50") Boring
G
Fine boring (dampened) Ø150-315mm
(5.9-12.4")
Tool holding
Fine boring with Coromant Capto or arbor H

mount (lightweight) Ø150-315mm (5.9-12.4")
Other information
Machinability
F 15
A Choice of tool
Choice of tools
Turning
Roughing Finishing
B
Parting and
grooving
C
Productive boring Single-edge boring Step boring Single-edge Reaming
boring
Threading
Productive boring Step-boring Single-edge boring

• High metal removal rate. • For rough boring with • High precision ine boring.
large stock removal.
D • Multi-edge boring, • Tolerance capability IT6.
inserts on the same level. • Improved chip control.
• Adjustability of 0,002 mm
(0.00008”).
Single-edge boring
Milling
• Improved chip control.

Reaming
E • Less machine-power
• Very good surface inish
demanding.
at high penetration rates.
• Suitable for mass
production.
Drilling
Engineered solutions
Boring
• Often a combination of multiple opera-

G tions in one tool.
• The operations can be completed during
one feed motion.
Tool holding
H
Other information
Machinability
F 16
Choice of tool
A
Rough boring tools
Turning
Rough boring tool with three inserts
First choice recommendation for medium and high power
machines is a rough boring tool with three cutting edges B
for optimized productivity. Which can also be conigured
for single-edge and step-boring.
Parting and
grooving
C
Rough boring tool with two inserts
Threading
A rough boring tool with two cutting edges is irst choice
for low to medium power machines, unstable operations
or large diameters.
D
Milling
Light weight rough boring tool E
Reduces tool assembly weight, for decreased momentum,

easier tool exchange and tool handling. For boring large
Drilling
diameters with increased stability without increased tool
weight.
F
Boring
Dampened rough boring tool for long overhangs

G
Choose dampened rough boring tools for overhangs
longer than 4 times the coupling diameter.
Tool holding
H
Other information
Machinability
F 17
A Choice of tool
Slides for rough boring tools

Turning
Slides with negative inserts
B • For stable conditions, choose negative

shape inserts for better insert economy.
• Use negative inserts in tough applica-
Parting and
grooving
tions that require strong inserts and

improved process security.
C
Slides with positive inserts
• In rough boring, it is an advantage to use
Threading
positive basic-shape inserts as they give

lower cutting forces compared to nega-
tive inserts.
D
• A small nose angle and small nose radius
also contribute to keeping the cutting
forces down.
Milling
E
Entering (lead) angle and insert shape
The entering (lead) angle of boring tools force, while a smaller entering (larger lead)
afects the direction and magnitude of angle results in a larger radial cutting force.
axial and radial forces. A larger entering
(smaller lead) angle produces a larger axial
Drilling
F Positive inserts Negative inserts

For interrupted cuts, sand inclusions,
stack boring etc. Through holes only.
Boring
84° 75° 84°

(6°) (15°) (6°)
G First choice for general operations, step
boring and for shoulder operations.
Tool holding
90° 90°
(0°) (0°)
For high feeds or improved surface inish
H with Wiper inserts in stable conditions.
Other information
95° 95°
Machinability
(-5°) (-5°)
F 18
Choice of tool
A
Fine boring tools
Turning
Single-edge ine boring tool
A single-edge ine boring tool is the irst choice for ine B

boring operations.
Parting and
grooving
C
Light weight ine boring tool
Threading
Reduces tool assembly weight, for decreased momentum,
easier tool exchange and tool handling. For boring large
diameters with increased stability without increased tool
weight. D
Fine boring head with ine boring bars
Milling
For small diameters a ine boring head with ine boring E
bars is required.
Drilling
F
Silent Tools for long overhangs
Silent Tools (dampened) are the irst choice for overhangs

longer than 4 times the coupling diameter.
Boring
G
Tool holding
Multi-edge reamer
Multi-edge reamers are suitable for high feeds in mass

production. H
Other information
Machinability
F 19
A Choice of tool
Cartridges for ine boring tools

Turning
General recommendations
Entering (lead) angle
B
afects the direction and magnitude of the axial
and radial cutting forces. The largest entering
(smallest lead) angle results in increased axial
Parting and
grooving
forces, which is beneicial in boring application.

Opposed to a smaller entering (larger lead) angle,
which results in larger radial forces, causing vibra-
C tion in the application.
Insert shape
Threading
Positive inserts 7°
clearance angle should be selected dependent on the cutting
edge engagement. The larger point angle, ensures
D insert strength and reliability, but also needs more
machine power and has a higher tendency to
vibrate due to a large cutting edge engagement.
Positive inserts 11° Minimizing the insert point angle can improve tool
clearance angle
Milling
stability and possible radial movements, giving

less variation and cutting force. Positive basic
E shape inserts with 7° clearance angles are irst
choice.
Insert nose radius

Drilling
is a key factor in boring operations. The selection

F of nose radius is dependent on depth of cut and
feed rate which inluences the surface inish, chip
breaking and insert strength. A large nose radius
will delect the boring tool more than a smaller
nose radius and be more prone to vibrations.
Boring
Using a light cutting insert geometry, thin coating

and small nose radius with lighter depths of cut
G contributes to keeping cutting forces low.
Tool holding
H
Other information
Machinability
F 20
Choice of tool
A
Tool overhang
Turning
• Choose the shortest possible adapter length.
• Choose the largest possible diameter/size of adapter.
B
• For long overhangs (larger than 4 x coupling diameter)
use dampened adapters.
Parting and
• If possible, use a tapered adapter to increase the static
grooving
stifness and to reduce the delection.
• For long overhangs, ensure rigid clamping with lange
contact to spindle if possible. C
Threading
D
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
F 21
A How to apply
How to apply
Hole tolerance
Turning
B Tolerances will be inluenced by: Always ensure a inal adjustment is made

after measurement of the hole diameter
• the clamping of the tool holder
while the tool is still in the machine
Parting and
• the ixture of the component spindle. This will compensate for any
grooving
misalignment that can happen between

• the wear of the inserts etc.
the machine-tool spindle and tool setting,
radial delections and insert wear.
C
Threading
D
Boring and reaming tools
Rough boring Single-edge ine Multi-edge reamer

Milling
tool with boring tool for high feed

multiple edges inishing
E
Drilling
IT6
IT7
F
IT8
IT9
Boring
G
Tool holding
H
Other information
Machinability
F 22
How to apply
A
Fine boring tools
Turning
Adjustable ine boring mechanism
Single-edge ine boring tools have adjust- B

ment possibilities to accurately pre-set the
cutting edge within microns.
Parting and
grooving
C
Threading
Tool delection
D
• Boring tools for inishing, with one cutting
edge, will experience some degree of
radial delection during machining due to
the cutting forces.
Milling
• The depth of cut and length of overhang
inluence the radial delection of the E
boring tool.
• The delection might cause undersized
holes or vibrations.
Drilling
Hole tolerance • A measuring cut is normally needed,
followed by a inal adjustment of the tool.
F
Boring
Ø25 mm
(Ø.9843") H7 G
Tool holding
Ø25 mm (Ø.9843")
Ø25.021 mm (Ø.9851")
H
Other information
Machinability
F 23
A How to apply
Boring tools – general

Turning
Cutting luid supply

Chip evacuation, cooling and lubrication between the tool and the
B
workpiece material are primary functions of cutting luid.
Parting and
• Apply cutting luid for optimized chip

grooving
evacuation, cooling and lubrication.
C • Afects hole quality and tool life.

• Internal cutting luid is recommended
in order to direct the luid to the cutting
zone.
Threading
Chip control and chip evacuation

Chip formation and chip evacuation are critical issues in boring
Milling
operations, especially in blind holes.
E Ideally, chips should be in the form of deined commas or spirals.
Cutting depth,
ap mm (inch) Factors that have an inluence on chip
Drilling
breaking are:
- the insert micro and macro geometry
F
- nose radius
- entering (lead) angle
- cutting depth
- feed
Boring
- cutting speed
G - material.
Feed, mm/r (inch/r)

Tool holding
H
Other information
Machinability
F 24
How to apply
A
Cutting data recommendations
Turning
Setting the right cutting speed (vc) and feed (fn) is dependent
on application. Increased cutting speed and/or feed, increases
the risk of poor process security and reliability, leading to B
poor chip evacuation, chip jamming and insert breakage.
Especially in deep hole applications. Low cutting speed can
generate increase chances for built-up edge (BUE), leading
Parting and
to bad surface inishes, higher cutting forces and decrease
grooving
in tool life. General cutting data for insert geometry and
grade can be followed, with the following exceptions:
C
- Rough boring
Max start value vc = 200 m/min (656 ft/min).
- Fine boring with ine boring adapters:
Threading
Max start value vc = 240 m/min (787 ft/min).
- Fine boring with ine boring bars:
Max start value vc = 90 – 120 m/min (295 – 394 ft/min).
- Fine boring: D
Max APMX = 0.5 mm (.020 inch).
Cutting speed is mainly limited by:
Milling
- vibration tendencies
- chip evacuation
- long overhangs.
E
Feed and cutting depth

Excessive cutting edge engagement, large depth of cut
Drilling
(ap) and/or feed (fn), can cause vibration and larger power
consumption. To small of cutting depth and the insert will
tend to ride on the pre-machined surface, only scratching F
and rubbing it, also leading to poor result in tool wear and
surface inish.
Power and torque consumption
Boring
When boring make sure the machine can prove suicient

power and torque.
G
Tool holding
H
Other information
Machinability
F 25
A How to apply
Tool maintenance and use of torque wrench

Turning
• Always use a torque wrench and apply the recommended

torque on screws for insert and tool assembly.
B
• Check inserts and insert seats regularly to be free from
dirt & are not damaged.- Clean all assembly items before
assembly
Parting and
grooving
• Replace worn or exhausted spare parts.

• Lubricate all assembly items as well as the ine boring
C adjustment mechanism with oil at least once a year.
• Use a suitable assembly mounting ixture and tool
pre-setter.
Threading
• When assembling dampened tools, never clamp straight

over the adaptor body. Adaptors are easily deformed due
D to the thin wall thickness.
• Check machine spindle run-out, wear and clamping force.
Milling
E
How to apply reaming tools
• The reamer should not be expected to correct any
positional or straightness errors in the pre-machined hole.
Drilling
• The straightness of the pre-machined hole should be less

F than 0.05 mm (.0020 inch).
• A small runout is very important for reaming operations.
• Maximum recommended runout is 5 microns.
Boring
• Make sure the reamer is concentric with the pre-machined

hole.
G • Choose the shortest possible tool holder and shank.
• Emulsion as cutting luid generates better tool life than oil.
Tool holding
• Use recommended cutting data.
H
Other information
Machinability
F 26
A
Troubleshooting
Troubleshooting
Turning
Factors that afect vibration tendencies
Vibration tendencies grow towards the right.

B
Parting and
grooving
Entering angle C
Threading
Lead angle
D
Corner radius
Micro and macro geometry
Milling
Edge design E
Depth of cut (DOC)
Drilling
• Decrease cutting speed. • Check that all units in the tool assembly
are assembled correctly with the correct F
• Apply step boring.
torque.
• Choose a 2-edge rough boring tool.
• Reduce feed or increase feed.
• Choose a light-cutting geometry and
• Use the largest tool diameter possible.
Boring
grade.
• Use the shortest tool overhang possible.
• Use a smaller nose radius.
G
• Check workpiece clamping.
• Check machine spindle, wear, clamping,
Tool holding
etc.
• Increase depth of cut (inishing).
• Decrease depth of cut (roughing). H
• Use dampened tools if long overhang.
Other information
Machinability
F 27
A Troubleshooting
Insert wear
Turning
Insert wear patterns and remedies in boring are generally

very similar to turning.
B
Chip breaking
Parting and
grooving
Cause Solution
Too short, hard. • Increase cutting speed.

C
• Decrease feed.
• Change geometry to a more
open chip breaker.
Threading
D
Too long. • Increase feed.
• Decrease cutting speed.
• Change geometry to a more
closed chip breaker.
Milling
E
Tool vibration
Too high feed. • Decrease feed.
Drilling
Too high speed. • Decrease speed.

Too large cutting depth. • Apply step boring.
F
Too high cutting forces. • Decrease depth of cut.

• Use positive inserts.
Boring
• Use smaller nose radius.
G
Feed marks
Tool holding
Too high feed. • Choose knife edge wiper

insert.
• Use larger nose radius.
H • Decrease feed.

Other information
Machinability
F 28
Troubleshooting
A
Turning
Cause Solution
Insert wear
B
Wrong cutting data. • Change cutting edge and
investigate reason for wear
pattern – cutting data, insert
Parting and
geometry and insert grade.
grooving
C
Chips scratching surface
Bad chip breaking. • Change cutting data.
Threading
• Change insert geometry.
D
Surface inish
Bad surface inish. • Increase speed.
• Use coolant.
Milling
• Use a cermet grade.
E
Machine power limitation
Limited machine power. • Decrease cutting data.
• Apply step boring.
Drilling
• Decrease number of inserts
in cut.
• Reduce depth of cut. F
Boring
Power and torque consumption

G
When rough boring, make sure Important parameters are:
the machine can provide suf- • Feed.
icient power and torque.
Tool holding
• Number of inserts.
• Diameter.
• Depth of cut.
H
Other information
Machinability
F 29
Tool holding
The clamping of a cutting tool can inluence the productivity
and performance of the cutting tool dramatically.
Therefore it is important to choose the right holding tools.
This chapter will simplify the decision process and give
guidelines how to apply and maintain the holding products.
• History and background G4
• Why modular tooling G8
• Turning centers G 16
• Machining centers G 25
• Multi-task machines G 30
• Chucks G 35
G3
A History and background
Tool holding systems

Turning
• The tool holding interface with the machine

plays a very important part in the cutting
B process.
• Stability, time for tool changing, accuracy,
lexibility, modularity, handling and storing
Parting and
is of vital importance for successful

grooving
machining.
• Compared to conventional shank tools,
C a quick change system can increase the
efective cutting time by 25% in turning
centers.
Threading
Tool holding systems today

Milling
E Machining centers
Drilling
Turning centers
Multi-task machines
F
Boring
G
• Tooling has evolved through the necessity • There are over 35 types of spindle
to produce new types of machine manu- interface on machines today, with as
facturing standards. many tooling options to support, hence
Tool holding
exchangeability and assortment availa-

• These tools have generally followed the
bility decreases dramatically.
spindle interface design of MTMs, with-
out any standardization controls.
H
Other information
Machinability
G4
History and background
A
History of machine tapers
Turning
• The irst version of this steep taper type
was introduced during the 1920's and
standardized (DIN) in 1974. B
• The taper was the basis of most machine
tool spindles, due to the long taper, giving
Parting and
secure contact and stability.
grooving
• It is still popular today, in various sizes
and diferent standards, using 7/24 taper.
They are however not suitable for both C
rotating and static applications.
Threading
D
Rotating machine interfaces
Milling
• There has been an ever increasing variety
of diferent rotating machine interfaces E
on the market today.
• Unfortunately, these systems are not
designed for both clamping in a spindle
Drilling
and modular use.
• None of these systems are suitable for F
rotating and static applications.
Boring
G
Tool holding
H
Other information
Machinability
G5
A History and background
Coromant Capto®
Turning
Three systems in one

B • Coromant Capto® was introduced in 1990.
• Coromant Capto® was adopted as an ISO Standard
during 2008.
Parting and
grooving
• Coromant Capto® is a true universal tooling system

for use in:
- Turning centers
C - Machining centers
- Multi-task machines
Threading
The history of the Coromant Capto® system

Milling
• Machining center / Rotating tools

E
Today
e M
Drilling
ng ac
hi
Coromant Capto®/
a
Solid holders Varilock k ch ne
ic in
Basic holders u te
Q r fa
F ce
1980 1990
Boring
• Turning center / Turning tools
G Modularity
Tool holding
Shank holders Block Tool Coromant Capto®/

System Clamping units
H
Other information
Machinability
G6
History and background
A
The history of the Coromant Capto® system
Turning
Quick change Integrated spindle
B
Parting and
grooving
C
Threading
D
- Multi-Task Machines
- Turning Centers - Vertical Lathes
- Vertical Lathes - Machining Centers with Turning
Milling
Increased machine utilization Increased stability and versatility
E
Modular systems
Drilling
F
Boring
G
Tool holding
- Machining Centers
- Multi-Task Machines
- Vertical Lathes H
Other information
Increased lexibility
Machinability
G7
A Why modular tooling
A dramatic development of the machines

Turning
Machining centers
B
Parting and
grooving
Turning centers
Multi-task machines
C
Threading
D
Milling
E Trends
Machines and machining methods
• Multi-task machines requiring one holder • Powerful interfaces in the machine
system for both spindle and turrets. control system for higher degrees of
Drilling
automation.
• Several turrets on multi-task machines
and turning centers. • 3-D models of tools and holders to
F
virtually check the machine process.
• More multi-function tools for multi-task
machines. • Integration of various manufacturing
technologies into fewer machine types.
• Driven tools in turning centers.
Boring
• High pressure coolant.
G
Tool holding
H
Other information
Machinability
G8
Why modular tooling
A
When to use quick change tooling
Turning
• Machine requires frequent setup
changes. B
• Measuring cuts are necessary to get
correct size.
Parting and
grooving
• Machining is performed with high cutting
data and relatively short tool life.
• One operator services more than one C
machine.
Threading
D
Reduce down time in your machines
Milling
Only 36% of the machine time is used for metal cutting
E
- Service and maintenance
Drilling
- Insert change and tool
change
F
- Measuring of the tool and
workpiece
Boring
- Change of workpiece
G
- Efective cutting time
Conventional shank Coromant Capto®
Tool holding
tools quick- change system
H
Quick change tooling ofers a productivity increase of 25%
Other information
Machinability
G9
Coromant Capto® system

Turning
In which machine types and sizes do we need a modular system?
B
Parting and
grooving
C
Threading
D
Milling
Horizontal machining center
E
Machining Center with:
• Coromant Capto® size C6 and bigger • Multi-task machine with need of long
Drilling
overhangs
• 7/24 tapers in size 40 and bigger
• Vertical Turning Center
F • HSK63 and bigger.
• Turning Center together with SL*.
*SL is a universal modular system of adaptors with

exchangeable cutting heads.
Boring
G
Tool holding
H
Other information
Machinability
G 10
Why modular tooling
A
Turning
Minimize tool holder inventory
By combining basic holders, adapters and (when needed) extensions or B
reductions, many diferent assemblies for diferent machines can
be built.
Parting and
grooving
Modular Solid
C
ISO 40 ISO 50 HSK 100 HSK 63
Threading
D
Milling
E
Number of items with modular tools: Total 64 items
Drilling
4 + 2 + 8 = 14 items
Modular tools give access to very large number of tooling solutions,

with very few items.
Boring
G
Tool holding
H
Other information
Machinability
G 11
The Coromant Capto® coupling

Turning
The unique Coromant Capto® coupling has

B som very speciic features:
• The good lange contact face in relation
to the ground taper polygon gives maxi-
Parting and
mum stability due to two-face contact

grooving
and interference it.

• There are four gripper grooves for the
C automatic tool change.
• There is one slot for angular positioning
of the cutting tool.
Threading
Gripper grooves
Milling
Slot for angular positioning

E
Drilling
F
Boring
G
Flange contact surface
Tool holding
The only universal coupling that can be used in all applications without compromise.
H
Other information
Machinability
G 12
Why modular tooling
A
Coupling features and beneits
Turning
The main feature of the coupling is the positive 3-way locking
B
1. The radial centering is taken care of by Due to the above features - radial and axial
the conical part of the polygon. contact and self centering ability - the
coupling has extremely good repeatability,
Parting and
grooving
2. The low taper angle makes it possible
within 2 microns (.00008 inch).
to transmit the full force into the lange
contact. The strength of the polygon The gripper grooves are designed to give
coupling makes it possible to clamp maximum bending stifness and a higher C
with higher force than other systems. clamping force, due to the fact that the
This is very important for the bending Capto polygon has a greater surface area.
stifness.
Threading
3. A polygon shape is self centering and
takes care of the orientation without the
need for a driving slot, therefore there D
is no play in the coupling. The polygon
shape is also unique due to its capability
to transmit high torque due to three
contact areas.
Milling
E
Drilling
1
F
2
Boring
3 G
Tool holding
3-way locking
H
Other information
Machinability
G 13
Transmission of torque
Turning
The polygon shape transmits torque

B without any loose parts such as pins
or keys.
• No pins, keys, etc.
Parting and
grooving
• No play in the coupling

• Symmetrical loads
C • Two face contact/high clamping force.
Threading
Six diferent coupling sizes

D
Milling
E
C3 C4 C5 C6 C8 C10
C3 = D 32 mm (1.260 inch) C6 = D 63 mm (2.480 inch)
Drilling
F
Diferent methods of clamping
One coupling ofers two methods of clamping.
Center bolt clamping

Boring
Segment clamping
G
Tool holding
H Clamping method for quick-change and For modular clamping solutions, e.g., when
automatic tool changing. using extensions and basic holders.
Other information
Machinability
G 14
Why modular tooling
A
Excellent repetitive accuracy and guaranteed

center height
Turning
A • The repeatable accuracy is ±2 microns
[µm] (±.00008 inch) of the center height, B
B length and the radial measurement
(A),(B),(C).
Parting and
• Few or no measuring cuts needed if
grooving
pre-measuring is used (irst component
right).
C C
Threading
D
Less vibration with stable coupling

In internal machining the Coromant Capto® coupling is an outstanding
Milling
solution to clamp the boring bar, with a irm secure grip around the
entire polygon.
E
The boring bar is very often clamped with
Drilling
2-3 screws. This causes problems with
vibration, bad surface inish, inserts worn
out quickly and production disturbances,
with downtime spent on adjusting cutting F
data and measuring the component.
Boring
G
Tool holding
H
Other information
Machinability
G 15
A Turning centers
Quick change tooling for turning centers

Turning
B
Parting and
grooving
C
Threading
D
Milling
E What is a turning center?

• The principle of lathes and turning centers • When a cutting tool is applied to the
is to cut a rotating component with a workpiece, it can be shaped to produce
stationary cutting tool. a component which has rotational
Drilling
symmetry.
• The cutting tool moves parallel and
perpendicular to the workpiece axis to
F provide the desired inished shape.
Boring
G The turning center has a choice of conigurations

• Horizontal and vertical design
Tool holding
• Sub-spindle for two-sided machining

• Driven tools
• Y-axis for eccentric boring and milling.
H
Other information
Machinability
G 16
Turning centers
A
Coniguration of a turning center
Turning
Spindle rotation and deinitions of axis
B
• Several multi-axis machine tool programs
can provide turning results from roughing
and grooving to threading and inishing.
Parting and
grooving
C
Threading
D
Milling
Quick change tooling for turning centers
E
A quick-change system ofers:
- faster and eicient tool changing
Drilling
- inserts which can be changed outside
the machine
- pre-setting possibilities. F
The most economical system for:

- small batch production, quicker setup
Boring
times
- operations with frequent insert changes. G
Less than 180° for clamp and unclamp

Tool holding
H
Other information
Machinability
G 17
A Turning centers
Typical clamping units for turning centers

Turning
B VDI angled Square shank Automatic unit

Camshaft activated Camshaft activated Hydraulically operated
Parting and
grooving
C
Threading
VDI straight Round shank Special applications

D Camshaft activated Segment clamping Camshaft activated
Milling
E
Drilling
F Diferent methods how to install quick change

Directly integrated into the turret
Boring
Coromant Capto® directly integrated in

turrets is the best solution to get maximum
performance out of the Coromant Capto®
G
coupling.
Tool holding
H
Other information
Machinability
G 18
Turning centers
A
Diferent methods how to install quick change
Turning
Converted by using standard clamping units
B
Coromant Capto® as a machine interface via clamping
units is a good alternative when it’s not possible to go
Parting and
for direct integration, (existing machines etc).
grooving
Five times faster tool change than with conventional
shank tools. C
Threading
D
Turning lathes can easily be converted to Coromant Capto®
Milling
quick change tools using standard clamping units. No
modiications to the turret, and no special adaptors required. E
Drilling
F
Boring
Internal tools External tools G

Tool holding
H
Other information
Machinability
G 19
A Turning centers
Machine adapted clamping units

Turning
Coromant Disc Interface (CDI)

B
• Flexible and symmetrical interface, 180°
mountable.
• Same interface for static and driven tool
Parting and
grooving
holders. Static and driven tool holders

can be used in all positions.
• Higher cutting performance.
C
• Longer cutting tool life.
• Better workpiece quality.
• More available tool length for radial drilling
Threading
operations.
• Increased production.
• Rationalized tooling.
D
• Reduction in tooling costs.
Milling
E
Drilling
Static clamping unit, Driven drill/milling unit,

straight straight
F
Boring
G
Static clamping unit, Driven drill/milling unit,
right angle right angle
Tool holding
H
Other information
Machinability
G 20
Turning centers
A
Turning
Coromant Bolt-on Interface (CBI)
B
• Flexible and symmetric interface, 180°
mountable.
• Same interface for static and driven
Parting and
grooving
tool holders.
• Static and driven tool holders can be
used in all positions.
C
• Higher cutting performance.
• Longer cutting tool life.
• Better workpiece quality.
Threading
• More available tool length for radial
drilling operations.
• Increased production.
D
• Rationalized tooling.
• Reduction in tooling costs.
Milling
E
Drilling
Driven tool Clamping unit for
holder external turning
F
Boring
G
Clamping unit for Double clamping unit
internal turning for external turning for
Tool holding
tool change with Y-axis
H
Other information
Machinability
G 21
A Turning centers
A quick change system

Turning
Insert change by using sister tools

B
Parting and
grooving
• Less downtime
Threading
• Few or no measuring cuts. Improved proitability

• No risk of losing insert screws in the chip conveyer
D • Ergonomic
• Easy to clean the tip seat outside the machine.
Milling
0.5 min 1.5 min

E
Drilling
F
Boring
G
Tool holding
Changing to a sister tool with a quick change system is faster than changing
the insert inside the machine.
H
Other information
Machinability
G 22
Turning centers
A
Diferent ways how to install quick change
Turning
Tooling alternatives in conventional turrets
A Hydraulically operated clamping units

B
A
• Manual push-button tool changing
Parting and
• Fully automatic tool changing possi-
grooving
bilities.
C
B B Shank type clamping units
• Square and round shank tools as well
Threading
C as cutting units for external and internal
operations.
C Clamping units for VDI turrets

• Angled and straight clamping units for
Milling
external and internal operations.
E
Drilling
F
Boring
G
Tool holding
H
Other information
Example of installations.
Machinability
G 23
A Turning centers
Coromant Capto® driven tool holders

Turning
Driven tool holders provide the key to dramatic improvements in machining

B economy by allowing milling, turning and drilling operations to be carried
out in a single setup.
Parting and
grooving
C
Threading
• Driven tool holders can be supplied for speciic machine requirements.

• Spindle dimensions
Milling
- Machine type and model

- Maximum turret swing diameter
E - Maximum tool length.
Drilling
F
Boring
G
Tool holding
H
Other information
Example of installations.
Machinability
G 24
Machining centers
A
Modular tooling for machining centers
Turning
B
Parting and
grooving
C
Threading
D
Milling
E
What is a machining center?

• A machining center is a multi-function • 5-axis machining centers add two more
Drilling
machine that typically combines boring, axes in addition to the three normal axes
drilling and milling tasks. (X/Y/Z).
F
• Machining centers could be in horizontal
design as well as vertical design. Boring
G
Tool holding
H
Other information
Machinability
G 25
A Machining centers

Turning
Coniguration of a vertical machining center

B
Parting and
grooving
C
Threading
Coniguration of a horizontal machining center

D
Milling
E
Drilling
F Machining centers can be horizontal and

vertical designs
• The basic type has 3 axes. The spindle is mounted along
the Z-axes.
Boring
• 4- and 5-axes machining centers adds more axes (A/B/C)

G in addition to the three normal axes (X/Y/Z).
• With several 5-axis machining centers, ones with a rotating
or indexing attachments, the ifth-axis moves around the
Tool holding
X-axis. (A-axis) and ones with a B-axis head, the ifth-axis

moves around the Y-axis. (B-axis).
• Often the B-axis controls the tilt of the cutting tool itself
H and the A- and C-axes allow the workpiece to be rotated.
Other information
Machinability
G 26
Machining centers
A
Modular tooling for machining centers
Turning
In a machining center a modular system
can provide many advantages such as: B
• Flexible tooling – the same tools can be
used in several machines and machine
Parting and
interfaces.
grooving
• Flexible tooling – build your own assem-
blies and reduce the need for special
signiicantly. C
• Reduced inventory.
Threading
D
Milling
Build your own assemblies
E
Use Coromant Capto® adaptors for all spindle interfaces
Drilling
Machine interface adaptor
Extension/reduction adaptor
Boring
Adaptor G
Tool holding
H
Other information
Machinability
G 27
A Machining centers
Minimize tool holder inventory in machining centers

Turning
Modular tools give access to a very large number of tooling solutions,

B with very few items!
Modular Solid
Parting and
grooving
C
Threading
Number of items with modular tools: Number of items solid tools:

4 x 3 x (30 + 10) = 480 items.
Milling
4 + 2 + 30 + 10 = 46 items.
Right combination for best possible rigidity

Drilling
Extension adaptors and reduction adaptors

F Extended tools for machining centers are With Coromant Capto® modular system
frequently required to be able to reach the it is possible to build an assembly, so the
surface to be machined. right length can be achieved.
Boring
G • It is important that the minimum length is

used, particularly when long overhangs
are required.
Tool holding
• With modular tools it is always possible

to use optimal cutting data for best
productivity!
H • Modular tools are built together in
minutes!
Other information
Machinability
• Get closer tolerances.
G 28
Machining centers
A
All main machine interfaces covered
Turning
B
Parting and
grooving
C
CAT-V 40 CAT-V BIG PLUS® 40
CAT-V 50 CAT-V BIG PLUS® 50
Threading
CAT-V 60
ISO 40 ISO BIG PLUS® 40
ISO 50 ISO BIG PLUS® 50
ISO 60 D
MAS-BT 30 MAS-BT BIG PLUS® 30
MAS-BT 60
Milling
E
Drilling
F
HSK A/C 40 Coromant Capto® C3
Boring

HSK A/C 125 Coromant Capto® C10 G
HSK A/C 160
HSK A/C/T 40
HSK A/C/T 63
Tool holding
HSK A/C/T 100

HSK F 80 (with pins)
H
Other information
Machinability
G 29
A Multi-task machines
Modular tooling for multi-task machines

Turning
B
Parting and
grooving
C
Threading
D
Milling
What is a multi-task machine?

Drilling
• Multi-task machines come in a variety of • In a multi-task machine, the workpiece

conigurations: can be completed in a single machine
F - horizontal or vertical design. setup, e.g., turning, milling, contouring
and milling of angled surfaces, and grinding.
- two spindles (main and sub) and a
B-axis spindle enable milling and • Multi-task machines are a combina-
turning operations on both front and tion of a turning center and a machining
Boring
back face of the workpiece. center.

- each spindle acts as a workpiece holder
G allowing multi-axis machining on either
front or back face of the workpiece.
Tool holding
H
Other information
Machinability
G 30
Multi-task machines
A
Deinitions of the spindle directions
Turning
The program language for deining the spindle direction
B
M03 = Clockwise spindle
direction
Parting and
grooving
M04 = Counterclockwise
spindle direction C
Threading
D
Milling
E
Coniguration of a multi-task machine
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
G 31
How to use modular tooling in a multi-task machine

Turning
The milling spindle in a multi-task machine Therefore multi-task machine tools needed
B tool should be able to carry both rotating a tooling system with unsurpassed rigidity
and non-rotating tools. Coromant Capto® and repetitive accuracy both radially and
is the only tooling system that can fulill axially, like Coromant Capto®.
this demand without compromise.
Parting and
grooving
Multi-task machine tools are often used

in “done-in-one” applications in which
C operations run from roughing to inishing
in one machine tool setup.
Threading
D
Milling
E
The Coromant Capto® tooling
system is directly integrated in
the spindle.
Drilling
F
Boring
G
Multi-task machine tool with Coromant Capto® integrated tool
spindle and lower turning turret with Coromant Capto® clamping
Turret with Coromant Capto®
Tool holding
units.
tooling system
H
Other information
Machinability
G 32
Multi-task machines
A
New multifunctional tools for multi-task machines
Turning
For taking advantage of versatile multi- - accessibility, stability and higher
task machine tools and to optimize their productivity B
eiciency, there is sometimes a demand
- reduced tool changing time
for running them with dedicated tooling.
These tools are only available with - saved tool pocket in tool magazine
Parting and
Coromant Capto® and have been invented
grooving
- cost reduction - one tool replaces
for multi-task machine tools, ofering:
many tools.
C
Threading
D
Milling
E
Drilling
Multifunctional tools Twin tools F
– one milling and four turning tools – two turning tools in one
in one Boring
G
Tool holding
Mini-turrets
– four turning tools in one H
Other information
Machinability
G 33
Build your own mini-turret

Turning
Four cutting heads applied to one tool holder
B Pick and choose from a large number of

Radial
exchangeable cutting heads for turning,
threading, parting and grooving opera-
Parting and
tions for building an optimized tool for the

grooving
component.
• Reduce tool changing time

C
• Save tool pockets in tool magazine
• For both external and internal use.
Threading
Axial
D
Milling
Use of adaptors in a multi-task machine

E Tool adaptors for shank tools
Turning tool adaptors for
- shanks
- bars
Drilling
- blades
- mini-turrets
F
…to make it possible to use shank tools
also in a multi-task machine with an inte-
grated modular tool system in the spindle.
Boring
G
Tool adaptor with blade for parting of Tool adaptor for boring bar
Tool holding
H
Other information
Machinability
G 34
Chucks
A
Chucks
Beneits of using hydraulic chucks
Turning
B
Hydraulic chuck Hydraulic chuck Hydraulic chuck Shrink it
Heavy duty design Slender design Pencil design
Parting and
grooving
C
Threading
D
Milling
Open sleeves Sealed sleeves
Direct clamping Direct clamping E
Drilling
ER collet chuck
Boring
G
Tool holding
H
Open sleeves Sealed sleeves
Other information
Machinability
G 35
A Chucks
Choice of chucks
Turning
Hydraulic Shrink it Mechanical ER collet Side-lock

chuck chuck chuck chuck adaptors
B Weldon, ISO
9766
Parting and
grooving
C
Threading
Pull out
security,
D torque
transmission
Milling
Easy handling
E
High precision,
run-out
Drilling
Flexibility
F
Accessibility
Boring
Very good Good Acceptable
G
Tool holding
H
Other information
Machinability
G 36
Chucks
A
Hydraulic chucks
Turning
• Best pull out security on the market -
clamping force repeats time after time.
• Precision run out < 4 µm (.00016") at 2.5 x B
DC - high precision repetition.
• Easy handling - torque wrench used for
Parting and
secure clamping.
grooving
C
Shrink it chuck
Threading
• High pull out security and high precision.
• Small nose diameter possible – good
accessibility.
• Symmetrical design. D
Milling
E
Mechanical chucks
• Cylindrical sleeves can be used – good
lexibility.
Drilling
• Accessibility not so good because of its
design (often Heavy Duty).
F
Boring
ER collet chuck G
• Very lexible in clamping diameters
thanks to collets.
Tool holding
• Not depending on shank tolerance h6.

• Low torque transmission and run-out.
H
Other information
Machinability
G 37
A Chucks
Side-lock adaptors Weldon, ISO 9766

Turning
• High torque transmission.

B • Low precision – low tool life and low
surface inish.
Parting and
grooving
C
Threading
Hydraulic chucks
The secret behind the high precision and pull-out security
D
• A new generation of hydraulic chucks • The secret behind the high precision and
provides highest precision and torque pull-out security of CoroChuck 930 is
transmission capability. the optimized design of the membrane.
It allows for secure clamping with two
Milling
supports on each side (fulcrums).
E
Drilling
Membrane
F
Pressure screw
Boring
Piston
G Collet
Clamping medium
Tool holding
(oil)
H
Other information
Machinability
G 38
Chucks
A
Try to minimize the gauge length
Turning
• It is important to maintain as short a
gauge length as possible to increase B
stability and reduce delection.
Overhang • Length reduction as little as 20% can
Parting and
have a signiicant reduction in delection
grooving
(-50%).
(-20%)
C
Tool protrusion
Threading
D
(–50%)
Milling
Inluence of run-out on tool life
E
• Runout should be < 0.006 mm
(< .001 inch).
• For every 0.01 mm (.0004 inch) runout -
up to 50% decrease in tool life.
Drilling
• More critical as tool diameter gets
smaller. F
Boring
G
Tool holding
H
Other information
Machinability
G 39
A Chucks
Tool holding requirements

Turning
Application - Roughing and semi-inishing

B • Main criteria = clamping force
• High torque capability
Parting and
• For best performance use cylindrical

grooving
shanks
• Versatility of collets.
C
Threading
Application - Finishing
• Main criteria = runout
D • Inluence on tool life and component
- inish and accuracy.
Milling
E
Unbalance in tool holders
Unbalance in tool holders causes:
Drilling
- poor surface inish

F - poor part tolerances
- reduction in tool life
- premature machine-spindle wear.
Boring
G
Tool holding
H
Other information
Machinability
G 40
G 41
F
E
Machinability Tool holding Boring Drilling Milling Threading Parting and Turning
A
H
C
G
Other information grooving
Machinability
Matching the most suitable cutting tool material (grade)
and insert geometry with the workpiece material to be
machined is important for a trouble-free and productive
machining process.
• Workpiece materials H4
• Manufacture of cemented carbide H 18
• The cutting edge H 29
• Cutting tool materials H 40
• Tool wear & maintenance H 52
Other information
• Machining economy H 63
• ISO 13399 - The industry standard H 78
• Formulas and deinitions H 81
• E-learning H 92
H3
A Workpiece materials
Workpiece materials
Turning
Six main groups

B The ISO standard material groups are divided into six diferent types. Each type
has unique properties regarding machinability and setups that make diferent
demands on the tool.
Parting and
grooving
ISO ISO ISO

C P M K
Threading
ISO ISO Heat Resistant Super ISO

D Non-ferrous Hardened steel
N S Alloys H
Milling
E
The largest variety of diferent types of The aircraft industry and manufacturers
P components is probably in the P-area N of aluminum automotive wheels
as it covers several diferent sectors in dominate the N-area.
the industry.
Drilling
F
In the M-area, a big part of the applica- Diicult to machine S-area materials
M tion is in gas and oil, tubes, langes, S are found in the aerospace, gas turbine
process industry and the pharma- and power generator industries.
ceutical business.
Boring
G
The K-area is dominated by automotive Hardened steel in the H-area are seen
K components, the machine builders and H in a variety of industries such as auto-
Tool holding
the iron works production. motive and their subcontractors, as well

as in machine builders and the die and
mold business.
H
Other information
Machinability
H4
Workpiece materials
A
Characteristics for chip formation and removal
Turning
Factors that must be identiied in order to - The cutting tool material (grade), e.g. coated
determine a material’s machinability: cemented carbide, ceramic, CBN, PCD, etc.
- Classiication, metallurgical/mechanical, of the These selections will have the greatest inlu- B
workpiece material. ence on the machinability of the material at
- The cutting edge micro and macro geometry hand.
Parting and
to be used.
grooving
ISO ISO ISO
P M K C
Threading
ISO ISO Heat Resistant Super ISO
Non-ferrous Hardened steel D
N S Alloys H
Milling
E
ISO-P materials are generally long Chip formation for ISO-K materials varies
P chipping and have a continuous, relatively K from near-powderlike chips to a long chip.
even low of chip formation. Variations The power needed to machine this material
usually depend on carbon content. group is generally low.
Drilling
– Low carbon content = tough sticky Note that there is a big diference between
material. gray cast iron (often near-powder) and
– High carbon content = brittle material. ductile iron, which many times has a chip
Cutting force and power needed varies breaking more similar to steel. F
very little.
Low power needed per mm3 (inch3), but

N
Boring
due to the high metal removal rate, it is

ISO-M forms a lamellar, irregular chip for- still a good idea to calculate the maximum
M mation where the cutting forces are higher power required.
G
compared to normal steel. There are many
diferent types of stainless steels.
Chip breaking varies depending on the The range is wide, but in general high
S
Tool holding
alloying properties and the heat treatment, cutting forces are present.
from easy to almost impossible-to-break
chips.
Often a continuous, red-glowing chip.
H This high temperature helps to lower the
kc1 value and is important to help out with H
the application.
Other information
Machinability
H5
The complex world of metal cutting

Turning
Many parameters inluence the cutting process

B
Parting and
grooving
C
Workpiece material Hardness Component
Threading
P Steel
D M Stainless steel
K Cast iron
Hardness Brinell
Milling
E
N Non-ferrous
S Heat resistant alloys

Drilling
F H Hardened steel
The ISO material groups Usually there is a relation Depending on the type of
are divided into 6 diferent between material hardness and material, set-up and way of
types where each type has tool life, as well as machining machining, diferent choice
Boring
unique properties regarding data and type of geometry of tooling is required to

machinability. and grade. The higher the perform diferent applica-
hardness, the shorter the tool tions turning, milling, drilling
G life, with more rapid wear on etc.
the cutting edge.
Tool holding
H
Other information

Machinability
H6
Workpiece materials
A
Turning
B
Parting and
grooving
C
Application Condition Cutting environment
Turning Cutting conditions
Threading
D
Milling
Milling
Coolant
E
Drilling
Clamping conditions
Drilling
Dry machining
H Roughing/
F
R Heavy Carbide performs best when
machining at elevated
M Medium temperatures, but needs to
M be constant. Dry conditions
Boring
L Finishing/ should therefore be conside-

F red irst choice, depending on
Light component requirements and G
machining conditions.
There are three major types All components are diferent However some grades are
of application, all requiring in look, shape and size. Some developed for both wet and
diferent tools, inserts and
Tool holding
will need various set-ups and dry conditions and used

grades. These also depend on require special attention to depending on component
the load on the cutting edge, the clamping conditions of material and quality require-
from inishing to roughing. the workpiece and cutting ments.
tool.
H
Other information
Machinability
H7
The interaction between workpiece material,

geometry and grade
Turning
Workpiece material • The interaction between an optimized

B
geometry and grade for a certain
workpiece material is the key for a
successful machining process.
Parting and
grooving
• These three basic factors must be

considered carefully and adapted for
each machining operation.
C
• The knowledge and understanding of
how to work with and adjust these factors
is of vital importance.
Threading
Insert grade Insert geometry

D
Workpiece materials, main groups

Milling
E Materials are classiied using MC codes
Steel Cast iron Heat resistant super alloys

and titanium
Drilling
F
P M K N S H
Boring
Stainless steel Non-ferrous Hardened material

G
Within each material group there are subgroups depending on the

Tool holding
hardness of the material, kc1 value, and metallurgical and mechanical

properties.
H
* MC = A new material classiication that replaces the CMC (Coromant Material
Other information
Classiication) codes.
Machinability
H8
Workpiece materials
A
MC code structure
Turning
The structure is set up so that the MC code can represent a variety of workpiece
material properties and characteristics using a combination of letters and numbers. B
Parting and
Example 1:
grooving
The code P1.2.Z.AN is interpreted this way:
P = ISO code for steel C
1 = material group: unalloyed steel
2 = material subgroup: carbon content ? 0.25% ≤0.55% C
Threading
Z = manufacturing process: forged/rolled/cold drawn
AN = heat treatment: annealed, supplied with hardness values
D
Example 2:
Milling
The code N1.3.C.UT is interpreted this way:
E
N = ISO code for non-ferrous metals
1 = material group: Aluminum alloys
3 = material subgroup: non-ferrous with Si content 1-13%
Drilling
C = manufacturing process: casting
UT = untreated F
Boring
By describing not only the material composition, but also the manufacturing
process and heat treatment, which inluences the mechanical properties,
a more exact description is available, which can be used to generate improved G
cutting data recommendations.
Tool holding
H
Other information
Machinability
H9
Steel ISO P – main characteristics

Turning
B
Parting and
grooving
C
Machining characteristics: What is steel?
- Long-chipping material. - Steel is the largest group in the metal
Threading
cutting area.
- Relatively easy, smooth chip control.
- Steels can be non-hardened or hardened
- Low carbon steel is sticky and needs
D and tempered with hardness up to 400
sharp cutting edges.
HB.
- Speciic cutting force kc:
- Steel is an alloy with the element iron ( Fe)
1500–3100 N/mm2
as the major component. It is produced
(217,500–449,500 lbs/inch2).
Milling
through a melting process.

- Cutting force, and the power needed to
- Unalloyed steels have a carbon content
E machine ISO P materials, stays within a
lower than 0,8 %, and only Fe, with no
limited range.
other alloying elements.
- Alloyed steels have a carbon content
which is lower than 1,7 % and alloying
Drilling
elements like Ni, Cr, Mo, V, W.
F
Boring
ISO MC Material
G P1 Unalloyed steel
Low-alloyed steel
Tool holding
P2 (≤5% alloying elements)

P
High-alloyed steel
P3 (>5% alloying elements)
H See product catalogs for details
Other information
on MC codes. Sintered steels

P4
Machinability
H 10
Workpiece materials
A
Stainless steel ISO M – main characteristics
Turning
B
Parting and
grooving
C
Machining characteristics: What is stainless steel?
- Long-chipping material. - Stainless steels are materials alloyed with
Threading
min 11–12% chromium.
- Chip control is fair in ferritic, to diicult in
austenitic and duplex. - The carbon content is often low (down to
max 0.01%). D
- Speciic cutting force:
1800–2850 N/mm2 - Alloys are mainly Ni (Nickel), Mo
(261,000–413,250 lbs/inch2). (Molybdenum), and Ti (Titanium).
- Machining creates high cutting forces, - The formed Cr2O3 layer on the steel
Milling
built-up edge, heat and deformation surface makes it non-corrosive.
hardening.
E
Drilling
F
Boring
ISO MC Material
P5 Ferritic/Martensitic stainless G
steel
Tool holding
M1 Austenitic stainless steels
M
M2 Super-austenitic, Ni≥20%
See product catalogs for details H

Other information
on MC codes. M3 Duplex (austenitic/ferritic)

Machinability
H 11
Cast iron ISO K – main characteristics

Turning
B
Parting and
grooving
C
Machining characteristics: What is cast iron?
- Short chipping material. - There are 3 main forms of cast iron:
Threading
gray (GCI), nodular (NCI) and compacted

- Good chip control in all conditions.
graphite (CGI).
D - Cast iron is an Fe-C composition with
790–1350 N/mm2
relatively high content of Si (1–3%).
(114,550–195,750 lbs/inch2).
- Carbon content is over 2% which is
- Machining at higher speeds creates
the max solubility of C in the Austenitic
abrasive wear.
Milling
phase.
- Moderate cutting forces.
- Cr (Chromium), Mo (Molybdenum), and V
E (Vanadium) form carbides which increase
strength and hardness, but lower
machinability.
Drilling
F
ISO MC Material
K1 Malleable cast iron

Boring
K2 Gray cast iron

G
K K3 Nodular SG iron
Tool holding
K4 Compacted graphite iron

Other information
on MC codes. K5 Austempered ductile iron

Machinability
H 12
Workpiece materials
A
Non-ferrous materials ISO N – main characteristics
Turning
B
Parting and
grooving
C
Machining characteristics: What is Non-ferrous material?
- Long-chipping material. - This group contains non-ferrous, soft
Threading
metals with hardness under 130 HB.
- Relatively easy chip control if alloyed.
- Non-ferrous (Al) alloys with up to 22%
- Non-ferrous (Al) is sticky and needs
silicon (Si) make up the largest part. D
sharp cutting edges.
- Copper, bronze, brass.
350–700 N/mm2 - Plastic.
(50,750–101,500 lbs/inch2).
Milling
- Composites (Kevlar).
- Cutting force, and the power needed to
machine ISO N materials, stays within a E
limited range.
Drilling
F
ISO MC Material Boring
N1 Non-ferrous-based alloys
G
N2 Magnesium-based alloys
Tool holding
N
N3 Copper-based alloys

Other information
on MC codes. N4 Zinc-based alloys

Machinability
H 13
Heat resistant super alloys and titanium ISO S – main

characteristics
Turning
B
Parting and
grooving
C
Machining characteristics: What are Heat Resistant Super Alloys?
- Long-chipping material. - Heat Resistant Super Alloys (HRSA)
Threading
include a great number of high alloyed

- Diicult chip control (segmented chips).
iron, nickel, cobalt or titanium based
- Negative rake angle is required with materials.
D ceramics, a positive rake angle with
Groups: Fe-based, Ni-based, Co-based
carbide.
Condition: Annealed, Solution heat
treated, Aged rolled, Forged, cast.
For HRSA:
Milling
2400–3100 N/mm2 Properties:

(348,000–449,500 lbs/inch2). - Increased alloy content (Co more than
E Ni), results in better resistance against
For titanium: heat, increased tensile strength and
1300–1400 N/mm2 higher corrosive resistance.
(188,500–203,000 lbs/inch2).
Drilling
- Cutting forces, and power required are

quite high.
F
ISO MC Material
S1 Iron-based alloys
Boring
S2 Nickel-based alloys
G
S3 Cobalt-based alloys
S
Tool holding
S4 Titanium-based alloys
S5 Tungsten-based alloys
on MC codes.
Other information
S6 Molybdenum-based alloys
Machinability
H 14
Workpiece materials
A
Hardened steel ISO H – main characteristics
Turning
B
Parting and
grooving
C
Machining characteristics: What is hardened steel?
- Long-chipping material. - Hardened steel is the smallest group
Threading
from a machining point of view.
- Fair chip control.
- This group contains hardened and
- Negative rake angle is required.
tempered steels with hardness D
- Speciic cutting force: >45–65 HRC.
2550–4870 N/mm2
- Typically, however, hard part turned
(369,750–706,150 lbs/inch2).
components can be found to be within
Milling
- Cutting forces and power required are the range of 55–68 HRC.
quite high.
E
Drilling
F
Boring
ISO MC Material
H1 Steels (45-65 HRC) G

Tool holding
H2 Chilled cast iron
H
H3 Stellites

Other information
on MC codes. H4 Ferro-TiC
Machinability
H 15
The speciic cutting force kc1

Turning
kc1 – the tabulated value of kc for 1 mm (.0394") chip thickness
B kc1
N/mm2
(lbs/in2)
• The cutting force (Fc)
Parting and
6000
grooving
is the force needed to

(870,000)
shear of a speciic chip
cross-section in certain
C conditions
5000
(725,000)
Fc
Threading
• This value (Fc) is used

in the calculation of the
4000
(580,000) power consumption
H needed for an operation
D
3000
(435,000) • The speciic cutting force
value (kc1) is a material
Milling
M constant, expressed in
P S N/mm2 or lbs/inch2
2000
E (290,000)
1000 K
(145,00) N
Drilling
See formulas section on speciic calculations.

Boring
kc1 values in N/mm2 (lbs/inch2)

G
1500 – 3100 350 – 1350
P (217,500 – 449,500)
N (50,750 – 195,750)
Tool holding
1800 – 2850 1300 – 3100

M (261,000 – 413,250) S (188,500 – 449,500)
H
790 – 1350 2550 – 4870
K H
Other information
(114,550 – 195,750) (369,750 – 706,150)

Machinability
H 16
Workpiece materials
A
The ISO nomenclature in the ISO-P area
Turning
Operations and working conditions
B
P01: Internal and external inishing turning; high cutting
Wear resistance speed; small chip area; good surface inish; narrow
tolerances; no vibrations.
Parting and
P 01
grooving
P10: Turning; copying; threading; milling; high cutting
speed; small to medium chip area.
P20: Turning; copying; medium cutting speed; facing with C
10 small chip area; medium to diicult conditions.
P30: Turning; milling facing; medium to low cutting speed;
Threading
medium to large chip area; includes operations with
20 tough conditions.
P40: Turning; facing; milling; cutting; grooving; low cutting
D
speed; large chip area; large possible chip angle;
30 very tough conditions.
P50: When very high toughness in the tool is needed in
turning, facing, grooving, cutting, low cutting speed,
Milling
40 large chip area, large possible chip angle, extremely
tough conditions.
E
50
Drilling
Toughness
F
The above diagram is related to
the ISO P area. These demands
also apply to all other ISO types
of material, i.e., M, K, N, S, H.
Boring
G
Tool holding
H
Other information
Machinability
H 17
A
Turning Manufacture of cemented carbide
B
Manufacture of
cemented carbide
Parting and
grooving
The manufacture of cemented carbide

C inserts is a carefully designed process,
where geometry and grade are balanced
to give a product perfectly matched to the
Threading
application.
D
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
H 18
Manufacture of cemented carbide
A
The development of cutting tool material
Turning
With the development of better carbide substrates,
coatings and geometries, productivity and cost savings B
have improved for the end user.
Large improvements in productivity were possible in the
Parting and
60s and 70s when the irst coatings were developed.
grooving
After this, the developments continued - with advanced
substrate design, new geometries, edge designs, new
advanced coating techniques and post treatment of C
coated edges.
Threading
D
The efect on end-user productivity

2006
A new insert
Milling
generation
1999
New generation E
coatings
1989
Functional
Drilling
gradients
1980
Thick non-ferrous
oxide coating F
1969
First coated
1957 insert
Indexable
inserts
Boring
G
Tool holding
H
Other information
Machinability
H 19
A Manufacture of cemented carbide
Powder production
Turning
There are two main elements of a cemented

B carbide insert:
- Tungsten Carbide (WC)
- Cobalt (Co)
Parting and
grooving
Other commonly used elements are Titanium, Tantalum

and Niobium Carbides. Designing diferent types of
powder and diferent percentages of the elements is
C what makes up the diferent grades.
The powder is milled and sprayed-dried, sifted and
poured into containers.
Threading
Raw material Milling

Milling
Niobium
E
(Ta, Nb)C Tantalum
(5%)
(Ti, W)C
Drilling
Co (8%) Titanium
(7%)
WC
F Cobalt (80%) Tungsten carbide
Cemented carbide powder

Spray drying
Boring
Ready to press
G
Tool holding
H
Other information
Machinability
H 20
A
Tungsten powder
Turning
The size of the tungsten carbide grains
The main raw material for the manufacture
of cemented carbide is tungsten-ore B
concentrate. Tungsten powder is produced
from tungstic oxide derived chemically
Parting and
from the raw material. By varying the con-
grooving
ditions of reduction, tungsten powder of
various grain size can be manufactured.
The carbide granules after spray-drying C
are small and vary in size depending on
grade.
0.10 mm
(.0039 inch)
Threading
D
Basic properties of cemented carbide

Apart from the grain size for the Tungsten toughness but also to a lower hardness
Milling
carbide (WC), the amount of binder phase which reduces the wear resistance of the
is an important factor determining the substrate.
characteristics of the carbide. Increasing
E
Cobalt-content, together with increasing
WC-grain size, contributes to increasing
Drilling
Amount of binder Toughness
Boring
G
Tool holding
H
Other information
Wear resistant WC grain size

Machinability
H 21
Pressing powder compacts

Turning
Top and bottom

B punches
Press force
20 - 50 tons
Parting and
grooving
C
Threading
D Die and
core pin
Milling
Inspection
E
The pressing operation consists of several pieces of tooling:
- Top and bottom punches
- Core pin
Drilling
- Cavity.
F
The pressing procedure:
- Powder is poured into the cavity
Boring
- Top and bottom punches come together (20-50 tons)

- The insert is picked and placed via robot onto a graphite tray
G
- Random SPC is performed, to check for weight.
Tool holding
The insert is 50% porous at this stage.
H
Other information
Machinability
H 22
A
Sintering the pressed inserts
Turning
Sintering consists of the following:
- Loading trays of inserts into a sintering - The insert will shrink 18% in all directions
B
furnace. during the sintering; this corresponds to
- The temperature is raised to ~1400° C about 50% in volume.
(~2550° F) .
Parting and
grooving
- This process melts the cobalt and the
cobalt acts as a binder.
Sintering
Threading
Insert trays D
Milling
E
Shrinking
Inspection rate
Drilling
F
Boring
2 3 G
1. Unsintered insert
Tool holding
2. Sintered insert
3. Coated insert
H
1
Other information
Machinability
H 23
Diferent types of grinding operations

Turning
B Top and bottom Free proiling Proiling

Parting and
grooving
C
g 00
Bor
Threading
Chamfer – negative land Periphery
D Neg. land
7 8 9
4 5 6
1 2 3
S5 S6 S7 S8
SI S2 S3 S4
Milling
Chamfer Borg 00
E
Drilling

F
The ER-treatment gives the cutting edge the inal micro-geometry.
• ER-treatment (Edge Roundness) is done

before coating.
Boring
• The relation between W/H depends on

G the application.
Tool holding
Generally the ER corresponds to the thickness

of a hair, diameter: ~80 µm (~.0031 inch).
H
Other information
Machinability
H 24
A
CVD – Chemical Vapor Deposition
Turning
Stacks of inserts are placed into a furnace, a series of gases are introduced
to the chamber, lines are purged and another series of gases introduced.
B
This is repeated until the layers of coating are complete. The process is
carried out at approx. 900° C (1650° F) for 30 hours. Thickness is approx
2-20 microns (.00008-.0008 inch).
Parting and
grooving
C
Threading
D
Milling
E
Drilling
F
The advantages of CVD coatings

Boring
• The ability to making thick coatings.

• Ability to make even coating thickness. G
• Very good adherence to the carbide
substrate.
Tool holding
• Very good wear resistance.

• Possibility to make oxide coatings.
H
Other information
Machinability
H 25
PVD – Physical Vapor Deposition

Turning
The inserts are loaded into the coating By using a gas as carrier, the ions can then
B chamber on trays. Metal source targets are be transported from the targets to the
placed on the reactor chamber walls. The inserts. As the inserts are cooler, the ions
most common source is titanium (Ti). The will condensate on the insert surface to
targets are heated to a temperature where form a coating.
Parting and
grooving
the solid metal ionizes.
C
Threading
D
Milling
E
Drilling
F
Boring
The coating thickness is in the range The advantages of PVD coating

of 2-6 microns (.00008-.0002 inch)
G • PVD provides good edge line toughness.
depending on application area for the
insert. • PVD coatings can maintain a “sharp”
cutting edge.
Tool holding
The most common PVD layers today are

TiN, Ti(C,N), (Ti,Al)N, (Ti,Al,Cr)N and now • PVD can be used on brazed tips.
also non-ferrous oxides.
• PVD can be used on solid carbide tools.
H
Other information
Machinability
H 26
A
PVD vs. CVD coating process
Turning
PVD (Physical Vapor Deposition) CVD (Chemical Vapor Deposition)
In a PVD coating process, the coating is In a CVD coating process, the coating is B
formed by metal vapor condensating on formed by a chemical reaction of diferent
insert surfaces. PVD works the same way gases. Temperature, time, gas low, gas
Parting and
as when humid air condensates on cold atmosphere, etc., are carefully monitored
grooving
roads and forms an ice layer on the road. to steer the deposition of the coating layers.
PVD is formed at a much lower tempe- Depending on the type of coating, the
rature than CVD. Normal PVD process temperature in the reactor is about 800 to C
temperatures are around 500° C (930° F). 1100 degrees C (1470 to 2000 degrees F).
The coating thickness is in the range The thicker the coating the longer the pro-
of 2-6 microns (.00008-.0002 inch) cess time. The thinnest CVD coating today
Threading
depending on application area for the is below 4 microns (.00016 inch) and the
insert. thickest is above 20 microns (.0008 inch).
Milling
E
~500°C (~930°F) ~1000°C (~1830°F)
~1/100000 atm ~1/20 atm
Drilling
F
Boring
G
Tool holding
• Thinner coating • Thicker coating

H
• Sharper edges • More wear resistant
Other information
• Tougher • Thermal resistant

Machinability
H 27
Vision control, marking and packaging

Turning
Before being packaged, each insert is inspected again

B and compared with th blueprints and batch rder. A laser
marks the insert with the correct grade, and it's placed in
a grey box with a printed label. It's now ready to be distri-
buted to customers.
Parting and
grooving
C
Threading
D Inspection
Marking
Packaging
Milling
Distribution Labeling
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
H 28
The cutting edge
A
Turning
B
The cutting edge
Parting and
grooving
The design of the cutting edge and insert
geometry is of vital importance for the C
chip formation, tool life and feed rate data
in metal cutting process.
Threading
D
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
H 29
A The cutting edge
The high cutting force on a cutting edge

Turning
Cemented carbide has a high compres- In order to understand the tough environ-
B sive strength resistance and can also ment of the cutting edge, you can ind
work at high temperatures without plastic two diferent cutting data conditions for a
deformation. It can also resist high cutting cutting unit below. They generate about
forces (Fc) without breaking, as long as the the same cutting force (Fc) on the cutting
Parting and
grooving
insert is well supported. edge.
ap = 13 mm ap = 8.1 mm
(.512 inch)
ap =13 mm Material: Steel (.319 inch)mm
Threading
a =8.1
p
CMC 02.1 180 HB
fn = 0.62 fn = 1.0 mm
mm (.024 in)
fn =0.62 (.039fnin)
=1.0
D
Milling
Fc = 1700 kp Fc = 1700 kp
(3750 lbf) (3750 lbf)
E
Drilling
The cutting force in these two cases is equivalent to the weight of a passenger car.
Boring
Calculation of Fc Material: MC P2 (low alloyed steel) 180 HB

Speciic cutting forces kc1 = 2100N/mm2 (304,563 lbs/in2)
G
Fc = kc1 x ap x fn
Fc = 2100N/mm2 x 13 mm x 0.62 mm = 16926 Newton (N) = 1700 kp
Tool holding
Fc = 304,563 lbs/in2 x .512" x .024" = 3742 pound force (lbf) = 1700 kp
1lbf = 0.4535 kilogram force (kg),

H 1N = 0.101 kg
kp = kilopond or kilogram force
Other information
Machinability
H 30
The cutting edge
A
The machining starts at the cutting edge
Turning
B
Parting and
grooving
C
Typical chip breaking

sequences with high
Threading
speed imaging.
D
Cutting zone temperatures
The maximum heat generated during This is where the maximum pressure
Milling
cutting is on the top part of the insert, from the material is, and, with the friction
1000° celsius (1832° fahrenheit), in the between chip and carbide, causes these
chip breaker, and close to the cutting high temperatures. E
edge.
Drilling
• The rake angle, geometry and feed play
an important role in the chip formation F
process.
• Removing heat from the cutting zone
through the chip (80%) is a key factor.
Boring
• The rest of the heat is usually evenly

distributed between the workpiece and G
the tool.
Tool holding
H
Other information
Machinability
H 31
A The cutting edge
The design of a modern insert

Turning
B
Parting and
grooving
C
Threading
A steel turning insert for medium turning.
Deinitions of terms and geometry design

Milling
E Nose cutting edge Main cutting edge

design design
25 mm
Drilling
(.010")
20°
F 5°
Macro geometry with
chip breaker • Cutting edge reinforce-
ment 0.25 mm (.010")
• Rake angle 20°
• Primary land 5°
Boring
Geometry for small

cutting depths
G
0.2 mm
(.008")
Tool holding
H
Other information
Machinability
H 32
The cutting edge
A
Turning
The ER treatment gives the cutting edge the inal
micro-geometry
B
• ER treatment (Edge Roundness) is done
Parting and
before coating, and gives the inal shape
grooving
of the cutting edge (micro-geometry).
• The relation between W/H depends on
the application.
C
Threading
Generally the ER
corresponds to the
thickness of a hair,
diameter: ~ 80 µm
(.0031 inch). D
Milling
A negative land increases the strength of the cutting edge E
In some cases inserts have a negative land and rein-

forced insert corners, making them stronger and more
secure in the intermittent cutting action.
Drilling
F
Negative
land 0.1 mm (.0039") Boring
G
Chamfer
Tool holding
• A negative land increases the strength of the cutting

edge, but also creates higher cutting forces.
H
Other information
Machinability
H 33
A The cutting edge
Insert rake angle

Turning
The rake angle can be either negative or positive.
B Based on that, there are negative and positive inserts,

where the clearance angles are either zero or several
degrees plus. This determines how the insert can be
tilted in the tool holder, and results in either a negative or
Parting and
grooving
positive cutting action.
C
• The insert rake angle is
the angle between the
top face of the insert and
Threading
the horizontal axis of the

workpiece.
D
Milling
E
Positive and negative cutting action
Turning needs a durable edge that can In drilling, the edge must be strong
Drilling
perform for a long time and often in enough to last at very low cutting speeds,
continuous cuts at high temperature. This and even at zero speed in the center of
F condition requires an edge with among the drill.
other things good chip breaking ability,
In most drilling applications there is also
good resistance against diferent types of
coolant present, mainly for chip transporta-
wear and against plastic deformation.
tion reasons which puts the edge under
Boring
In milling, which always has an intermittent extra stress from temperature variations.
cutting action, the edge needs to have good To be able to transport the chips from
G bulk strength to resist breakage. A large the narrow chip lutes and from inside the
variation in cutting edge temperature due hole, good chip breaking into short chips
to interrupted cuts also makes resistance is an important factor.
Tool holding
to thermal cracks of vital importance.
H
Other information
Machinability
H 34
The cutting edge
A
Peak performance in machining
Turning
Dedicated inserts for diferent applications
There are major diferences in insert geometry and grade requirements B
between applications in turning, milling and drilling.
Parting and
grooving
Turning • Needs a durable edge that can perform
for a long time, and often in continuous
cuts at high temperature. C
• Good chip breaking ability.
• Good resistance against diferent types
Threading
of wear and against plastic deformation.
P
D
M Milling • The cutting action is always intermittent
and the edge needs to have good bulk
strength to resist breaking.
Milling
K • Variations in cutting edge temperature
due to the interrupted cuts also mean E
that the resistance to thermal cracks is
N of vital importance.
Drilling
S
F
Drilling • The edge must be strong enough to last
at very low cutting speeds; in fact, at zero
H speed in the center of the drill.
Boring
• Coolant is present, mainly for chip trans-

portation reasons, which puts the edge
under extra stress from temperature G
variations.
• To transport the chips from the narrow
Tool holding
chip lutes and from inside the hole, good

chip breaking is important.
H
Other information
Machinability
H 35
A The cutting edge
Six main groups of workpiece materials

Turning
Diferent characteristics for removing chips

B Good chip forming usually results in high cutting forces and excess heat,
depending on the material. This can lead to low cutting speeds with adhesive
stresses as a result. On the other hand, materials like non-ferrous, unalloyed
Parting and
steels and low-strength cast iron produce less cutting force.

grooving
C
Threading
D
Milling

E
Drilling
Non-ferrous Heat resistant alloys Hardened steel

Boring
G
Tool holding
H
Other information
Machinability
H 36
The cutting edge
A
From universal to optimized turning inserts
Turning
General inserts
• General geometry B
• Optimizing with grades
• Performance compromised
Parting and
grooving
Application area
Dedicated inserts C
• Dedicated geometries and grades
• Optimized performance according to
Threading
workpiece machinability
Application area D
Dedicated inserts for the ISO P, M, K and S areas

The diferent micro- and macro-geometries
Milling
are adapted to the various requirements in
the applications and materials.
E
Workpiece material Finishing Medium Roughing
Drilling
0.32 mm
0.7 mm 0.2 mm
(.013")
(.028") (.008")
0.32 mm
0.29 mm
(.013")
(.011")
Boring
G
0.1 mm 0.25 mm
(.004") (.010")
Tool holding
H
Other information
Machinability
H 37
A The cutting edge
Type of application - Turning

Turning
ap Depth of cut,
mm (inch) Rough Turning
• Operations for maximum stock removal and/
B R or severe conditions
• High D.O.C. and feed rate combinations
• Operations requiring highest edge security
Parting and
grooving
Medium Turning
C
M • Most applications – general purpose
• Medium operations to light roughing
• Wide range of D.O.C. and feed rate combinations
Threading
Finish Turning
F • Operations at light depths of cut (ap) and low feed rates
• Operations requiring low cutting forces
D
fn
Feed, mm/r (inch/r)
Milling
Selecting the insert geometry in turning

E
Drilling
Finishing (F) Medium (M) Roughing (R)

Boring

geometry
• Finish machining • Rough machining
G • Medium feed rates
Tool holding
light roughing.
H
Other information
Machinability
H 38
The cutting edge
A
Type of application - Milling
Turning
ap Depth of cut,
mm (inch) Heavy Milling
• Operations at maximum stock removal and/
H or severe conditions B
• Larger depth of cut and feed rate
• Operations requiring highest edge security
Parting and
grooving
Medium Milling
M • Most applications – general purpose milling
• Medium operations to light roughing C
• Medium depth of cut and feed rate
Threading
Light Milling
L • Operations at small depth of cut and low feed rates
• Operations requiring low cutting forces
D
Feed fz, mm/tooth (inch/tooth)
Milling
Selecting the insert geometry in milling
E
Drilling
F
Light (-L) Medium (-M) Heavy (-H) Boring

geometry
• Light machining • Heavy machining
• Medium feed rates G
Tool holding
light roughing.
H
Other information
Machinability
H 39
A Cutting tool materials
Cutting tool materials

Turning
The selection of cutting tool material and grade is an important factor

to consider when planning a successful metal cutting operation.
B
A basic knowledge of each cutting tool material and its performance is
therefore important to be able to make the correct selection for each
application. This should take into consideration the workpiece material
Parting and
grooving
to be machined, the component type and shape, machining conditions

and the level of surface quality required for each operation.
C
Threading
D
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
H 40
A
Diferent types of cutting tool materials
Turning
Hardness
B
CD

1 1. Diamond
Parting and
grooving
2
CB

3
2. Cubic boron nitride
C
4
5

CC
Threading
3. Ceramics

6 CT
D
4. Cermets
GC
Milling
5. Coated carbide
E
HSS
6. High speed steel
Toughness
Drilling
F
The ideal cutting tool material should:
- be hard, to resist lank wear and deformation
- be tough, to resist bulk breakage
Boring
- not chemically interact with the workpiece material

- be chemically stable to resist oxidation and difusion G
- have good resistance to sudden thermal changes.
Tool holding
H
Other information
Machinability
H 41
The main range of cutting tool materials

Turning
• Uncoated cemented carbide (HW)

B • Coated cemented carbide (HC)
• Cermet (HT, HC)
Parting and
• Ceramic (CA, CN, CC)

grooving
• Cubic boron nitride (BN)
C • Polycrystalline diamond (DP, HC)

Threading
D - (HW) Uncoated hard metal - (CM) Mixed ceramics containing ¹) Polycrystalline diamond and
containing primarily tungsten primarily aluminum oxide (Al2O3) cubic boron nitride are also
carbide (WC). but containing components called superhard cutting
- (HT) Uncoated hard metal, also other than oxides. materials.
called cermet, containing - (CN) Nitride ceramics containing
primarily titanium carbides (TIC) primarily silicon nitride (Si3N4).
Milling
or titanium nitrides (TIN) or both. - (CC) Ceramics as above, but

- (HC) Hard metals as above, but coated.
coated. - (DP) Polycrystalline diamond ¹
E - (CA) Oxide ceramics containing - (BN) Cubic boron nitride ¹
primarily aluminum oxide
(Al2O3).
Drilling
Uncoated cemented carbide

F
Characteristics, features and beneits
• Used in moderate to diicult applications
related to steel, HRSA, titanium, cast iron and
non-ferrous in turning, milling and drilling.
Boring
• Good combination of abrasive wear resistance

and toughness.
G • Gives sharp cutting edges.
• Good edge security but limited wear resistance
at higher speeds.
Tool holding
• Represents a small portion of the total grade

program.
H
Other information

Machinability
H 42
A
 Coated cemented carbide
Turning
• General use in all kinds of components and
materials for turning, milling and drilling B
applications.
• Extremely good combination of wear resistance
and toughness in a variety of jobs.
Parting and
grooving
• Consists of a large variety of grades with hard to
tough substrates, usually with gradient sintering,
and various coatings of CVD and PVD-type.
• Shows very good wear characteristics with long C
tool life.
• Dominates the insert program, with increasing
share.
Threading
Cermet
• Used in inishing and semi-inishing applications D
where close tolerance and good surface inish is
required.
• Chemically stable with a hard and wear resistant
substrate.
Milling
• Consists of Titanium based (TiC, TiCN) cemented
carbide with cobalt as a binder.
• PVD-coating adds wear resistance and tool life. E
“Self sharpening ” properties. Limited toughness
behavior.
• Quite low share of total insert program.
Drilling
F
Ceramic
• Depending on type of ceramic, the grades are
mainly used in cast iron and steel, hardened
materials and HRSA.
Boring
• Ceramic grades are generally wear resistant and

with good hot-hardness. Wide application area in
diferent types of material and component. G
• Ceramics are considered brittle and need stable
conditions. With additions in the mix and whisker
Tool holding
reinforced ceramic, toughness is improved.

• Fairly low share of total insert usage, but increased
usage in the aerospace and hardened steel-cast
iron areas.
H
Other information

Machinability
H 43
 Cubic boron nitride

Turning

• For inish turning of hardened steel. Roughing
B of gray cast iron at high cutting speeds. Rough
turning of rolls in white/chilled cast iron.
• Applications that require extreme wear resi-
stance and toughness.
Parting and
grooving
• CBN consists of Boron nitride with Ceramic or

Titanium nitride binder.
• Resists high cutting temperatures at high
C cutting speeds.
• Special application area with small volume
inserts. Trend is towards a higher volume of
hard materials to be cut.
Threading
D
Polycrystalline diamond
• Turning of normal non-ferrous at low tempera-
ture and very abrasive hypereutectic non-
Milling
ferrous. Used in non-metal and non-ferrous

materials.
E • Extremely wear resistant grades. Sensitive to
chipping.
• Brazed-in corners of polycrystalline diamond
(PCD tip) to an insert or thin diamond coated
ilm on a substrate.
Drilling
• Long tool life and extremely good wear resi-

stance. Decomposes at high temperatures.
F Dissolves easily in iron.
• Fairly low portion of the insert program, with
special limited applications.
Boring
G
Tool holding
H
Other information
Machinability
H 44
A
The development of cutting tool material
Turning
The development of cutting tool material through the years can be seen in
the reduced time taken to machine a component 500 mm long, with 100 mm B
diameter (19.685 inch long, with 3.937 inch diameter) from 1900 to today.
Parting and
grooving
At the beginning of the last century, cutting tool The introduction of coated carbide again
material was only slightly harder than the material lowered the cutting time to 1.5 minutes. C
which needed to be cut. Therefore tool life was
Today with improved geometries and new coating
poor, and cutting speed and feed had to be
technique we have reached below 1 minute in
kept very low.
cutting time for the 500 mm (19.685 inch) steel
Threading
The introduction of HSS brought major improve- bar.
ments, which resulted in reduced cutting time.
In addition to traditional uncoated and coated
20 years later uncoated cemented carbide carbide, new cutting tool materials like cermet,
brought down the required time in cut to a ceramic, cubic boron nitride and diamond, D
staggering 6 minutes. have contributed to optimized and improved
productivity.
Milling
E
Time
(Minutes) Carbon steel
Drilling
ø100 mm
(ø3.937")
F
High speed steel (HSS) 500 mm
(19.685")
Boring
Cemented carbide
G
Tool holding
Coated carbide
Insert geometries, new coatings
New cutting tool materials

H
Other information
Machinability
H 45
What is cemented carbide and a grade?

Turning
• Cemented carbide is a powder metall-

urgical material consisting of:
B
- hard-particles of tungsten carbide (WC)
- a binder metal, cobalt (Co)
Parting and
grooving
- hard-particles of Ti, Ta, Nb (titanium,

tantalum, niobium-carbides).
C
• A grade represents the hardness or
toughness of the insert, and is deter-
Threading
mined by the mixture of ingredients

which make up the substrate.
D
Milling
E
Coating of cemented carbide
• Coating of cemented carbide was
Drilling
developed in the 1960s.

• A thin Titanium Nitride coating layer was
F added, only a few microns thick. This
improved the performance of carbide
overnight.
• Coatings ofer improved wear resistance
Boring
giving longer tool life and possibility to

use higher cutting data.
G
•Today modern grades are coated with
diferent carbide, nitride and oxide layers.
Tool holding
H
Other information
Machinability
H 46
A
Microstructure of cemented carbide
Turning
Cemented carbide consists of hard The gamma phase has a better hot
particles (carbides) in a binder matrix. hardness and is less reactive at elevated
temperatures, so is often seen in grades B
The binder is more or less in all cases
where the cutting temperature can get
cobalt (Co) but could also be Nickel (Ni).
high. WC has a better abrasive wear
The hard particles consist mainly of
Parting and
resistance.
grooving
tungsten carbide (WC) with a possible
addition of gamma phase (Ti-, Ta- Nb-
carbides and nitrides).
C
Threading
Elements: D
Alpha-phase
WC (tungsten carbide)
Alpha-phase (WC)
Milling
Gamma-phase
Gamma-phase (TiC) (Ti,Ta,Nb)C E
(titanium, tantalum,
niobium-carbides)
Beta-phase (Co)
Drilling
Beta-phase
Co (cobalt)
F
Hair diameter
Boring
= 50-70 µm (.0020-.0028")
G
Tool holding
H
Other information
Machinability
H 47
Fundamental characteristics
Turning
Apart from the grain size of the tungsten An increase in Co content and WC grain
carbide (WC), the amount of binder phase size contributes to an increase in bulk
B cobalt (Co) is an important factor deter- toughness, but also lowers the hardness.
mining the characteristics of the carbide. As a result, the substrate has less resist-
The Co content in Sandvik Coromant ance to plastic deformation, which means
Parting and
grades is generally 4–15% of the total less wear resistance/lower practical tool
grooving
weight. life.
C
Threading
Amount of binder
Toughness
D
Milling
E
Drilling
F
Boring
Wear resistant WC grain size
G
Tool holding
H
Other information
Machinability
H 48
A
Coating design
Turning
Many factors inluence the behavior of
the insert:
B
- Coating process
- Coating material
Parting and
grooving
- Coating thickness
- Post treatment
- Surface morphology. C
Threading
D
Milling
Example of modern steel turning grades E
Structure and build-up of the coating layers
Drilling
Wear resistance P Toughness
F
Boring
Gradient substrate for optimized hardness and toughness

G
Tool holding
ISO P01 – P15 ISO P05 – P30 ISO P10 – P35 ISO P20 – P45
Thicker coatings mean more wear resistance. H

Other information
Harder substrates mean more deformation resistance.

Machinability
H 49
Grade design
Turning
Coatings and substrates vary with the type of application

B
Parting and
grooving
K05 – K15 P05 – P35 M15 M25 M35

Threading
Thicker coatings mean more wear resistance.

Harder substrates mean more deformation resistance.
D
The coating of a modern turning grade

Milling
E The grade plays a very important part of the performance

Al2O3
– Coating for chemical and
thermal wear resistance
Drilling
F TiCN
– MTCVD coating for
mechanical wear resistance
Boring
Functional gradient
G – For optimized hardness and
toughness
Tool holding
Cemented carbide
– Plastic deformation
resistance
H
Other information
Machinability
H 50
A
Properties of diferent coating materials
Turning
CVD coating of inserts
Chemical Vapor Deposition B
• The most common CVD layers today are
Parting and
TiN, Ti(C,N) and Al2O3.
grooving
TiN
• TiCN provides lank wear resistance.
Al2O3 • Al2O3 provides temperature protection C
(plastic deformation resistance).
Ti(C,N) • TiN provides easy wear detection.
Threading
D
TiN = Titanium nitride
Ti(C,N) = Titanium carbonitride
Al2O3 = Non-ferrous oxide
Milling
E
PVD coating of inserts
Drilling
Physical Vapor Deposition
• PVD coatings are generally tougher than F
CVD coatings.
• PVD coatings are often used in combina-
TiAlN
tion with ine-grained substrates to coat
Boring
“sharp” cutting edges.

• Total thickness of the PVD layers is often G
between 3 – 6 μm (.0001 – .0002 inch).
• The coating is applied at approx. 500° C
Tool holding
(932° F).
TiAlN = Titanium aluminum nitride

H
Other information
Machinability
H 51
F
E
A
H
C
G
H 52
Tool wear & maintenance
• Tool wear
• Maintenance
Tool wear &
maintenance
H 61
H 53
A
The tough environment in metal cutting
Turning
Diferent wear mechanisms on the inserts
B
Type of load Symbol Wear picture Cause
Parting and
grooving
Mechanical stress on
Mechanical the insert edge causes C
breakage.
Threading
Temperature varia-
tions cause cracks and
Thermal heat generates plastic D
deformation (PD) on
the insert edge.
Milling
A chemical reaction
between carbide E
Chemical and working material
causes wear.
Drilling
In cast iron the SiC F
Abrasive inclusions can wear on
the insert edge.
Boring
BUE
With sticky material, G
Adhesive built-up layers/edges
are formed.
Tool holding
BUE = Built-Up Edge

H
PD = Plastic Deformation
Other information
Machinability
H 53
A Tool wear & maintenance
Wear pictures, cause and remedy

Turning
Some of the most common wear patterns

B
Flank wear (abrasive)
Flank wear is one of the most common wear types and it occurs on the lank face of
Parting and
the insert (tool). This is the preferred wear pattern.

grooving
Cause Remedy
During cutting, tool material is Reducing the cutting speed
lost on the lank face due to and simultaneously increasing
C friction against the surface of the feed will result in increased
the work piece material. Wear tool life with retained produc-
typically begins at the edge tivity.
line and gradually develops
Threading
downward.
D
Crater wear (chemical)
Cause Remedy
Crater wear occurs as a result Lowering the cutting speed
Milling
of chip contact with the rake and choosing an insert (tool)

face of the insert (tool). with the right geometry and a
more wear resistant coating
E will increase the tool life.
Drilling
F Plastic deformation (thermal)

Plastic deformation is a permanent change in the shape of the cutting edge,
where the edge has either sufered an inward deformation (edge impression) or a
downward deformation (edge depression).
Boring
Cause Remedy
The cutting edge is subjected Plastic deformation can be
to high cutting forces and dealt with by using grades with
G temperatures resulting in a higher hot hardness. Coatings
stress state, exceeding the improve the plastic deforma-
tool materials yield strength tion resistance of the insert
and temperature. (tool).
Tool holding
Edge depression
H
Other information

Machinability
Edge impression
H 54
A
Turning
B
Flaking
Parting and
Flaking usually occurs when machining in materials with smearing properties.
grooving
Cause Remedy
An adhesive load can develop, Increasing the cutting speed
where the cutting edge is as well as selecting an insert
subjected to tensile stresses. with a thinner coating will C
This may lead to the detach- reduce the laking on the tool.
ment of the coating, exposing
sublayers or substrate.
Threading
D
Cracks (thermal)
Milling
Cracks are narrow openings in which new boundary surfaces have been formed
through rupture. Some cracks are conined to the coating, while others extend down
into the substrate. Comb cracks are roughly perpendicular to the edge line and most
often thermal cracks. E
Cause Remedy
Comb cracks form as a To prevent this, a tougher
result of rapid luctuations insert grade can be used and
in temperature. the coolant should be applied
Drilling
in large amounts or not at all.
Boring
Chipping (mechanical)
Chipping consists of minor damage to the edge line. The diference between chipping
and fracture is that with chipping the insert can still be used.
G
Cause Remedy
There are many combinations Diferent preventative measu-
Tool holding
of wear mechanisms that can res can be taken to minimize

cause chipping. However, the chipping, depending on which
most common are thermo- wear mechanism/mechanisms
mechanical and adhesive. that caused it.
H
Other information

Machinability
H 55
Notch wear
Notch wear is characterised by excessive localised damage at maximum cutting depth
Turning
but can also occur on secondary edge.
B
Cause Remedy
Depending upon if the chemical For work-hardening materials,
wear dominates the notch select a smaller entering angle
Parting and
wear, which proceeds more and/or vary the depth of cut.

grooving
regularly, as in the picture,

compared to irregular growth
of adhesive or thermal wear. In
C the latter case work hardening
and burr formation are impor-
tant factors for notch wear.
Threading
D Fracture
Fracture is deined as the breakout of a large part of the cutting edge, where the insert
can no longer be applied.
Cause Remedy
The cutting edge has been Identify and prevent the original
Milling
exposed to a greater load than wear type, selecting proper

it can resist. This could be the cutting data and checking
E result of allowing the wear to stability of setup.
progress too far leading to
increased cutting forces. It can
also be caused prematurely
due to the wrong cutting data
or stability issues in the setup.
Drilling
Built up edge (adhesive)

Boring
Built up edge (BUE) is an accumulation of material against the rake face.

Cause Remedy
G Built up material can form on Increasing the cutting speed
the top of the cutting edge, can prevent the formation of
which separates the cutting BUE. In softer, stickier materials
edge from the material. Resulting a sharper edge will help.
Tool holding
in increased cutting forces,

leading to failure or releasing
and taking away parts of the
coating and even substrate
layers,
H
Other information
Machinability
H 56
A
Consequences of poor tool maintenance
Turning
B
Parting and
grooving
C
Threading
D
Milling
E
Drilling
• Damaged inserts
• Damaged shims F
• Damaged tool holders

• Damaged components
Boring
• Damaged machine
G
Tool holding
Result:
• Reduced production
• Higher production costs H
Other information
Machinability
H 57
Inspection of tool
Turning
Visually inspect shims & shim seats
B • Check shim damage.

• Clean insert seat and damaged location and
support for cutting edge.
Damage
Parting and
• If necessary index or replace shim.

grooving
• Ensure correct insert location against support

points.
C • It is important to ensure that shim corners
Chip breakage impression
have not been knocked of during machining or
handling.
Threading
Inspect pockets
D
• Pockets damaged or plastic deformation.
• Oversized pockets due to wear. The insert
does not sit properly in the pocket sides. Use
a 0.02 mm (.0008 inch) shim to check the gap.
Milling
• Small gaps in the corners, between the shim

and the bottom of the pocket.
E
Drilling
The importance of using the correct wrench

F
Why use the proper wrenches?
• Extends life of screw and wrench.
• Reduces risk of stripping screw.
Boring
G What is the proper way to tighten an insert

screw?
• Important to use the proper wrench.
Tool holding
• Always use correct torque. Values are marked

on tool and shown in product catalog.
• Common sense!
H
Other information
Machinability
H 58
A
Torx Plus® wrenches
Turning
Torx Plus from Sandvik Coromant
Nm (lbs-in)
B
Parting and
grooving
C
Torx Plus® vs. Torx
Threading
Cross section
Torx Plus® Torx
Torx Plus® D
Milling
E
Torx Plus is a registered trademark of Standard Torx

Camcar-Textron (USA) screw
Drilling
F
Torx Plus® wrenches with adjustable torque Boring
• On parting and grooving tools an

adjustable torque wrench is required, as
the torque is not related to screw size. G
• It should of course be used on all
products with a clamp screw.
Tool holding
H
Other information
Machinability
H 59
Insert screws / clamping screws

Turning
• Screw threads, heads and Torx sockets

should be in good condition.
B
• Use correct keys.
• Ensure correct screw-tightening torque.
Parting and
• Apply suicient screw lubrication to

grooving
prevent seizure. Lubricant should be

applied to the screw thread as well as the
C screw-head face.
• Replace worn or exhausted screws.
Threading
D
Milling
Important!
Use Anti-seize for screw heads
E and threads
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
H 60
A
Tool maintenance
Turning
Contact faces
• Always check supporting and contact
B
faces of tool holders, milling cutters and
drills, making sure there is no damage or
dirt.
Parting and
grooving
• In boring operations it is especially
important to have the best possible
clamping. If the bar is not supported to
C
the end of the holder, overhang will be
increased and create vibration.
Threading
80° point Production security D
angle
• It is important to select the correct insert
size, insert shape and geometry and
insert nose radius to achieve good chip
Milling
low.
IC
- Select largest possible point angle on
E
the insert for strength and economy.
- Select largest possible nose radius for
L insert strength.
Drilling
RE - Select a smaller nose radius if there is a
L = cutting edge length (insert size) tendency for vibration.
F
RE = nose radius
Stability
Boring
• Stability is the key factor for successful

metal cutting, afecting machining costs G
and productivity.
• Make sure that any unnecessary play,
Tool holding
overhang, weakness, etc., has been

eliminated and that correct types and
sizes of tools are employed for the job.
H
Other information
Machinability
H 61
Insert handling
Turning
Inserts are placed in segregated packages

in order to prevent insert to insert contact,
B as this may damage the carbide with micro
fracturing and/or chipping. Which may reduce
insert performance and life. It’s recommended
Parting and
that inserts remain in their original packaging

grooving
until they are applied in the machining process.
C
Threading
D Summary of maintenance checklist

 Check tool wear and shims for damage.
 Make sure insert seat is clean.

Milling
E  Make sure of correct insert location.
 Make sure correct keys and drivers are used.
 Insert screws should be correctly tightened.

Drilling
F  Lubricate screws before tool assembly.
 Make sure contact faces are clean and undamaged

on tools, holding tools and machine spindles.
Boring
 Make sure boring bars are clamped well and that

G holders are undamaged at the end.
 A well organized, maintained and documented tool

Tool holding
inventory is a production cost saver.
 Stability is always a critical factor in any metal cutting

H operation.
Other information
Machinability
H 62
How to improve
machining economy
Machining economy
H 63
H 64
Machining economy
F
E
A
H
C
G
A Machining economy
Doing more machining in the same production time

Turning
B
Productivity deinition
Parting and
grooving
The value of output pro-

duced divided by the value
of input or resources.
C
= Output / Input
Threading
D
Attack the productivity gap
In all industrial operations, the cost of running the
operation, e.g. for labor, raw material, equipment, etc.,
Milling
is increasing at a faster rate than the price of the goods

that are sold. In order to bridge that gap, one needs
E to continuously increase eiciency, resulting in higher
productivity. Bridging this gap is the only way to stay
competitive and ultimately to stay in business.
Drilling
135
130
Boring
125 Cost development

G 120
115
110
Tool holding
105 Productivity gap

100
Price development
95
H
Other information
Source: Mechanical Industry in OECD.

Machinability
H 64
Machining economy
A
Maximizing productivity
Turning
The three main machining parameters, cutting speed, feed, and depth of cut, have an
efect on tool life. The depth of cut has the smallest efect followed by the feed rate.
Cutting speed has the largest efect by far on insert tool life. B
Parting and
Depth of cut, mm (inch)
grooving
C
Threading
Feed, mm/rev (inch/rev)
Milling
Cutting speed, m/min (ft/min)
Optimizing the depth of cut, feed

rate and then the cutting speed E
is the best way to maximize the
productivity.
Drilling
Productivity “Q” is measured as the amount of material removed in a ixed time period,
cm3/min (inch3/min).
F
Turning Milling
vf
Boring
G
Tool holding
Metric Metric
ap × ae × vf
Q = vc × ap × fn Q= 1000
Inch Inch
H
Other information
Q = vc × ap × fn × 12 Q = ap × ae × vf
Machinability
H 65
A Machining economy
Maximizing productivity – examples

Turning
Metal removal rates for a ixed depth of cut of 3.0 mm (.118 inch) using:
B Low alloy steel, Insert: CNMG 432-PM 4225 (CNMG 120408-PM 4225)
P MC P2
3.0 3.0 3.0
ap, mm (inch)
Parting and
Hardness, HB 180 (.118) (.118) (.118)

grooving
0.15 0.3 0.5

fn, mm/r (inch/r)
(.006) (.012) (.020)
C 425 345 275
vc, m/min (ft/min)
(1394) (1132) (902)
Threading
Q, cm3/min 191 310 412*

(inch3/min) (12) (19) (25)*
D
* Slowest cutting speed with the highest feed =
highest productivity
Milling
Using a trigon W-style insert, versus a C-style double-sided or

E single-sided insert
Trigon shape
Low alloy steel,
P MC P2 Insert: double-sided for medium machining.
3/4 mm
Drilling
Hardness, HB 180 No of passes / (.118 /.157 inch)

cutting depth, ap 1/3 mm
F (.039/.118 inch)
Machining time, Tc 22 seconds
15 mm (.591")
Rhombic shape
Boring
Insert: double sided for medium machining.

No of passes / 3/5 mm
G cutting depth, ap (.118/.197 inch)

Tool holding
50 mm
(1.969") Insert: Single sided for rough machining.
No of passes / 2/7.5 mm
cutting depth, ap (.079/.295 inch)
H
Other information

Machinability
H 66
Machining economy
A
Value adding time
Turning
Cutting time B
Machining time
Non-cutting
Parting and
and tool
Production time (planned) Tool change Set-up and gauge
grooving
change time
machine stopped
Work piece change
Other
Breakdowns
C
Other time
Cutting time = 60% x 50% x 80% = 24%
Threading
D
Machining economy
Milling
E
Drilling
• Variable costs • Fixed costs
Costs incurred only during production: Costs which exist even when not in F
- cutting tools, consumables (3%) production:
- workpiece materials (17%). - machine and tool holders (27%)
- labor (31%)
- buildings, administration, etc. (22%).
Boring
G
Tool holding
H
Other information
Machinability
H 67
A Machining economy
Machine tool utilization

Turning
Cost, tool life or productivity

B The cost of the tooling, an easily measured value, is
always under price or discount pressure, but even
when the price is reduced by 30% it only inluences
the component cost by 1%.
Parting and
grooving
We have a similar result of a 1% cost saving when

tool life is increased by 50%.
C Increasing the cutting data by only 20% will dramatically
reduce component costs and lead to a 15% component
saving.
Threading
D
• Decreased cost:
A 30% decrease in price
Milling
only reduces total cost per

component by 1%.
E
Drilling
• Increased tool life:

A 50% increase in tool life only reduces
F total cost per component by 1%.
15%
Boring
• Increased cutting data:

G
A 20% increase in cutting
data reduces total cost per
Tool holding
component by more than

15%.
H
Other information
Machinability
H 68
Machining economy
A
Machine tool utilization
Turning
Cost, tool life or productivity
Example: B
Shop spends $10,000
to make 1000 parts.
Parting and
grooving
Machine cost is $10.00
per part.
Threading
Lower Increase
Variable Today price Tool life cutting data
– Tooling $ .30 $ .21 $ .20 $ .45 D
– Material $ 1.70 $ 1.70 $ 1.70 $ 1.70
Milling
Fixed
– Machinery $ 2.70 $ 2.70 $ 2.70 $ 2.16 E
– Labor $ 3.10 $ 3.10 $ 3.10 $ 2.48
– Building $ 2.20 $ 2.20 $ 2.20 $ 1.76
Drilling
Cost per part $ 10.00 $ 9.91 $ 9.90 $ 8.55
Savings 1% 1% 15% Boring
G
Tool holding
H
Other information
Machinability
H 69
A Machining economy
Machining ecomomy
Turning
Cutting data and cost

B • Cutting speed has no efect on ixed 2. The lowest point on the Production
costs. cost curve corresponds to the
economic cutting speed.
• As cutting speed increases more parts
Parting and
are produced per hour and therefore 3. The highest point on the Production
grooving
cost per part is reduced. cost curve corresponds to the

maximum cutting speed.
• As cutting speed increases more tools
C are used and therefore cost per part The speed between these two points is
increases. the High Eiciency Range, which is where
If we add all costs together we will get we should be trying to operate.
Threading
the curve of total Production cost.

1. As speed increases the Parts per hour
increase until we reach a point where
D we are spending a disproportionate
amount of time changing tools and
production rate will start to decrease.
Milling
E
Parts per hour
Cost per part
Drilling
Production rate
Production cost
F
Tool cost
Boring
G
Tool holding
Fixed cost
Machine cost
H
Cutting
High Eiciency
Other information
Economic Speed for maximum speed

speed Range production
Machinability
H 70
Machining economy
A
Base for cutting data recommendations
Turning
Compensation of cutting speed for increased tool life or
higher metal removal
B
Tool life Increase tool life (example)
• All recommended cutting data is based • Our Recommended cutting data is
Parting and
on 15 minutes of tool life. 225 m/min (738 ft/min).
grooving
• Looking at the chart below 15 min • To increase tool life by 30%, we look at
tool life = a factor of 1.0. the factor for 20 minutes of tool life =
0.93. C
• Multiple the factor for desired minutes
by the recommended cutting speed. • Multiple the factor for desired minutes
by the recommended cutting speed.
Threading
• 225 m/min x 0.93 = 209 m/min
(738 ft/min x 0.93 = 686 ft/min).
D
Milling
Tool life (min) 10 15 20 25 30 45 60
Correction
factor 1.11 1.0 0.93 0.88 0.84 0.75 0.70
E
Higher metal removal rate Higher metal removal rate (example)
Drilling
• Recommended cutting data is based on • The Recommended cutting data is
15 minutes of tool life. 225 m/min (738 ft/min).
F
• To obtain higher metal removal rates, we • To increase metal removal by 10%, we
would move in the opposite direction on look at the factor for 10 minutes = 1.11.
the chart. Decreasing the minutes of tool
• Multiple the factor for desired minutes by
life to gain higher metal removal.
Boring
the recommended cutting speed.

• Multiple the factor for desired minutes
• 225 m/min x 1.11 = 250 m/min
by the recommended cutting speed.
(738 ft/min x 1.11 = 819 ft/min). G
Tool holding
H
Other information
Machinability
H 71
A Machining economy
Compensation of cutting speed for diferences in material hardness

Turning
Hardness
• Cutting speed recommendations are • Each ISO/ANSI material group is associated
B
based on the material reference and with a multiplying factor for reduced/
their respective hardness. increased hardness of material
(example ISO/ANSI P = 180 HB and has a
Parting and
• Metal material hardness is measured

grooving
factor of 1.0).
in Hardness Brinell (HB) or Hardness
Rockwell “C” scale (HRC) example: ISO/ • Use the chart below for correction fac-
ANSI P = 180 HB, ISO/ANSI H = 60 HRC. tors and multiply by the recommended
C cutting speed for the chosen insert
• The hardness (HB) column is the base
grade.
hardness for each material group and
cutting speeds are recommended for
Threading
this base hardness (note: your material

could be harder/softer).
D
Milling
E Reduced hardness Increased hardness

ISO/
ANSI MC(1) HB(2) -60 -40 -20 0 +20 +40 +60 +80 +100
P P2 HB 180 1.44 1.25 1.11 1.0 0.91 0.84 0.77 0.72 0.67
Drilling
M M1 HB 180 1.42 1.24 1.11 1.0 0.91 0.84 0.78 0.73 0.68
F K2 HB 220 1.21 1.13 1.06 1.0 0.95 0.90 0.86 0.82 0.79
K
K3 HB 250 1.33 1.21 1.09 1.0 0.91 0.84 0.75 0.70 0.65
N N1 HB 75 1.05 1.0 0.95
Boring
S S2 HB 350 1.12 1.0 0.89
G H H1 HRC(3) 60 1.07 1.0 0.97

1) MC = material classiication code
2) HB = Hardness Brinell
Tool holding
3) HRC = Hardness Rockwell
H
Other information
Machinability
H 72
Machining economy
A
Example of Conversion table for hardness scale
Turning
Material speciications maybe given in diferent forms,
example: HB, HRC, Tensile Strength or Speciic Cutting
forces. B
Parting and
Vickers Customer workpiece
grooving
Tensile strength Brinell Rockwell
N/mm2 lbs/inch2) HV HB HRC HRB material (match to information
255 36,975 80 76.0 – – on chart)
270 39,150 85 80.7 – 41.0
285 41,325 90 85.5 – 48.0 Tensile strength = 950 N/mm2 C
305 44,225 95 90.2 – 52.0
(137,750 lbs/inch2)
320 46,400 100 95.0 – 56.2
350 50,750 110 105 – 62.3 HB = 280, HRC = 29.2
Threading
385 55,825 120 114 – 66.7
415 60,175 130 124 – 71.2
450 65,250 140 133 – 75.0
480 69,600 150 143 – 78.7
510 73,950 160 152 – 81.7 D
545 79,025 170 162 – 85.0
575 83,375 180 171 – 87.5
610 88,450 190 181 – 89.5
640 92,800 200 190 – 91.5
Milling
660 95,700 205 195 – 92.5
675 97,875 210 199 – 93.5
690 100,050 215 204 – 94.0
705 102,225 220 209 – 95.0 E
720 104,400 225 214 – 96.0
740 107,300 230 219 – 96.7
770 111,650 240 228 20.3 98.1
800 116,000 250 238 22.2 99.5
Drilling
820 118,900 255 242 23.1 –
835 121,075 260 247 24.0 (101)
850 123,250 265 252 24.8 –
865 125,425 270 257 25.6 (102) F
900 130,500 280 266 27.1 –
930 134,850 290 276 28.5 (105)
950 137,750 295 280 29.2 –
965 139,925 300 285 29.8 –
Boring
995 144,275 310 295 31.0 –
G
Tool holding
H
Other information
Machinability
H 73
A Machining economy
Example of conversion table, inding the factor for hardness

Turning
Diagram form for P, M and K

B
ISO Steel, HB180 ISO Gray cast iron, HB220
P MC P2 K MC K2
Parting and
grooving
ISO Stainless steel, HB180 ISO Nodular cast iron, HB250

M MC M1 K MC K3
C
Threading
D
Factor for cutting speed
Milling
N/mm2 400 470 540 610 675 745 810 880 950 1015 1085 1150 1220
Drilling
F Speciic cutting forces N/mm2 (lbs/in2)

Hardness Brinell (HB)
Customer workpiece material

Boring
4140 Steel
Tensile strength = 950 N/mm2
G (137,786 lbs/inch2)
HB = 280, HRC = 29.2
Tool holding
Calculating hardness
factor = 0.67
H
Other information
Machinability
H 74
Machining economy
A
Compensation of cutting speed for diferences in material hardness
Turning
Example:
• Recommended cutting data is 415 m/min (1360 ft/min) for P Steel
B
material 180 HB.
• Customer workpiece material = 280 HB P Steel material.
Parting and
grooving
• Calculating hardness factor, Customer material =280 HB – Material
reference 180 HB = +100 HB in increased hardness (factor = 0.67).
• Use the factor to recalculate cutting speed for the material hardness
C
415 m/min x 0.67 = 278 m/min (1360 ft/min x 0.67 = 911 ft/min).
Threading
D
Reduced hardness Increased hardness
ISO/
ANSI MC(1) HB(2) -60 -40 -20 0 +20 +40 +60 +80 +100
P P2 HB 180 1.44 1.25 1.11 1.0 0.91 0.84 0.77 0.72 0.67
Milling
M M1 HB 180 1.42 1.24 1.11 1.0 0.91 0.84 0.78 0.73 0.68
K2 HB 220 1.21 1.13 1.06 1.0 0.95 0.90 0.86 0.82 0.79 E
K
K3 HB 250 1.33 1.21 1.09 1.0 0.91 0.84 0.75 0.70 0.65
N N1 HB 75 1.05 1.0 0.95
S S2 HB 350 1.12 1.0 0.89
Drilling
H H1 HRC(3) 60 1.07 1.0 0.97
F
1) MC = material classiication code
2) HB = Hardness Brinell
3) HRC = Hardness Rockwell Boring
G
Tool holding
H
Other information
Machinability
H 75
A Machining economy
Compensation of cutting speed and feed data for Turning

Turning
How to use the diagram

This diagram shows a simple method of adjusting the starting
B
values for cutting speed and feed recommendations.
Recommended cutting data for inserts are based on 15 minutes
Parting and
of tool life (in cut time), as well as maintaining chip formation and
grooving
this will remain the same with the values taken from this diagram.
C
Threading
0.25(.010)
0.20(.008)
Feed (fn) mm/rev (inches/rev)
Increased
1 0.15(.006)
Recommended starting values
➤
0.01(.004)
D
➤
0.05(.002)
+
-0.05(-.002)
➤
Decreased
-0.10(-.004)
Milling
-0.15(-.006) 2
-0.20(-.008) ➤
E
-0.25(-.010)
Decreased Cutting Speed (vc) % percentage Increased

Drilling
Example 1: Productivity increase

- Increasing the feed rate by 0.15 (.006”) to give a new starting
value of 0.45 mm/r (.018 in/r).
+ Recommended starting
values
F
- Calculate the new cutting speed of -12% from the diagram by CNMG 12 04 08-PM
intersecting feed with Start value line and cutting speed axis. (CNMG 432 – PM)
P15 grade
- New cutting data = 0.45 mm/r (.018 in/r) and 415 x .88 =
365 m/min (1360 x .88 = 1197 ft/min) Metal removal +30%. 3 mm (.118”) - Depth of cut
0.3 mm/r (.012 in/r) – Feed
Boring
Rate
Example 2: Better Surface inish 415 m/min (1360 ft/min) –
G Cutting speed
- Increasing the cutting speed by 15% to give a new starting
value of 477 m/min (1564 ft/min).
- Calculate the new cutting feed of -0.175 (-.0075”) from the diagram
Tool holding
by intersecting speed with Start value line and feed axis.

- New cutting data = 477 m/min (1564 ft/min) and 0.3 – 0.175 =
0.125 mm/r (.012”- .0075” = .0045 in/r) improved Surface inish.
H
Other information
Machinability
H 76
Machining economy
A
How can you improve productivity?
Turning
Things to consider
• Identify material hardness HB, B
Speciic cutting forces or Tensile
strength N/mm2 (lbs/inch2).
Parting and
grooving
• Choose the correct geometry.
• Choose the correct grade.
• Use given cutting data values, C
compensate for material hardness
factor.
Threading
• Create a stable environment for
component and tools.
Machining tips for improved tool life
Milling
• Identify material hardness HB, Speciic
cutting forces or Tensile strength N/mm2 E
(lbs/inch2).
Insert wear • Use given cutting data values,
compensate for material hardness
Drilling
factor.
• Create a stable environment for
component and tools. F
• Choose the right combination of nose
radius and geometry.
Boring
In cut time • Use climb milling over conventional,

when ever possible.
• Make use of all available insert corners G
• Consider chamfering operations with
Tool holding
worn inserts.
H
Other information
Good stability = Successful metal cutting

Machinability
H 77
F
E
A
H
C
G
H 78
ISO 13399 - The industry standard
ISO 13399
standard
ISO 13399
The industry
H 79
A
Turning
Variations in terminology among cutting tool suppliers
make collection and transfer of information complex.
At the same time, more and more advanced functionality B
in modern manufacturing systems rely on access to
relevant and exact information.
Parting and
grooving
C
A common language is valuable from a system to system
point of view, but will also make life easier for users. ISO
13399 is the international standard simplifying exchange
Threading
of data for cutting tools and is a globally recognized way of
describing cutting tool data.
D
Milling
ISO 13399 - What it means for the industry E
The international standard deines attributes of the tool,

for example functional length, cutting diameter, maximum
depth of cut in a standard way. Each tool is deined by the
Drilling
standardized parameters.
(shank diameter)
Boring
th) DMM
LF leng
a l
t ion
EDMIL nc G
(fu
(end mill)
ZYL-01
Tool holding
(straight shank -no

features)
DCX APMX
(cutting diameter (depth of cut maximum) H
Other information
maximum)
Machinability
H 79
A ISO 13399 - The industry standard
ISO 13399 - What it means for the industry

Turning
When the industry share the same parameters and deinitions,

communicating tool information between software systems becomes
B very straight forward. In the picture you see that three diferent suppliers
call a diameter D3, DC and D respectively. It creates a lot of confusion
for programmers. In the ISO 13399 standard, the diameter will always
Parting and
be named DCX.
grooving
C
Threading
D
Milling
E
Drilling
A full list of parameters is available on www.sandvik.coromant.com

F
Boring
G
Tool holding
H
Other information
Machinability
H 80
Formulas and deinitions
A
Turning
B
Formulas &
deinitions
Parting and
grooving
Glossary of terms H 82
C
Turning H 84
Threading
Milling H 86
Drilling H 88 D
Boring H 90
Milling
E
Drilling
E-learning F
E-learning and app information H 92 Boring
G
Tool holding
H
Other information
Machinability
H 81
A Formulas and deinitions
Glossary of terms
Turning
B ×n
π × Dm
vc = 1000
Parting and
grooving
C
ae (Working engagement) working engagement fz (Feed per tooth) the transportation of an
of the cutting tool with the workpiece, measured efective cutting edge (Zc) in the direction of
in a direction parallel to the plane Pfe (Primary feed motion for rotation center of the tool
Threading
motion/Resultant cutting direction) and per- which moves through the workpiece as the
pendicular to the direction of feed motion. tool makes one complete revolution. In the
Measured in millimeters (mm) or inches. case of turning, the distance is measured as
the workpiece makes one complete revolution.
ap (Cutting depth) cutting width perpendicular
D Measured in mm/tooth or inches/tooth.
to direction of feed motion. Note: When drilling,
radial cutting depth is denoted with ap, the hex (Maximum chip thickness) is the maximum
same symbol as for axial cutting depth/cutting thickness of the non-deformed chip at the right
width when milling. Measured in millimeters angles of the cutting edge, and it is inluenced
(mm) or inches. by the radial engagement, edge preparation
Milling
of the insert and feed per tooth. Keep in mind,

DC (Cutting diameter) diameter of a circle
however, that diferent radial widths of cut and
created by a cutting reference point revolving
E diferent entering (lead) angles require feed rate
around the tool axis of a rotating tool item.
adjustments to maintain proper chip thickness.
Note: The diameter refers to the machined
Measured in millimeters (mm) or inches.
peripheral surface. Measured in millimeters
(mm) or inches. hm (Average chip thickness) is the average
thickness of the non-deformed chip at the right
Dcap (Cutting diameter at depth of cut)
angles of the cutting edge, and it is inluenced
Drilling
diameter at the distance ap from the plane Pfe

by the radial engagement, edge preparation
through point PK, measured in base plane 1
of the insert and feed per tooth. Keep in mind,
(Bp1). Measured in millimeters (mm) or inches.
F however, that diferent radial widths of cut and
Dm (Machined diameter) machined diameter of diferent entering (lead) angles require feed rate
the workpiece. Measured in millimeters (mm) or adjustments to maintain proper chip thickness.
inches. Measured in millimeters (mm) or inches.
Ff (Feed force) component of the total force KAPR (Entering angle) Angle between the
Boring
obtained by perpendicular projection on the cutting edge plane and the tool feed plane
direction of the feed motion (i.e. in direction of measured in a plane parallel the xy – plane.
vector vf). Feed force for a given engagement
G kc (Speciic cutting force) cutting force/area for
and is measured in newton (N) and pound-force
a given chip thickness in tangential direction.
(lbf).
(Speciic cutting force coeicient for material
fn (Feed per revolution) the transportation of and tool combination) and is measured in
Tool holding
the tool in the direction of feed motion during newton/square millimeters (N/mm2) and
one revolution of rotation. Regardless of the pounds/square inch (lbs/in2).
number of efective cutting edges on the tool.
kc1 (Speciic cutting force coeicient) cutting
In the case of turning, the distance is measured
force/area for a chip thickness of 1 mm (.0394”)
H as the workpiece makes one complete revolu-
in tangential direction. (Material constant:
tion. Measured in mm/revolution or inches/
speciic cutting force coeicient. Traditionally
Other information
revolution.
named kc 1.1) and is measured in newton/
Machinability
square millimeters (N/mm2) and pounds/square

inch (lbs/in2).
H 82
A
Turning
× kc B
× D C × fn
vc 103
Pc = 240 ×
Parting and
grooving
DC
γ0 (efective rake angle) The speciic force

C
lm (Machined length) length of cutting engage-
ment over all passes. Measured in millimeters gets reduced by one percent for each degree
(mm) or inches. of rake angle. Measured in degrees.
Threading
Mc (Rise in speciic cutting force) rise in speciic Zc (efective cutting edge count) number of
force as a function of reduced chip thickness. cutting edges that are efective around the tool
Can be found in the work material property from item.
cutting data tables and is measured as a ratio.
Is also closely associated with speciic cutting Zn (mounted insert count) number of cutting D
force coeicient (kc1). edges of the tool item axis.
n (Spindle speed) frequency of the spindle
rotation. Measured in revolutions/minute (rpm).
Milling
Pc (Cutting power) cutting power generated
by the removal of chips. Measured in kilowatts
(kW) and/or horsepower (Hp)
E
PSIR (Lead angle) Angle between the cutting
edge plane and a plane perpendicular to the
tool feed plane measured in a plane parallel the
xz – plane.
Drilling
Q (Material removal rate) deined as the volume
of material removed divided by the machining
time. Another way to deine Q is to imagine an
"instantaneous" material removal rate as the F
rate at which the cross-section area of material
being removed moves through the work piece.
It is measured in cubic centimeters/minute
(cm3/min) and cubic inches/minute (in3/min).
Boring
Tc (Cutting time total) period of time for

cutting engagement over all passes. Measured
in minutes. G
vc (Cutting speed) the instantaneous velocity
of the cutting motion of a selected point on
Tool holding
the cutting edge relative to the workpiece.

Measured in surface meter/minute or feet/
minute.
vf (Table feed / Penetration rate) the distance,
in millimeters or inches, that a cutting tool
moves through the workpiece in one minute.
H
Measured in mm/minute or inches/minute.
Other information
Machinability
H 83
Formulas and deinitions for turning - METRIC

Turning
Cutting speed, m/min
vc = π × Dm × n
B
1000
Parting and
grooving
Spindle speed, rpm

C
π × Dm
vc × 1000
n=
Threading
Machining time, min

D lm
Tc =
Designation/
fn × n
deinition
Symbol
Unit
Milling
Metal removal rate, cm3/min

E Dm Machined diameter mm
Q = vc × ap × fn fn Feed per revolution mm/r
ap Cutting depth mm
vc Cutting speed m/min
n Spindle speed rpm
Net power kW
Drilling
Pc
Speciic cutting forces
γ0
Q Metal removal rate cm3/min
1 mc
hm Average chip thickness mm
F kc = kc1×
hm ( ( (
× 1 - 100 ( hex
Tc
lm
Maximum chip thickness
Period of engagement
Machined length
mm
min
mm
Speciic cutting force N/mm2
γ0 Efective rake angle

kc
KAPR Entering angle degree
degree
Boring
Average chip thickness
G hm = fn × sin KAPR
Tool holding
Net power, kW
Pc =
H 60 × 103
Other information
Machinability
H 84
A
Formulas and deinitions for turning - INCH
Turning
Cutting speed, ft/min
π × Dm × n
B
vc =
12
Parting and
grooving
Spindle speed, rpm
C
π × Dm
vc × 12
n=
Threading
Machining time, min
lm D
Tc =
Designation/
fn × n
deinition
Symbol
Unit
Milling
Metal removal rate, inch3/min
Dm Machined diameter inch E
Q = vc × ap × fn × 12 fn Feed per revolution inch/r
ap Cutting depth inch
vc Cutting speed ft/min
n Spindle speed rpm
Net power HP
Drilling
Pc
Speciic cutting forces
γ0
Q Metal removal rate inch3/min
mc hm Average chip thickness inch
( ( (
0.0394
kc = kc1× hm × 1- 100 ( hex
Tc
lm
Maximum chip thickness
Period of engagement
Machined length
inch
min
mm
F
Speciic cutting force lbs/inch2
γ0
kc
PSIR Lead angle degree
Efective rake angle degree
Boring
Average chip thickness
hm = fn × sin (90 PSIR) G

Tool holding
Net power, HP
Pc =
33 × 103 H
Other information
Machinability
H 85
Formulas and deinitions for milling - METRIC

Turning
Table feed, mm/min

B
vf = fz × n × zc
Parting and
grooving
C π × Dcap × n
vc =
1000
Threading
Spindle speed, r/min
Designation/
π × Dcap
vc × 1000
n=
D deinition
Symbol
Unit
Feed per tooth, mm
ae Working engagement mm
Milling
vf ap Cutting depth mm
fz = Dcap Cutting diameter at cutting
n × zc depth ap mm
E DC Cutter diameter mm
fz Feed per tooth mm
Feed per revolution, mm/rev fn Feed per revolution mm/r
n Spindle speed rpm
vf vc Cutting speed m/min
fn =
Drilling
n vf Table feed mm/min

zc Number of efective teeth pcs
hex Maximum chip thickness mm
F hm Average chip thickness mm
Metal removal rate, cm3/min kc Speciic cutting force N/mm2
Pc Net power kW
ap × ae × vf Mc Torque Nm
Q= Q Metal removal rate cm3/min
1000
Boring
KAPR Entering angle degree
G Net power, kW
ae × ap × vf × kc
Pc =
Tool holding
60 × 106
Torque, Nm
H Pc × 30 × 103
Mc =
Other information
π×n
Machinability
H 86
A
Formulas and deinitions for milling - INCH
Turning
Table feed, inch/min
B
vf = fz × n × zc
Parting and
grooving
π × Dcap × n C
vc =
12
Threading
Spindle speed, rpm
Designation/
π × Dcap
vc × 12
n= deinition
D
Symbol
Unit
Feed per tooth, inch
ae Working engagement inch
Milling
vf ap Cutting depth inch
fz = Dcap Cutting diameter at cutting
n × zc depth ap inch
DC Cutter diameter inch E
fz Feed per tooth inch
Feed per revolution, inch/rev fn Feed per revolution inch
n Spindle speed rpm
vf vc Cutting speed ft/min
fn =
Drilling
n vf Table feed inch/min
zc Number of efective teeth pcs
hex Maximum chip thickness inch
hm Average chip thickness inch F
Metal removal rate, inch3/min kc Speciic cutting force lbs/inch2
Pc Net power HP
Mc Torque lbf ft
Q = ap × ae × vf Q Metal removal rate inch3/min
Boring
Net power, HP G
ae × ap × vf × kc
Pc =
Tool holding
396 × 103
Torque, lbf ft
Pc × 16501 H
Mc =
Other information
π×n
Machinability
H 87
Formulas and deinitions for drilling - METRIC

Turning
B Penetration rate, mm/min
vf = fn × n
Parting and
grooving

π × DC × n
C
vc =
1000
Threading
Designation/
D Spindle speed, r/min deinition
Symbol
π × DC
vc × 1000
Unit
n=
Milling
DC Drill diameter mm
fn Feed per revolution mm/r
Feed force, N n Spindle speed rpm
E vc Cutting speed m/min
DC vf Penetration rate mm/min
Ff ≈ 0.5×kc × fn × sin KAPR Ff Feed force N
2 kc Speciic cutting force N/mm2
Mc Torque Nm
Drilling
Pc Net power kW
Metal removal rate, cm3/min KAPR Entering angle degree
F
vc × DC × fn
Q=
4
Boring
Net power, kW
G
vc × DC × fn × kc
Pc =
240 × 103
Tool holding
Torque, Nm
H
π×n
Pc × 30 × 103
Mc =
Other information
Machinability
H 88
A
Formulas and deinitions for drilling - INCH
Turning
Penetration rate, inch/min B
vf = fn × n
Parting and
grooving
π × DC × n
C
vc =
12
Threading
Spindle speed, rpm Designation/
D
deinition
π × DC
vc × 12
Symbol
n=
Unit
Milling
DC Drill diameter inch
Feed force, N fn Feed per revolution inch/r
n Spindle speed rpm
DC vc Cutting speed ft/min E
Ff ≈ 0.5×kc × × fn × sin PSIR vf Penetration rate inch/min
2 Ff Feed force N
kc Speciic cutting force lbs/inch2
Note: DC needs to be converted into
Mc Torque lbf ft
millimeters
Drilling
Pc Net power HP
F
Metal removal rate, inch3/min
Q = vc × DC × fn × 3
Boring
Net power, HP G
vc × DC × fn × kc
Pc =
Tool holding
132 × 103
Torque, lbf ft
H
π×n
Pc × 16501
Mc =
Other information
Machinability
H 89
Formulas and deinitions for boring - METRIC

Turning
B Penetration rate, mm/min
vf = fn × n
Parting and
grooving

π × DC × n
C
vc =
1000
Threading
Spindle speed, r/min Designation/

D deinition
Symbol
π × DC
vc × 1000
n=
Unit
Milling
DC Drill diameter mm
fn Feed per revolution mm/r
Feed per revolution, mm/r n Spindle speed rpm
E vc Cutting speed m/min
vf Table speed mm/min
fn = zc × fz Ff Feed force N
kc Speciic cutting force N/mm2
Mc Torque Nm
Drilling
Pc Net power kW
Metal removal rate, cm3/min KAPR Entering angle degree
F zc Number of efective teeth pcs
vc × DC × fn (zc = 1 for step boring)
Q=
4
Boring
Net power, kW
G
Pc =
60 × 103 ( 1–
ap
DC (
Tool holding
Torque, Nm Feed force, N

H Pc × 30 × 103
π ×n
Mc = Ff ≈ 0.5 × kc × ap × fn × sin KAPR
Other information
Machinability
H 90
A
Formulas and deinitions for boring - INCH
Turning
Penetration rate, inch/min B
vf = fn × n
Parting and
grooving
π × DC × n
C
vc =
12
Threading
Designation/
Spindle speed, rpm
D
deinition
Symbol
π × DC
v × 12
n= c
Unit
Milling
DC Drill diameter inch
fn Feed per revolution inch/r
Feed per revolution, inch/rev n Spindle speed rpm
vc Cutting speed ft/min E
vf Table speed inch/min
fn = zc × fz Ff Feed force N
kc Speciic cutting force lbs/inch2
Mc Torque lbf ft
Drilling
Pc Net power HP
Metal removal rate, inch3/min PSIR Lead angle degree
zc Number of efective teeth pcs F
(zc = 1 for step boring)
Q = vc × DC × fn × 3
Boring
Net power, HP
G
Pc =
132 × 103 ( 1–
ap
DC (
Tool holding
Torque, lbf ft Feed force, N

Pc × 16501 H
π×n
Mc = Ff ≈ 0.5 × kc × ap × fn × sin KAPR
Other information
Machinability
H 91
A E-learning
University level online training

Turning
The Metal Cutting Technology e-learning is the ideal complement to a classroom

education - or the perfect solution to develop new skills in whatever location you
B may be. Learn the fundamentals of Metal Cutting Technology through the extensive
75 courses, covering most application areas of metal cutting. Save your progress
and track your achievements as you advance.
Parting and
grooving
Register at metalcuttingknowledge.com and start your free training.
C
Threading
E-learning
Metal cutting
D
technology
Sign up for free online training
Milling
E
Drilling
F
Boring
G
Support in the palm of your hand
Tool holding
Learning metal cutting requires the mindset of an engineer

and strong support along the way. Sandvik Coromant
provides several advanced and useful calculators and apps
for your mobile devices, free of charge.
H
Find the support you need on sandvik.coromant.com/apps
Other information
Machinability
H 92
Head oice:
AB Sandvik Coromant
SE-811 81 Sandviken, Sweden
E-mail: info.coromant@sandvik.com
www.sandvik.coromant.com
C-2920:40 en-GB © AB Sandvik Coromant 2017.11

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© AB Sandvik Coromant 2017.11

Turning generates cylindrical and rounded forms with a

• Choice of inserts – how to apply A 22

• Choice of tools – how to apply

General turning operations

Turning is the combination of two movements – rotation

can be fed towards the center (facing of) at the end of

Turning and facing as axial and radial tool movements.

F Three common turning operations:

The spindle speed rpm (revolution per minute) is B

of the diameter, pi (π) and the spindle speed (n)

in the revolutions per minute (rpm). The circum-

Calculation of the circumference (C)

Dm2 = 100 mm (3.937 inch)

Dm1 = 50 mm (1.969 inch)

Example of cutting speed calculation

Diameter, Dm1 = 50 mm (1.969 inch)

F Diameter, Dm2 = 80 mm (3.150 inch)

3.14 × 50 × 2000 314 3.14 × 1.969 × 2000 1030

1000 m/min 12 ft/min

The cutting edge approach to the work-

(PSIR), the angle between the cutting edge

Calculating cutting data

400 ×1000 1312 × 12

E Inclination and rake angles

Rake angle Inclination angle

tendency and chip formation.

Cutting depth and chip formation

Feed rate Cutting edge length G

along the cut per revolu-

Insert shape selection, entering angle (lead angle) and

Maximum chip thickness hex

Possible entering (lead) angle positions for insert shapes

CNMG DNMG WNMG

F Entering angle KAPR: Entering angle KAPR: Entering angle KAPR:

SNMG RCMT TNMG

45°, 75° Variable 93°, 91°, 60°

Entering angle KAPR: Lead angle PSIR:

The efect of entering angle (lead angle) on chip thickness

Entering angle KAPR 95° 75° 60° 45° 90° min C

Contact length la, D

B Production planning process

Dimension and type of

Workpiece material and

2 Machine Machine parameters

E Type of turning tool:

Cutting data, tool path,

1. Component and the workpiece material

• Use all possible support

General application - Turning with rhombic inserts

• For turning and facing

Turning with wiper inserts

F • Increased ability to hold

• The depth of cut should be no less then

exceed the general recommendation of

External Turning - negative inserts

Overview of tool holders

G • Negative insert • Negative insert • Negative/positive • Negative inserts

• Modular/shank • Modular/shank systems • Precision coolant

External Turning - positive inserts

Overview of tool holders

• Positive insert • Positive insert • Negative/positive • Positive insert G