Training Handbook: Metal Cutting Technology

Training
Handbook
METAL CUTTING TECHNOLOGY
Metal Cutting Technology training handbook
This handbook will serve as your main source of information throughout the
Sandvik Coromant metal cutting training and may also be used as reference
in your future endeavors.
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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 off B 22
Tool holding
- General grooving B 26
- Circlip grooving B 28 History and background G4
- Face grooving B 29 Why modular tooling G8
- Profiling 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 definitions 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 off) 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
- Profiling
G
Tool holding
H
Other information
Machinability
A4
Theory
A
Definitions 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
Definition of cutting speed
The definition of cutting speed (vc) as the result E
of the diameter, pi (π) and the spindle speed (n)
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)
n = spindle speed, (rpm)
C = Circumference, π x Dm mm (inch)
Boring
π (pi) = 3.14
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)

Turning
• Circumference = π x diameter
• π (pi) = 3.14
B
Parting and
Example:
grooving
Dm2 = 1
00 mm (3.937 inch)
C = 3.14 x 100
C
= 314 mm
C = 3.14 x 3.937
= 12.362 inch
Threading
Dm1 = 5
0 mm (1.969 inch)
C = 3.14 x 50
D = 157 mm
C = 3.14 x 1.969
= 6.183 inch
Example of cutting speed calculation

Milling
E The cutting speed differs 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
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.
Feed
Threading
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 influences, 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 difference 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
vc × 1000 vc × 12
D n= r/min n= r/min
π × Dm π × Dm
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
the cut. The rake angle of the insert itself holder. When mounted in the tool holder,
Tool holding
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 affects tool strength, power consump- cutting angle with which the cutting edge
H tion, finishing ability of the tool, vibration cuts.
tendency and chip formation.
Other information
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 effective cutting edge length E
Drilling
F
Boring
Feed rate Cutting edge length G

The feed rate (fn) is the The effective 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 effect the chip formation, in angle or larger lead angle.
that the chip cross-section changes.
The direction of chip flow is also changed.
Parting and
grooving
C
Entering angle KAPR (Lead angle PSIR)
• Is defined 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:
45°, 75° Variable 93°, 91°, 60°
Tool holding
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 effect 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
1 0.96 0.87 0.71 Variable
Threading
compared to feed,
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)
Calculating power consumption
Milling
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 sufficient power for
the operation and is measured in kW and fn = cutting feed mm/rev (inch/rev)
Drilling
HP. The efficiency factor of the machine is
ap = depth of cut mm (inch)
also of great importance.
F
kc = specific 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
- Profiling
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 profiling)
grooving
• External, internal
• Roughing, medium or finishing
• Tool paths C
• Number of passes
• Tolerances.
Threading
Steel
Material D
P
• Machinability
M Stainless steel • Cast or pre-machined
K Cast iron • Chip breaking
• Hardness
Milling
N Non-ferrous • Alloy elements.
S Heat resistant super alloys E
and titanium
H Hardened steel
2. Machine parameters
Drilling
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 fluid 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
Turning with wiper inserts

Threading
Advantages Disadvantages
• Increase feed and gain • In back turning and
D productivity profiling the wiper edge
is not effective.
• Use normal feed rate and
gain surface quality
• Productivity booster.
Milling
E
Coromant unique Turning concepts
Advantages
• Increased cutting data in
Drilling
profiling
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 • Efficient and productive turning.
Other information
Machinability
A 14
Selection procedure
A
4. How to apply
Turning
Important application considerations
The tool path has a significant impact on
B
the machining process.
It influences:
- Chip control
Parting and
grooving
- Insert wear
- Surface quality
- Tool life.
C
In practice, the tool holder, insert geometry,
grade, workpiece material and tool path
influences the cycle time and productivity
Threading
considerably.
5. Troubleshooting
Milling
Some areas to consider
E
Insert clearance angle
• Use positive inserts for lower cutting
forces in general and for internal turning.
Drilling
Chip breaking
• Optimize the chip breaking by changing
Negative style Positive style 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 flank 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. Profiling
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. Profiling B
3. Facing
Parting and
grooving
C
1
2
Threading
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)
1 3. Internal turning
Parting and
(Exchangeable inserts)
grooving
2
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
Screw clamping system
Other information
5°/7°
Machinability
A 20
System overview
A
Modern insert clamping for turning tools
Turning
Rigid clamping
• Negative inserts B
• Excellent clamping
Parting and
• Easy indexing.
grooving
C
Lever clamping
Threading
• Negative inserts
• Free chip flow D
• Easy indexing.
Milling
E
Screw clamping
• Positive inserts
Drilling
• Secure clamping of the
insert
F
• Free chip flow.
Boring
Screw clamping system, 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 effect 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 specific 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
understanding of how
Milling
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 different materials. ISO-standard, where each group has
Each material has its own unique unique properties regarding machinability.
characteristics influenced by the alloying
elements, heat treatment, hardness, etc.
Parting and
This strongly influences the selection of

grooving
cutting tool geometry, grade and cutting

data.
C
Workpiece material groups

Threading
Steel • ISO P – Steel is the largest material

D P group in the metal cutting area, ranging
from unalloyed to high-alloyed material
including steel castings and ferritic and
martensitic stainless steels. The
machinability is normally good, but differs
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. Different 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 difficult. All cast irons contain silicon
carbide (SiC) which is very abrasive to the
Parting and
cutting edge.
grooving
C
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
materials. They are sticky, create built-up
Drilling
edge, workharden and generate heat,
very similar to the ISO M-area, but they
are much more difficult 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 difficult 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 differences in the six material groups is through the force
(FT) needed to shear off a specific chip cross-section in certain conditions.
B This value, the specific 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 = specific 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-
curved, leads to the chips contact with the clearance tact with the surface that
Drilling
being parted as they come face of the insert or tool has just been machined.
off 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 finish is needed,
lead to chip hammering, because of possible
Boring
where the chip damages damage caused to the

the insert. component.
G
Tool holding
H
Other information

Machinability
A 28
A
Chip formation varies with different parameters
Turning
Chip formation varies with depth of cut, feed, material and tool geometry.
B
Self-breaking Against the tool Against the workpiece
Parting and
grooving
ap
ap
KAPR C
Threading
D
Insert rake angle
Milling
The rake angle (γ) gamma (GAMO) is a measurement of the edge in rela-
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
H
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
clearance angle tangential to the workpiece while the positive insert has this clearance
grooving
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.
Insert geometries
Drilling
F
Metal cutting is very much the science of removing chips from the workpiece material in
the right way. Chips have to be shaped and broken off into lengths that are manageable
in the machine.
Boring
• In milling and drilling a lot of parameters influence the

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

• Removing heat from the cutting zone through the chip
(80%) is a key issue.
H
Other information
Machinability
A 30
Choice of inserts – geometries
A
The design of a modern insert
Turning
Definitions of terms and geometry design
B
Nose radius edge Main cutting edge
design design
Parting and
grooving
0.25 mm
(.010")
20° C
5°
Macro geometry with • Cutting edge rein-
chip breaker
Threading
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 final micro-geometry.
Drilling
• ER-treatment is done before coating, and F
gives the final shape of the cutting edge
(micro-geometry).
• The relationship between W/H is what
Boring
makes inserts suitable for different

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

Turning
A chip breaking diagram for an insert

geometry is defined 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 finish.
D
Feed, fn mm/r (inch/r)
Three main methods in Turning

Milling
E R = Roughing Roughing
M = Medium machining • Maximum metal removal rate and/or
severe conditions
F = Finishing
• Large cutting depth and feed rate
Drilling
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
(.236) 6.0
grooving
Medium – M
Medium operations to light roughing.
(.157) 4.0 Wide range of depth of cut and feed rate C
combinations.
(.079) 2.0 Finishing – F
Threading
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
acceptable chip
Boring
(.236) 6.0
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 Feed, fn mm/r (inch/r)
Other information
(.004) (.008) (.012) (.016) (.020) (.024) (.028)


Machinability
A 33
 Medium machining of
steel CMC 02.1 PM Chip breaking area:
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
the insert for strength and economy.
grooving
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 different micro and macro-geometries are adapted to the various
requirements in the applications.
Milling
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 profiling.
fn = .006 – .020 inch/r
Threading
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
0.20 mm (.008 in.)
loading the cutting edge.
(.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
material and machinability.
Other information
Application area
Machinability
A 36
A
Inserts for general turning
Turning
The choice of different 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.
• Available as double/single-
Parting and
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 flank wear and
deformation
Boring
- be tough to resist bulk breakage

- not chemically interact with the G
workpiece material
- be chemically stable to resist oxidation
Tool holding
and diffusion
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 N
itride ceramics containing
primarily silicon nitride (Si3N4).
- Coated cemented carbides (HC)
Parting and
• CC Ceramics as above, but coated.

grooving
- Cermets (HT, HC)

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

• CA O
xide ceramics containing primarily
D aluminum oxide (Al2O3).
• CM M
ixed 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
Good
grooving
C
Average
Threading
Difficult
Good Average Difficult
Milling
Machining conditions
E
Good conditions
• Continuous cuts
• High speeds
• Pre-machined workpiece
Drilling
• Excellent component clamping
• Small overhangs.
F
Average conditions
• Profiling cuts
Boring
• Moderate speeds
• Forged or cast workpiece
• Good component clamping. G
Difficult 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 influences the wear during the

cutting action in different 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

- 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 influence 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
leads to a weaker cutting edge.
Parting and
Each shape has unique properties:
grooving
- some provide the highest roughing
strength.
C
- others give the best profiling 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
• Decreased cutting forces
Tool holding
• Increased cutting forces

• Increased vibration. • Decreased vibration.
H
Other information
Machinability
A 41
A Choice of inserts – shape
Factors affecting 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-
finishing + ++ + ++ ++
D Finishing + + ++ ++ ++
Longitudinal turning ++ + + ++ +
Milling
Profiling + + ++ ++
E
Facing + ++ ++ + + +
Operational versatility + ++ + + ++ +
Drilling
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 (first 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
Effect of small and large nose radius
Milling
RE
RE E
RE
Drilling
F
Small corner radius Large corner radius

Boring
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 first choice

Turning
With a small nose radius, the radial cutting forces can be kept to a minimum, while
utilizing the advantages of a larger nose radius leads to a stronger cutting edge, better
B surface texture and more even pressure on the cutting edge.
Parting and
grooving
DOC
C
DOC
DOC
Threading
D
• The relationship between nose radius and DOC (depth of cut) affects vibration tendencies.
It is often an advantage to choose a nose radius which is smaller than the DOC.
Milling
E Effect 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 first
choice where it’s C
possible.
Limitations
Threading
Conventional insert • General limitation is
vibration
Rmax • Visually, surfaces can D
rISO look different even
though the measured
surface is great.
Milling
E
Wiper – Technical solution
• One wiper cutting edge is based on
3-9 radii.
Drilling
• Contact surface between insert and
component is longer with wipers. F
• Longer contact surface makes a better
surface finish.
• 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

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

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

grooving
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 profile
Achieved surface – traditional ISO inserts and wipers

Drilling
F Ra
(µm)
(236) 6.00
(197) 5.00 Insert geometry

Boring
(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 affect tool life
Turning
Use the potential of: B
- ap – to reduce number of cuts
- fn – for shorter cutting time
Parting and
grooving
- vc – for best tool life
Threading
Cutting speed D
Tool life
vc – large effect on tool life.

Adjust vc for best economy
Milling
Cutting speed vc E
Drilling
Feed
Tool life
fn – less effect on tool life than vc

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

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

• Rapid flank wear • Built-up edge
Parting and
• Poor finish • Uneconomical.

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

D
The single largest factor determining productivity
Too high Too low

Milling
• Loss of chip control • Stringers

• Poor surface finish • Uneconomical.
E
• Cratering, plastic
deformation
• High power consumption
Drilling
• Chip welding
F • Chip hammering.
Boring
Effects 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
Tool selection and how to apply
Turning
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 defined 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.
• Holders with entering angles of 95° and 93° (lead angles of –5°
Parting and
and –3°) are commonly used.

grooving
• Alternatives to the C-style insert are D-style (55°), W-style (80°)

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

• The effective 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 / Benefits
• 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 / Benefits
• 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 profile turning
B • In profile 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
should be selected for strength and cost

grooving
efficiency, 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°
and 35°.
Threading
• The entering/lead and insert nose angle are

both important factors for accessibility. The
D work piece profile 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
(small lead angle) (large lead angle)
Drilling
F
Ff = axial
Ff = axial
Fp = radial Fp = radial
Boring
G • Forces directed toward the chuck. Less • Forces are directed both axially and radially.
tendency for vibration.
• Reduced load on the cutting edge.
• Higher cutting forces especially at
Tool holding
• 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
B
Pocketing
Profiling
turning
Facing
Parting and
++ = Recommended
grooving
+ = Alternative
C
Rhombic 80° ++ +
+ ++ +
Threading
Rhombic 55°
Round + + + ++ D
Square + ++
Triangular + + +
Milling
Trigon 80° + + E
Rhombic 35° +
Drilling
Selecting the insert clearance angle F
Wedge Screw Concept

Lever Rigid clamping
Boring
clamping clamping clamping
G
Tool holding
H
Other information
Machinability
A 53
A Choice of tools - internal turning
Internal turning
Tool selection and how to apply
Turning
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
effect 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 • Chip size • Reduced length
Boring
• Insert shape, negative/ • Chip control • Increased diameters

G positive
• Techniques • Optimized shape
• Insert geometry
• Coolant. • Different tool materials
Tool holding
• Nose radius
• Clamping
• Corner radius.
• Dampened solutions.
H
Other information
Machinability
A 54
Choice of tools – internal turning
A
Effect of cutting forces on internal turning
Turning
Radial and tangential cutting forces deflect the boring bar
B
Tangential cutting force, Ft
• 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

deflection.
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
Profiling
Threading
Versatility and accessibility is the determining factor.

• The effective 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 deflection
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 Profiling 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 deflection
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) affects
cutting forces vibration tendencies.
Tool holding
- Small due too high • Less force in radial direc-

friction between the tool tion = less deflection.
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
Benefits:
grooving
• Cutting edge in right position
C • Best cutting action gives better surface finish

• 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 filled 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 affect vibration tendencies
Turning
Vibration tendencies grow towards the right
B
Parting and
grooving
Entering angle
C
Lead angle
Threading
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 affect 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)
• Use a positive basic-shape insert, as • Choose a corner radius which is some-
Tool holding
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 difficulties.
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 different 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 14 10 7 6 4 length:
Milling
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
coupling size F = Dampened, carbide shank bar
Other information
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
A 16 T D C L N R
Boring
G
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
coupling size F = Dampened, carbide shank bar
Other information
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
Inscribed circle is indicated in 1/8"
grooving
A G
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
Chip control
Turning
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 finish
Problem Cause Solution
Turning
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 finished 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

with too small nose radius larger nose radius.
Milling
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 flank 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
of cut. cut.
Boring
G
• Tool incorrectly positioned. • Check the center height.
Tool holding
H
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 offers • Extend the clamping length D
insufficient rigidity. of the boring bar.
• Use EasyFix for cylindrical
bars.
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
A 71
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 off
Turning
B
Chip evacuation is essential
Chip evacuation is a critical factor in parting operations. There is
little opportunity to break chips in the confined 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 difficult in the confined 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 off – definition of terms
n
Boring
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 off 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-off. 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
(.079 inch)
Other information
Machinability
B5
A Theory
Grooving– definition 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– definition of terms
The feed has a great influence on chip formation, chip breaking, and
thickness, and also influences how chips form in the insert geometry.
In sideways turning or profiling (fnz), the depth of the cut (ap) will also
Drilling
influence chip formation. The groove diameter for the first cut must be
F within the range specified 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 first groove diameter
(2 on this illustration)
H
DAXX = maximum first 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
2 Machine
Milling
E
Type of tool:
- Spring-clamp
3 Choice of tool - Screw-clamp
Drilling
- Insert type
Cutting data, method,

cutting fluid, 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
larger diameters
Boring
• Component clamping
G
• Turret interface
• Tool changing times/number of tools in
Tool holding
turret
• Chip evacuation
H • Cutting fluid and coolant.

Other information
Machinability
B8
Selection procedure
A
3. Choice of tools
Turning
Example of different machining methods
B
Multiple grooving
• Multiple grooving is the best method for
Parting and
rough grooving when the depth is bigger
grooving
than the width.
• Make a “fork”. This will improve chip flow 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
radial forces.
Boring
• 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
(.002 inch) / rev approximately 2 mm

grooving
2 mm (.079 inch) before center.

(.079 inch)
• Use shortest possible overhang, OH mm
C Max ±0.1 mm
(±.004 inch) (inch).
• Largest height dimension on blade for
bending stiffness.
Threading
• Use coolant to improve chip flow.
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 fluid.
Tool holding
H
Other information
Machinability
B 10
System overview
A
System overview
Turning
External parting and grooving
B
1. Parting-off solid bars and tubes 4. Shallow to deep grooving
2. Turning and recessing 5. Face grooving
Parting and
3. Undercutting 6. Profiling
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. Profiling
1 G
3
Tool holding
1 H
Other information
2
Machinability
B 11
A System overview
Different systems
Turning
Insert type
B
CoroCut CoroCut Circlip
Application CoroCut2 CoroCut1 CoroCut3 QD QF 266
Parting and
Parting
grooving
(Cut off)
Medium Deep Shallow Deep
C
Grooving
Threading
Face groov-
ing
D
Turning
Milling
Profiling
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
Different 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
D
Grooving – depth ranges
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
Different systems
B
Internal grooving – min hole diameter
Parting and
grooving
C
Threading
≥4.2 ≥10 ≥12 ≥25

(≥.165) (≥.394) (≥.472) (≥.984)
D
Milling
E 4.2 10 12 25
Min. hole
diameter,
(.165) (.394) (.472) (.984) mm (inch)
Drilling
F Face grooving – hole diameter range
Ø6.2 Ø12 Ø23

Boring
(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
Machining (Cut off)
Grooving Turning Profiling C
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 off 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
• Profiling 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 deflection
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
• Overhang (OH) should be as small as
Threading
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
7 x DMM.
Boring
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
Deep parting
Threading
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
• Largest height dimension
Tool holding
• Maximum blade width.
H
Other information
Machinability
B 18
A
Spring-clamp design blades
Turning
Features/Benefits
• Quicker insert change B

• Cut off larger diameter
• Adjustability
Parting and
• Deep grooving
grooving
• Double ended
• Radial feed only
C
Threading
Screw-clamp and spring-lock design holders
D
Features/Benefits
• Smaller diameters
• Shallow grooving
Milling
• Radial & axial feed
• Increased rigidity
E
• Single ended
Drilling
Screw-clamp design holders for 3-edge inserts F
Features/Benefits
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-off 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 will leave material in center (PIP).
Tool holding
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 different
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 finish
• Straighter cut
F
• Pip stays on part falling off.
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 off – how to apply
Parting off
Turning
Pip reduction by using different 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 off component
- Tool will leave material in center (pip).
R
L
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 flow. (A neutral insert directs the
chip straight out of the groove).
Milling
Parting-off tubes
Drilling
Use insert with the smallest possible width (CW) to

F save material, minimize cutting force and environmental
impact.
Boring
G
Parting-off 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 fluid
Cutting fluid 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 effect on chip
formation
• Directly at the cutting
Tool holding
edge • Prevents chip jamming

• Precision coolant. • Adds tool life.
H
Other information
Machinability
B 23
A Parting off – how to apply
Practical hints
Max ±0.1 mm
Turning
(±.004 inch) • Center height is important,

±0.1 mm (±.004 inch).
B
• If subspindle is used, pull
away the component
approximately 2 mm
Parting and
ø2 mm
grooving
(.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 off – 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 finishing 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
• For internal grooving there is also a wide

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

D 3-edge inserts 2-edge inserts • For best economy, use 3-edge inserts in
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
Internal Internal/external Milling is an alternative for non-rotating

Boring
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) (1.535 - 2.480 inch)
Other information
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
• The inner and outer diameters of the
grooving
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
groove.
grooving
• 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
- check center height
Threading
- lift the tool above center line.
D
Roughing and finishing a face groove
Roughing Finishing
Milling
E
2
1
Drilling
First cut (1) always starts Machine the first cut (1) within the given diameter range.
F
on the largest diameter
Cut two (2) finishes the diameter. Always start outside
and works inwards. The
and turn inwards.
first cut offers chip control
but less chip breaking.
Boring
Finally, cut three (3) finishes 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 Profiling – how to apply
Profiling
Turning
When machining components with

complex shapes, profiling inserts offer
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 profiling
C operations in view of achieving maximum
stablility.
• A neutral tool holder is suitable for both
opening up or completing a recess.
Threading
• 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 finish.
Other information
• In unstable setups, use ramping to avoid vibrations.

Machinability
B 32
Turning – how to apply
A
Profile 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
the component radius.
grooving
• 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 finishing 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
insert with rail shape if possible.
Milling
• 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
Axial turning
Milling
Surface finish E
• This wiper effect generates high quality
surface finish.
• You get the best wiper effect when you
Drilling
Ra max “find” the right combination between feed
(fn) and blade deflection.
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
tion
wear edge C
Solution
Threading
More positive
geometry ++
D
Tougher grade ++
Milling
More wear
resistant grade ++ + + E
Increase cutting
speed +
Drilling
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.
• Use tools with precision
Parting and
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
Vibration
Turning
• 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).
nent overhang.
Parting and
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-profile 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
The threading methods
Turning
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
Different 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
Turning
B
ap = total depth of thread mm (inch)
Parting and
grooving
nap = number of passes
Threading
P = pitch, mm or threads
per inch (TPI.) D
β = angle of the thread
d1 = minor diameter external
Milling
D1 = minor diameter internal
d2 = pitch diameter external E
D2 = pitch diameter internal
d = major diameter external
D = major diameter internal
Drilling
ϕ = helix angle of the thread
F
Boring
G
Tool holding
H
Other information
Machinability

C5
A Theory
 Definitions of terms
Turning
1. Root
• The bottom surface joining the two
B adjacent flanks 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 flanks.
C
Threading
Helix angle
D • The helix angle (ϕ) is dependent on and
related to the diameter and pitch (P) of
the thread.
• By changing the shim, the flank clearance
of the insert is adjusted.
Milling
• The angle of inclination is lambda (λ).

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.
• Aggressive cutting data can lead to
Tool holding
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°
P *ns
tan λ =
π × d2
Milling
* ns = number of starts
E
Pitch, mm Threads/inch
Drilling
F
Boring
G
Tool holding
H
Other information
Workpiece mm
diameter inch
Machinability
C7
A Theory
Selecting shims for inclination

Turning
The diameter and pitch influence 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
2
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
profile
H
Pitch
Other information
Internal (O)
External, no marking Carbide grade
Machinability
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 profile
Threading
and quantity
Machine parameters
2 Machine
Milling
E
Type of tool:
- Multi-point
3 Choice of tool - Full profile
Drilling
- V-profile
Cutting data,
infeed etc.
4 How to apply
Boring
G
Tool holding
Remedies and
5 Troubleshooting
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 profile (metric, UN, etc.)

• Pitch size
• Number of thread starts
Threading
• Tolerance (profile, 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
• Clamping of the workpiece
Tool holding
• 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
Different ways to make threads
Multi-point inserts
B
A full profile (topping) insert with several Advantages
teeth reduces the number of required • Reduced number of
in-feeds and generates high productivity, infeeds
Parting and
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 sufficient room
Sufficient room behind the thread is also behind the thread.
Threading
needed.
D
Full profile inserts
The thread is cut by the insert with good Advantages
control over the geometrical properties • Better control over the
Milling
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
one pitch.
Drilling
putting high requirements on setup and
overhang.
F
V-profile inserts
The insert can accommodate a range Advantages
Boring
of pitches thus reducing stock. The • Flexibility, the same insert

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

• 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 significant impact on
the thread machining process.
Parting and
It influences:
grooving
- chip control
- insert wear
C - thread quality
- tool life.
In practice, the machine tool, insert geometry, work-

Threading
piece material and thread pitch influence 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 sufficient and even clearance
(insert – inclination shims).
Insert geometry
• Make sure the right insert geometry is used
(A, F, or C geometries).
Boring
Insert grade
G • Select the correct grade based on the material and
λ toughness demands.
Cutting data
Tool holding
• If necessary change cutting speed and number of

passes.
H
Other information
Machinability
C 12
System overview
A
System overview
External thread turning
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
Min hole: 12 mm 4
Drilling
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
2. Exchangeable cutting head
Tool holding
thread turning tools

3. Conventional threading
4. Oil pipe threading H
*TPI = Threads per inch
Other information
*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 threading
Parting and
thread turning
grooving
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 fire 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
General usage Aerospace

Drilling
• 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
thickness of pipe.
Boring
(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 fire.
H
Other information
Machinability
C 16
System overview
A
Insert types
Turning
Three different types of thread turning inserts
B
Full profile inserts
• For high productivity in threading.
Parting and
grooving
C
V-profile inserts - 60º and 55º
• For threading with minimum tool
Threading
inventory.
D
Multi-point inserts
• For highly productive, economic thread
turning in mass production.
Milling
E
Three different 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 fixed 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
Coromant Capto® Shank tool
Other information
Exchangable cutting
internal coupling
head
Machinability
C 18
How to apply
A
How to apply
Three different types of infeed
Turning
The infeed method can have a significant In practice, the machine tool, insert B
impact on the thread machining process. geometry, workpiece material and
It influences: thread pitch influence the choice of
Parting and
- chip control infeed method.
grooving
- insert wear
- thread quality
- tool life. C
Modified flank infeed
Threading
• Most newer CNC machines can be programmed for
modified flank.
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 modified flank infeed.
Drilling
Radial infeed
• Used by all manual machines and most canned CNC F
programs.
• First choice for work hardening materials and suitable for
fine pitches.
Boring
G
Incremental infeed
Tool holding
• Normally used with very large profiles 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
Modified flank 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 flow Chip flow
D
Milling
Feed direction
Feed direction
E
• Better chip control
• Better surfaces
C-geometry
Drilling
insert • For C-geometry insert, modified flank 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 stiff “V” chip.

G • Even insert wear.
• Insert tip exposed to high temperatures, which restricts
depth of infeed.
Tool holding
• Suitable for fine 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 profiles.
• Even insert wear and longest tool life in very
coarse threads. B
• Chips are directed both ways, making control
difficult.
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 first
This is the most common pass
method in CNC programs.
• Follows recommendation on
Milling
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.
• Offers 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 profile 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 finish diameter of
the thread.
Infeed values recommendations

Threading
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
(nap) 32 28 24 20 18 16 14 13 12 11 10 9 8 7 6 5 4.5 4
Boring
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
16 .004 .004
Machinability
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.
• Cutting edge will rub (break).
Parting and
grooving
Too low cutting edge
• The thread profile 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
Negative shims must be used in a pull threading application.
Other information
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, first
Threading
is used (A, F, or C). choice - multi-point insert, second

choice - full profile single point insert,
• Ensure there is sufficient and even
third choice - V-profile insert.
D clearance (insert-inclination shims) to
achieve correct flank clearance by
selecting the appropriate shim.
• If threads are rejected, check entire
setup, including machine tool.
Milling
• Check the available CNC program for

E thread turning.
• Optimize infeed method, number and
size of passes.
• Ensure the correct cutting speed for
Drilling
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
coolant. Reduce the largest infeed
grooving
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 coated.
Milling
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-
rial, which leads to chipping.
Drilling
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 modified flank infeed.
5. Correct center height.
H
Other information
Machinability

C 25
A Troubleshooting
 Problem Cause Solution
Rapid flank 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 flank wear

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

not agree with the lead flank, for C-geometry; 1°
angle of the thread. from flank.
2. Change shim to obtain
D Poor surface on one flank 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-
sure of tail stock/face drive.
Drilling
Minimize overhang of tool.

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

bars.
Boring
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 finish
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. modified flank infeed.
Parting and
grooving
Poor chip control C
1. Incorrect method of infeed. 1. Modified flank infeed 3 - 5°.
2. Incorrect thread geometry. 2. Use C-geometry with
modified flank infeed 1°.
Threading
Shallow profile D
1. Wrong center height. 1. Adjust center height.
2. Insert breakage. 2. Change cutting edge.
Excessive wear.
Milling
Incorrect thread profile
E
1. Unsuitable thread profile 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 modified flank infeed.

cutting edge can cause
chipping.
3. Profile with too small thread
profile angle. H
Other information
Machinability
C 27
A
Turning
B
Parting and
Tapping
grooving
• 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
B
1. Rake angle
2. Relief (clearence)
Parting and
grooving
3. Chamfer angle
4. Chamfer (length)
5. Spiral point angle C
6. Spiral angle
7. Pitch
Threading
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
Medium chamfer Short chamfer

Boring
Cutting tap Cutting tap

G
Tool holding
Forming tap Forming tap
H
Other information
Machinability
C 29
A Theory
Different 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
Different types of tapping processes
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
C 30
Tapping process A
Geometries for different types of holes
Turning
Spiral point tap for through holes Spiral flute 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 flute 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
influences
Parting and
grooving
• Chip evacuation
• Thread quality
C • Tool life.
Threading
D
Coolant supply
Internal or external External coolant supply Different cutting fluid/
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
formation is good
Boring
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 fluid used
coolant nozzle (two if drill
depths above 3 times in the machine
is stationary) should be
the diameter.
Tool holding
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 Benefits 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
wide clamping range
grooving
• Tension and compression
to eliminate feed error.
C
Threading
D
Coromant Capto®
Milling
Rigid ER collet chuck Benefits 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
Benefits 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 float compensation for elimination of oversized
threading. First choice for CNC machine tools and synchronized tapping
operations. B
Benefits and recommendations
Parting and
• High volume production / high precision
grooving
• Reduces thrust force on tap flanks
• 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 flat 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
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 = Effective cutting speed m/min
(ft/min)
Threading
DC = Cutter diameter mm (inch)

DCX = Maximum cutting diameter
D mm (inch)
Milling
Spindle speed (n) in rpm is the number of revolutions the milling tool
Drilling
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.
Specified cutter diameter (DCX), having an effective cutting depth to
diameter (DC), which is the basis for the cutting speed vc or ve.
Boring
G
Tool holding
H
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 = Effective 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)
Feed per tooth, fz mm/tooth (inch/tooth), is a value in milling for calculating
Drilling
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 effective number of teeth (zc) is G
the number of effective teeth in cut.
Feed per revolution (fn) in mm/rev (inch/rev) is a value used specifically for
Tool holding
feed calculations and often to determine the finishing capability of a cutter.
H
Other information

Machinability
D5
A Theory
Definitions 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 specific 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 = Specific cutting force N/mm2
(lbs/inch2)
Pc = Net power kW (Hp)
The net power (Pc) is the power the
Drilling
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 efficiency of the machine must
ap × ae × vf × kc
be taken into consideration when selecting Pc = kW
cutting data. 60 × 106
The torque (Mc) is the torque value Inch

Boring
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 specific cutting force value (kc1) is a Metric
Tool holding
material constant, expressed in N/mm2 Pc × 30 × 103

(lbs/inch2). The values can be found in our Mc = Nm
main ordering catalog and technical guide. π×n
Inch
H
Pc × 16501
lbf ft
Other information
Mc =
π×n
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 effect is chip thickness.
avoided, resulting in less
Parting and
heat and minimal work-
grooving
hardening tendency.
Conventional milling
The feed direction of the • In conventional milling
Threading
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 off 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 different 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 he centerline of the cutter is well outside the workpiece

T
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

edge, ae = 50% of DC.
Boring
• 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
Parting and
grooving
Type of operation and
method
C
1 Component
Workpiece material and
Threading
quantity
Milling
E
3 Choice of tool Select type of cutter
Drilling
F
4 How to apply Cutting data, method etc.

Boring
G
Tool holding
5 Troubleshooting Remedies and solutions
H
Other information
Machinability
D9

Turning
B Geometric shape
• Flat surface
• Deep cavities
Parting and
grooving
• Thin walls/bases
• Slots.
C
Threading
P M K Material Tolerances
N S H • Machinability • Dimensional accuracy
D
• Cast or pre-machined • Surface finish
• 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/
configuration
Tool holding
• Workpiece clamping.
H
Other information
Machinability
D 10
Selection procedure
A
3. Choice of tools
Turning
Different ways to optimize milling
Cutters with round inserts B
• Robust milling cutters • Round inserts require
Parting and
more stable machines.
grooving
• Very flexible for face
milling and profiling
• 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
is very important.
grooving
• It affects both produc Chip formation through

tivity and stability. cutter positioning
C
• Always use climb milling
Insert geometry
• Move the cutter off 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

finish
• Check the wear pattern
and if necessary adjust • Check spindle runout
the cutting data • Use wiper inserts
accordingly.
Boring
• Decrease feed per tooth.
G Vibration
• Weak fixture
• Long tool overhang
Tool holding
• Weak workpiece
• Size of spindle taper.
H
Other information
Machinability
D 12
System overview
A
System overview
Face milling
Turning
B
Cutters for general use
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
H
Other information

Machinability
D 14
System overview
A
 Profiling
Turning
Cutters for general use – roughing
B
Round insert
Parting and
Round insert end mill
grooving
cutter
Threading
D
Cutters for general use – finishing

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 off 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 configura 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 off Chamfering Profile 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
flat faces, shoulders and slots.

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

F
Boring
G
Parting off 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
and opportunities on the
Threading
tooling, such as:
• Increased flexibility
D
• Fewer machines/setups to
complete a component
• Reduced stability
Milling
• Longer tool lengths
• Lower depth of cut. E
Drilling
Profile 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 profile 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 Definitions of terms and geometry design

Corner design Main cutting edge design
0.13
0.13
Drilling
(.005)
(.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 Difficult conditions
Drilling
Type of application
ap Depth of cut, F
mm (inch) Heavy milling
H • Operation for maximum stock removal and/or severe
conditions.
• Larger depth of cut and feed rate.
Boring
• Operations requiring highest edge security.
Medium milling G
M • Most applications – general purpose milling.
• Medium operations to light roughing.
Tool holding
• Medium depth of cut and feed rate.
Light milling
L • Operations at small depth of cut and low feed rates.
• Operations requiring low cutting forces. H
Other information
fn
Feed, mm/tooth (inch/tooth)
Machinability
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 finish in milling

E
Surface
roughness • Use wiper inserts for
higher productivity and
improved surface finish
Drilling
One wiper
Standard insert insert • Limit the feed to 60% of
F the parallel land
• Mount the wiper inserts
correctly
fn
• Set the wiper inserts
fn1 = ≤0.8 x bs1 (fn1 fn1 = ≤0.6 x bs2 Feed, mm/tooth
Boring
= ≤.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
Difficult
Threading
Good Average Difficult
D
Define 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 influences the wear during the cutting
action in different 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 K
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
• Small machines/limited • Heat resistant materials.
Milling
horsepower • Usually first choice.

E • Deep, full slotting
operations
• Differential 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
Differential pitch
Turning
In general, the coarser the cutter pitch, Differential 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 differential-pitched cutter
may be required in more difficult cases
Parting and
to eliminate troublesome harmonics.
grooving
C
Threading
Normal pitch
D
Differential pitch
Milling
Differential 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
Effect of entering angle (90º)
B • Thin-walled components
• Axially weak fixtured components
• Square shoulder
Parting and
grooving
• hex = fz (In case ae > 50% x DC).
C
Effect of entering angle (45º)
• General purpose 1st choice
Threading
• Reduced vibration on long tool overhang

• Chip thinning effect allows increased productivity
D
• fz = 1.41 x hex (Compensating for entering angle).
Milling
E Effect 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 effect for heat resistant
alloys
KAPR
• hex = depends on ap.
Boring
G 10° entering angle

• High-feed milling cutters
• A thin chip is generated, allows very high feeds
Tool holding
per tooth
• Axial cutting force is directed towards the spindle
and stabilize it.
H
Other information
Machinability
D 32
A
Feed compensation for different 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 specific
Drilling
depth (inch).
√
Dcap = DC + iC2 – (iC – 2 × ap)2 F
Facemilling round insert (ap<iC/2) (inch).

Boring
hex × iC
fz = G
2 × √ ap × iC – ap 2
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
vc × 1000 vc × 12
Milling
n= (rpm) n= (rpm)
π × DC π × DC
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

1000
Machinability
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
A
General tu rning
Cutting data MILLING
Milling with large engagement C

Milling with large engagement
Specific
cutting force
Hardness
Brinell CT530 GC1010
B
kc 1
Max chip thickness, hex mm
Pa rting and grooving
Threading
CMC 0.1 – 0.15 – 0.2 0.05 – 0.1 – 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
01.5
1800
2000
210
300
0.25
0.25
315–290–60
235–210–95
-
- C 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 0.25 230–205–85 180-165-135
Threading
03.13 Hardened tool steel 2150 200 0.25 190–170–55 150-135-110
03.21 2900 300 0.25 165–150–35 130-120-100
03.22 3100 380 0.25 105–95–85 80-75-60
Milling
Castings
06.1
06.2
Unalloyed
Low alloyed (alloying elements 5%)
1400
1600
150
200
0.25
0.25
305–280–50
245–220–00
245-220-180
195-175-145 D
06.3 High alloyed (alloying elements > 5%) 1950 200 0.25 180–160–45 140-130-105
Specific
cutting force
kc 1
Hardness
Brinell CT530 GC1025 E
Max chip thickness, hex mm
CMC
ISO No. 85Material
× 4 × 600 × 1700 3.346mc× .157 × 23.6 × 246500
0.1 – 0.15 – 0.2 0.05 – 0.1 – 0.2
= 5.8 kW = 7.7 Hp
N/mm2 HB Cutting speed vc, m/min
PMc = Pc =
Milling
Stainless steel
05.11 60 × 10
Ferritic/martensitic 6
Non-hardened 1800 200 396
0.21 × 285
10–255
3
–230 255 –225 –180
05.12 PH-hardened 2850 330 0.21 205 –185 –165 180 –160 –130 E
Drilling
05.13 Hardened 2350 330 0.21 215 –190 –170 185 –165 –135
Austenitic
05.21 Non-hardened 1950 200 0.21 265 –240 –215 250 –225 –180
05.22 PH-hardened 2850 330 0.21 200 –175 –160 170 –155 –125
Austenitic-ferritic (Duplex)
F
05.51 Non-weldable 0.05%C 2000 230 0.21 260 –235 –210 205 –185 –145
Drilling
05.52 Weldable < 0.05%C 2450 260 0.21 230 –205 –185 175 –155 –125
The calculation above is approximate and valid for an average

Stainless steel – Cast
Ferritic/martensitic
chip15.12
thickness (hm) of 1 mm (0.039 inch)
2450 . F
15.11 Non-hardened
1700 200 0.25 255 –230 –205 225 –200 –160
PH-hardened 330 0.25 180 –160 –145 155 –140 –115
For 15.22
a more accurate value of power consumption (Pc0.25
) the k180
15.13 Hardened 2150 330 0.25 195 –175 –155 170 –155 –120
15.21 Austenitic
1800
PH-hardened
2450
200
330
0.25
c –160 –145
255 –225 –205 235 –210 –170
160 –140 –115
value should be calculated accordingly.
Austenitic-ferritic (Duplex)
Boring
15.51 Non-weldable 0.05%C

1800 230 0.25 245 –220 –195 195 –175 –140
15.52 Weldable < 0.05%C 2250 260 0.25 215 –190 –170 160 –145 –115
Boring
Metric Specific
cutting force
Hardness
Brinell CB50 CC6090
( )
hm = Average chip – 0.2 thickness G
kc 1
Max chip thickness, h mm ex
CMC 0.1 – 0.15 0.1 – 0.2 – 0.3 G
γo
γo
ISO No. Material N/mm2 HB mc Cutting speed vc, m/min
kc07.1= kc1 × hm -mc

Malleable cast iron
× 1 – (N/mm2) = I0.28
nsert rake angle1200 –980 –800
Tool holding systems
K
Ferritic (short chipping) 790 130 -
07.2 Pearlitic (long chipping)
100 900
mc = Chip thickness compensation
230 0.28 - 980 –810 –660
Tool holding
Grey cast iron
factor
08.1 Low tensile strength 890 180 0.28 850 –720 –620 1300–1100–890
08.2 High tensile strength 1100 245 0.28 910 –780 –670 1050–860–700
Nodular cast iron
Inch09.2
09.1 Ferritic 900
kc = S0.28pecific
160 0.28
cutting
-
force
920–760–620
( )( )
Pearlitic 1350 250 495 –420 –360 760 –630 –510
1) 45-60 entering angle. Positive cutting geometry and coolant should be used. H
-mc
γo kc1 = Specific cutting force for average
kc = kc1 × 0.039 × 1 – H
Multi-task machining
(lbs/inch2) 100 mm chip 125

thickness 1125mm (0.039 inch).
Conditions:
Cutter, dia. mm, centered
hm 100
mm over the workpiece. Working
Other information
engagement 100 mm.

Machinability
I
D 35
formation
MILLING Cutting data
A1
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 sufficient 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 configuration. Also
Tool holding
quality demands on the surface to be machined.
H
Other information
Machinability

D 36
Troubleshooting
A
P10-P50 Choice of insert grade

 ISO
P
• 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
the tool diameter, vibration tendencies can
grooving
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
and monitor tool wear.
Tool holding
H
Other information
Machinability
D 37
2
Drilling
Drilling covers methods of making cylindrical holes in a
workpiece with metal cutting tools
• Theory E4
• Selection procedure E 15
• System overview E 20
• How to apply E 26
• Hole quality and tolerances E 38
• Troubleshooting E 43
E3
A Theory
The drilling process

Turning
• The drill is always engulfed in the work-

B
piece, leaving no view of the operation.
• Chips must be controlled.
Parting and
• Chip evacuation is essential; it affects

grooving
hole quality, tool life and reliability.
C
Threading
Four common drilling methods

Milling
E
Drilling Trepanning
Drilling is classified into
four common methods:
Drilling
- Drilling
F - Trepanning
- Chamfer drilling
- Step drilling.
Boring
Chamfer drilling Step drilling

G
Tool holding
H
Other information
Machinability
E4
Theory
A
The most common holes
Turning
B
Parting and
grooving
C
Threading
1 2 3 4 5 6 7
D
The most common holes are:
Milling
1 Holes with clearance for bolts
2 Holes with a screw thread
E
3 Countersink holes
4 Pressed fit holes
Drilling
5 Slip fit holes
6 Holes that form channels F
7 Holes to remove weight for balancing.
Boring
G
Tool holding
H
Other information
Machinability
E5
A Theory
Maximum hole depth

Turning
Hole depth (LU) determines the choice of

B tool.
Chip evacuation
Maximum hole depth is a function of hole
diameter DC and hole depth (LU).
Parting and
Example: max hole depth LU = 3 x DC.

grooving
C
Threading
DC
D
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
E6
Theory
A
Drilling theory
Cutting speeds for indexable drills
Turning
B
• Cutting speed (vc) for indexable drills
declines from 100% at the periphery
to zero at the center.
Parting and
grooving
• The central insert operates from cutting
speed zero to approx. 50% of vc max.
The peripheral insert works from 50% of C
vc max up to 100% of vc max.
• One effective cutting edge/rev: = zc.
50% of vc max vc = 0
Threading
vc max
Milling
E
Cutting speeds for solid and exchangeable tip drills
Drilling
• Two effective cutting edges, from the
center to the periphery. F
• Two edges/rev: = zc.
Boring
vc max
Tool holding
H
Other information
Machinability
E7
A Theory
Solid carbide drill (SCD) vs. high speed drills (HSS)

Turning
Point angle and chisel edge

B
Solid carbide drill • Chisel edge is practically
eliminated with the solid
carbide drill.
Parting and
grooving
• The axial cutting force is

reduced considerably,
because the chisel edge
C is eliminated on solid
140º point angle carbide drills.
Chisel edge • This results in better

Threading
HSS drill centering features and

cuts chips close to the
center of the drill point.
D This eliminates the need
for a center drill.
Milling
118º point angle

E
1 Main cutting edge 2 Solid carbide drill -

4 1 Advantages
2 Chisel edge
Drilling
• Chisel edge is practically

3 Primary clearance
F eliminated
6
4 Secondary clearance
8 • The main cutting edge
5 Flute reaches the center point
3
6 Margin 7 • Gives longer life and
Boring
5 productivity
7 First split
• Lower thrust and torque
G 8 Negative chamfer 2
1
• Better tolerances.
9 Clearance surface.
Tool holding
9
H
5
Other information
Machinability
E8
Theory
A
Turning
Cutting speed
vc = cutting speed m/min (ft/min) B
fn = feed per revolution mm/r
(inch/r)
Parting and
vf = penetration rate mm/min
grooving
(inch/min)
DC = drill diameter mm (inch)
C
Metric
π × DC × n
vc = m/min
Threading
1000
Inch
π × DC × n D
vc = ft/min
12
Productivity in drilling is strongly
related to the penetration rate, vf.
vf = fn × n mm/min (inch/min)
Milling
Cutting speeds for indexable drills E
Cutting speed (vc) for indexable drills declines 50% of vc max
vc = 0
from 100 % at the periphery to zero at the
center. vc max
Drilling
The central insert operates from cutting
speed zero to approx. 50% of vc max.
The peripheral insert works from 50% of vc F
max up to 100% of vc max.
One effective cutting edge/rev: = zc.
Boring
G
Cutting speeds for solid and exchangeable tip drills
Two edges, from the center to the periphery.
Tool holding
vc = max
Two edges/rev: = zc.
H
Other information
Machinability

E9
A Theory

Effects of cutting speed – vc m/min (ft/min)
Turning
• Affects the power Pc kW (Hp) and torque Mc Nm (lbf-ft).

B
• The largest factor determining tool life.
• Higher speed generates higher temperature and
Parting and
increased flank wear, especially on the peripheral

grooving
corner.
• Higher speed is beneficial for chip formation in long
C
chipping, soft materials, i.e., low carbon steel.
• Affects sound levels.
Threading
D
Milling
E
Too high cutting speed causes:
- rapid flank wear
- plastic deformation
Drilling
- poor hole quality

- bad hole tolerance.
F vc = 0
50% of vc max
Too low cutting speed causes:
vc max
- built-up edge
- bad chip evacuation
Boring
- longer time in cut

- higher risk of drill breakage
G
- reduced hole quality.
Tool holding
H
Other information
Machinability
E 10
Theory
A
Feed rate
Effects of feed rate – fn mm/r (inch/r)
Turning
• Affects the feed force Ff (N), power Pc kW (Hp) and
B
torque Mc Nm (lbf-ft).
• Controls chip formation.
Parting and
• Contributes to hole quality.
grooving
• Primarily influences surface finish.
• Contributes to mechanical and thermal stress. C
Threading
fn = fz × 2 mm/r (inch/r) D
High feed rate:

- harder chip breaking
Milling
- reduced time in cut.
Low feed rate: E

- longer, thinner chips
- quality improvement
- accelerated tool wear
Drilling
- longer time in cut.
F
*Note: Feed rate must correlate with cutting speed.
Boring
G
Tool holding
H
Other information
Machinability
E 11
A Theory
Approximate calculation of power consumption

Turning
CoroDrill® 880 CoroDrill® Delta-C

B n = spindle speed (rpm)
fn = feed per revolution mm/rev
Parting and
(inch/rev)
grooving

(inch/min)
C DC = drill diameter mm (inch)
fz = feed per edge mm (inch)
kc1 = specific cutting force N/mm2
Threading
(lbf ft/inch2)
Pc = power consumption kW (Hp)
D Ff = feed force (N)
Mc = torque Nm (lbf ft)
Milling
Metric Inch
E
fn × vc × DC × kc fn × vc × DC × kc
Pc = kW Pc = Hp
240 × 103 132 × 103
Drilling
ISO P Specific cutting Specific cutting Hardness

F force force Brinell
kc1 1.0 kc1 .0394
MC No. CMC No. Material N/mm2 lbs/in2 HB mc
Steel Unalloyed
Boring
P1.1.Z.AN 01.1 C = 0.1-0.25% 1500 216.500 125 0.25
P1.2.Z.AN 01.2 C= 0.25-0.55% 1600 233.000 150 0.25

G P1.3.Z.AN 01.3 C = 0.55-0.80% 1700 247.000 170 0.25
P1.3.Z.AN 01.4 High carbon steel, annealed 1800 260.500 210 0.25
P1.3.Z.HT 01.5 Hardened and tempered 2000 291.500 300 0.25

Tool holding
Low alloyed
(alloying elements ≤ 5%)
P2.1.Z.AN 02.1 Non-hardened 1700 246.500 175 0.25

H P2.5.Z.HT 02.2 Hardened and tempered 1900 278.500 300 0.25
Other information
For information about the kc1 value, see page H16.

Machinability
E 12
Theory
A
Accurate calculation of power consumption
Turning
CoroDrill® 880 CoroDrill® Delta-C
B
Parting and
grooving
KAPR = 70°
KAPR = 88°
C
γ0 = 30°
Threading
D
Metric Inch
fn × vc × DC × kc fn × vc × DC × kc
Pc = kW Pc = Hp
240 × 103 132 × 103
Milling
( )
γ0 E
kc = kc1 × (fz × sin KAPR )-mc × 1–
100
Drilling
ISO P Specific cutting
force
Specific cutting
force
Hardness
Brinell
F
kc1 1.0 kc1 .0394
MC No. CMC No. Material N/mm2 lbs/in2 HB mc
Steel Unalloyed
Boring
P1.1.Z.AN 01.1 C = 0.1-0.25% 1500 216.500 125 0.25
P1.2.Z.AN 01.2 C= 0.25-0.55% 1600 233.000 150 0.25
P1.3.Z.AN 01.3 C = 0.55-0.80% 1700 247.000 170 0.25 G

P1.3.Z.AN 01.4 High carbon steel, annealed 1800 260.500 210 0.25
P1.3.Z.HT 01.5 Hardened and tempered 2000 291.500 300 0.25

Tool holding
Low alloyed
(alloying elements ≤ 5%)
P2.1.Z.AN 02.1 Non-hardened 1700 246.500 175 0.25
P2.5.Z.HT 02.2 Hardened and tempered 1900 278.500 300 0.25 H

Other information
For information about the kc1 value, see page H16.

Machinability
E 13
A Theory
Calculation of torque and feed force

Turning
B n = Spindle speed (rpm)

fn = Feed per revolution mm/rev
(inch/rev)
Parting and
grooving
DC = Drill diameter mm (inch)

Power
consumption kc1 = Specific cutting force
C kW (Hp) N/mm2 (lbf ft/inch2)
Ff = Feed force (N)
Mc = Torque Nm (lbf ft)
Threading
D Torque Nm
(lbf ft)
Milling
Feed force (N) DC f × sin KAPR (N)

Ff ≈ 0.5 × kc × n
E 2
Metric Inch
Drilling
Pc × 30 × 103 Pc × 16501
Mc = (Nm) Mc = (lbf ft)
F π×n π×n
Boring
G
Tool holding
H
Other information
Machinability
E 14
Selection procedure
A
Turning
Parting and
grooving
Hole dimension
and quality
C
1 Component
Workpiece material, shape
Threading
and quantity
Milling
E
Type of tool and machining

3 Choice of tool
Drilling
method
Cutting data, coolant,

4 How to apply
Boring
etc.
G
Tool holding
Remedies and
5 Troubleshooting
solutions
H
Other information
Machinability
E 15

Turning
Material: Component:
B • Machinability • Is the component rotation symmetric?

• Chip breaking Use a rotating or stationary drill?
• Hardness • Clamping, hole size and depth. Also is the
Parting and
• Alloy elements. component sensitive to feed force and/or

grooving
vibrations?
• Is a tool extension needed to reach the
C surface where the hole will be drilled i.e.
long tool overhangs?
• Component features, does something
Threading
complicate the process? Are there

inclined, concave or convex surfaces?
Crossing holes?
D
Milling
2. Important machine considerations

Drilling
Condition of the machine:

F
- Machine stability
- Spindle speed
- Coolant supply
Boring
- Coolant flow and pressure

G - Clamping of the workpiece
- Horizontal or vertical spindle
- Power and torque
Tool holding
- Tool magazine.
H
Other information
Machinability
E 16
Selection procedure
A
3. Choice of drilling tools
Turning
Different ways to make a hole
The basic parameters are: The hole type, and the required precision B
affect tool choice.
• Diameter
• Depth Drilling can be affected by irregular or
Parting and
• Quality (tolerance, surface finish, angled entry/exit surfaces and by cross
grooving
straightness). holes.
Drilling Step/chamfer drilling Helical interpolation
Threading
D
Milling
E
Advantages Advantages Advantages

• Simple standard tools • Reduces the number of • Simple standard tools
Drilling
operations
• Relatively flexible. • Very flexible
• Fastest way to make a
• Low cutting forces. F
step/chamfer hole.
Disadvantages Disadvantages Disadvantages

• Two tools, adapters and • Requires more power and • Longer cycle times.
Boring
basic holders stability

• Requires an extra tool and • Less flexibility. G
operation if it is a step/
chamfer hole
Tool holding
• Depending on choice
- Productivity
- Hole quality.
H
Other information
Machinability
E 17
4. How to apply
Turning

B
Tool holding
• Always use shortest possible drill and
Parting and
overhang to reduce tool deflection and

grooving
vibrations, keeping in mind proper chip

evacuation.
C
• For best stability and hole quality, use
modular tools, hydro-mechanical or
hydraulic holding tools.
Threading
D
Tool runout
• Minimum tool runout is essential for
successful drilling.
Milling
E
Chip evacuation and cutting fluid
• Chip formation and evacuation is the
dominant factor in drilling and affects
Drilling
hole quality.
F
Grade and geometry

Boring
Cutting Thicker and stiffer

speed chips
• Use recommended grade and geometry.
G
• Use recommended cutting parameters.
• To ensure a stable process, make sure to
Tool holding
achieve good chip formation by adjusting

cutting parameters.
More open due
to less friction
H
Other information
Machinability
Feed
E 18
Selection procedure
A
5. Troubleshooting
Turning
B
Insert wear and tool life
- Check wear pattern and if necessary adjust cutting
Parting and
data accordingly or change grade.
grooving
Chip evacuation
C
- Check chip breaking and cutting fluid supply, if
necessary change chip breaker and/or cutting
parameters accordingly.
Threading
ø25 mm (ø.984 in)
Hole quality and tolerances
- Check clamping of drill/workpiece, feed rate, machine
D
conditions and chip evacuation.
Cutting data
Milling
- Correct cutting speed and feed rate is essential for
high productivity and tool life. E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
E 19
A System overview
Drilling tools
Turning
Drilling tools covering diameters from 0.30 mm up to 110 mm (.0118 inch up

to 4.331 inch) and even larger as engineered products.
B
Parting and
grooving
Irregular surface and cross-hole

Conventional drilling drilling
C
Threading
D
Milling
E
Drilling
Length diameter
ratio
F
30xDC Deep hole drill
Solid carbide drill

20xDC
Boring
G 15xDC
10xDC
Tool holding
Large diameter
Trepanning drill
Short hole drill drill
5xDC
Exchangeable
H tip drill
Drill diameter, DC
Other information
10 20 30 40 50 60 70 80 110 mm
Machinability
(.394) (.787) (1.181) (1.575) (1.969) (2.362) (2.756) (3.150) (4.331) (inch)
E 20
System overview
A
Choice of drilling tools
Turning
Step and chamfer drilling
B
Chamfer drilling Step or step and chamfer drilling
Parting and
grooving
C
Threading
D
Milling
E
Other methods
Drilling
Radial adjusted Solid drilling
drilling
F
Plunge drilling
Helical interpolation
Boring
Trepanning G
Tool holding
H
Other information
Machinability
E 21
A System overview
Diameter and hole depth

Turning
Positioning of short hole drills

B Indexable insert drills Application areas
Always to be considered • Medium and large

as the first choice due to diameter holes
Parting and
lower cost per hole. They

grooving
• Medium tolerance
are also very versatile demands
tools. • Blind holes requiring a
C
“flat” bottom
• Plunge drilling or boring
operations.
Threading
D
Solid carbide drills
First choice for smaller • Small diameter
diameters and when closer • Close or precision
hole tolerance is required. tolerance holes
Milling
• Short to relatively deep

E holes.
Drilling
F Exchangeable tip drills

First choice for medium • Medium diameter
diameter holes where the • Close hole tolerances
exchangeable tip provides • Steel body provide
Boring
for an economical solution. toughness

• Short to relatively deep
G holes.
Tool holding
H
Other information
Machinability
E 22
System overview
A
Indexable insert drills
Turning
The basic drill
B
• The most economical way to
produce a hole.
Parting and
grooving
• For all workpiece materials.
• Standard, Tailor Made and special drills
available. C
• A versatile tool that can do more than
just drilling.
Threading
D
Milling
E
Mounting options
Different mounting options are available, which enables
the user to mount the drill to almost all machine configu-
Drilling
rations. Today, machine tool manufacturers are offering
mounting options integrated to the spindle.
F
Cylindrical shank Coromant Capto® Cylindrical with flat

coupling
Boring
G
Tool holding
P-shank Whistle Notch Other modular systems
H
Other information
Machinability
E 23
A System overview
Solid carbide drills

Turning
The basic Material-optimized drills

choice
B
Parting and
grooving
C P M K P M K N S
N S H
Threading
Application-optimized drills
D Precision
Chamfer drill drill for
hard steel
Milling
P M K P
E N S H H
Drilling
F
Short hole drills – ISO material groups
ISO material group
P M K N S H
Boring
G Solid carbide +++ +++ +++ +++ +++ +++

drills
Tool holding
Exchangeable tip +++ +++ +++ ++ ++ +

drills
H Indexable insert
drills
+++ +++ +++ +++ +++ +++
Other information
Machinability
E 24
System overview
A
Large hole diameters
Turning
Large diameter drill
Indexable insert drills are available in diameters up to B

84 mm (3.307 inch).
Parting and
grooving
C
Threading
Trepanning drill
Trepanning is used for larger hole diameters and where
D
machine power is limited, because it is not as power
consuming as solid drilling. Trepanning drills are available
up to diameter 110 mm (4.331 inch).
Note: These drills are for a through hole application only.
Milling
E
Drilling
Milling, helical interpolation
F
A milling cutter with helical or circular interpolation can be
used instead of drills or boring tools. The method is less
productive but can be an alternative when chip breaking
is a problem.
Boring
G
Tool holding
H
Other information
Machinability
E 25
A How to apply
How to apply
Turning
B Setup routine
• Use the shortest possible drill.
Parting and
• Check programming length.

grooving
• Start drilling with a mid-range recommended feed rate

and cutting speed to a depth of 3.2 mm (.125 inch).
C
• Check chip formation and measure hole size.
• Inspect the drill to make sure no drill-to-hole rubbing is
taking place.
Threading
• Increase or decrease feed rate and/or cutting speed

according to chip formation, vibration, hole-surface
D quality, etc.
Milling
Chip formation - Indexable

Drilling
• Improved chip evacuation is initially • Rectification involves selecting the

achieved by improving chip formation. correct insert geometry and adjusting
F cutting data.
• Long chips may cause chip jamming in
the drill flutes. • Apply insert geometries to suit different
materials and cutting conditions.
• Also the surface finish may be affected
and the insert or tool may be at risk.
Boring
G
Tool holding
H
Other information
Excellent Acceptable Not acceptable

Machinability
E 26
How to apply
A
Rotating indexable drill
Turning
Alignment
• If over- or under-sized holes are produced or if the
B
center insert tends to chip, it is often because the drill
is off center.
• Turning the drill 180° in its holder may solve this
Parting and
grooving
problem.
• But it is important to ensure that the center axis of the
drill and the axis of rotation are parallel in order C
to achieve accurate holes.
• The machine spindle and the holder must be in good
Threading
condition.
Milling
Radial adjustment E
Adjustable holder
• Setting is achieved by turning the scale ring surrounding
the holder, marked in increments of 0.05 mm (.002 inch),
Drilling
indicating a diametrical movement of the tool.
• Radial adjustment -0.2 /+0.7 mm (-.008 /+.028 inch). F
Note that the adjustment range for the drill should not
be exceeded. (Maximum adjustment can be seen on the
ordering pages in the catalog).
Boring
• It may be necessary to reduce the feed/rev (fn) due to

longer tool overhang and less balanced cutting forces
created by the offsetting. G
• Sleeves are used to adapt various ISO shank sizes for
one holder.
Tool holding
H
Other information
Machinability
E 27
A How to apply
Adjustable sleeve for drills with ISO 9766 shanks

Turning
B
Parting and
grooving
C
Rotating drill – eccentric sleeve
Drill diameter can be adjusted for closer
Threading
hole tolerance. The adjustment range is

approx. ±0.3 mm (±.012), but adjustment
D in the negative direction should be made
only if the drill produces an oversized hole
(not in order to achieve undersized holes).
• One dot increases/decreases the
diameter by 0.10 mm (.004 inch).
Milling
• Increase the diameter by turning the

E sleeve clockwise.
• Decrease the diameter by turning the
sleeve counterclockwise.
• Use both screws to clamp the drill in the
Drilling
fixture and make sure the bolts in the

holder are long enough.
F
Boring
G
Tool holding
H
Other information
Machinability
E 28
How to apply
A
Non-rotating drill
Turning
Alignment
• The total runout between the center line B

0.03 mm (.001 inch)
of the machine and the workpiece must
not exceed 0.03 mm (.001 inch) .
Parting and
• The drill should be mounted so that the
grooving
top face of the peripheral insert is parallel
to the machine’s transverse movement
(usually X-axis). C
Threading
D
Milling
Dial indicator and test bar
• Misalignment also has the effect of radial E
offsetting, which produces either an over-
or under-sized hole.
• Testing can be carried out with a dial
Drilling
indicator together with a test bar.
Drill with four flats F
• Another way is by making a drill with four

flats equally positioned around the drill
shank.
Boring
• Make holes with the drill mounted in each

of the four flat positions. Hole measure- G
ment will indicate the state of machine
alignment.
Tool holding
H
Other information
Machinability
E 29
A How to apply
Deflection of turret
Turning
Problem solving
B • Deflection of the turret on a CNC lathe
B can be caused by the feed force.
Parting and
grooving
• First, check if you can minimize torque by

A mounting the tool differently.
Position B is preferable to position A.
C
Threading
Peripheral insert
Milling
• To avoid wear on the drill body and

Drilling
retraction marks in the hole, mount the

drill with the peripheral insert as shown
F in the picture.
• Finally, a reduction of the feed/revolution
(fn) can be made to minimize the feed
force.
Boring
Feed force
G
Tool holding
H
Other information
Machinability
E 30
How to apply
A
Radial offset
Turning
• Holes can be drilled larger than the nominal size of the
drill as well as enlarged and finished with a subsequent
boring pass. B
• Non-rotating indexable insert drills can also be used to

generate tapered holes.
Parting and
grooving
• Also chamfering and reliefs can be machined
with the drill.
• A hole which is to be threaded can be prepared in one C
pass along with chamfering.
Threading
D
Irregular surfaces and pre-drilled holes
Milling
When entering or exiting an irregular surface there is a E
risk of the inserts chipping.
• The feed rate should therefore be reduced.
• A pre-drilled hole should be small rather than large -
Drilling
not more than 25% of the drill diameter - to avoid drill
deflection. F
• However, reduced feed does allow broad machining of
pre-drilled holes. Boring
G
Tool holding
H
Other information
Machinability

E 31
A How to apply
 Entering non-flat surfaces

Turning
A B C D
B
Parting and
grooving
Convex surface Concave surface Inclined surface Irregular surfaces

C • Normally no feed • Reduce feed to • With entering • Reduce feed 1/3
reduction needed. 1/3 of original feed angle of 2º–89º, of original feed
rate. reduce feed to 1/3 rate.
of original feed
Threading
rate.
D
Milling
E
Solid carbide and exchangeable tip drills
Alignment
Drilling
Rotating drill Minimum tool runout is one of the main

F criteria for successful use of solid carbide
0.02 mm (.0008 inch)
drills.
The runout should not exceed 0.02 mm
(.0008 inch) in order to achieve:
Boring
- close hole tolerance
G - good surface finish

Stationary drill - long and consistent tool life.
Tool holding
0.02 mm (.0008 inch)
H
Other information
Machinability

E 32
How to apply
A
 Tool holding
Turning
B
• A collet and tool shank in bad condition
will ruin an otherwise perfect setup.
Parting and
• Make sure that the TIR (Total Indicator
grooving
Readout) is within 0.02 mm (.0008 inch).
• An unacceptable runout can be tempo-
rarily reduced by turning the drill or the C
collet 90° or 180° to find lowest TIR.
Threading
D
For best performance use hydro-mechanical,

hydraulic or shrink fit chuck.
Milling
E
Solid carbide and exchangeable tip drills
Drilling
F
Boring
G
Solid carbide drills Exchangeable-tip drills
• Not recommended due to risk of • Not possible to enlarge existing holes
Tool holding
chipping on cutting edge. by counter-boring because no chip

breaking will take place.
H
Other information
Machinability
E 33
A How to apply
Entering non-flat surfaces

Turning
When entering non-flat surfaces there is a risk of drill deflection. To avoid this, the feed
can be reduced when entering.
B
Parting and
grooving
C
Convex surface Concave surface Inclined surface Irregular surfaces
Drill if radius is > 4 Drill if radius is > 15 Inclinations up to Reduce feed rate to
Threading
times drill diam- times drill diameter 10º, reduce the ¼ of normal rate to
eter and the hole and the hole is feed to 1/3 of normal avoid chipping on
is perpendicular to perpendicular to feed rate during the cutting edges.
D the radius. the radius. entrance. More
Reduce feed 50% Reduce feed 25% than 10º, not
of normal rate of normal rate recommended.
during entrance. during entrance. Mill a small flat on
surface, then drill
Milling
the hole.
E
Chip formation – Solid carbide and exchangeable tip drills

Drilling
• Improved chip evacuation is initially achieved by improving

chip formation.
F • Long chips may cause chip jamming in the drill flutes.
• Also the surface finish may be affected and the insert or
tool may be at risk.
• Make sure the right cutting data and drill/tip geometry is
used to suit different materials and cutting conditions.
Boring
G
Tool holding
Start chip
Note: The start chip from entry

into the workpiece is always
long and does not create any Excellent Acceptable Chip jamming
H
problems.
Other information
Machinability
E 34
How to apply
A
Coolant supply
Internal coolant supply
Turning
• Always to be preferred especially in
long- chipping materials and when drilling B
deeper holes (4-5 x DC).
External coolant supply
Parting and
grooving
• Can be used when chip formation
is good and when the hole depth is
shallow.
C
Compressed air, minimal lubrication or
dry drilling
• Can be successful in favorable condi-
Threading
tions, but is generally not recommended.
The cutting fluid
Milling
Soluble oil (emulsion)
E
• 5 to 12% oil (10-25% for stainless steels).
• EP (extreme pressure) additives.
Neat oil
Drilling
• always with EP additives.
• increases tool life in ISO-M and ISO-S applications
F
• both solid carbide and indexable insert drills work well
with neat oil.
Mist cutting fluid or minimal lubrication

Boring
• can be used with good performance in materials with

favorable chip forming.
G
Dry drilling, without any coolant
• can be performed in short-chipping materials.
Tool holding
• hole depths up to 3 times the diameter.

• preferably in horizontal applications.
• tool life will be influenced negatively.
H
Other information
Machinability
E 35
A How to apply
Coolant – Important for successful performance

Turning
Coolant supply is essential in drilling and influences:

B - chip evacuation
- hole quality
- tool life.
Parting and
grooving
•The cubic capacity of the coolant tank should be

between 5-10 times larger than the volume of coolant
that the pump supplies per minute.
C
• The volume capacity can be checked using a stopwatch
and a suitably-sized bucket.
Threading
D Coolant
Internal or external
• Is always to be preferred to avoid chip jamming.
Milling
• Should always be used at hole depths above 3 times the

E diameter.
• A horizontal drill should have a flow of coolant coming
out of the drill without any downward drop for at least
30 cm (12").
Drilling

F • Can be acceptable in short-chipping materials.
• To improve chip evacuation at least one coolant nozzle
(two if drill is stationary) should be directed close to the
tool axis.
• Can sometimes help to avoid built-up edge formation
Boring
due to a higher edge temperature.
G Compressed air, minimal lubrication or dry drilling

• Can be used with an Exchangeable tip drill under
favorable conditions in short chipping materials.
Tool holding
• Solid carbide drills work well in these types of

applications.
H
Other information
Machinability
E 36
How to apply
A
Safety precautions
Turning
Safety against • Guarding against through-hole discs
dangerous discs B
is important to avoid damage or injury,
especially when using non-rotating drills.
Parting and
grooving
C
Threading
D
Rotating stop • A rotation stop may be necessary for
is an important
rotating drills.
measure
Milling
• If the coolant contains chip particles,
the slit seatings may seize and as a
result the housing will rotate.
E
• If the rotating connector has not been

used for a long time, check that the
holder rotates in the housing before
Drilling
the machine spindle is started.
Boring
G
Tool holding
H
Other information
Machinability
E 37
A Hole quality and tolerance
Hole quality and tolerance

Turning
Steps to ensure good hole quality in drilling

B
• The machine tool should be in good
condition.
Parting and
grooving
• Tool holding influences hole quality

and tool life.
C • Use the shortest possible drill for
maximum stability.
• Chip breaking and chip evacuation
Threading
must always be satisfactory.

• Coolant supply and coolant pressure
is important.
D
Milling
Hole and hole tolerance

Drilling
Hole dimensions are characterized by

Dmax three parameters:
F Dmin - nominal value (the theoretical exact value)
- tolerance width (a number), e.g., IT 7
according to ISO
Boring
- position of the tolerance (designated by

capital letters according to ISO).
G
Tool holding
Dmax minus Dmin is the tolerance width,

also called, e.g., IT 7.
H
Other information
Machinability
E 38
A
Hole tolerance according to ISO
Turning
Diameter range, mm/inch
B
3–6 6–10 10–18 18–30 30–50 50–80
Examples 80–120
.118– .236– .394– .709– 1.181– 1.969– 3.150–
Tolerance
Parting and
.236 .394 .709 1.181 1.969 3.150 4.724
grooving
IT6 0.008 0.009 0.011 0.013 0.016 0.019 0.022 
.0003 .0004 .0004 .0005 .0006 .0007 .0009  Bearings

IT7 0.012 0.015 0.018 0.021 0.025 0.030 0.035 C
.0005 .0006 .0007 .0008 .0010 .0012 .0014
IT8 0.018 0.022 0.027 0.033 0.039 0.046 0.054  1)
.0007 .0009 .0011 .0013 .0015 .0018 .0021  Holes for
 threading
Threading
IT9 0.030 0.036 0.043 0.052 0.062 0.074 0.087
.0012 .0014 .0017 .0020 .0002 .0029 .0034
 Normal tap
IT10 0.048 0.058 0.070 0.084 0.100 0.120 0.140  holes
.0019 .0022 .0028 .0033 .0039 .0047 .0055  D
IT11 0.075 0.090 0.110 0.130 0.160 0.190 0.220
.0030 .0035 .0043 .0051 .0062 .0074 .0089
IT12 0.120 0.150 0.180 0.210 0.250 0.300 0.350
.0047 .0059 .0071 .0083 .0098 .0118 .0138
Milling
IT13 0.180 0.220 0.270 0.330 0.390 0.460 0.540
.0071 .0087 .0106 .0130 .0154 .0181 .0213 E
1) Holes for threading with fluteless taps (rolled threads)
Drilling
• The lower the IT-number, the closer the tolerance.
• The tolerance for one IT-class grows with larger diameters.
F
Example: Ø 15.00 mm (.591 inch)

H10
Boring
0.07 mm
(+.003 inch)
Nominal value: 15.00 mm (.591 inch)
+0.00 G
Tolerance width: 0.07 mm (.003 inch)
(IT 10 acc. to ISO)
Tool holding
Position: 0 to plus
(H acc. to ISO)
H
Other information
Machinability
E 39
A Hole quality and tolerance
Hole tolerances according to ISO

The hole tolerance is often
Turning
connected to the tolerance

of an axle, that should fit
B Hole the hole.
Axle
Ø 20 mm Ø 20 mm
(.787 inch) (.787 inch) H7
Parting and
h7
grooving
C
Threading
Hole and axle tolerance according to ISO

D
Axle tolerance position is denominated by lower case letters corresponding to the
hole tolerance in upper case letters. The figure below gives a complete picture.
Milling
Most common
Drilling
F Hole larger Axle larger than

than axle hole
Boring
Running fit Slide fit Drive fit Interface

Tool holding
Play Grip = negative play

(bearings) (fix joints)
H
Other information
Machinability
E 40
A
Hole and tool tolerance
Turning
Obtainable hole tolerance with different tools
Drill diameter DC tolerance B
Drill tolerance
Parting and
DC DMM • The drill is ground to a certain diameter
grooving
tolerance, designated by lower case
letters according to ISO.
DC tolerance for a solid carbide drill and a C
exchangeable tip drill
The hole tolerance
• For modern solid carbide or exchange-
Threading
able tip drills, the hole tolerance is very
close to the drill tolerance.
D
Milling
E
Solid carbide drills Exchangeable tip drills Indexable insert drill
Drilling
F
Tolerance
IT6
Boring
IT7
G
IT8
IT9 With pre-setting

Tool holding
IT10
IT11
IT12 H
Other information
IT13
Machinability
E 41
A Hole quality and tolerances

Turning
Drill tolerance Hole tolerance

• The diameter tolerance of an indexable • Indexable insert drills give an optimal
B insert drill is a combination of the tip seat cutting force balance and a plus tole
tolerance in the drill body and the insert rance (oversized) hole, because most
tolerance. holes are with H-tolerance.
Parting and
grooving
C
DC DMM
Threading
Drill depth 2-3 x DC

D Drill diameter, mm (inch) 12 – 43.99 44 – 52.99 53 – 63.5
(.472 – 1.732) (1.732 – 2.086) (2.087 – 2.5)
Hole tolerance, mm (inch) 0/+0.25 0/+0.28 0/+0.3
(0/+.0098) (0/+.011) (0/+.0118)
Tolerance DC, mm (inch)
0/+0.2 0/+0.25 0/+0.28
Milling
(0/+.0079) (0/+.0098) (0/+.011)
E Drill depth 4-5 x DC

Drill diameter, mm (inch) 12 – 43.99 44 – 52.99 53 – 63.5
(.472 – 1.732) (1.732 – 2.086) (2.087 – 2.5)
Hole tolerance, mm (inch) 0/+0.4 0/+0.43 0/+0.45
Drilling
(0/+.0157) (0/+.0169) (0/+.0177)

Tolerance DC, mm (inch)
+0.04/+0.24 +0.04/+0.29 +0.04/+0.32
F (+.0016/+.0094) (+.0016/+.0114) (+.0016/+.0126)
How to improve the hole tolerance

One way of eliminating the manufacturing tole
Boring
rance of the drill body and inserts is to preset

the drill.
G Ø25.084 mm (Ø.9876 in) This can be done in a lathe or with an adjustable
Ø25 mm (Ø.9843 in) holder/sleeve, see page E28.
Tool holding
A tolerance width (IT) inside 0.10 mm (.004 inch)

Ø25 mm can then be obtained.
(Ø.9843 inch)
H10 Hole size can be influenced by changing insert
H geometry on one of the inserts.
Other information
Machinability
E 42
Troubleshooting
A
Troubleshooting
Indexable insert drill
Turning
Problem Solution
B
Oversized holes Rotating drill Non-rotating drill
1. Increase coolant flow, clean 1. Check alignment on lathe.
Parting and
filter, clear coolant holes in drill. 2. Rotate drill 180°.
grooving
2. Try a tougher geometry on pe- 3. Try a tougher geometry on pe-
ripheral side (keep center insert). ripheral side (keep center insert).
Undersized holes Rotating drill Non-rotating drill
Threading
1. Increase coolant flow, clean 1. Stationary:
filter, clear coolant holes in drill. Check alignment on lathe.
2. Try a tougher geometry on 2. Stationary:
center side and a light cutting Rotate drill 180°.
geometry on peripheral side. D
3. Try a tougher geometry on
center side (keep peripheral).
Milling
Pin in hole Rotating drill Non-rotating drill
1. Increase coolant flow, clean 1. Check alignment on lathe.
filter, clear coolant holes in drill. 2. Increase coolant flow, clean E
2. Try a different geometry on filter, clear coolant holes in drill.
peripheral side and adjust feed 3. Shorten drill overhang.
rate within recommended cut-
ting data. 4. Try a different geometry on
peripheral side and adjust feed
3. Shorten drill overhang.
Drilling
rate within recommended
4. Use a lower feed rate during the cutting data.
first 3 mm of the hole depth.
F
Vibrations 1. Shorten drill overhang, Improve the workpiece stability.

2. Reduce cutting speed.
3. Try a different geometry on peripheral side and adjust feed
Boring
rate within recommended cutting data.
Insufficient machine 1. Reduce feed.

Tool holding
torque 2. Choose a light cutting geometry to lower the cutting force.
H
Other information
Mc Nm (lbf-ft)
Machinability

E 43
A Troubleshooting

Problem Solution
Turning
Insufficient machine 1. Reduce cutting speed.

B power 2. Reduce cutting feed.
3. Choose a light cutting geometry to lower the cutting force.
Parting and
grooving
Pc kW (HP)
Hole not symmetrical Hole widens at bottom (due to chip jam on center insert)
C 1. Increase coolant flow, clean filter, clear coolant holes in drill.
2. Try a different geometry on peripheral side and adjust feed
rate within recommended cutting data.
3.Shorten drill overhang.
Threading
D Poor tool life 1. Adjust to higher or lower cutting speed depending on type of
wear.
2. Choose a light-cutting geometry to lower the cutting force.
3. Increase feed
Milling
E
Broken insert screws 1. Use torque wrench to fasten the screw together,
apply Anti-seize.
2. Check and change insert screw on a regular basis.
Drilling
Bad surface finish 1. Important to have good chip control.

2. Reduce feed (if it is important to keep vf, increase speed as
well).
Boring
3. Increase coolant flow, clean filter, clear coolant holes in drill.

4. Shorten drill overhang, improve the workpiece stability.
G
Chip jamming in the drill Caused by long chips

Tool holding
flutes 1. Check geometry and cutting data recommendations.

2. Increase coolant flow, clean filter, clear coolant holes in drill.
3. Reduce feed within recommended cutting data.
4. Increase cutting speed within recommended cutting data.
H
Other information
Machinability
E 44
Troubleshooting
A
Tool wear – Indexable insert drill
Turning
Flank wear
B
a) Cutting speed too high. a) Reduce cutting speed.
b) Insufficiently wear resistant b) Choose a more wear resistant
grade. grade.
Parting and
grooving
Crater wear C
Peripheral insert Peripheral insert
• Diffusion wear caused by • Select a more wear resistant
Threading
temperature too high on rake grade.
face. • Reduce speed.
Central insert: Central insert: D

• Abrasive wear caused by built-up • Reduce feed.
edge and smearing.
General:
• Choose a more positive geometry
Milling
i.e. -LM.
E
Plastic deformation (peripheral insert)
a) Cutting temperature (cutting a–b) Select a more wear resistant
speed) too high, combined with grade with better resistance
high pressure (feed, hardness of to plastic deformation.
Drilling
workpiece). a–b) Reduce cutting speed.
b) As a final result of excessive a) Reduce feed.
flank wear and/or crater wear. F
Chipping
Boring
a) Insufficent toughness of grade. a) Select a tougher grade.

b) Insert geometry too weak. b) Select a stronger geometry.
G
c) Built-up edge (BUE). c) Increase cutting speed or select
d) Irregular surface. a more positive geometry.
e) Bad stability. d) Reduce feed at entrance.
Tool holding
f) Sand inclusions (cast iron). e) Improve stability.

f) Choose a stronger geometry.
Reduce feed.
H
Other information
Machinability

E 45
A Troubleshooting

Turning
Built-up edge (BUE)

B a) Low cutting speed (temperature a) Increase cutting speed or change
too low at the cutting edge). to a coated grade.
b) Cutting geometry too negative. b) Select a more positive geometry
Parting and
c) Very sticky material, such as i.e. -LM.

grooving
certain stainless steels and pure c-d) Increase oil mixture and
aluminum. volume/pressure in cutting fluid.
d) Percent of oil mixture in cutting
C fluid too low.
Threading
D
Chip evacuation - general recommendations
Checkpoints and remedies
Milling
1. Make sure the right cutting data and drill

E geometry are used.
2. Inspect chip form (compare with picture
on page E 26).
3. Check if the cutting fluid flow and
Drilling
pressure can be increased.
F 4. Inspect the cutting edges. Chipping on

the edge can cause long chips because
the chip is divided. Also a large Built-up-
edge can cause poor chip forming.
5. Check if the machinability has changed
Boring
due to a new batch of workpiece

G material. Cutting data may need to be
adjusted.
6. Adjust feed and speed. See diagram on
Tool holding
page E 18.
H
Other information
Machinability
E 46
Troubleshooting
A
Peck drilling – solid carbide / exchangeable tip drills
Turning
Peck drilling can be used if no other solution can be found.
There are two different ways to perform a peck drilling cycle:
B
1 2 3 4 5 6 7 8 - Method 1 for best productivity
Parting and
Do not retract the drill more than
grooving
approx. 0.3 mm (.012 inch) from the
hole bottom. Alternatively, make a
periodical stop, while the drill is still
rotating, before continuing to drill. C
Threading
1 2 3 4 5 6 7 8 - Method 2 for best chip evacuation
After each drilling cycle, retract the
drill out from the hole to ensure that
no chips are stuck onto the drill. D
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
E 47
A Troubleshooting
Tool wear – solid carbide / exchangeable tip drills

Turning
Cause Solution
B
Built-up edge
1. Cutting speed too low and edge 1. Increase cutting speed or use
temperature too high external cutting fluid
Parting and
grooving
2. Negative land too large 2. Sharper cutting edge

3. No coating 3. Coating on the edge
4. Percentage of oil in the cutting 4. Increase the percentage of oil in
C fluid too low the cutting fluid
Chipping on the edge corner

Threading
1. Unstable fixturing 1. Check fixture

2. TIR too large 2. Check radial runout
D 3. Intermittent cutting 3. Decrease the feed
4. Insufficient cutting fluid 4. Check cutting fluid supply
(thermal cracking) 5. Check the tool holder
5. Unstable tool holding
Milling
Flank wear on the cutting edges

E 1. Cutting speed too high 1. Decrease the cutting speed
2. Feed too low 2. Increase the feed
3. Grade too soft 3. Change to harder grade
4. Lack of cutting fluid 4. Check for proper cutting fluid
Drilling
supply
F
Chipping on the cutting edge
1. Unstable conditions 1. Check the setup
2. Maximum allowed wear 2. Replace drill sooner
exceeded 3. Change to softer grade
Boring
3. Grade too hard
Wear on the circular lands

Tool holding
1. TIR too large 1. Check the radial runout

2. Cutting fluid too weak 2. Use neat oil or stronger
3.Cutting speed too high emulsion
4. Abrasive material 3. Decrease cutting speed
H 4. Change to harder grade
Other information
Machinability
E 48
Troubleshooting
A
Turning
Cause Solution
Wear on the chisel edge

B
1. Cutting speed too low 1. Increase cutting speed
2. Feed too high 2. Decrease feed
Parting and
grooving
3. Chisel edge too small 3. Check dimensions
C
Wear due to plastic deformation
1. Cutting speed and/or feed too 1. Decrease the cutting speed
high and/or feed
Threading
2. Not enough cutting fluid supply 2. Increase cutting fluid pressure
3. Unsuitable drill/grade 3. Use a harder grade
D
Thermal cracks (notches)

1. Inconsistent cutting fluid 1. Check cutting fluid supply
Milling
2. Fill cutting fluid tank
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
E 49
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,
flame-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 different 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 flexible solution

symmetrical components components machined in where one milling cutter
in a turning lathe. a machining center. can be used for different
diameters.
• Profiling can be carried • Flexible tool solutions
with adjustable diameters. • Saves space in the tool
Boring
out with standard boring

bars. magazine.
• Highly productive in
G • Very flexible tool solutions roughing operations. • Good solution when chip
with interchangeable breaking is a problem.
• High quality hole tolerance
cutting heads.
and surface finish. • High quality demands of
Tool holding
the machine (for finishing).
H
Other information
Machinability
F4
Theory
A
Turning
Definitions of cutting data terms
n = spindle speed (rpm) B
ap = radial depth of cut mm (inch)
Parting and
fn = feed per revolution mm/r
grooving
(inch/r)
DC = boring diameter mm (inch)
C
(inch/min)
DC
fz = feed per tooth mm/rev (inch/rev)
Cutting speed
Threading
zc = effective number of teeth that
The boring tool rotates at a certain number machine the final surface
of revolutions (n) per minute generating a
certain diameter (DC). This gives a specific
D
cutting speed (vc) measured in m/min Metric
(ft/min) at the cutting edge.
π × DC × n (m/min)
vc =
1000
Milling
Inch E
Feed
π × DC × n
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 effective teeth (zc). The
vf = fn × n mm/min (inch/min) F
feed rate is the key value in determining
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 difference
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) fn = feed per revolution mm/r
Parting and
grooving
(inch/r)
DC = boring diameter mm (inch)
C kc = specific cutting force N/mm2
Mc Nm (lbf ft)
(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
Mc = (Nm)
The net power (Pc) is the power the π×n
machine must be able to provide to the
cutting edges in order to drive the cutting
Drilling
action. The mechanical and electrical Inch

efficiency of the machine must be taken
F into consideration when selecting cutting Pc × 16501
Mc = (lbf ft)
data. π×n
Boring
Net power, kW
( )
G Specific cutting force 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 different 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 finish 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
finish boring an adjustable single-edge tool is used for
closer hole tolerances, (fn = fz).
Boring
Reaming
Tool holding
Reaming is a light finishing 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

Milling
3 Choice of tool Type of tool

Drilling
Cutting data,
4 How to apply
Boring
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 finish and tolerance.
Material
P M K • Machinability
Milling
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 stiffness and torque transmission are the

foremost important factors when choosing a tool holder
B for boring operations. Choose the tool according to your
specific 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 finishing.
• 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
• For best stability and hole quality use
grooving
Coromant Capto®, dampened tools and
tapered shanks.
C
Tool considerations
• Consider entering (lead) angle, insert
Threading
geometry and grade.
Chip evacuation and cutting fluid D

• Chip formation and evacuation are im-
portant factors in boring and affect 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 fluid
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 finishing. B
Dampened adapter with two

Tool with one insert and tool
Parting and
inserts Large diameter tool with two
grooving
inserts with two inserts
Threading
Tool with three inserts
D
Milling
E
Fine boring tools
Fine boring operations are performed to finalize hole within tolerance
and surface finish 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
fine 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

mount (lightweight) Ø150-315mm (5.9-12.4")
H
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 fine boring.
D large stock removal.
• 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 finish
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 configured
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 first 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
tions that require strong inserts and

grooving
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)
affects 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

or interrupted cuts, sand inclusions,
F
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 finish
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 fine boring tool
A single-edge fine boring tool is the first choice for fine B

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

Turning
General recommendations
Entering (lead) angle
B
affects 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 beneficial 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 stability and possible radial movements, giving
Milling
less variation and cutting force. Positive basic

E shape inserts with 7° clearance angles are first
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 influences the surface finish, chip
breaking and insert strength. A large nose radius
will deflect 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
stiffness and to reduce the deflection.
• For long overhangs, ensure rigid clamping with flange
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 influenced by: Always ensure a final 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 fixture 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 deflections and insert wear.
C
Threading
D
Boring and reaming tools
Rough boring Single-edge fine Multi-edge reamer

Milling
tool with boring tool for high feed

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

ment possibilities to accurately pre-set the
cutting edge within microns.
Parting and
grooving
C
Threading
Tool deflection
D
• Boring tools for finishing, with one cutting
edge, will experience some degree of
radial deflection during machining due to
the cutting forces.
Milling
• The depth of cut and length of overhang
influence the radial deflection of the E
boring tool.
• The deflection might cause undersized
holes or vibrations.
Drilling
Hole tolerance • A measuring cut is normally needed,
followed by a final 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 fluid supply

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

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

• Internal cutting fluid is recommended
in order to direct the fluid 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 defined commas or spirals.
Cutting depth,
ap mm (inch) Factors that have an influence 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 finishes, 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 fine boring adapters:
Threading
Max start value vc = 240 m/min (787 ft/min).
- Fine boring with fine 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 finish.
Power and torque consumption
Boring
When boring make sure the machine can prove sufficient

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 fine boring
C adjustment mechanism with oil at least once a year.
• Use a suitable assembly mounting fixture 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 fluid generates better tool life than oil.
Tool holding
• Use recommended cutting data.
H
Other information
Machinability
F 26
A
Troubleshooting
Troubleshooting
Turning
Factors that affect 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
• Apply step boring.
are assembled correctly with the correct F
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 (finishing).
• 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

Cause Solution
Turning
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 finish
Bad surface finish. • 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.
ficient 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 influence 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,
flexibility, 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
effective cutting time by 25% in turning
centers.
Threading
Tool holding systems today

Milling
E Machining centers
Turning centers
Drilling
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 first 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 different 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 different 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
ng ac
Drilling
a hi
Solid holders Varilock Coromant Capto®/ 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 flexibility
Machinability
G7
A Why modular tooling
A dramatic development of the machines

Turning
Machining centers
B
Parting and
Turning centers
grooving
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
• Machining is performed with high cutting
grooving
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
- Effective cutting time
Conventional shank Coromant Capto®
Tool holding
tools quick- change system
H
Quick change tooling offers 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
Horizontal machining center

Milling
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 different assemblies for different 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 specific features:
• The good flange contact face in relation
to the ground taper polygon gives maxi-
Parting and
mum stability due to two-face contact

grooving
and interference fit.

• 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 benefits
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
2. The low taper angle makes it possible
grooving
within 2 microns (.00008 inch).
to transmit the full force into the flange
contact. The strength of the polygon The gripper grooves are designed to give
coupling makes it possible to clamp maximum bending stiffness 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.
stiffness.
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
• No play in the coupling

grooving
• Symmetrical loads
C • Two face contact/high clamping force.
Threading
Six different 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
Different methods of clamping
One coupling offers two methods of clamping.
Segment clamping Center bolt clamping

Boring
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 (first 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 firm secure grip around the
entire polygon.
E
The boring bar is very often clamped with

2-3 screws. This causes problems with
Drilling
vibration, bad surface finish, 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 finished shape.
Boring
G The turning center has a choice of configurations

• Horizontal and vertical design
• Sub-spindle for two-sided machining
Tool holding
• Driven tools
• Y-axis for eccentric boring and milling.
H
Other information
Machinability
G 16
Turning centers
A
Configuration of a turning center
Turning
Spindle rotation and definitions of axis
B
• Several multi-axis machine tool programs
can provide turning results from roughing
and grooving to threading and finishing.
Parting and
grooving
C
Threading
D
Milling
Quick change tooling for turning centers
E
A quick-change system offers:
- faster and efficient tool changing
- inserts which can be changed outside
Drilling
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 Different methods how to install quick change

Directly integrated into the turret
Coromant Capto® directly integrated in

Boring
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
Different 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
modifications 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 profitability

• 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
Different 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 specific 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
Configuration of a vertical machining center

B
Parting and
grooving
C
Threading
Configuration 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 fifth-axis moves around the
Tool holding
X-axis. (A-axis) and ones with a B-axis head, the fifth-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
• F
lexible tooling – build your own assem-
blies and reduce the need for special
significantly. 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 + 2 + 30 + 10 = 46 items. 4 x 3 x (30 + 10) = 480 items.
Milling
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
• Get closer tolerances.

Machinability
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

configurations: 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
Definitions of the spindle directions
Turning
The program language for defining the spindle direction
B
M03 = Clockwise spindle
direction
Parting and
grooving
M04 = Counterclockwise
spindle direction C
Threading
D
Milling
E
Configuration 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 fulfill 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 finishing
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
efficiency, 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, offering:
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-
tions for building an optimized tool for the
Parting and
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 off Tool adaptor for boring bar
Tool holding
H
Other information
Machinability
G 34
Chucks
A
Chucks
Benefits of using hydraulic chucks
Turning
B
Hydraulic chuck Hydraulic chuck Hydraulic chuck Shrink fit
Heavy duty design Slender design Pencil design
Parting and
grooving
C
Threading
D
Milling
Open sleeves Sealed sleeves
Direct clamping Direct clamping E
ER collet chuck
Drilling
F
Boring
G
Tool holding
H
Open sleeves Sealed sleeves
Other information
Machinability
G 35
A Chucks
Choice of chucks
Turning
Hydraulic Shrink fit 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
secure clamping.
Parting and
grooving
C
Shrink fit 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
flexibility.
Drilling
• Accessibility not so good because of its
design (often Heavy Duty).
F
Boring
ER collet chuck G
• Very flexible 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 finish.
Parting and
grooving
Hydraulic chucks
Threading
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 deflection.
Overhang • Length reduction as little as 20% can
Parting and
have a significant reduction in deflection
grooving
(-50%).
(-20%)
C
Tool protrusion
Threading
D
(–50%)
Milling
Influence 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-finishing

B • Main criteria = clamping force
• High torque capability
• For best performance use cylindrical
Parting and
grooving
shanks
• Versatility of collets.
C
Application - Finishing
Threading
• Main criteria = runout

D • Influence on tool life and component
- finish and accuracy.
Milling
E
Unbalance in tool holders
Unbalance in tool holders causes:
Drilling
- poor surface finish

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
A
H
C
G
Machinability Tool holding Boring Drilling Milling Threading Parting and Turning
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 definitions H 81
• E-learning H 92
H3
A Workpiece materials
Workpiece materials
Six main groups
Turning
B The ISO standard material groups are divided into six different types. Each type
has unique properties regarding machinability and setups that make different
demands on the tool.
Parting and
grooving
ISO ISO ISO

C P M K
Threading
D ISO
Non-ferrous
ISO Heat Resistant Super ISO
Hardened steel
N S Alloys H
Milling
E
The largest variety of different types of The aircraft industry and manufacturers
P components is probably in the P-area N of aluminum automotive wheels
as it covers several different sectors in dominate the N-area.
the industry.
Drilling
F
In the M-area, a big part of the applica- Difficult to machine S-area materials
M tion is in gas and oil, tubes, flanges, 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 identified in order to - The cutting tool material (grade), e.g. coated
determine a material’s machinability: cemented carbide, ceramic, CBN, PCD, etc.
- Classification, metallurgical/mechanical, of the These selections will have the greatest influ- B
workpiece material. ence on the machinability of the material at
- The cutting edge micro and macro geometry hand.
to be used.
Parting and
grooving
ISO ISO ISO
P M K C
Threading
ISO ISO Heat Resistant Super ISO
D
Non-ferrous Hardened steel
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 flow 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 difference 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
different 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 influence 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 different between material hardness and material, set-up and way of
types where each type has tool life, as well as machining machining, different choice
Boring
unique properties regarding data and type of geometry of tooling is required to

machinability. and grade. The higher the perform different 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
Coolant
Milling
E
Drilling
Clamping conditions
Drilling
Dry machining
F
H Roughing/
R Heavy Carbide performs best when
machining at elevated
M Medium temperatures, but needs to
M be constant. Dry conditions
Boring
Finishing/ should therefore be conside

L
F red first choice, depending on
Light component requirements and G
machining conditions.
There are three major types All components are different However some grades are
of application, all requiring in look, shape and size. Some developed for both wet and
different tools, inserts and will need various set-ups and
Tool holding
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 finishing 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 classified 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 classification that replaces the CMC (Coromant Material
Other information
Classification) 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
Example 1:
Parting and
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 influences 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.
- Specific 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).
through a melting process.
Milling
- 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
on MC codes.
Other information
P4 Sintered steels
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 difficult in
austenitic and duplex. - The carbon content is often low (down to
max 0.01%). D
- Specific 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

on MC codes.
Other information
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.
phase.
Milling
- 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

on MC codes.
Other information
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).
- Composites (Kevlar).
Milling
- 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
N
Tool holding
N3 Copper-based alloys

on MC codes. N4 Zinc-based alloys
Other information
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

- Difficult 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
- Specific 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
- Cutting forces and power required are the range of 55–68 HRC.
Milling
quite high.
E
Drilling
F
Boring
ISO MC Material
H1 Steels (45-65 HRC) G

Tool holding
H2 Chilled cast iron
H
H3 Stellites

on MC codes.
Other information
H4 Ferro-TiC
Machinability
H 15
The specific 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 is the force needed to

grooving
(870,000)
shear off a specific chip
cross-section in certain
C conditions
5000
(725,000)
Fc • This value (Fc) is used

Threading
in the calculation of the

4000
(580,000) power consumption
H needed for an operation
D
3000
(435,000) • The specific 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 specific 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 finishing turning; high cutting
Wear resistance speed; small chip area; good surface finish; 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 difficult conditions.
P30: Turning; milling facing; medium to low cutting speed;
Threading
medium to large chip area; includes operations with
20 tough conditions.
P40: T
urning; 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
large chip area, large possible chip angle, extremely
40 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
application.
Threading
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 first 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 effect on end-user productivity

2006
A new insert
generation
Milling
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
Other commonly used elements are Titanium, Tantalum

grooving
and Niobium Carbides. Designing different types of

powder and different percentages of the elements is
C what makes up the different 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
Ready to press
Boring
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
- This process melts the cobalt and the
grooving
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
Different types of grinding operations

Turning
B Top and bottom Free profiling Profiling

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

F
The ER-treatment gives the cutting edge the final 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
the solid metal ionizes.

grooving
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 depending on application area for the
• PVD provides good edge line toughness.
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 different
insert surfaces. PVD works the same way gases. Temperature, time, gas flow, 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 find
work at high temperatures without plastic two different 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
insert is well supported. edge.

grooving
C
ap =13 mm ap =8.1 mm
ap = 13 mm ap = 8.1 mm
ap(.512
=13 inch)
ap =13
mm mm Material: Steel (.319 ainch)
p =8.1
a =8.1 mmmm
Threading
p
CMC 02.1 180 HB
fn =0.62 fn =1.0
fn = 0.62 fn = 1.0 mm
mm fn =0.62
(.024
fn =0.62 in) fn =1.0
(.039fnin)
=1.0
D
Milling
Fc = 1700 kp Fc = 1700 kp
Ft(3750
=1700lbf)
Ft kp
=1700
Ft =1700 kp kp FF
t =1700 (3750
kp kp
t =1700
Ft =1700 kp 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

Specific 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.
Definitions 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 final
micro-geometry
B
• ER treatment (Edge Roundness) is done
Parting and
before coating, and gives the final 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
positive cutting action.

grooving
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 different 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 flutes 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 different applications
There are major differences 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 different 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.
K
Milling
• 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.
• Coolant is present, mainly for chip trans-
Boring
portation reasons, which puts the edge

under extra stress from temperature G
variations.
• To transport the chips from the narrow
Tool holding
chip flutes 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
Different 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 different micro- and macro-geometries
Milling
are adapted to the various requirements in
the applications and materials.
E
Workpiece material Finishing Medium Roughing
0.32 mm
Drilling
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
B R • Operations for maximum stock removal and/
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
light roughing.
Tool holding
H
Other information
Machinability
H 38
The cutting edge
A
Type of application - Milling
Turning
ap Depth of cut,
mm (inch) Heavy Milling
H • Operations at maximum stock removal and/
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

Boring
geometry
• Light machining • Heavy machining
• Medium feed rates G
light roughing.
Tool holding
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
to be machined, the component type and shape, machining conditions

grooving
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
Different 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
4. Cermets
D

GC
Milling
5. Coated carbide
E

HSS
6. High speed steel
Toughness
Drilling
F
The ideal cutting tool material should:
- be hard, to resist flank wear and deformation
- be tough, to resist bulk breakage
Boring
- not chemically interact with the workpiece material

- be chemically stable to resist oxidation and diffusion 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

containing primarily tungsten
- (CM) Mixed ceramics containing
primarily aluminum oxide (Al2O3)
¹) P
olycrystalline diamond and
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 benefits
• Used in moderate to difficult 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 finishing and semi-finishing applications D
where close tolerance and good surface finish 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
different 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 finish 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
film 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
Coated carbide
Tool holding
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-
mined by the mixture of ingredients
Threading
which make up the substrate.
D
Milling
E
Coating of cemented carbide
• Coating of cemented carbide was
developed in the 1960s.
Drilling
• A thin Titanium Nitride coating layer was

F added, only a few microns thick. This
improved the performance of carbide
overnight.
• Coatings offer improved wear resistance
Boring
giving longer tool life and possibility to

use higher cutting data.
G
•Today modern grades are coated with
different 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.
tungsten carbide (WC) with a possible
grooving
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 influence the behavior of
the insert:
B
- Coating process
- Coating material
Parting and
- Coating thickness
grooving
- 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

Harder substrates mean more deformation resistance.
Other information
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 different 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 flank 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 fine-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
Different 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 flank 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 flank 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 suffered an inward deformation (edge impression) or a
downward deformation (edge depression).
Cause Remedy
Boring
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
Edge depression and temperature. (tool).
Tool holding
H
Other information
Machinability
Edge impression 
H 54
A
Turning
B
Flaking
Flaking usually occurs when machining in materials with smearing properties.
Parting and
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 flaking on the tool.
ment of the coating, exposing
sublayers or substrate.
Threading
D
Cracks (thermal)
Cracks are narrow openings in which new boundary surfaces have been formed
Milling
through rupture. Some cracks are confined 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 fluctuations 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 difference between chipping
and fracture is that with chipping the insert can still be used.
G
Cause Remedy
There are many combinations Different 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 defined 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)

Built up edge (BUE) is an accumulation of material against the rake face.
Boring
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 off 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
• On parting and grooving tools an

Boring
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 sufficient 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
Important!
Milling
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
flow.
IC
- Select largest possible point angle on
E
the insert for strength and economy.
- Select largest possible nose radius for
L insert strength.
RE
Drilling
- 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, affecting 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.
Milling
 Make sure insert seat is clean.
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 definition
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 efficiency, 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
effect on tool life. The depth of cut has the smallest effect followed by the feed rate.
Cutting speed has the largest effect by far on insert tool life. B
Parting and
Depth of cut, mm (inch)
grooving
C
Threading
Feed, mm/rev (inch/rev)
Cutting speed, m/min (ft/min)
Milling
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 fixed 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 fixed depth of cut of 3.0 mm (.118 inch) using:
B
P Low alloy steel,
MC P2
Insert: CNMG 432-PM 4225 (CNMG 120408-PM 4225)
3.0 3.0 3.0
ap, mm (inch)
(.118) (.118) (.118)
Parting and
Hardness, HB 180
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
cm3/min
Q, 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
P Low alloy steel,
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
Insert: double sided for medium machining.
Boring
No of passes / 3/5 mm
G cutting depth, ap (.118/.197 inch)

50 mm
Tool holding
(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
and tool
Parting and
Production time (planned) Tool change Set-up and gauge
change time
grooving
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 influences
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
only reduces total cost per
Milling
component by 1%.
E
• Increased tool life:

Drilling
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
Machine cost is $10.00
grooving
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 effect on fixed 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 Efficiency Range, which is where
If we add all costs together we will get we should be trying to operate.
the curve of total Production cost.
Threading
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
Production rate
Drilling
Production cost
F
Tool cost
Boring
G
Tool holding
Fixed cost
Machine cost
H
Cutting
Economic High Efficiency Speed for maximum speed
Other information
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.
the recommended cutting speed.
Boring
• Multiple the factor for desired minutes

• 225 m/min x 1.11 = 250 m/min
by the recommended cutting speed. G
(738 ft/min x 1.11 = 819 ft/min).
Tool holding
H
Other information
Machinability
H 71
A Machining economy
Compensation of cutting speed for differences 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
• Metal material hardness is measured
Parting and
factor of 1.0).
grooving
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 classification code
2) HB = Hardness Brinell
3) HRC = Hardness Rockwell
Tool holding
H
Other information
Machinability
H 72
Machining economy
A
Example of Conversion table for hardness scale
Turning
Material specifications maybe given in different forms,
example: HB, HRC, Tensile Strength or Specific Cutting
forces. B
Parting and
Tensile strength Vickers Brinell Rockwell Customer workpiece
grooving
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 –
995 144,275 310 295 31.0 –
Boring
G
Tool holding
H
Other information
Machinability
H 73
A Machining economy
Example of conversion table, finding 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 Specific cutting forces N/mm2 (lbs/in2)

Hardness Brinell (HB)
Customer workpiece material

4140 Steel
Boring
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 differences 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
• Calculating hardness factor, Customer material =280 HB – Material
grooving
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 classification 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
of tool life (in cut time), as well as maintaining chip formation and
Parting 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)
1 Recommended starting values

Increased
➤ 0.15(.006)
D 0.01(.004)
➤
0.05(.002)
+
-0.05(-.002)
➤
Decreased
-0.10(-.004)
Milling
-0.15(-.006) 2
E -0.20(-.008) ➤
-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 finish 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 finish.
H
Other information
Machinability
H 76
Machining economy
A
How can you improve productivity?
Turning
Things to consider
• Identify material hardness HB, B
Specific cutting forces or Tensile
strength N/mm2 (lbs/inch2).
Parting and
• Choose the correct geometry.
grooving
• 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, Specific
cutting forces or Tensile strength N/mm2 E
(lbs/inch2).
Insert wear • Use given cutting data values,
compensate for material hardness
factor.
Drilling
• Create a stable environment for
component and tools. F
• Choose the right combination of nose
radius and geometry.
In cut time • Use climb milling over conventional,
Boring
when ever possible.

• Make use of all available insert corners G
• Consider chamfering operations with
worn inserts.
Tool holding
H
Good stability = Successful metal cutting
Other information
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 defines attributes of the tool,

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

features)
DCX APMX
(cutting diameter (depth of cut maximum) H
maximum)
Other information
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 definitions,

communicating tool information between software systems becomes
B very straight forward. In the picture you see that three different 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 definitions
A
Turning
B
Formulas &
definitions
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 definitions
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 effective 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.
D ap (Cutting depth) cutting width perpendicular
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 influenced
(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 different radial widths of cut and
created by a cutting reference point revolving
E different 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 influenced
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 different radial widths of cut and
Dm (Machined diameter) machined diameter of different 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 and is measured in newton (N) and pound-force
kc (Specific cutting force) cutting force/area for
a given chip thickness in tangential direction.
(lbf).
(Specific cutting force coefficient 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 effective cutting edges on the tool.
kc1 (Specific cutting force coefficient) 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/
specific cutting force coefficient. Traditionally
revolution.
Other information
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
C
lm (Machined length) length of cutting engage- γ0 (effective rake angle) The specific force
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 specific cutting force) rise in specific Zc (effective cutting edge count) number of
force as a function of reduced chip thickness. cutting edges that are effective 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 specific cutting Zn (mounted insert count) number of cutting D
force coefficient (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) defined as the volume
of material removed divided by the machining
time. Another way to define 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
the cutting edge relative to the workpiece.
Tool holding
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 definitions for turning - METRIC

Turning
Cutting speed, m/min

B
vc = π × Dm × n
1000
Parting and
grooving
Spindle speed, rpm

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

D lm
Tc =
fn × n
Designation/
definition
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
Pc Net power kW
Drilling
Specific cutting forces Q Metal removal rate cm3/min

1 mc
( ( ( (
hm Average chip thickness mm
γ0 hex Maximum chip thickness mm
F kc = kc1× × 1 - 100
hm Tc Period of engagement min
lm Machined length mm
kc Specific cutting force N/mm2
KAPR Entering angle degree
Average chip thickness
γ0 Effective rake angle degree
Boring
G hm = fn × sin KAPR
Tool holding
Net power, kW
Pc =
H 60 × 103
Other information
Machinability
H 84
A
Formulas and definitions for turning - INCH
Turning
Cutting speed, ft/min
B
π × Dm × n
vc =
12
Parting and
grooving
Spindle speed, rpm
C
vc × 12
n=
π × Dm
Threading
Machining time, min
lm D
Tc =
fn × n
Designation/
definition
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
Pc Net power HP
Drilling
Specific cutting forces Q Metal removal rate inch3/min
mc
( ( ( (
hm Average chip thickness inch
0.0394 γ0 hex Maximum chip thickness inch
kc = kc1× hm × 1- F
100 Tc Period of engagement min
lm Machined length mm
kc Specific cutting force lbs/inch2
PSIR Lead angle degree
Average chip thickness
γ0 Effective rake angle degree
Boring
hm = fn × sin KAPR G
Tool holding
Net power, HP
Pc =
33 × 103 H
Other information
Machinability
H 85
Formulas and definitions for milling - METRIC

Turning
Table feed, mm/min

B
vf = fz × n × zc
Parting and
grooving
Cutting speed, m/min
C π × Dcap × n
vc =
1000
Threading
Spindle speed, r/min
Designation/
vc × 1000
n=
D π × Dcap definition
Symbol
Unit
Feed per tooth, mm
ae Working engagement mm
vf
Milling
ap Cutting depth mm
fz = Dcap Cutting diameter at cutting
n × zc mm
depth ap
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 effective teeth pcs
hex Maximum chip thickness mm
F hm Average chip thickness mm
Metal removal rate, cm3/min kc Specific cutting force N/mm2
Pc Net power kW
ap × ae × vf Mc Torque Nm
Q= Q Metal removal rate cm3/min
1000 KAPR Entering angle degree
Boring
G Net power, kW Specific cutting forces
( ) ( )
mc
ae × ap × vf × kc 1 γo
Pc = kc = kc1 × × 1 –
Tool holding
60 × 106 hm 100
Torque, Nm
H Pc × 30 × 103
Mc =
Other information
π×n
Machinability
H 86
A
Formulas and definitions for milling - INCH
Turning
Table feed, inch/min
B
vf = fz × n × zc
Parting and
grooving
Cutting speed, ft/min
π × Dcap × n C
vc =
12
Threading
Spindle speed, rpm
vc × 12 Designation/
n= definition
π × Dcap D
Symbol
Unit
Feed per tooth, inch
ae Working engagement inch
vf
Milling
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 effective teeth pcs
hex Maximum chip thickness inch
hm Average chip thickness inch F
Metal removal rate, inch3/min kc Specific 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 Specific cutting forces G
( ) ( )
mc
ae × ap × vf × kc 0.039 γo
Pc = kc = kc1 × × 1 –
Tool holding
396 × 103 hm 100
Torque, lbf ft
Pc × 16501 H
Mc =
Other information
π×n
Machinability
H 87
Formulas and definitions for drilling - METRIC

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

π × DC × n
vc =
1000
Threading
Designation/
D Spindle speed, r/min definition
Symbol
vc × 1000
Unit
n=
π × DC
DC Drill diameter mm
Milling
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 Specific cutting force N/mm2
Mc Torque Nm
Pc Net power kW
Drilling
Q Metal removal rate cm3/min

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
Pc × 30 × 103
Mc =
Other information
π×n
Machinability
H 88
A
Formulas and definitions for drilling - INCH
Turning
Penetration rate, inch/min B
vf = fn × n
Parting and
grooving
Cutting speed, ft/min C
π × DC × n
vc =
12
Threading
Spindle speed, rpm Designation/
D
definition
vc × 12
Symbol
n=
π × DC
Unit
DC Drill diameter inch
Milling
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
Note: DC needs to be converted into
Mc Torque lbf ft
millimeters Pc Net power HP
Drilling
Q Metal removal rate inch3/min
F
Metal removal rate, inch3/min
Q = vc × DC × fn × 3
Boring
Net power, HP G
vc × DC × fn × kc
Pc =
132 × 103
Tool holding
Torque, lbf ft
H
Pc × 16501
Mc =
Other information
π×n
Machinability
H 89
Formulas and definitions for boring - METRIC

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

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

D definition
vc × 1000
Symbol
n=
Unit
π × DC
DC Drill diameter mm
Milling
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 Specific cutting force N/mm2
Mc Torque Nm
Net power kW
Drilling
Pc
Q Metal removal rate cm3/min
Metal removal rate, cm3/min KAPR Entering angle degree
F zc Number of effective teeth pcs
vc × DC × fn (zc = 1 for step boring)
Q=
4
Boring
Net power, kW
( (
G
vc × ap × fn × kc ap
Pc = 1–
60 × 103 DC
Tool holding
Torque, Nm Feed force, N

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

Pc × 16501 H
Mc = Ff ≈ 0.5 × kc × ap × fn × sin KAPR
Other information
π×n
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
Register at metalcuttingknowledge.com and start your free training.

grooving
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 office:
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

Training Handbook: Metal Cutting Technology

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Training Handbook: Metal Cutting Technology

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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 off) 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

Calculation of the circumference (C)

Example of cutting speed calculation

E The cutting speed differs depending on the workpiece diameter.

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

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

Lead angle PSIR: Lead angle PSIR: Lead angle PSIR:

Entering angle KAPR: Lead angle PSIR:

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

Entering angle KAPR 95° 75° 60° 45° 90° min C

Contact length la, D

Calculating power consumption

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

• Modular/shank • iLock™ interface systems • Modular/shank

Internal turning, negative/positive inserts

Positive inserts Negative inserts

• Choice of inserts – how to apply A 22

• Choice of tools – how to apply

1. Component and the workpiece material

• Use all possible support

• For turning and facing

F • Increased ability to hold

• The depth of cut should be no less then

G • Negative insert • Negative insert • Negative/positive • Negative inserts

• Modular/shank • Modular/shank systems • Precision coolant

• Positive insert • Positive insert • Negative/positive • Positive insert G

• Modular/shank • iLock™ interface systems • Modular/shank

G • Negative/positive insert • Positive insert • Dampened boring bars

• Dampened modular/ • Modular/boring bars.

• Positive insert • Quick change tools • Positive insert

• Positive insert • Positive insert • Positive insert

• Very secure clamping

• Insert shape, size, nose radius A 41

• Cutting data effect on tool life A 47

Steel • ISO P – Steel is the largest material

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

Aluminum • ISO N – Non-ferrous metals are softer

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

• P materials have a kc1 variation of:

H • K materials have a kc1 variation of:

• H materials have a kc1 variation of:

• Zero clearance between the front

• Low cutting forces

• In milling and drilling a lot of parameters influence the

ap mm (inch) • Cutting depth (ap) and feed (fn) must be

• Medium operations to light roughing

• Dedicated geometries and

Negative, double/single-sided inserts • A negative insert has a