1.11.21 - geers industrie
TRANSCRIPT
1.1 1.2 1.3
Carbon SteelApplication Material Group
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© DORMER 2006All rights reserved under the “Dormer” registered trademark. Although every effort has been made to ensure the accuracy of the information contained herein, no responsibility for loss or damage occasioned to any person acting from action as a result of any material in this publication can be accepted by the editors, publishers or product manufacturers.
2
BS
SSU
SAU
NS
JIS
1.1
230M
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60G
1212
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1.2
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40,
4360
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1312
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30
G10
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217
210
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HB
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DIN
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<400
1.10
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100
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<700
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<850
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60
Gen
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Info
rmat
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Exa
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3
Contents
Classification of workpiece materials 2Application Material Groups 4Introduction to Carbon Steels 5Machinability of Carbon Steels 6 Hints when machining Carbon Steels 6AMG 1.1 7AMG 1.2 8AMG 1.3 9General Hints on Drilling 10Drill Feed Chart 11Drill Selection 12General Hints on Tapping 14Drill diameters for cutting taps 15Tap Selection 16General Hints on Milling 18Milling parameters 19Applications 20Milling Feed Charts 20Milling Cutters Selection 24Table of cutting speeds 26
Gen
eral
Info
rmat
ion
4
Application Material Groups
Application Material Groups (“AMGs”) are designed to assist in the selection of the optimum cutting tool for a particular application.
Dormer classifies materials into 10 major Application Material Groups. Each major group is divided into sub-groups on the basis of material properties, such as hardness and strength, and chip formation. This booklet concentrates on sub-groups 1.1 – 1.3 – Carbon Steels.
Examples of national designations within each sub-group are shown on page 2.
This booklet contains a selection of tools that are rated “excellent” for machining Carbon Steels. Please see the Dormer catalogue or Product Selector for the full range, or contact your local Dormer representative or Technical Helpdesk if you need further advice.
Gen
eral
Info
rmat
ion
5
Introduction to Carbon Steels
Carbon steels or unalloyed steels are materials made up of iron and carbon. The percentage of carbon has a dramatic effect on the properties of the material and therefore on the uses for which it is suitable.
Carbon steels may be classified into 3 major groups:-
AMG Type of steel % of carbon
Properties
1.1 Magnetic soft steel (mild steel)
Low0.03 – 0.25%
Ductile and easily cold worked
1.2 Structural steel/case carburising steel
Medium0.15- 0.40%
Wear resistant
1.3 Plain carbon steel High0.4 - 1.2%
Wear resistant and tough
Gen
eral
Info
rmat
ion
6
Machinability of Carbon Steels
In general terms, as the carbon level increases, the hardness and tensile strength of the material also increase. The low carbon grades often have very small additions of sulphur or lead to give free machining properties. Without the addition of these elements, steels with carbon levels below 0.3% tend to smear the cutting edges (built-up edge), resulting in short tool life. Manganese is also added (up to approximately 1%) to some grades to improve mechanical properties, but this will reduce machinability, particularly on steels with carbon levels over 0.3%. For information specific to each sub-group, see pages 7 - 9.
Hints when machining Carbon Steels
• These sub-groups of steel materials are extensive, which makes it important to find out the properties of the material to be machined. Use the Dormer Product Selector to find the correct AMG classification, which in turn will help you to find the correct tool for the application.
• In general, a non-alloyed or low-alloyed material is soft and sticky. Use sharp tools with positive geometries.
• Tool steels can be hardened to various degrees. It is important to be aware of both material grade and hardness in order to select the correct tool configuration for the application.
• For Carbon Steels, about 0.2 – 0.25% Carbon provides the best machinability. Above and below this level, machinability is generally lower.
Gen
eral
Info
rmat
ion
7
1.1 Magnetic Soft SteelHardness <120 HBTensile strength <400 N/mm2
Typical Composition
This group of steels is characterised by low carbon levels. They are magnetic at ambient temperatures and are very ductile. Typical carbon levels are below 0.25%.
Special grades are produced with additions of sulphur or lead to promote free machining properties. Due to their very low carbon content, these steels do not respond to heat treatment.
Examples of uses
They are used in the manufacture of drinks cans and car bodies, and as low duty constructional steels.
Gen
eral
Info
rmat
ion
8
1.2Structural Steel / Case Carburising Steel Hardness <200 HBTensile strength <700 N/mm2
Typical Composition
This group of steels is similar to 1.1, except that the physical properties are higher, and manganese and carbon levels are generally higher. Medium carbon steels (eg. 0.5%) have a good balance of ductility and strength.
Within this group of steels are low carbon carburising steels, which respond to surface hardening when heated in carbon-rich gas.
Examples of uses
Typical applications are rails and rail products, couplings, crankshafts, axles, bolts, rods, gears, forgings, tubes, plates and constructional steels.
Gen
eral
Info
rmat
ion
9
1.3 Plain Carbon SteelHardness <250 HB Tensile strength <850 N/mm2
Typical Composition
This group of steels covers steels which can be heat-treated. Generally, they have higher hardness and tensile strength, compared to AMG groups 1.1 and 1.2, but significantly less ductility.
These higher carbon steels (over 0.4% carbon) have high resistance to wear but low ductility. On these materials, machinability in the annealed (softened) state reduces as carbon content increases.
Examples of uses
Typical applications are cutting tools, railway lines, razors and wood-working tools.
Gen
eral
Info
rmat
ion
10
General Hints on Drilling
1. Select the most appropriate drill for the application, bearing in mind the material to be machined, the capability of the machine tool and the coolant to be used.
2. Flexibility within the component and machine tool spindle can cause damage to the drill as well as the component and machine - ensure maximum stability at all times. This can be improved by selecting the shortest possible drill for the application.
3. Tool holding is an important aspect of the drilling operation and the drill cannot be allowed to slip or move in the tool holder.
4. The use of suitable coolants and lubricants are recommended as required by the particular drilling operation. When using coolants and lubricants, ensure a copious supply, especially at the drill point.
5. Swarf evacuation whilst drilling is essential in ensuring the correct drilling procedure. Never allow the swarf to become stationary in the flute.
6. When regrinding a drill, always makes sure that the correct point geometry is produced and that any wear has been removed.
Ø [m
m]
12
34
56
810
1215
1620
2530
4050
F0.
018
0.05
00.
073
0.08
40.
095
0.10
90.
138
0.16
50.
178
0.20
20.
210
0.24
80.
275
0.29
50.
320.
343
G0.
019
0.05
60.
084
0.09
60.
109
0.12
60.
160
0.19
00.
205
0.23
10.
240
0.28
00.
310
0.33
00.
355
0.37
5H
0.02
00.
066
0.10
20.
116
0.13
00.
150
0.19
00.
228
0.24
30.
271
0.28
00.
320
0.35
50.
375
0.39
80.
418
I0.
021
0.07
60.
119
0.13
40.
150
0.17
30.
220
0.26
50.
280
0.31
00.
320
0.36
00.
400
0.42
00.
440.
46J
0.02
40.
084
0.13
50.
152
0.17
00.
197
0.25
00.
298
0.31
50.
349
0.36
00.
405
0.44
50.
465
0.48
50.
503
K0.
026
0.09
20.
150
0.17
00.
190
0.22
00.
280
0.33
00.
350
0.38
80.
400
0.45
00.
490
0.51
00.
530.
545
L0.
028
0.10
10.
165
0.18
60.
208
0.24
00.
305
0.36
00.
385
0.41
90.
430
0.48
50.
525
0.54
50.
568
0.58
8M
0.03
00.
110
0.18
00.
202
0.22
50.
260
0.33
00.
390
0.42
00.
450
0.46
00.
520
0.56
00.
580
0.60
50.
63U
0.02
60.
048
0.07
00.
080
0.09
00.
107
0.14
00.
170
0.20
00.
223
0.23
00.
240
V0.
038
0.06
90.
100
0.11
50.
130
0.15
30.
200
0.25
00.
280
0.31
00.
320
0.34
0W
0.04
90.
089
0.13
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150
0.17
00.
200
0.26
00.
330
0.38
00.
418
0.43
00.
450
X0.
056
0.10
30.
150
0.18
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210
0.25
00.
330
0.42
00.
480
0.53
30.
550
0.58
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0.06
80.
124
0.18
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220
0.26
00.
317
0.43
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550
0.70
00.
700
0.70
00.
740
Z0.
094
0.17
20.
250
0.32
50.
400
0.53
30.
800
1.00
01.
100
1.17
51.
200
1.20
0
11
mm
/rev
± 25
%
A022 A520 R022 R520
0.50 - 16.00
3.0 - 13.0
3.0 - 17/32
3.0 - 16.5
■35K ■57M ■75V ■100X■32K ■47M ■65V ■90X■25I ■40K ■65V ■90X
1.11.21.3
12■ ●
ExcellentGood
1.11.21.3
13
A002 A510 A553 A554 R002 R510 R553 R570
1.0 - 16.0 3.0 - 14.0 5.0 - 20.0 5.0 - 30.0 3.0 - 14.0 3.0 - 14.25 5.0 - 20.0 3.00
- 5/8
■47J ■57M ■85L ■85L ■75U ■100W ■150V ■ 135V■40J ■47M ■70L ■70L ■65U ■90W ■135V ■ 120V■35F ■40K ■60L ■60L ■65U ■90W ■135U ■ 110U
14
General Hints on Tapping
1. Select the correct design of tap for the component material and type of hole, i.e. through or blind, from the Application Material Groups chart.
2. Ensure the component is securely clamped - lateral movement may cause tap breakage or poor quality threads.
3. Select the correct size of drill (see opposite). Always ensure that work hardening of the component material is kept to a minimum.
4. Select the correct cutting speed as shown in the tap selection pages, the catalogue or the Product Selector.
5. Use appropriate cutting fluid for correct application.
6. In NC applications ensure that the feed value chosen for the program is correct. When using a tapping attachment, 95% to 97% of the pitch is recommended to allow the tap to generate its own pitch.
7. Where possible, hold the tap in a good quality torque limiting tapping attachment, which ensures free axial movement of the tap and presents it squarely to the hole. It also protects the tap from breakage if accidentally ‘bottomed’ in a blind hole.
8. Ensure smooth entry of the tap into the hole, as an uneven feed may cause ‘bell mouthing’.
M mm mm mm1.6 0.35 1.321 1.25 3/641.8 0.35 1.521 1.45 542 0.4 1.679 1.6 1/162.2 0.45 1.833 1.75 502.5 0.45 2.138 2.05 463 0.5 2.599 2.5 403.5 0.6 3.010 2.9 334 0.7 3.422 3.3 304.5 0.75 3.878 3.8 275 0.8 4.334 4.2 196 1 5.153 5 97 1 6.153 6 15/648 1.25 6.912 6.8 H9 1.25 7.912 7.8 5/1610 1.5 8.676 8.5 Q11 1.5 9.676 9.5 3/812 1.75 10.441 10.3 Y14 2 12.210 12 15/3216 2 14.210 14 35/6418 2.5 15.744 15.5 39/6420 2.5 17.744 17.5 11/1622 2.5 19.744 19.5 49/6424 3 21.252 21 53/6427 3 24.252 24 61/6430 3.5 26.771 26.5 1.3/64
15
D = Dnom- P
M mm mm
4 0.70 3.405 0.80 4.306 1.00 5.108 1.25 6.9010 1.50 8.7012 1.75 10.4014 2.00 12.2516 2.00 14.25
Drill diameter can be calculated from:
METRIC COARSE THREAD
RECOMMENDED DIAMETERS WHEN USING DORMER ADX AND CDX DRILLS
The above table for drill diameters refer to ordinary standard drills. Modern drills such as Dormer ADX and CDX produce a smaller and more accurate hole which makes it necessary to increase the diameter of the drill in order to avoid breakage of the tap.Please see the small table to the left.
D = Drill diameter (mm)
Dnom = Tap nominal diameter (mm)
P = Tap pitch (mm)
METRIC COARSE THREAD FOR ADX/CDX
Max. DRILL DRILLInternal
Pitch Diam. Diam. Diam.inch
TAP DRILLPitch Diameter
Drill Diameters for Cutting Taps - Recommendation tables
E348 E349 E206 E257 E375 E376 E350 E351 E213
M3 - M10
M12 - M30
M3 - M10
M4 - M30
M6 - M10
M12 - M20
M3 - M10
M12 - M30
M3 - M10
■25 ■25 ■40 ■40 ■40 ■40 ■25 ■25 ■40■22 ■22 ■40 ■40 ■40 ■40 ■22 ■22 ■40■18 ■18 ■32 ■32 ■32 ■32 ■18 ■18 ■32
1.11.21.3
DIN
16■ ●
ExcellentGood
Other thread forms available. Please see Dormer catalogue.
E264 E460 E461 E402 E001 E003 E049 E050 E051
M12 - M30
M6 - M10
M12 - M20
M3 - M30
M3 - M24
M3 - M24
M3 - M20
M3 - M20
M6 - M20
■40 ■40 ■40 ■30 ■25 ■25 ■40 ■25 ■40■40 ■40 ■40 ■30 ■22 ■22 ■40 ■22 ■40■32 ■32 ■32 ■25 ■18 ■18 ■32 ■18 ■32
ISO
1.11.21.3
17
Other thread forms available. Please see Dormer catalogue.
18
General Hints on Milling
1. Where possible, use climb milling (down milling) for longer tool life. Climb milling allows easier chip disposal, less wear, improved surface finish and lower power requirements compared to conventional milling (up milling).
2. Always use a cutter in good condition.
3. Use well-maintained machine tools with sufficient power.
4. Use correct clamping system according to working operation and type of tool.
5. Check for damage or wear on the tool shank or in the holder itself.
6. Use the shortest cutters recommended for your application and work as close to the machine head as possible.
7. For optimum productivity, use coated or Solid Carbide cutters.
19
Milling parameters
1. Identify the type of end milling to be carried out - type of end mill - type of centre
2. Consider the condition and the age of the machine tool.
3. Select the best end mill dimensions in order to minimize the deflection and bending stress
- the highest rigidity - the largest mill diameter - avoid excessive overhand of the tool from the tool
holder.
4. Choose the number of flutes - more flutes - decreased space for chips - increased rigidity - allows faster table feed - less flutes - increased space for chips - decreased rigidity - easy chip ejection.
5. Determining the correct cutting speed and feed rate can only be done when the following factors are known:
- type of material to be machined - end mill material - power available at the spindle - type of finish.
20
For details on how to use the feed charts in the tables which follow, please see below.
Slotting Roughing
Ball nose Finishing
Application
Ø m
mm
m/z
± 2
5%1
23
45
68
1012
1416
1820
2225
2830
3236
40↕
0,5D
↔ D
A0,
004
0,00
80,
013
0,01
70,
024
0,02
90,
043
0,06
00,
072
0,08
40,
096
0,09
70,
096
0,09
90,
105
0,10
90,
108
0,10
60,
108
0,10
8
B0,
004
0,00
70,
012
0,01
50,
022
0,02
60,
039
0,05
40,
065
0,07
60,
086
0,08
70,
086
0,08
90,
095
0,09
80,
097
0,09
50,
097
0,09
7
↕ D
↔ 0
,8D
G0,
026
0,03
40,
036
0,04
30,
050
0,05
70,
064
0,07
10,
071
0,05
40,
053
0,05
40,
053
0,05
60,
057
H0,
023
0,03
10,
032
0,03
90,
045
0,05
10,
058
0,06
40,
064
0,04
90,
048
0,04
90,
048
0,05
00,
051
↕ 1,
5D↔
0,2
5DM
0,00
80,
012
0,01
80,
023
0,03
10,
041
0,05
70,
069
0,08
00,
091
0,10
30,
114
0,09
00,
103
0,08
50,
091
0,09
70,
110
0,10
7
N0,
007
0,01
10,
016
0,02
10,
028
0,03
70,
051
0,06
20,
072
0,08
20,
093
0,10
30,
081
0,09
30,
077
0,08
20,
087
0,09
90,
096
↕ 1,
5D↔
0,1
DS
0,01
00,
015
0,02
30,
029
0,03
90,
051
0,07
10,
086
0,10
00,
114
0,12
90,
143
0,11
30,
129
0,10
70,
114
0,12
20,
137
0,13
3
T0,
009
0,01
40,
021
0,02
60,
035
0,04
60,
064
0,07
70,
090
0,10
30,
116
0,12
90,
102
0,11
60,
096
0,10
30,
110
0,12
30,
120
21
Z
Ø m
m
m
m/z
±
25%
>0,5
0.6
0.8
12
34
56
810
1214
1618
20
>4
↕ 1,
5↔
0,0
5
A0.
015
0.02
00.
025
0.03
00.
035
0.04
00.
050
0.06
0
B0.
045
0.05
00.
060
0.07
50.
080
0.09
00.
100
0.11
0
C0.
065
0.07
50.
090
0.11
00.
120
0.13
00.
150
0.17
0
3-4
↕ 1,
5↔
0,1
A0.
010
0.02
00.
030
0.04
00.
045
0.05
00.
060
0.07
50.
080
0.09
00.
100
0.12
0
B0.
015
0.03
00.
040
0.05
50.
065
0.07
50.
090
0.11
00.
120
0.13
00.
150
0.17
0
C0.
015
0.03
00.
040
0.05
50.
085
0.10
00.
120
0.14
00.
150
0.17
00.
200
0.22
0
3-4
↕ 1
↔ 0
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A0.
001
0.00
30.
005
0.00
80.
010
0.01
30.
020
0.02
70.
035
0.04
00.
050
0.05
50.
060
B0.
002
0.00
40.
008
0.01
20.
015
0.02
00.
030
0.04
00.
050
0.06
00.
070
0.08
00.
090
C0.
003
0.00
50.
010
0.01
50.
020
0.02
50.
040
0.05
00.
065
0.08
00.
090
0.10
50.
120
2-3
↕ 0,
5↔
1
A0.
001
0.00
10.
002
0.00
20.
005
0.00
90.
013
0.01
70.
020
0.02
30.
035
0.04
00.
050
0.05
50.
060
0.07
0
B0.
001
0.00
20.
003
0.00
30.
007
0.01
30.
020
0.02
50.
030
0.03
50.
050
0.06
00.
070
0.08
00.
090
0.10
0
C0.
002
0.00
30.
004
0.00
40.
009
0.01
70.
025
0.03
30.
040
0.04
50.
065
0.08
00.
090
0.10
50.
120
0.13
0
3-4
↕ 0,
5↔
1
↕ 1
↔ 0
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B0.
035
0.04
00.
055
0.06
50.
080
0.09
00.
100
0.11
0
S15
0, S
302,
S30
8, S
250
22
Z
Ø m
m
m
m/z
±
25%
23
45
68
1012
1416
20
3-4
↕ 1,
5↔
0,1
A0.
012
0.01
90.
028
0.03
60.
048
0.04
80.
070
0.08
00.
090
0.10
70.
134
B0.
015
0.02
20.
034
0.04
20.
057
0.05
70.
079
0.09
40.
110
0.12
60.
155
C0.
016
0.02
50.
038
0.04
70.
063
0.06
30.
088
0.10
60.
123
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26
Gen
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Info
rmat
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Tabl
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Cut
ting
Spe
eds,
<10
mm PE
RIP
HE
RA
L C
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SP
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D
RE
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ON
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58
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7080
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0
1626
3250
6682
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519
723
026
229
633
036
249
5
mm
11,1
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322
928
743
057
371
686
011
4614
3317
1920
0622
9225
7928
6531
5242
9812
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212
265
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531
663
796
1061
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1592
1857
2122
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2918
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568
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111
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2824
5033
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170
212
318
424
531
637
849
1061
1273
1485
1698
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2122
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150
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0314
0316
0418
0420
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298
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318
398
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557
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716
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875
1194
50,0
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5164
9512
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919
125
531
838
244
650
957
363
770
095
5
27
Gen
eral
Info
rmat
ion
Tabl
e of
Cut
ting
Spe
eds,
>10
mm PE
RIP
HE
RA
L C
UTT
ING
SP
EE
D
RE
VO
LUTI
ON
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