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Laboratory for Manufacturing Systems and Automation
COMPUTER NUMERICAL CONTROL COMPUTER NUMERICAL CONTROL
OF MACHINE TOOLSOF MACHINE TOOLS
COMPUTER NUMERICAL CONTROL COMPUTER NUMERICAL CONTROL
OF MACHINE TOOLSOF MACHINE TOOLS
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
Laboratory for Manufacturing Systems and Automation
Department of Mechanical Engineering and Aeronautics
University of Patras, Greece
Chapter 3: Chapter 3:
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
Process Planning and Tool SelectionProcess Planning and Tool Selection
Objectives of Chapter 3Objectives of Chapter 3
�� ListList thethe stepssteps involvedinvolved inin processprocess planningplanning
�� ListList thethe factorsfactors thatthat influenceinfluence thethe selectionselection ofof anan NCNC
machine,machine, workholdingworkholding devices,devices, andand toolingtooling
�� DescribeDescribe thethe typestypes ofof toolstools availableavailable forfor holehole operationsoperations
�� DescribeDescribe thethe typestypes ofof toolstools availableavailable forfor millingmilling operationsoperations
�� DetermineDetermine thethe properproper gradegrade ofof carbidecarbide insertinsert forfor aa givengiven
�� ListList thethe stepssteps involvedinvolved inin processprocess planningplanning
�� ListList thethe factorsfactors thatthat influenceinfluence thethe selectionselection ofof anan NCNC
machine,machine, workholdingworkholding devices,devices, andand toolingtooling
�� DescribeDescribe thethe typestypes ofof toolstools availableavailable forfor holehole operationsoperations
�� DescribeDescribe thethe typestypes ofof toolstools availableavailable forfor millingmilling operationsoperations
�� DetermineDetermine thethe properproper gradegrade ofof carbidecarbide insertinsert forfor aa givengiven
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
�� DetermineDetermine thethe properproper gradegrade ofof carbidecarbide insertinsert forfor aa givengiven
materialmaterial
�� DescribeDescribe somesome commoncommon NCNC turningturning tooltool typestypes
�� DetermineDetermine thethe properproper spindlespindle RPMRPM toto obtainobtain aa givengiven cuttingcutting
speedspeed
�� ExplainExplain thethe importanceimportance ofof properproper feedratesfeedrates
�� DetermineDetermine thethe properproper gradegrade ofof carbidecarbide insertinsert forfor aa givengiven
materialmaterial
�� DescribeDescribe somesome commoncommon NCNC turningturning tooltool typestypes
�� DetermineDetermine thethe properproper spindlespindle RPMRPM toto obtainobtain aa givengiven cuttingcutting
speedspeed
�� ExplainExplain thethe importanceimportance ofof properproper feedratesfeedrates
Process PlanningProcess Planning
DEFINITIONDEFINITION:: ProcessProcess PlanningPlanning isis thethe termterm usedused toto describedescribe
thethe developmentdevelopment ofof anan NCNC partpart programprogram
Decisions which must be made by the NC programmer to Decisions which must be made by the NC programmer to
successfully program a part:successfully program a part:
DEFINITIONDEFINITION:: ProcessProcess PlanningPlanning isis thethe termterm usedused toto describedescribe
thethe developmentdevelopment ofof anan NCNC partpart programprogram
Decisions which must be made by the NC programmer to Decisions which must be made by the NC programmer to
successfully program a part:successfully program a part:
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
�� MachineMachine SelectionSelection:: WhichWhich NCNC machinemachine shouldshould bebe used?used?
�� FixturingFixturing:: HowHow willwill thethe partpart bebe heldheld inin thethe machine?machine?
�� StrategyStrategy:: WhatWhat machiningmachining operationsoperations && strategystrategy willwill bebe used?used?
�� ToolTool SelectionSelection:: WhatWhat cuttingcutting toolstools willwill bebe used?used?
�� MachineMachine SelectionSelection:: WhichWhich NCNC machinemachine shouldshould bebe used?used?
�� FixturingFixturing:: HowHow willwill thethe partpart bebe heldheld inin thethe machine?machine?
�� StrategyStrategy:: WhatWhat machiningmachining operationsoperations && strategystrategy willwill bebe used?used?
�� ToolTool SelectionSelection:: WhatWhat cuttingcutting toolstools willwill bebe used?used?
Process PlanningProcess Planning
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
The collaboration between CAM, CAPP and CAD systems (Ming et al. 2008)
Process PlanningProcess Planning
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
Role of CAM in a typical product lifecycle (Zeid 1991)
Process PlanningProcess Planning
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
Manufacturing information flow in the state-of-the-art CAD/CAM/CNC chain (Newman et al. 2008)
Process PlanningProcess Planning
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
CAD/CAM links and flow of a computer-aided system (Rehg and Kraebber 2005)
Evolution of turning machinesEvolution of turning machines
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
‘‘‘‘04040404’’’’03030303’’’’02020202’’’’01010101’’’’00000000’’’’99999999’’’’98989898’’’’97979797’’’’96969696’’’’95959595’’’’94949494’’’’93939393’’’’92929292’’’’91919191’’’’90909090 ‘‘‘‘04040404’’’’03030303’’’’02020202’’’’01010101’’’’00000000’’’’99999999’’’’98989898’’’’97979797’’’’96969696’’’’95959595’’’’94949494’’’’93939393’’’’92929292’’’’91919191’’’’90909090
Round partsRound partsRound partsRound parts
Square partsSquare partsSquare partsSquare partsSquare partsSquare partsSquare partsSquare parts
Complex Complex Complex Complex shape partsshape partsshape partsshape partsComplex Complex Complex Complex
shape partsshape partsshape partsshape parts
year
Evolution of turning machinesEvolution of turning machines
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
Process PlanningProcess Planning
MachineMachine SelectionSelection:: ThisThis decisiondecision isis basedbased onon aa numbernumber ofof factorsfactors::
�� WhatWhat isis thethe programmer’sprogrammer’s experienceexperience??
�� WhatWhat machinesmachines areare available?available?
�� HowHow manymany partsparts areare inin thethe order?order?
�� AreAre therethere enoughenough partsparts toto justifyjustify thethe setupsetup timetime andand higherhigher perper hourhour runrun
MachineMachine SelectionSelection:: ThisThis decisiondecision isis basedbased onon aa numbernumber ofof factorsfactors::
�� WhatWhat isis thethe programmer’sprogrammer’s experienceexperience??
�� WhatWhat machinesmachines areare available?available?
�� HowHow manymany partsparts areare inin thethe order?order?
�� AreAre therethere enoughenough partsparts toto justifyjustify thethe setupsetup timetime andand higherhigher perper hourhour runrun
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
�� AreAre therethere enoughenough partsparts toto justifyjustify thethe setupsetup timetime andand higherhigher perper hourhour runrun
costcost onon aa moremore complexcomplex machine?machine?
�� IsIs thethe particularparticular partpart bestbest suitedsuited forfor aa lathelathe oror aa millingmilling machinemachine
application?application?
�� IsIs thethe verticalvertical oror horizontalhorizontal spindlespindle preferred?preferred?
NoteNote:: VerticalVertical spindlesspindles areare advantageousadvantageous forfor holehole drillingdrilling andand boringboring
operationsoperations.. TheThe horizontalhorizontal orientationorientation ofof thethe spindlespindle causescauses thethe chipschips toto fallfall
awayaway fromfrom thethe tool,tool, whereaswhereas verticalvertical spindlesspindles tendtend toto keepkeep thethe chipschips packedpacked
aroundaround thethe tooltool
�� AreAre therethere enoughenough partsparts toto justifyjustify thethe setupsetup timetime andand higherhigher perper hourhour runrun
costcost onon aa moremore complexcomplex machine?machine?
�� IsIs thethe particularparticular partpart bestbest suitedsuited forfor aa lathelathe oror aa millingmilling machinemachine
application?application?
�� IsIs thethe verticalvertical oror horizontalhorizontal spindlespindle preferred?preferred?
NoteNote:: VerticalVertical spindlesspindles areare advantageousadvantageous forfor holehole drillingdrilling andand boringboring
operationsoperations.. TheThe horizontalhorizontal orientationorientation ofof thethe spindlespindle causescauses thethe chipschips toto fallfall
awayaway fromfrom thethe tool,tool, whereaswhereas verticalvertical spindlesspindles tendtend toto keepkeep thethe chipschips packedpacked
aroundaround thethe tooltool
Three possible types of machine structureThree possible types of machine structure
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
Horizontal typeHorizontal type Double column type Double column type Vertical typeVertical type
Sample configuration of recent multiSample configuration of recent multi--functional machine toolfunctional machine tool
・4 spindles 9 axes
・2-axis Lathe +
5-axis Machining center
Headstock 2
Headstock 1
X
Z
C BC
Tool spindle (Upper turret)
・4 spindles 9 axes
・2-axis Lathe +
5-axis Machining center
Headstock 2
Headstock 1
X
Z
C BC
Tool spindle (Upper turret)
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
Headstock 2
Lower turret
X
Z
C BC
A
Y
Headstock 2
Lower turret
X
Z
C BC
A
Y
An example of combined multiAn example of combined multi--axis machine tool (Source: Mori Seiki)axis machine tool (Source: Mori Seiki)
No.1 HeadstockNo.1 HeadstockNo.1 HeadstockNo.1 Headstock
No.1 Tool postNo.1 Tool postNo.1 Tool postNo.1 Tool post
No.2 HeadstockNo.2 HeadstockNo.2 HeadstockNo.2 Headstock
XY
Z
BC
XZ
C
No.1 HeadstockNo.1 HeadstockNo.1 HeadstockNo.1 Headstock
No.1 Tool postNo.1 Tool postNo.1 Tool postNo.1 Tool post
No.2 HeadstockNo.2 HeadstockNo.2 HeadstockNo.2 Headstock
No.1 HeadstockNo.1 HeadstockNo.1 HeadstockNo.1 Headstock
No.1 Tool postNo.1 Tool postNo.1 Tool postNo.1 Tool post
No.2 HeadstockNo.2 HeadstockNo.2 HeadstockNo.2 Headstock
XY
Z
BC
XZ
C
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
No.2 Tool postNo.2 Tool postNo.2 Tool postNo.2 Tool post
No.2 HeadstockNo.2 HeadstockNo.2 HeadstockNo.2 Headstock
No.2 Tool postNo.2 Tool postNo.2 Tool postNo.2 Tool post
No.2 HeadstockNo.2 HeadstockNo.2 HeadstockNo.2 Headstock
No.2 Tool postNo.2 Tool postNo.2 Tool postNo.2 Tool post
No.2 HeadstockNo.2 HeadstockNo.2 HeadstockNo.2 Headstock
(a) 5(a) 5--axis controlaxis control
The optimum angle is indexed The optimum angle is indexed
and fixed with two rotating axes and fixed with two rotating axes
according to the shape to be according to the shape to be
Comparison between 5Comparison between 5--axis control and 3+2 axis controlaxis control and 3+2 axis control
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
(a) 5(a) 5--axis controlaxis control
(b) 3+2 axis control(b) 3+2 axis control
according to the shape to be according to the shape to be
machined. machined.
Normal orthogonal 3Normal orthogonal 3--axis axis
machining is performed at that machining is performed at that
location.location.
FixturingFixturing:: DecisionDecision onon howhow thethe workpieceworkpiece shouldshould bebe heldheld
�� WillWill standardstandard holdingholding devicesdevices (clamps,(clamps, millmill vises,vises, chucks,chucks, andand soso on)on)
suffice,suffice, oror willwill specialspecial fixturingfixturing needneed toto bebe developed?developed?
�� WhatWhat quantityquantity ofof partsparts willwill bebe run?run?
NoteNote:: AA largelarge numbernumber ofof partsparts meanmean thatthat specialspecial fixturingfixturing toto shortenshorten thethe
FixturingFixturing:: DecisionDecision onon howhow thethe workpieceworkpiece shouldshould bebe heldheld
�� WillWill standardstandard holdingholding devicesdevices (clamps,(clamps, millmill vises,vises, chucks,chucks, andand soso on)on)
suffice,suffice, oror willwill specialspecial fixturingfixturing needneed toto bebe developed?developed?
�� WhatWhat quantityquantity ofof partsparts willwill bebe run?run?
NoteNote:: AA largelarge numbernumber ofof partsparts meanmean thatthat specialspecial fixturingfixturing toto shortenshorten thethe
Process PlanningProcess Planning
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
machiningmachining cyclecycle maymay bebe feasible,feasible, eveneven ifif conventionalconventional workholdingworkholding methodsmethods
wouldwould otherwiseotherwise bebe usedused
�� HowHow elaborateelaborate doesdoes thethe fixturingfixturing needneed toto be?be?
NoteNote:: IfIf manymany partpart runsruns areare foreseen,foreseen, aa moremore durabledurable fixturefixture mustmust bebe
designeddesigned.. IfIf onlyonly oneone oror twotwo partpart runsruns areare projected,projected, aa simplersimpler fixturefixture cancan bebe
usedused..
�� WhatWhat willwill makemake thethe bestbest qualityquality part?part?
machiningmachining cyclecycle maymay bebe feasible,feasible, eveneven ifif conventionalconventional workholdingworkholding methodsmethods
wouldwould otherwiseotherwise bebe usedused
�� HowHow elaborateelaborate doesdoes thethe fixturingfixturing needneed toto be?be?
NoteNote:: IfIf manymany partpart runsruns areare foreseen,foreseen, aa moremore durabledurable fixturefixture mustmust bebe
designeddesigned.. IfIf onlyonly oneone oror twotwo partpart runsruns areare projected,projected, aa simplersimpler fixturefixture cancan bebe
usedused..
�� WhatWhat willwill makemake thethe bestbest qualityquality part?part?
Process PlanningProcess Planning
MachiningMachining StrategyStrategy::
Must be developed before the NC program can be written and Must be developed before the NC program can be written and machining machining
sequencessequences used in a part program are determined by the following used in a part program are determined by the following
decisionsdecisions
MachiningMachining StrategyStrategy::
Must be developed before the NC program can be written and Must be developed before the NC program can be written and machining machining
sequencessequences used in a part program are determined by the following used in a part program are determined by the following
decisionsdecisions
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
�� WhatWhat isis thethe programmer’sprogrammer’s experienceexperience??
�� WhatWhat isis thethe shapeshape ofof thethe partpart
�� WhatWhat isis thethe blueprintblueprint tolerancetolerance??
�� WhatWhat toolingtooling isis available?available?
�� HowHow manymany partsparts areare inin thethe order?order?
�� WhatWhat isis thethe programmer’sprogrammer’s experienceexperience??
�� WhatWhat isis thethe shapeshape ofof thethe partpart
�� WhatWhat isis thethe blueprintblueprint tolerancetolerance??
�� WhatWhat toolingtooling isis available?available?
�� HowHow manymany partsparts areare inin thethe order?order?
Process PlanningProcess Planning
ToolTool SelectionSelection::
TheThe finalfinal importantimportant stepstep inin processprocess planningplanning basedbased onon thethe followingfollowing decisionsdecisions
ToolTool SelectionSelection::
TheThe finalfinal importantimportant stepstep inin processprocess planningplanning basedbased onon thethe followingfollowing decisionsdecisions
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
�� WhatWhat toolstools areare availableavailable??
�� WhatWhat machiningmachining strategystrategy isis toto bebe used?used?
�� HowHow manymany partsparts areare inin thethe order?order?
NoteNote:: IfIf aa largelarge numbernumber ofof partsparts areare inin thethe order,order, specialspecial timesavingtimesaving
toolstools cancan bebe mademade oror purchasedpurchased
�� WhatWhat areare thethe blueprintblueprint tolerancestolerances??
�� WhatWhat machinemachine isis beingbeing used?used?
�� WhatWhat toolstools areare availableavailable??
�� WhatWhat machiningmachining strategystrategy isis toto bebe used?used?
�� HowHow manymany partsparts areare inin thethe order?order?
NoteNote:: IfIf aa largelarge numbernumber ofof partsparts areare inin thethe order,order, specialspecial timesavingtimesaving
toolstools cancan bebe mademade oror purchasedpurchased
�� WhatWhat areare thethe blueprintblueprint tolerancestolerances??
�� WhatWhat machinemachine isis beingbeing used?used?
Process PlanningProcess Planning
NCNC SetupSetup SheetSheet::
�� TheThe programmerprogrammer mustmust
communicatecommunicate toto thethe
setupsetup personnelpersonnel inin thethe
shopshop whatwhat toolstools andand
fixturesfixtures areare toto bebe usedused
inin thethe NCNC programprogram
NCNC SetupSetup SheetSheet::
�� TheThe programmerprogrammer mustmust
communicatecommunicate toto thethe
setupsetup personnelpersonnel inin thethe
shopshop whatwhat toolstools andand
fixturesfixtures areare toto bebe usedused
inin thethe NCNC programprogram
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGURE 3FIGURE 3--1: NC Setup Sheet for a CNC machining center1: NC Setup Sheet for a CNC machining centerFIGURE 3FIGURE 3--1: NC Setup Sheet for a CNC machining center1: NC Setup Sheet for a CNC machining center
�� TheThe informationinformation isis
placedplaced onon SetupSetup
SheetsSheets
�� TheThe SetupSetup SheetSheet
shouldshould containcontain allall
necessarynecessary informationinformation
toto prepareprepare forfor thethe jobjob
�� TheThe informationinformation isis
placedplaced onon SetupSetup
SheetsSheets
�� TheThe SetupSetup SheetSheet
shouldshould containcontain allall
necessarynecessary informationinformation
toto prepareprepare forfor thethe jobjob
Process PlanningProcess Planning
NCNC SetupSetup SheetSheet::
�� SpecialSpecial instructionsinstructions toto
thethe setupsetup personnelpersonnel oror
machinemachine operatorsoperators
shouldshould bebe includedincluded
NCNC SetupSetup SheetSheet::
�� SpecialSpecial instructionsinstructions toto
thethe setupsetup personnelpersonnel oror
machinemachine operatorsoperators
shouldshould bebe includedincluded
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGURE 3FIGURE 3--2 NC Setup Sheet for a CNC lathe2 NC Setup Sheet for a CNC latheFIGURE 3FIGURE 3--2 NC Setup Sheet for a CNC lathe2 NC Setup Sheet for a CNC lathe
shouldshould bebe includedincluded
�� SpecialSpecial notesnotes regardingregarding
toolingtooling shouldshould alsoalso bebe
includedincluded
shouldshould bebe includedincluded
�� SpecialSpecial notesnotes regardingregarding
toolingtooling shouldshould alsoalso bebe
includedincluded
Process PlanningProcess Planning
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
Tooling for Numerical ControlTooling for Numerical Control
CuttingCutting ToolTool MaterialsMaterials
Cutting Tools are available in three basic types: Cutting Tools are available in three basic types:
CuttingCutting ToolTool MaterialsMaterials
Cutting Tools are available in three basic types: Cutting Tools are available in three basic types:
Cutting Tool Cutting Tool MaterialsMaterials
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
MaterialsMaterials
High Speed High Speed SteelSteel
TUNGSTEN TUNGSTEN CarbideCarbide
CeramicCeramic
Tooling for Numerical ControlTooling for Numerical Control
HighHigh SpeedSpeed SteelSteel (HSS)(HSS)
HSSHSS toolstools havehave thethe followingfollowing advantagesadvantages overover CarbideCarbide::
�� HSS HSS costs lesscosts less than Carbide or Ceramic toolingthan Carbide or Ceramic tooling
�� HSS is HSS is less brittleless brittle and not as likely to break during interrupted cutsand not as likely to break during interrupted cuts
�� The tools can be The tools can be resharpenedresharpened easilyeasily
HighHigh SpeedSpeed SteelSteel (HSS)(HSS)
HSSHSS toolstools havehave thethe followingfollowing advantagesadvantages overover CarbideCarbide::
�� HSS HSS costs lesscosts less than Carbide or Ceramic toolingthan Carbide or Ceramic tooling
�� HSS is HSS is less brittleless brittle and not as likely to break during interrupted cutsand not as likely to break during interrupted cuts
�� The tools can be The tools can be resharpenedresharpened easilyeasily
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
HSS tools have the following HSS tools have the following disadvantagesdisadvantages::
�� HSS does not hold up as well as Carbide or Ceramic at the high HSS does not hold up as well as Carbide or Ceramic at the high
temperatures generated during machiningtemperatures generated during machining
�� HSS does not cut hard materials wellHSS does not cut hard materials well
HSS tools have the following HSS tools have the following disadvantagesdisadvantages::
�� HSS does not hold up as well as Carbide or Ceramic at the high HSS does not hold up as well as Carbide or Ceramic at the high
temperatures generated during machiningtemperatures generated during machining
�� HSS does not cut hard materials wellHSS does not cut hard materials well
Tooling for Numerical ControlTooling for Numerical Control
TungstenTungsten CarbideCarbide (Carbide)(Carbide)
Carbide Tools come in one of three basic typesCarbide Tools come in one of three basic types
TungstenTungsten CarbideCarbide (Carbide)(Carbide)
Carbide Tools come in one of three basic typesCarbide Tools come in one of three basic types
Carbide ToolsCarbide Tools
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
Carbide ToolsCarbide Tools
Solid CarbideSolid CarbideToolsTools
Brazed Brazed CarbideCarbideToolsTools
Inserted Inserted CarbideCarbide
ToolingTooling
Tooling for Numerical ControlTooling for Numerical Control
TungstenTungsten CarbideCarbide
�� SolidSolid CarbideCarbide ToolsTools areare mademade fromfrom aa solidsolid piecepiece ofof carbidecarbide
�� BrazedBrazed CarbideCarbide ToolsTools useuse aa carbidecarbide cuttingcutting tiptip brazedbrazed inin aa steelsteel shankshank
�� InsertedInserted CarbideCarbide ToolingTooling utilizesutilizes indexableindexable insertsinserts mademade ofof carbidecarbide whichwhich
areare heldheld inin steelsteel tooltool holdersholders
TUNGSTENTUNGSTEN CarbideCarbide havehave thethe followingfollowing advantagesadvantages overover HSSHSS::
TungstenTungsten CarbideCarbide
�� SolidSolid CarbideCarbide ToolsTools areare mademade fromfrom aa solidsolid piecepiece ofof carbidecarbide
�� BrazedBrazed CarbideCarbide ToolsTools useuse aa carbidecarbide cuttingcutting tiptip brazedbrazed inin aa steelsteel shankshank
�� InsertedInserted CarbideCarbide ToolingTooling utilizesutilizes indexableindexable insertsinserts mademade ofof carbidecarbide whichwhich
areare heldheld inin steelsteel tooltool holdersholders
TUNGSTENTUNGSTEN CarbideCarbide havehave thethe followingfollowing advantagesadvantages overover HSSHSS::
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
TUNGSTENTUNGSTEN CarbideCarbide havehave thethe followingfollowing advantagesadvantages overover HSSHSS::
�� Carbide Carbide holds up wellholds up well at elevated temperaturesat elevated temperatures
�� Carbide can Carbide can cut hard materialscut hard materials wellwell
�� Solid carbide tools Solid carbide tools absorb workpiece vibrationabsorb workpiece vibration and reduce the amount of and reduce the amount of
‘’chatter’’ generated during machining‘’chatter’’ generated during machining
�� When inserted cutters are used, the When inserted cutters are used, the inserts can be easily changedinserts can be easily changed or or
indexed, rather than replacing the whole toolindexed, rather than replacing the whole tool
TUNGSTENTUNGSTEN CarbideCarbide havehave thethe followingfollowing advantagesadvantages overover HSSHSS::
�� Carbide Carbide holds up wellholds up well at elevated temperaturesat elevated temperatures
�� Carbide can Carbide can cut hard materialscut hard materials wellwell
�� Solid carbide tools Solid carbide tools absorb workpiece vibrationabsorb workpiece vibration and reduce the amount of and reduce the amount of
‘’chatter’’ generated during machining‘’chatter’’ generated during machining
�� When inserted cutters are used, the When inserted cutters are used, the inserts can be easily changedinserts can be easily changed or or
indexed, rather than replacing the whole toolindexed, rather than replacing the whole tool
Tooling for Numerical ControlTooling for Numerical Control
TungstenTungsten CarbideCarbide
TUNGSTENTUNGSTEN CarbideCarbide havehave thethe followingfollowing disadvantagesdisadvantages overover HSSHSS::
�� Carbide Carbide costs morecosts more than High Speed Steel Toolsthan High Speed Steel Tools
�� Carbide is Carbide is more brittlemore brittle than HSS and has a tendency to chip during than HSS and has a tendency to chip during
interrupted cutsinterrupted cuts
TungstenTungsten CarbideCarbide
TUNGSTENTUNGSTEN CarbideCarbide havehave thethe followingfollowing disadvantagesdisadvantages overover HSSHSS::
�� Carbide Carbide costs morecosts more than High Speed Steel Toolsthan High Speed Steel Tools
�� Carbide is Carbide is more brittlemore brittle than HSS and has a tendency to chip during than HSS and has a tendency to chip during
interrupted cutsinterrupted cuts
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
interrupted cutsinterrupted cuts
�� Carbide is Carbide is harder to resharpenharder to resharpen and requires diamond grinding wheelsand requires diamond grinding wheels
interrupted cutsinterrupted cuts
�� Carbide is Carbide is harder to resharpenharder to resharpen and requires diamond grinding wheelsand requires diamond grinding wheels
Tooling for Numerical ControlTooling for Numerical Control
CeramicCeramic ToolingTooling�� HasHas mademade greatgreat advancesadvances inin thethe pastpast severalseveral yearsyears
�� OnceOnce veryvery expensiveexpensive –– SomeSome CeramicCeramic insertsinserts costcost nownow lessless thanthan aa
CarbideCarbide
CeramicCeramic hashas thethe followingfollowing advantagesadvantages::
�� Ceramic is sometimes Ceramic is sometimes less expensive than carbideless expensive than carbide when used in insert when used in insert
toolingtooling
CeramicCeramic ToolingTooling�� HasHas mademade greatgreat advancesadvances inin thethe pastpast severalseveral yearsyears
�� OnceOnce veryvery expensiveexpensive –– SomeSome CeramicCeramic insertsinserts costcost nownow lessless thanthan aa
CarbideCarbide
CeramicCeramic hashas thethe followingfollowing advantagesadvantages::
�� Ceramic is sometimes Ceramic is sometimes less expensive than carbideless expensive than carbide when used in insert when used in insert
toolingtooling
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
toolingtooling
�� Ceramic will cut Ceramic will cut harder materials at a faster rateharder materials at a faster rate
�� Ceramic has Ceramic has superior heat hardnesssuperior heat hardness
Ceramic has the following Ceramic has the following disadvantagesdisadvantages::
�� Ceramic is Ceramic is more brittlemore brittle than HSS or carbidethan HSS or carbide
�� Ceramic must run within its given surface speed parametersCeramic must run within its given surface speed parameters
NoteNote:: If run too slowly, the insert will break down quickly. Many If run too slowly, the insert will break down quickly. Many
machines do not have the spindle RPM range needed to use ceramicsmachines do not have the spindle RPM range needed to use ceramics
toolingtooling
�� Ceramic will cut Ceramic will cut harder materials at a faster rateharder materials at a faster rate
�� Ceramic has Ceramic has superior heat hardnesssuperior heat hardness
Ceramic has the following Ceramic has the following disadvantagesdisadvantages::
�� Ceramic is Ceramic is more brittlemore brittle than HSS or carbidethan HSS or carbide
�� Ceramic must run within its given surface speed parametersCeramic must run within its given surface speed parameters
NoteNote:: If run too slowly, the insert will break down quickly. Many If run too slowly, the insert will break down quickly. Many
machines do not have the spindle RPM range needed to use ceramicsmachines do not have the spindle RPM range needed to use ceramics
Tooling for Numerical ControlTooling for Numerical Control
FieldsFields ofof ApplicationApplication�� HighHigh SpeedSpeed SteelSteel isis usedused onon::
��AluminumAluminum alloysalloys
��OtherOther nonnon ferrousferrous alloysalloys
�� CarbideCarbide isis usedused onon::
��HighHigh siliconsilicon aluminumsaluminums
��SteelsSteels
��StainlessStainless steelssteels
FieldsFields ofof ApplicationApplication�� HighHigh SpeedSpeed SteelSteel isis usedused onon::
��AluminumAluminum alloysalloys
��OtherOther nonnon ferrousferrous alloysalloys
�� CarbideCarbide isis usedused onon::
��HighHigh siliconsilicon aluminumsaluminums
��SteelsSteels
��StainlessStainless steelssteels
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
��StainlessStainless steelssteels
��ExoticExotic metalsmetals
�� Ceramic insertsCeramic inserts are used on:are used on:
��Hard steelsHard steels
��Exotic metalsExotic metals
Note 1Note 1:: Inserted Carbide Tooling is becoming the preferred for any CNC applicationInserted Carbide Tooling is becoming the preferred for any CNC application
Note 2Note 2:: Some Carbide inserts are coated with special substances (e.g. titanium Some Carbide inserts are coated with special substances (e.g. titanium
nitride) increasing tool life up to 20 time nitride) increasing tool life up to 20 time –– using recommended cutting speeds and using recommended cutting speeds and
feedratesfeedrates
��StainlessStainless steelssteels
��ExoticExotic metalsmetals
�� Ceramic insertsCeramic inserts are used on:are used on:
��Hard steelsHard steels
��Exotic metalsExotic metals
Note 1Note 1:: Inserted Carbide Tooling is becoming the preferred for any CNC applicationInserted Carbide Tooling is becoming the preferred for any CNC application
Note 2Note 2:: Some Carbide inserts are coated with special substances (e.g. titanium Some Carbide inserts are coated with special substances (e.g. titanium
nitride) increasing tool life up to 20 time nitride) increasing tool life up to 20 time –– using recommended cutting speeds and using recommended cutting speeds and
feedratesfeedrates
Tooling for Hole OperationsTooling for Hole Operations
ToolingTooling forfor HoleHole OperationsOperations
There are four basic hole operations that are performed on NC There are four basic hole operations that are performed on NC
machinerymachinery
ToolingTooling forfor HoleHole OperationsOperations
There are four basic hole operations that are performed on NC There are four basic hole operations that are performed on NC
machinerymachinery
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
Tooling for Tooling for Hole Hole
OperationsOperations
DrillingDrilling ReamingReaming BoringBoring TappingTapping
Tooling for Hole OperationsTooling for Hole Operations
DrillingDrilling�� DrillsDrills areare availableavailable inin differentdifferent stylesstyles forfor differentdifferent materialsmaterials (Fig(Fig.. 33--33 showsshows
aa standardstandard twisttwist drill)drill)
�� TwistTwist drillsdrills remainremain oneone ofof thethe mostmost commoncommon toolstools forfor makingmaking holesholes
�� DrillsDrills havehave aa tendencytendency toto walkwalk asas drill,drill, resultingresulting inin aa holehole thatthat itit isis notnot trulytruly
straightstraight
�� CenterCenter drillsdrills (Fig(Fig.. 33--44)) areare oftenoften usedused toto predrillpredrill aa pilotpilot holehole toto helphelp twisttwist drilldrill
toto startstart straightstraight
DrillingDrilling�� DrillsDrills areare availableavailable inin differentdifferent stylesstyles forfor differentdifferent materialsmaterials (Fig(Fig.. 33--33 showsshows
aa standardstandard twisttwist drill)drill)
�� TwistTwist drillsdrills remainremain oneone ofof thethe mostmost commoncommon toolstools forfor makingmaking holesholes
�� DrillsDrills havehave aa tendencytendency toto walkwalk asas drill,drill, resultingresulting inin aa holehole thatthat itit isis notnot trulytruly
straightstraight
�� CenterCenter drillsdrills (Fig(Fig.. 33--44)) areare oftenoften usedused toto predrillpredrill aa pilotpilot holehole toto helphelp twisttwist drilldrill
toto startstart straightstraight
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGURE 3FIGURE 3--3 Tapered shank twist drill 3 Tapered shank twist drill FIGURE 3FIGURE 3--3 Tapered shank twist drill 3 Tapered shank twist drill
toto startstart straightstraight
�� DrillsDrills alsoalso produceproduce triangulartriangular-- shapedshaped holesholes
toto startstart straightstraight
�� DrillsDrills alsoalso produceproduce triangulartriangular-- shapedshaped holesholes
FIGURE 3FIGURE 3--4 Center drill 4 Center drill FIGURE 3FIGURE 3--4 Center drill 4 Center drill
Tooling for Hole OperationsTooling for Hole Operations
DrillingDrilling�� IfIf thethe holehole tolerancetolerance isis closercloser thanthan 00..003003 inchinch aa secondarysecondary holehole operationoperation
shouldshould toto usedused toto sizesize thethe holehole suchsuch asas BoringBoring oror ReamingReaming
�� LargeLarge holesholes areare sometimesometime producedproduced byby spadespade drillsdrills (Fig(Fig.. 33--55))
�� TheThe flatflat bladesblades inin spadespade drillsdrills allowallow goodgood chipchip flowflow andand economicaleconomical
replacementreplacement ofof thethe drilldrill tiptip
DrillingDrilling�� IfIf thethe holehole tolerancetolerance isis closercloser thanthan 00..003003 inchinch aa secondarysecondary holehole operationoperation
shouldshould toto usedused toto sizesize thethe holehole suchsuch asas BoringBoring oror ReamingReaming
�� LargeLarge holesholes areare sometimesometime producedproduced byby spadespade drillsdrills (Fig(Fig.. 33--55))
�� TheThe flatflat bladesblades inin spadespade drillsdrills allowallow goodgood chipchip flowflow andand economicaleconomical
replacementreplacement ofof thethe drilldrill tiptip
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGURE 3FIGURE 3--5 Spade drill 5 Spade drill FIGURE 3FIGURE 3--5 Spade drill 5 Spade drill
Tooling for Hole OperationsTooling for Hole Operations
�� DrillDrill pointpoint angleangle mustmust bebe consideredconsidered whenwhen
selectingselecting aa drilldrill
�� TheThe harderharder thethe materialmaterial toto bebe cutcut thethe gratergrater
thethe drilldrill pointpoint angleangle needsneeds toto bebe toto maintainmaintain
satisfactorysatisfactory tooltool lifelife
�� MildMild steelsteel isis usuallyusually cutcut withwith aa 118118--degreedegree
includedincluded angleangle drilldrill pointpoint
�� StainlessStainless steelssteels oftenoften useuse aa 135135--degreedegree drilldrill
pointpoint
�� DrillDrill pointpoint angleangle mustmust bebe consideredconsidered whenwhen
selectingselecting aa drilldrill
�� TheThe harderharder thethe materialmaterial toto bebe cutcut thethe gratergrater
thethe drilldrill pointpoint angleangle needsneeds toto bebe toto maintainmaintain
satisfactorysatisfactory tooltool lifelife
�� MildMild steelsteel isis usuallyusually cutcut withwith aa 118118--degreedegree
includedincluded angleangle drilldrill pointpoint
�� StainlessStainless steelssteels oftenoften useuse aa 135135--degreedegree drilldrill
pointpoint
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGURE 3FIGURE 3--6 (Courtesy Carboloy Inc., A 6 (Courtesy Carboloy Inc., A
Seco Tools Company)Seco Tools Company)
FIGURE 3FIGURE 3--6 (Courtesy Carboloy Inc., A 6 (Courtesy Carboloy Inc., A
Seco Tools Company)Seco Tools Company)
pointpoint
TypesTypes ofof DrillsDrills
�� HSSHSS drillsdrills areare thethe mostmost commoncommon
�� BrazedBrazed carbidecarbide andand solidsolid carbidecarbide
�� CarbideCarbide drilldrill chipchip whenwhen drillingdrilling holesholes
�� WhenWhen drillingdrilling hardhard materialsmaterials CobaltCobalt drillsdrills areare
usedused (HSS(HSS withwith Cobalt)Cobalt)
�� CobaltCobalt drillsdrills havehave greatergreater heatheat hardnesshardness
thanthan HSSHSS drillsdrills
�� SpecialSpecial drillsdrills withwith CarbideCarbide insertsinserts (Fig(Fig.. 33--66))
pointpoint
TypesTypes ofof DrillsDrills
�� HSSHSS drillsdrills areare thethe mostmost commoncommon
�� BrazedBrazed carbidecarbide andand solidsolid carbidecarbide
�� CarbideCarbide drilldrill chipchip whenwhen drillingdrilling holesholes
�� WhenWhen drillingdrilling hardhard materialsmaterials CobaltCobalt drillsdrills areare
usedused (HSS(HSS withwith Cobalt)Cobalt)
�� CobaltCobalt drillsdrills havehave greatergreater heatheat hardnesshardness
thanthan HSSHSS drillsdrills
�� SpecialSpecial drillsdrills withwith CarbideCarbide insertsinserts (Fig(Fig.. 33--66))
Tooling for Hole OperationsTooling for Hole Operations
ReamingReaming�� ReamingReaming isis usedused toto removeremove aa smallsmall amountamount ofof metalmetal fromfrom anan existingexisting holehole
asas aa finishingfinishing operationoperation
�� ReamingReaming isis aa precisionprecision operationoperation whichwhich willwill holdhold aa tolerancetolerance ofof +/+/-- 00..00020002
inchinch easilyeasily
�� ReamingReaming needsneeds aa pilotpilot holehole
�� ReamersReamers areare expensiveexpensive
�� StraightStraight flutedfluted reamersreamers (Fig(Fig.. 33--77))
ReamingReaming�� ReamingReaming isis usedused toto removeremove aa smallsmall amountamount ofof metalmetal fromfrom anan existingexisting holehole
asas aa finishingfinishing operationoperation
�� ReamingReaming isis aa precisionprecision operationoperation whichwhich willwill holdhold aa tolerancetolerance ofof +/+/-- 00..00020002
inchinch easilyeasily
�� ReamingReaming needsneeds aa pilotpilot holehole
�� ReamersReamers areare expensiveexpensive
�� StraightStraight flutedfluted reamersreamers (Fig(Fig.. 33--77))
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGURE 3FIGURE 3--7 Straight flute chucking reamer 7 Straight flute chucking reamer
(Photo courtesy of DoALL Manufacturing)(Photo courtesy of DoALL Manufacturing)
FIGURE 3FIGURE 3--7 Straight flute chucking reamer 7 Straight flute chucking reamer
(Photo courtesy of DoALL Manufacturing)(Photo courtesy of DoALL Manufacturing)
�� StraightStraight flutedfluted reamersreamers (Fig(Fig.. 33--77))�� StraightStraight flutedfluted reamersreamers (Fig(Fig.. 33--77))
Tooling for Hole OperationsTooling for Hole Operations
ReamingReaming�� SpiralSpiral flutedfluted reamersreamers (Fig(Fig.. 33--88))
�� SpiralSpiral flutedfluted reamersreamers produceproduce betterbetter surfacesurface finishesfinishes thanthan straightstraight flutesflutes
�� SpiralSpiral flutedfluted reamersreamers areare moremore difficultdifficult toto resharpenresharpen thanthan straightstraight flutedfluted
�� ReamersReamers areare availableavailable inin threethree basicbasic tooltool materialsmaterials::
��HSSHSS
��BrazedBrazed carbidecarbide
ReamingReaming�� SpiralSpiral flutedfluted reamersreamers (Fig(Fig.. 33--88))
�� SpiralSpiral flutedfluted reamersreamers produceproduce betterbetter surfacesurface finishesfinishes thanthan straightstraight flutesflutes
�� SpiralSpiral flutedfluted reamersreamers areare moremore difficultdifficult toto resharpenresharpen thanthan straightstraight flutedfluted
�� ReamersReamers areare availableavailable inin threethree basicbasic tooltool materialsmaterials::
��HSSHSS
��BrazedBrazed carbidecarbide
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGURE 3FIGURE 3--8 Spiral flute chucking reamers 8 Spiral flute chucking reamers
(Photo courtesy of DoALL Manufacturing)(Photo courtesy of DoALL Manufacturing)
FIGURE 3FIGURE 3--8 Spiral flute chucking reamers 8 Spiral flute chucking reamers
(Photo courtesy of DoALL Manufacturing)(Photo courtesy of DoALL Manufacturing)
��SolidSolid carbidecarbide��SolidSolid carbidecarbide
Tooling for Hole OperationsTooling for Hole Operations
BoringBoring
Boring removes metal from an existing hole with a singleBoring removes metal from an existing hole with a single--point boring barpoint boring bar
�� BoringBoring headsheads areare availableavailable inin twotwo designsdesigns::
��OffsetOffset inin whichwhich thethe boringboring barbar isis aa separateseparate tooltool insertedinserted intointo thethe headhead
��CartridgeCartridge whichwhich useuse anan adjustableadjustable insertinsert inin placeplace ofof aa boringboring barbar
BoringBoring
Boring removes metal from an existing hole with a singleBoring removes metal from an existing hole with a single--point boring barpoint boring bar
�� BoringBoring headsheads areare availableavailable inin twotwo designsdesigns::
��OffsetOffset inin whichwhich thethe boringboring barbar isis aa separateseparate tooltool insertedinserted intointo thethe headhead
��CartridgeCartridge whichwhich useuse anan adjustableadjustable insertinsert inin placeplace ofof aa boringboring barbar
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
�� BoringBoring barsbars areare availableavailable inin fourfour materialmaterial typestypes::
��HighHigh SpeedSpeed SteelSteel (HSS)(HSS)
��SolidSolid carbidecarbide –– upup toto ½½--inchinch diameterdiameter
��BrazedBrazed carbidecarbide –– upup toto ½½--inchinch diameterdiameter
��InsertedInserted carbidecarbide -- forfor largelarge holesholes
�� BoringBoring BarsBars movemove ofof--centre,centre, produceproduce veryvery round,round, straightstraight hole,hole, tighttight specsspecs
�� BoringBoring barsbars areare availableavailable inin fourfour materialmaterial typestypes::
��HighHigh SpeedSpeed SteelSteel (HSS)(HSS)
��SolidSolid carbidecarbide –– upup toto ½½--inchinch diameterdiameter
��BrazedBrazed carbidecarbide –– upup toto ½½--inchinch diameterdiameter
��InsertedInserted carbidecarbide -- forfor largelarge holesholes
�� BoringBoring BarsBars movemove ofof--centre,centre, produceproduce veryvery round,round, straightstraight hole,hole, tighttight specsspecs
Tooling for Hole OperationsTooling for Hole Operations
TappingTappingTaping is used to produce internally threaded holes Taping is used to produce internally threaded holes (Milling, Turning)(Milling, Turning)
�� TheyThey areare availableavailable inin differentdifferent fluteflute designsdesigns::
��StandardStandard machinemachine screwscrew tapstaps (Fig(Fig.. 33--99)) areare widelywidely usedused whenwhen
tappingtapping blindblind holesholes
��SpiralSpiral pointedpointed tapstaps (gun(gun taps)taps) whichwhich areare preferredpreferred forfor thruthru--holehole
operationsoperations –– shootshoot chipschips forwardforward andand outout ofof thethe bottombottom ofof thethe holehole
��HighHigh--spiralspiral tapstaps (Fig(Fig.. 33--1010)) areare usedused forfor soft,soft, stringystringy materialmaterial (e(e..gg..
TappingTappingTaping is used to produce internally threaded holes Taping is used to produce internally threaded holes (Milling, Turning)(Milling, Turning)
�� TheyThey areare availableavailable inin differentdifferent fluteflute designsdesigns::
��StandardStandard machinemachine screwscrew tapstaps (Fig(Fig.. 33--99)) areare widelywidely usedused whenwhen
tappingtapping blindblind holesholes
��SpiralSpiral pointedpointed tapstaps (gun(gun taps)taps) whichwhich areare preferredpreferred forfor thruthru--holehole
operationsoperations –– shootshoot chipschips forwardforward andand outout ofof thethe bottombottom ofof thethe holehole
��HighHigh--spiralspiral tapstaps (Fig(Fig.. 33--1010)) areare usedused forfor soft,soft, stringystringy materialmaterial (e(e..gg..
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGURE 3FIGURE 3--9 Machining screw tap9 Machining screw tapFIGURE 3FIGURE 3--9 Machining screw tap9 Machining screw tap
��HighHigh--spiralspiral tapstaps (Fig(Fig.. 33--1010)) areare usedused forfor soft,soft, stringystringy materialmaterial (e(e..gg..
Aluminum)Aluminum)
��HighHigh--spiralspiral tapstaps (Fig(Fig.. 33--1010)) areare usedused forfor soft,soft, stringystringy materialmaterial (e(e..gg..
Aluminum)Aluminum)
FIGURE 3FIGURE 3--10 High spiral coated tap10 High spiral coated tapFIGURE 3FIGURE 3--10 High spiral coated tap10 High spiral coated tap
Milling CuttersMilling Cutters
MillingMilling CuttersCutters�� TheThe greatestgreatest advancesadvances inin toolingtooling forfor NCNC havehave takentaken inin thethe areaarea ofof InsertedInserted
MillingMilling CuttersCutters
�� MillingMilling allowsallows thethe contouringcontouring capabilitiescapabilities ofof thethe NCNC machinemachine toto bebe usedused toto
efficientlyefficiently performperform operationsoperations thatthat wouldwould requirerequire specialspecial toolingtooling ifif donedone
manuallymanually
MillingMilling CuttersCutters�� TheThe greatestgreatest advancesadvances inin toolingtooling forfor NCNC havehave takentaken inin thethe areaarea ofof InsertedInserted
MillingMilling CuttersCutters
�� MillingMilling allowsallows thethe contouringcontouring capabilitiescapabilities ofof thethe NCNC machinemachine toto bebe usedused toto
efficientlyefficiently performperform operationsoperations thatthat wouldwould requirerequire specialspecial toolingtooling ifif donedone
manuallymanually
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
Milling CuttersMilling Cutters
Solid Milling Solid Milling CuttersCutters
Inserted Inserted Milling CuttersMilling Cutters
Milling CuttersMilling Cutters
MillingMilling CuttersCutters
CanCan alsoalso bebe furtherfurther classifiedclassified inin::
MillingMilling CuttersCutters
CanCan alsoalso bebe furtherfurther classifiedclassified inin::
Milling Milling CuttersCutters
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
CuttersCutters
End MillsEnd Mills Face MillsFace Mills
Milling CuttersMilling Cutters
ThreadThread HobHob�� AA specialspecial millingmilling cuttercutter usedused toto millmill aa threadthread inin aa workpieceworkpiece
�� ThreadThread hobshobs makemake useuse ofof anan NCNC machine’smachine’s helicalhelical interpolationinterpolation
capabilitiescapabilities
ThreadThread HobHob�� AA specialspecial millingmilling cuttercutter usedused toto millmill aa threadthread inin aa workpieceworkpiece
�� ThreadThread hobshobs makemake useuse ofof anan NCNC machine’smachine’s helicalhelical interpolationinterpolation
capabilitiescapabilities
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGURE 3FIGURE 3--11 Thread hob (Photo courtesy of GTE Valenite)11 Thread hob (Photo courtesy of GTE Valenite)FIGURE 3FIGURE 3--11 Thread hob (Photo courtesy of GTE Valenite)11 Thread hob (Photo courtesy of GTE Valenite)
Milling CuttersMilling Cutters
EndEnd MillsMills�� EndEnd MillsMills areare availableavailable inin::
�� HighHigh SpeedSpeed SteelSteel (HSS)(HSS)
�� SolidSolid CarbideCarbide
�� EndEnd MillsMills areare availableavailable inin diametersdiameters::
�� FromFrom 00..032032 inchinch toto 00..500500 inchinch
�� Inserted End MillsInserted End Mills are available in diameters:are available in diameters:
�� From 0.500 inch to 3 inchFrom 0.500 inch to 3 inch
EndEnd MillsMills�� EndEnd MillsMills areare availableavailable inin::
�� HighHigh SpeedSpeed SteelSteel (HSS)(HSS)
�� SolidSolid CarbideCarbide
�� EndEnd MillsMills areare availableavailable inin diametersdiameters::
�� FromFrom 00..032032 inchinch toto 00..500500 inchinch
�� Inserted End MillsInserted End Mills are available in diameters:are available in diameters:
�� From 0.500 inch to 3 inchFrom 0.500 inch to 3 inch
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
�� From 0.500 inch to 3 inchFrom 0.500 inch to 3 inch
Note 1Note 1:: TwoTwo--flute cutters with deeper gullets are well suited for roughing operationsflute cutters with deeper gullets are well suited for roughing operations
Note 2Note 2:: FourFour--flute end mills are more rigid because of their thicker coreflute end mills are more rigid because of their thicker core
�� From 0.500 inch to 3 inchFrom 0.500 inch to 3 inch
Note 1Note 1:: TwoTwo--flute cutters with deeper gullets are well suited for roughing operationsflute cutters with deeper gullets are well suited for roughing operations
Note 2Note 2:: FourFour--flute end mills are more rigid because of their thicker coreflute end mills are more rigid because of their thicker core
FIGUREFIGURE 33--1212 SingleSingle end,end, multiplemultiple fluteflute endend mill,mill,
standardstandard lengthlength flutesflutes (Photo(Photo courtesycourtesy ofof
SharpaloySharpaloy Division,Division, PrecisionPrecision IndustriesIndustries IncInc..))
FIGUREFIGURE 33--1212 SingleSingle end,end, multiplemultiple fluteflute endend mill,mill,
standardstandard lengthlength flutesflutes (Photo(Photo courtesycourtesy ofof
SharpaloySharpaloy Division,Division, PrecisionPrecision IndustriesIndustries IncInc..))
FIGUREFIGURE 33--1313 SolidSolid carbide,carbide, twotwo--flute,flute, endend millmill
(Photo(Photo courtesycourtesy ofof DoALLDoALL Manufacturing)Manufacturing)
FIGUREFIGURE 33--1313 SolidSolid carbide,carbide, twotwo--flute,flute, endend millmill
(Photo(Photo courtesycourtesy ofof DoALLDoALL Manufacturing)Manufacturing)
Milling CuttersMilling Cutters
EndEnd MillsMills�� InsertedInserted cutterscutters areare preferredpreferred forfor NCNC applicationsapplications (Fig(Fig.. 33--1414,, 33--1515))
�� InsertsInserts areare lessless expensiveexpensive toto replacereplace thanthan anan entireentire tooltool
�� ByBy indexingindexing thethe insertsinserts fourfour oror sixsix cuttingcutting edgesedges cancan bebe usedused onon oneone insertinsert
�� WhenWhen thethe insertinsert isis usedused upup itit isis thrownthrown awayaway ratherrather thanthan rere--sharpenedsharpened
�� InsertedInserted cutterscutters maymay usedused onon manymany typestypes ofof workpieceworkpiece materialsmaterials byby changingchanging thethe
insertsinserts fromfrom oneone designeddesigned forfor AluminumAluminum toto oneone designeddesigned forfor StainlessStainless SteelSteel
EndEnd MillsMills�� InsertedInserted cutterscutters areare preferredpreferred forfor NCNC applicationsapplications (Fig(Fig.. 33--1414,, 33--1515))
�� InsertsInserts areare lessless expensiveexpensive toto replacereplace thanthan anan entireentire tooltool
�� ByBy indexingindexing thethe insertsinserts fourfour oror sixsix cuttingcutting edgesedges cancan bebe usedused onon oneone insertinsert
�� WhenWhen thethe insertinsert isis usedused upup itit isis thrownthrown awayaway ratherrather thanthan rere--sharpenedsharpened
�� InsertedInserted cutterscutters maymay usedused onon manymany typestypes ofof workpieceworkpiece materialsmaterials byby changingchanging thethe
insertsinserts fromfrom oneone designeddesigned forfor AluminumAluminum toto oneone designeddesigned forfor StainlessStainless SteelSteel
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGURE 3FIGURE 3--14 Inserted carbide end mills 14 Inserted carbide end mills FIGURE 3FIGURE 3--14 Inserted carbide end mills 14 Inserted carbide end mills
FIGUREFIGURE 33--1515 ‘’Centerdex’’‘’Centerdex’’ twotwo--fluteflute insertedinserted endend
millsmills (Photo(Photo courtesycourtesy ofof GTEGTE Valenite)Valenite)
FIGUREFIGURE 33--1515 ‘’Centerdex’’‘’Centerdex’’ twotwo--fluteflute insertedinserted endend
millsmills (Photo(Photo courtesycourtesy ofof GTEGTE Valenite)Valenite)
Milling CuttersMilling Cutters
EndEnd MillsMills�� BallBall EndEnd MillsMills usingusing insertsinserts (Fig(Fig.. 33--1616,, 33--1717))
�� BallBall EndEnd MillsMills areare alsoalso availableavailable inin HSSHSS andand SolidSolid CarbideCarbide
�� BallBall MillsMills areare usedused forfor three,three, fourfour oror fivefive –– axisaxis contouringcontouring workwork wherewhere ZZ
axisaxis isis usedused
�� TheyThey areare alsoalso usedused toto produceproduce aa radiusradius inin aa partpart
EndEnd MillsMills�� BallBall EndEnd MillsMills usingusing insertsinserts (Fig(Fig.. 33--1616,, 33--1717))
�� BallBall EndEnd MillsMills areare alsoalso availableavailable inin HSSHSS andand SolidSolid CarbideCarbide
�� BallBall MillsMills areare usedused forfor three,three, fourfour oror fivefive –– axisaxis contouringcontouring workwork wherewhere ZZ
axisaxis isis usedused
�� TheyThey areare alsoalso usedused toto produceproduce aa radiusradius inin aa partpart
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGUREFIGURE 33--1616 BallBall nosenose endend millsmills featuredfeatured roundround
insertsinserts (Photo(Photo courtesycourtesy ofof GTEGTE Valenite)Valenite)
FIGUREFIGURE 33--1616 BallBall nosenose endend millsmills featuredfeatured roundround
insertsinserts (Photo(Photo courtesycourtesy ofof GTEGTE Valenite)Valenite)FIGUREFIGURE 33--1717 BallBall nosenose endend millsmills featuringfeaturing
triangulartriangular insertsinserts (Photo(Photo courtesycourtesy ofof GTEGTE Valenite)Valenite)
FIGUREFIGURE 33--1717 BallBall nosenose endend millsmills featuringfeaturing
triangulartriangular insertsinserts (Photo(Photo courtesycourtesy ofof GTEGTE Valenite)Valenite)
Milling CuttersMilling Cutters
EndEnd MillsMills�� InsertedInserted EndEnd MillMill (Cyclo(Cyclo Mill)Mill)
designeddesigned byby VALENITEVALENITE GTEGTE (Fig(Fig..
33--1818))
�� CycloCyclo MillMill usesuses aa seriesseries ofof roundround
insertsinserts staggeredstaggered onon aa helicalhelical
EndEnd MillsMills�� InsertedInserted EndEnd MillMill (Cyclo(Cyclo Mill)Mill)
designeddesigned byby VALENITEVALENITE GTEGTE (Fig(Fig..
33--1818))
�� CycloCyclo MillMill usesuses aa seriesseries ofof roundround
insertsinserts staggeredstaggered onon aa helicalhelical
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGUREFIGURE 33--1818 ‘’Cyclo‘’Cyclo Mill’’Mill’’ specialspecial multimulti--insertedinserted
millingmilling cuttercutter (Photo(Photo courtesycourtesy ofof GTEGTE Valenite)Valenite)
FIGUREFIGURE 33--1818 ‘’Cyclo‘’Cyclo Mill’’Mill’’ specialspecial multimulti--insertedinserted
millingmilling cuttercutter (Photo(Photo courtesycourtesy ofof GTEGTE Valenite)Valenite)
insertsinserts staggeredstaggered onon aa helicalhelical
patternpattern
�� CycloCyclo MillMill cancan removeremove largelarge
amountamount ofof materialmaterial atat highhigh speedsspeeds
�� CycloCyclo MillMill waswas developeddeveloped forfor NCNC
useuse
insertsinserts staggeredstaggered onon aa helicalhelical
patternpattern
�� CycloCyclo MillMill cancan removeremove largelarge
amountamount ofof materialmaterial atat highhigh speedsspeeds
�� CycloCyclo MillMill waswas developeddeveloped forfor NCNC
useuse
Milling CuttersMilling Cutters
FaceFace MillsMills�� FaceFace MillsMills areare designeddesigned toto removeremove largelarge amountsamounts ofof materialmaterial fromfrom thethe faceface
ofof thethe workpieceworkpiece
�� FaceFace MillsMills areare manufacturedmanufactured inin::
�� HighHigh SpeedSpeed SteelSteel (HSS)(HSS)
�� BrazedBrazed CarbideCarbide
�� InsertedInserted CarbideCarbide (the(the mostmost commoncommon typetype ofof facingfacing tool)tool)
�� FaceFace MillsMills areare availableavailable inin twotwo sizessizes:: FromFrom 22 inchinch toto overover 88 inchinch inin diameterdiameter
FaceFace MillsMills�� FaceFace MillsMills areare designeddesigned toto removeremove largelarge amountsamounts ofof materialmaterial fromfrom thethe faceface
ofof thethe workpieceworkpiece
�� FaceFace MillsMills areare manufacturedmanufactured inin::
�� HighHigh SpeedSpeed SteelSteel (HSS)(HSS)
�� BrazedBrazed CarbideCarbide
�� InsertedInserted CarbideCarbide (the(the mostmost commoncommon typetype ofof facingfacing tool)tool)
�� FaceFace MillsMills areare availableavailable inin twotwo sizessizes:: FromFrom 22 inchinch toto overover 88 inchinch inin diameterdiameter
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGUREFIGURE 33--1919 AA commoncommon typetype ofof CarbideCarbide insertedinserted
faceface millmill (Photo(Photo courtesycourtesy ofof GTEGTE Valenite)Valenite)
FIGUREFIGURE 33--1919 AA commoncommon typetype ofof CarbideCarbide insertedinserted
faceface millmill (Photo(Photo courtesycourtesy ofof GTEGTE Valenite)Valenite)
�� FaceFace MillsMills areare availableavailable inin twotwo sizessizes:: FromFrom 22 inchinch toto overover 88 inchinch inin diameterdiameter
Note 1Note 1:: The cost of HSS and Brazed Carbide limit their application to special situationsThe cost of HSS and Brazed Carbide limit their application to special situations
�� FaceFace MillsMills areare availableavailable inin twotwo sizessizes:: FromFrom 22 inchinch toto overover 88 inchinch inin diameterdiameter
Note 1Note 1:: The cost of HSS and Brazed Carbide limit their application to special situationsThe cost of HSS and Brazed Carbide limit their application to special situations
Milling CuttersMilling Cutters
FaceFace MillsMills�� LargeLarge DiameterDiameter FaceFace MillMill
(Fig(Fig.. 33--2020))
�� LargeLarge numbernumber ofof insertsinserts
usedused
�� CycloCyclo MillMill waswas developeddeveloped
forfor NCNC useuse
FaceFace MillsMills�� LargeLarge DiameterDiameter FaceFace MillMill
(Fig(Fig.. 33--2020))
�� LargeLarge numbernumber ofof insertsinserts
usedused
�� CycloCyclo MillMill waswas developeddeveloped
forfor NCNC useuse
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGUREFIGURE 33--2020 LargeLarge insertedinserted faceface millmill –– notenote numbernumber ofof
insertsinserts onon cuttercutter (Photo(Photo courtesycourtesy ofof GTEGTE Valenite)Valenite)
FIGUREFIGURE 33--2020 LargeLarge insertedinserted faceface millmill –– notenote numbernumber ofof
insertsinserts onon cuttercutter (Photo(Photo courtesycourtesy ofof GTEGTE Valenite)Valenite)
Milling CuttersMilling Cutters
FaceFace MillsMills�� PlungePlunge andand ProfileProfile CutterCutter
(Fig(Fig.. 33--2121))
�� ItIt isis designeddesigned toto plungeplunge intointo
thethe materialmaterial firstfirst andand thenthen
beggingbegging thethe cuttingcutting pathpath
�� TheThe designdesign isis aa crosscross
FaceFace MillsMills�� PlungePlunge andand ProfileProfile CutterCutter
(Fig(Fig.. 33--2121))
�� ItIt isis designeddesigned toto plungeplunge intointo
thethe materialmaterial firstfirst andand thenthen
beggingbegging thethe cuttingcutting pathpath
�� TheThe designdesign isis aa crosscross
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGUREFIGURE 33--2121 PlungePlunge andand profileprofile insertedinserted millingmilling
cuttercutter (Photo(Photo courtesycourtesy ofof GTEGTE Valenite)Valenite)
FIGUREFIGURE 33--2121 PlungePlunge andand profileprofile insertedinserted millingmilling
cuttercutter (Photo(Photo courtesycourtesy ofof GTEGTE Valenite)Valenite)
�� TheThe designdesign isis aa crosscross
betweenbetween EndEnd MillMill andand FaceFace
MillMill
�� TheThe designdesign isis aa crosscross
betweenbetween EndEnd MillMill andand FaceFace
MillMill
Special Inserted CuttersSpecial Inserted Cutters
SpecialSpecial InsertedInserted CuttersCutters�� AA numbernumber ofof specialspecial toolstools havehave beenbeen developeddeveloped forfor useuse withwith CNCCNC
�� TheThe NCNC programmerprogrammer isis alwaysalways confrontedconfronted withwith newnew ideasideas toto improveimprove
productivityproductivity
�� Prospective and experiencedProspective and experienced programmers should spent time looking at programmers should spent time looking at
SpecialSpecial InsertedInserted CuttersCutters�� AA numbernumber ofof specialspecial toolstools havehave beenbeen developeddeveloped forfor useuse withwith CNCCNC
�� TheThe NCNC programmerprogrammer isis alwaysalways confrontedconfronted withwith newnew ideasideas toto improveimprove
productivityproductivity
�� Prospective and experiencedProspective and experienced programmers should spent time looking at programmers should spent time looking at
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
�� Prospective and experiencedProspective and experienced programmers should spent time looking at programmers should spent time looking at
tooling catalogs to become acquainted with current tooling developmentstooling catalogs to become acquainted with current tooling developments
�� Figures 3Figures 3--22 through 322 through 3--24 illustrate some of the current tooling ideas 24 illustrate some of the current tooling ideas
developed developed specifically for NC applicationsspecifically for NC applications
�� Prospective and experiencedProspective and experienced programmers should spent time looking at programmers should spent time looking at
tooling catalogs to become acquainted with current tooling developmentstooling catalogs to become acquainted with current tooling developments
�� Figures 3Figures 3--22 through 322 through 3--24 illustrate some of the current tooling ideas 24 illustrate some of the current tooling ideas
developed developed specifically for NC applicationsspecifically for NC applications
Special Inserted CuttersSpecial Inserted Cutters
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGUREFIGURE 33--2323 (Photo(Photo courtesycourtesy ofof GTEGTE Valenite)Valenite)
SpecialSpecial insertedinserted toolingtooling forfor useuse withwith NCNC.. FromFrom toptop
toto bottombottom::
�� anan insertedinserted millingmilling cuttercutter withwith
interchangeableinterchangeable toolingtooling extensionsextensions
�� aa machinemachine taptap inin aa taptap holderholder withwith
interchangeableinterchangeable toolingtooling extensionsextensions
�� anan insertedinserted drilldrill mountedmounted inin aa holderholder
withwith interchangeableinterchangeable extensionsextensions
FIGUREFIGURE 33--2323 (Photo(Photo courtesycourtesy ofof GTEGTE Valenite)Valenite)
SpecialSpecial insertedinserted toolingtooling forfor useuse withwith NCNC.. FromFrom toptop
toto bottombottom::
�� anan insertedinserted millingmilling cuttercutter withwith
interchangeableinterchangeable toolingtooling extensionsextensions
�� aa machinemachine taptap inin aa taptap holderholder withwith
interchangeableinterchangeable toolingtooling extensionsextensions
�� anan insertedinserted drilldrill mountedmounted inin aa holderholder
withwith interchangeableinterchangeable extensionsextensions
FIGUREFIGURE 33--2222
SpecialSpecial smallsmall diameterdiameter insertedinserted endend millmill
(Photo(Photo courtesycourtesy ofof GTEGTE Valenite)Valenite)
FIGUREFIGURE 33--2222
SpecialSpecial smallsmall diameterdiameter insertedinserted endend millmill
(Photo(Photo courtesycourtesy ofof GTEGTE Valenite)Valenite)
Special Inserted CuttersSpecial Inserted Cutters
FIGUREFIGURE 33--2424 (Photo(Photo courtesycourtesy ofof GTEGTE
Valenite)Valenite)
AnAn NCNC toolingtooling systemsystem featuringfeaturing::
�� tooltool adaptersadapters
�� interchangeableinterchangeable extensionsextensions
FIGUREFIGURE 33--2424 (Photo(Photo courtesycourtesy ofof GTEGTE
Valenite)Valenite)
AnAn NCNC toolingtooling systemsystem featuringfeaturing::
�� tooltool adaptersadapters
�� interchangeableinterchangeable extensionsextensions
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
�� interchangeableinterchangeable extensionsextensions
�� tooltool bodiesbodies
�� boringboring headsheads
�� arborsarbors
�� interchangeableinterchangeable extensionsextensions
�� tooltool bodiesbodies
�� boringboring headsheads
�� arborsarbors
Special Inserted CuttersSpecial Inserted Cutters
CarbideCarbide InsertsInserts andand theirtheir SelectionSelection�� CarbideCarbide InsertsInserts areare manufacturedmanufactured inin aa varietyvariety ofof TYPESTYPES andand
GRADESGRADES
�� TheThe TYPETYPE ofof thethe insertinsert describesdescribes thethe SHAPESHAPE ofof thethe insertinsert
CarbideCarbide InsertsInserts andand theirtheir SelectionSelection�� CarbideCarbide InsertsInserts areare manufacturedmanufactured inin aa varietyvariety ofof TYPESTYPES andand
GRADESGRADES
�� TheThe TYPETYPE ofof thethe insertinsert describesdescribes thethe SHAPESHAPE ofof thethe insertinsert
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
CommonCommonInsertInsert
SHAPESSHAPES
TriangularTriangular 8080oo DiamondDiamond 5555oo DiamondDiamond RoundRound
Special Inserted CuttersSpecial Inserted Cutters
CarbideCarbide InsertsInserts andand theirtheir SelectionSelection
�� TheThe GRADEGRADE ofof insertinsert describesdescribes thethe HARDNESSHARDNESS ofof thethe insertinsert andand thethe
applicationapplication forfor whichwhich itit waswas developeddeveloped
�� EachEach TYPETYPE ofof insertinsert isis identifiedidentified byby aa DesignationDesignation CodeCode
CarbideCarbide InsertsInserts andand theirtheir SelectionSelection
�� TheThe GRADEGRADE ofof insertinsert describesdescribes thethe HARDNESSHARDNESS ofof thethe insertinsert andand thethe
applicationapplication forfor whichwhich itit waswas developeddeveloped
�� EachEach TYPETYPE ofof insertinsert isis identifiedidentified byby aa DesignationDesignation CodeCode
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
�� TheThe IdentificationIdentification SystemSystem usedused onon anan insertinsert willwill varyvary dependingdepending onon
thethe manufacturermanufacturer (Fig(Fig.. 33--2525))
�� TheThe IdentificationIdentification SystemSystem usedused onon anan insertinsert willwill varyvary dependingdepending onon
thethe manufacturermanufacturer (Fig(Fig.. 33--2525))
Special Inserted CuttersSpecial Inserted Cutters
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGUREFIGURE 33--2525 CarbideCarbide insertinsert identificationidentification systemsystem (Courtesy(Courtesy ofof CarboloyCarboloy IncInc..,, AA SecoSeco ToolsTools Company)Company)FIGUREFIGURE 33--2525 CarbideCarbide insertinsert identificationidentification systemsystem (Courtesy(Courtesy ofof CarboloyCarboloy IncInc..,, AA SecoSeco ToolsTools Company)Company)
Special Inserted CuttersSpecial Inserted Cutters
CarbideCarbide InsertInsert GradingGrading SystemSystem::
�� EachEach GRADEGRADE ofof CarbideCarbide isis designateddesignated
byby anan ANSIANSI “C”“C” numbernumber fromfrom CC11 toto
CC88
�� EachEach GRADEGRADE ofof CarbideCarbide hashas alsoalso
beenbeen classifiedclassified byby ISOISO
�� TheThe ISOISO designationdesignation usesuses “K”“K” oror “P”“P”
numbernumber dependingdepending onon insertinsert hardnesshardness
�� InIn thethe USAUSA thethe ANSIANSI systemsystem isis
CarbideCarbide InsertInsert GradingGrading SystemSystem::
�� EachEach GRADEGRADE ofof CarbideCarbide isis designateddesignated
byby anan ANSIANSI “C”“C” numbernumber fromfrom CC11 toto
CC88
�� EachEach GRADEGRADE ofof CarbideCarbide hashas alsoalso
beenbeen classifiedclassified byby ISOISO
�� TheThe ISOISO designationdesignation usesuses “K”“K” oror “P”“P”
numbernumber dependingdepending onon insertinsert hardnesshardness
�� InIn thethe USAUSA thethe ANSIANSI systemsystem isis
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGUREFIGURE 33--2626 CarbideCarbide insertinsert gradesgradesFIGUREFIGURE 33--2626 CarbideCarbide insertinsert gradesgrades
�� InIn thethe USAUSA thethe ANSIANSI systemsystem isis
generallygenerally usedused
�� InIn otherother countriescountries thethe ISOISO isis followedfollowed
�� ManufacturersManufacturers developdevelop theirtheir ownown
GRADEGRADE systemsystem basedbased onon thethe ANSIANSI oror
ISOISO ratingrating (Fig(Fig 33--2626))
�� TheThe programmerprogrammer isis necessarynecessary toto
consultconsult thethe individualindividual manufacturersmanufacturers
catalogcatalog toto arrivearrive thethe properproper gradegrade
numbernumber
�� InIn thethe USAUSA thethe ANSIANSI systemsystem isis
generallygenerally usedused
�� InIn otherother countriescountries thethe ISOISO isis followedfollowed
�� ManufacturersManufacturers developdevelop theirtheir ownown
GRADEGRADE systemsystem basedbased onon thethe ANSIANSI oror
ISOISO ratingrating (Fig(Fig 33--2626))
�� TheThe programmerprogrammer isis necessarynecessary toto
consultconsult thethe individualindividual manufacturersmanufacturers
catalogcatalog toto arrivearrive thethe properproper gradegrade
numbernumber
Special Inserted CuttersSpecial Inserted Cutters
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGUREFIGURE 33--2727 ToolholderToolholder andand boringboring barbar sectionssections ––
boringboring barbar stylesstyles (Courtesy(Courtesy ofof CarboloyCarboloy IncInc..,, AA
SecoSeco ToolsTools Company)Company)
FIGUREFIGURE 33--2727 ToolholderToolholder andand boringboring barbar sectionssections ––
boringboring barbar stylesstyles (Courtesy(Courtesy ofof CarboloyCarboloy IncInc..,, AA
SecoSeco ToolsTools Company)Company)
FIGUREFIGURE 33--2828 ToolTool holderholder andand boringboring barbar
selectionselection –– tooltool holderholder stylesstyles (Courtesy(Courtesy ofof
CarboloyCarboloy IncInc..,, AA SecoSeco ToolsTools Company)Company)
FIGUREFIGURE 33--2828 ToolTool holderholder andand boringboring barbar
selectionselection –– tooltool holderholder stylesstyles (Courtesy(Courtesy ofof
CarboloyCarboloy IncInc..,, AA SecoSeco ToolsTools Company)Company)
A Processing ExampleA Processing Example
ExampleExample::
�� AA partpart toto bebe machinedmachined fromfrom aluminiumaluminium
castingcasting
�� TheThe castcast hashas 00..250250--inchinch diameterdiameter ofof stockstock toto
bebe removedremoved fromfrom 44..000000 andand 33..000000––inchinch
diametersdiameters
�� TheThe centercenter ofof thethe castcast waswas coredcored toto 11..000000--inchinch
ExampleExample::
�� AA partpart toto bebe machinedmachined fromfrom aluminiumaluminium
castingcasting
�� TheThe castcast hashas 00..250250--inchinch diameterdiameter ofof stockstock toto
bebe removedremoved fromfrom 44..000000 andand 33..000000––inchinch
diametersdiameters
�� TheThe centercenter ofof thethe castcast waswas coredcored toto 11..000000--inchinch
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGUREFIGURE 33--2929 PartPart drawingdrawingFIGUREFIGURE 33--2929 PartPart drawingdrawing
�� TheThe centercenter ofof thethe castcast waswas coredcored toto 11..000000--inchinch
�� TheThe 11..000000--inchinch heightheight waswas castcast atat 11..250250 inchinch
�� TheThe 44..000000--inchinch diameterdiameter andand thethe 00..3838--inchinch areare
toto bebe donedone onon aa conventionalconventional lathelathe
�� TheThe partpart willwill bebe routedrouted onon aa VerticalVertical NCNC
MachiningMachining CenterCenter
�� AA fixturefixture forfor clampingclamping thethe partpart onon thethe CNCCNC
verticalvertical machiningmachining centercenter isis neededneeded
�� TheThe centercenter ofof thethe castcast waswas coredcored toto 11..000000--inchinch
�� TheThe 11..000000--inchinch heightheight waswas castcast atat 11..250250 inchinch
�� TheThe 44..000000--inchinch diameterdiameter andand thethe 00..3838--inchinch areare
toto bebe donedone onon aa conventionalconventional lathelathe
�� TheThe partpart willwill bebe routedrouted onon aa VerticalVertical NCNC
MachiningMachining CenterCenter
�� AA fixturefixture forfor clampingclamping thethe partpart onon thethe CNCCNC
verticalvertical machiningmachining centercenter isis neededneeded
A Processing ExampleA Processing Example
The sequence of the machining operation at the vertical NC The sequence of the machining operation at the vertical NC
machining center was planned as follows:machining center was planned as follows:
�� FaceFace thethe 11..000000 andand ..2525 dimensionsdimensions usingusing aa 3311//44 carbidecarbide insertedinserted faceface
millmill
�� CenterCenter drilldrill thethe ..188188 andand ..250250 diameterdiameter holesholes.. AA 9090--degreedegree centercenter drilldrill
waswas chosenchosen.. TheThe 9090--degreedegree chamferchamfer willwill provideprovide anan edgeedge breakbreak atat
thethe drilleddrilled hole,hole, therebythereby reducingreducing thethe amountamount ofof deburrdeburr timetime
�� DrillDrill thethe ..188188 diameterdiameter holesholes usingusing aa 33// drilldrill.. SinceSince drillsdrills almostalmost
The sequence of the machining operation at the vertical NC The sequence of the machining operation at the vertical NC
machining center was planned as follows:machining center was planned as follows:
�� FaceFace thethe 11..000000 andand ..2525 dimensionsdimensions usingusing aa 3311//44 carbidecarbide insertedinserted faceface
millmill
�� CenterCenter drilldrill thethe ..188188 andand ..250250 diameterdiameter holesholes.. AA 9090--degreedegree centercenter drilldrill
waswas chosenchosen.. TheThe 9090--degreedegree chamferchamfer willwill provideprovide anan edgeedge breakbreak atat
thethe drilleddrilled hole,hole, therebythereby reducingreducing thethe amountamount ofof deburrdeburr timetime
�� DrillDrill thethe ..188188 diameterdiameter holesholes usingusing aa 33// drilldrill.. SinceSince drillsdrills almostalmost
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
�� DrillDrill thethe ..188188 diameterdiameter holesholes usingusing aa 33//1616 drilldrill.. SinceSince drillsdrills almostalmost
alwaysalways drilldrill ..001001 oror moremore oversize,oversize, thethe holehole willwill bebe comfortablycomfortably withinwithin
tolerancetolerance
�� DrillDrill thethe ..250250 diameterdiameter holehole usingusing aa 11//44 drilldrill
�� MillMill thethe 33..000000 diameterdiameter usingusing aa 1111//44 diameterdiameter insertedinserted helicalhelical endend millmill..
TheThe endend millmill hashas insertsinserts upup thethe sidessides ofof thethe insert,insert, allowingallowing sideside
cuttingcutting upup toto 22..0000 deepdeep
�� UsingUsing thethe samesame endend mill,mill, millmill thethe 11..500500 diameterdiameter borebore
�� DrillDrill thethe ..188188 diameterdiameter holesholes usingusing aa 33//1616 drilldrill.. SinceSince drillsdrills almostalmost
alwaysalways drilldrill ..001001 oror moremore oversize,oversize, thethe holehole willwill bebe comfortablycomfortably withinwithin
tolerancetolerance
�� DrillDrill thethe ..250250 diameterdiameter holehole usingusing aa 11//44 drilldrill
�� MillMill thethe 33..000000 diameterdiameter usingusing aa 1111//44 diameterdiameter insertedinserted helicalhelical endend millmill..
TheThe endend millmill hashas insertsinserts upup thethe sidessides ofof thethe insert,insert, allowingallowing sideside
cuttingcutting upup toto 22..0000 deepdeep
�� UsingUsing thethe samesame endend mill,mill, millmill thethe 11..500500 diameterdiameter borebore
A Processing ExampleA Processing Example
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGURE 3FIGURE 3--30 Manufacturing process for part shown in Figure 330 Manufacturing process for part shown in Figure 3--2929FIGURE 3FIGURE 3--30 Manufacturing process for part shown in Figure 330 Manufacturing process for part shown in Figure 3--2929
A Processing ExampleA Processing Example
TheThe fixturefixture designdesign waswas basedbased onon thethe followingfollowing factorsfactors::
�� TheThe 44..000000 diameterdiameter andand ..3838 dimensionsdimensions werewere completedcompleted inin
thethe previousprevious operation,operation, makingmaking thisthis featurefeature thethe logicallogical choicechoice
forfor locatinglocating thethe partpart
�� TheThe runrun quantityquantity isis onlyonly 200200 partsparts.. TheThe fixturefixture designdesign isis
simple,simple, makingmaking itit economicaleconomical toto buildbuild
TheThe fixturefixture designdesign waswas basedbased onon thethe followingfollowing factorsfactors::
�� TheThe 44..000000 diameterdiameter andand ..3838 dimensionsdimensions werewere completedcompleted inin
thethe previousprevious operation,operation, makingmaking thisthis featurefeature thethe logicallogical choicechoice
forfor locatinglocating thethe partpart
�� TheThe runrun quantityquantity isis onlyonly 200200 partsparts.. TheThe fixturefixture designdesign isis
simple,simple, makingmaking itit economicaleconomical toto buildbuild
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
simple,simple, makingmaking itit economicaleconomical toto buildbuild
�� TheThe designdesign isis easyeasy toto loadload
simple,simple, makingmaking itit economicaleconomical toto buildbuild
�� TheThe designdesign isis easyeasy toto loadload
A Processing ExampleA Processing Example
FixtureFixture ConceptConcept::
�� TheThe fixturefixture isis usedused toto holdhold
thethe partpart
�� TheThe fixturefixture isis developeddeveloped byby
thethe NCNC programmerprogrammer
�� TheThe partpart willwill bebe nestednested inin thethe
44..00150015--inchinch diameterdiameter fixturefixture
FixtureFixture ConceptConcept::
�� TheThe fixturefixture isis usedused toto holdhold
thethe partpart
�� TheThe fixturefixture isis developeddeveloped byby
thethe NCNC programmerprogrammer
�� TheThe partpart willwill bebe nestednested inin thethe
44..00150015--inchinch diameterdiameter fixturefixture
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGUREFIGURE 33--3131 FixtureFixture conceptconceptFIGUREFIGURE 33--3131 FixtureFixture conceptconcept
44..00150015--inchinch diameterdiameter fixturefixture
borebore
�� TheThe partpart willwill bebe clampedclamped withwith
44 swivellingswivelling clampsclamps
�� TheThe swivellingswivelling clampsclamps areare
purchasedpurchased fromfrom thethe toolingtooling
suppliersupplier
44..00150015--inchinch diameterdiameter fixturefixture
borebore
�� TheThe partpart willwill bebe clampedclamped withwith
44 swivellingswivelling clampsclamps
�� TheThe swivellingswivelling clampsclamps areare
purchasedpurchased fromfrom thethe toolingtooling
suppliersupplier
A Processing ExampleA Processing Example
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
FIGUREFIGURE 33--3232 NCNC setupsetup sheetsheet forfor CNCCNC machiningmachining centercenterFIGUREFIGURE 33--3232 NCNC setupsetup sheetsheet forfor CNCCNC machiningmachining centercenter
Speed and FeedsSpeed and Feeds
InsertInsert ShapeShapeInsertInsert ShapeShape
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
Speed and FeedsSpeed and Feeds
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
Speed and FeedsSpeed and Feeds
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
Speed and FeedsSpeed and Feeds
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
Speed and FeedsSpeed and Feeds
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
Speed and FeedsSpeed and Feeds
SpeedSpeed andand FeedsFeeds
The efficiency and the life of a cutting tool depend on the The efficiency and the life of a cutting tool depend on the
cutting feed and the feedrate at which it is runcutting feed and the feedrate at which it is run
Cutting SpeedCutting Speed
�� The The cutting speedcutting speed is the is the edgeedge or or circumferentialcircumferential speed of a toolspeed of a tool
�� In a machining center or In a machining center or millingmilling machine the machine the cutting speedcutting speed refers to the refers to the
edge speed of the rotating cutter edge speed of the rotating cutter
SpeedSpeed andand FeedsFeeds
The efficiency and the life of a cutting tool depend on the The efficiency and the life of a cutting tool depend on the
cutting feed and the feedrate at which it is runcutting feed and the feedrate at which it is run
Cutting SpeedCutting Speed
�� The The cutting speedcutting speed is the is the edgeedge or or circumferentialcircumferential speed of a toolspeed of a tool
�� In a machining center or In a machining center or millingmilling machine the machine the cutting speedcutting speed refers to the refers to the
edge speed of the rotating cutter edge speed of the rotating cutter
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
edge speed of the rotating cutter edge speed of the rotating cutter
�� In a turning center or In a turning center or lathelathe application the application the cutting speedcutting speed refers to the refers to the
edge speed of the rotating workpieceedge speed of the rotating workpiece
�� Cutting Speed (CS)Cutting Speed (CS) is expressed in is expressed in surface feet per minute (sfm)surface feet per minute (sfm)
�� CSCS is the number of feet a given point on a rotating part moves in one is the number of feet a given point on a rotating part moves in one
minuteminute
�� Proper Proper CSCS varies from material to material varies from material to material –– the softer the material the the softer the material the
higher the cutting speedhigher the cutting speed
edge speed of the rotating cutter edge speed of the rotating cutter
�� In a turning center or In a turning center or lathelathe application the application the cutting speedcutting speed refers to the refers to the
edge speed of the rotating workpieceedge speed of the rotating workpiece
�� Cutting Speed (CS)Cutting Speed (CS) is expressed in is expressed in surface feet per minute (sfm)surface feet per minute (sfm)
�� CSCS is the number of feet a given point on a rotating part moves in one is the number of feet a given point on a rotating part moves in one
minuteminute
�� Proper Proper CSCS varies from material to material varies from material to material –– the softer the material the the softer the material the
higher the cutting speedhigher the cutting speed
Speed and FeedsSpeed and Feeds
Cutting Speed DataCutting Speed Data
��The following rates are averages for The following rates are averages for highhigh--speed steel (HSS)speed steel (HSS) cutters. cutters.
��For For carbide cutterscarbide cutters, , double the cutting speed valuedouble the cutting speed value
Cutting speeds for LATHES:Cutting speeds for LATHES:
MATERIALMATERIALCUTTING SPEED (sfm)CUTTING SPEED (sfm)
Tool steelTool steel 5050
Cutting Speed DataCutting Speed Data
��The following rates are averages for The following rates are averages for highhigh--speed steel (HSS)speed steel (HSS) cutters. cutters.
��For For carbide cutterscarbide cutters, , double the cutting speed valuedouble the cutting speed value
Cutting speeds for LATHES:Cutting speeds for LATHES:
MATERIALMATERIALCUTTING SPEED (sfm)CUTTING SPEED (sfm)
Tool steelTool steel 5050
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
Tool steelTool steel 5050
Cast ironCast iron 6060
Mild steelMild steel 100100
Brass, soft bronze Brass, soft bronze 200200
Aluminum, magnesiumAluminum, magnesium 300300
Tool steelTool steel 5050
Cast ironCast iron 6060
Mild steelMild steel 100100
Brass, soft bronze Brass, soft bronze 200200
Aluminum, magnesiumAluminum, magnesium 300300
Speed and FeedsSpeed and Feeds
Cutting Speed DataCutting Speed DataCutting Speed DataCutting Speed DataCutting Speed for DRILLSCutting Speed for DRILLS
MATERIALMATERIAL CUTTING SPEED CUTTING SPEED
(sfm) (sfm)
Tool steelTool steel 5050
Cast ironCast iron 6060
Mild steelMild steel 100100
Brass, soft bronzeBrass, soft bronze 200200
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
Aluminum, magnesiumAluminum, magnesium 300300
Cutting speeds for MILLINGCutting speeds for MILLING
MATERIALMATERIAL CUTTING SPEED CUTTING SPEED
(sfm)(sfm)
Tool steelTool steel 4040
Cast ironCast iron 5050
Mild steelMild steel 8080
Brass, soft bronzeBrass, soft bronze 160160
Aluminum, magnesiumAluminum, magnesium 200200
Speed and FeedsSpeed and Feeds
CuttingCutting SpeedSpeed
�� CuttingCutting SpeedSpeed (CS)(CS) andand SpindleSpindle rpmrpm areare twotwo differentdifferent thingsthings::
ExampleExample::
�� AA 00..250250--inchinch diameterdiameter drilldrill turningturning atat 11,,200200 rpmrpm hashas aa CSCS ofof caca 7575 sfmsfm
�� AA 00..500500--inchinch diameterdiameter drilldrill turningturning atat 11,,200200 rpmrpm hashas aa CSCS ofof caca 150150 sfmsfm
�� TheThe spindlespindle necessarynecessary rpmrpm toto achieveachieve aa givengiven CSCS cancan bebe calculatedcalculated byby
thethe formulaformula::
CuttingCutting SpeedSpeed
�� CuttingCutting SpeedSpeed (CS)(CS) andand SpindleSpindle rpmrpm areare twotwo differentdifferent thingsthings::
ExampleExample::
�� AA 00..250250--inchinch diameterdiameter drilldrill turningturning atat 11,,200200 rpmrpm hashas aa CSCS ofof caca 7575 sfmsfm
�� AA 00..500500--inchinch diameterdiameter drilldrill turningturning atat 11,,200200 rpmrpm hashas aa CSCS ofof caca 150150 sfmsfm
�� TheThe spindlespindle necessarynecessary rpmrpm toto achieveachieve aa givengiven CSCS cancan bebe calculatedcalculated byby
thethe formulaformula::
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
thethe formulaformula::thethe formulaformula::
π×
=
D
12xCSrpm
WhereWhere :: CSCS == cuttingcutting speedspeed inin surfacesurface feetfeet perper minuteminute (sfm)(sfm)
DD == diameterdiameter inin inchesinches ofof thethe tooltool oror workpieceworkpiece diameterdiameter forfor lathelathe
ππ == 33..14161416
WhereWhere :: CSCS == cuttingcutting speedspeed inin surfacesurface feetfeet perper minuteminute (sfm)(sfm)
DD == diameterdiameter inin inchesinches ofof thethe tooltool oror workpieceworkpiece diameterdiameter forfor lathelathe
ππ == 33..14161416
Speed and FeedsSpeed and Feeds
CuttingCutting SpeedSpeed�� TheThe cuttingcutting speedspeed ofof aa particularparticular tooltool cancan bebe determineddetermined fromfrom thethe rpmrpm
usingusing thethe formulaformula::
CuttingCutting SpeedSpeed�� TheThe cuttingcutting speedspeed ofof aa particularparticular tooltool cancan bebe determineddetermined fromfrom thethe rpmrpm
usingusing thethe formulaformula::
12
rpmDCS
×π×
=
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
�� OnOn thethe shopshop floorfloor thethe formulasformulas areare oftenoften simplifiedsimplified
�� TheThe followingfollowing formulasformulas willwill yieldyield resultsresults similarsimilar toto thethe formulasformulas justjust givengiven::
�� OnOn thethe shopshop floorfloor thethe formulasformulas areare oftenoften simplifiedsimplified
�� TheThe followingfollowing formulasformulas willwill yieldyield resultsresults similarsimilar toto thethe formulasformulas justjust givengiven::
4
DrpmCS
×
=
D
4CSrpm
×
=
Speed and FeedsSpeed and Feeds
SpeedSpeed andand FeedsFeeds
Important NoteImportant Note
�� For For TurningTurning applications the applications the Diameter of the WorkpieceDiameter of the Workpiece rather than the rather than the
tool diameter is used to determine the tool diameter is used to determine the cutting speedcutting speed and and spindle speedspindle speed
SpeedSpeed andand FeedsFeeds
Important NoteImportant Note
�� For For TurningTurning applications the applications the Diameter of the WorkpieceDiameter of the Workpiece rather than the rather than the
tool diameter is used to determine the tool diameter is used to determine the cutting speedcutting speed and and spindle speedspindle speed
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
tool diameter is used to determine the tool diameter is used to determine the cutting speedcutting speed and and spindle speedspindle speed
�� For For MillingMilling applications the applications the Diameter of the ToolDiameter of the Tool is used to determine the is used to determine the
cutting speed and spindle speedcutting speed and spindle speed
tool diameter is used to determine the tool diameter is used to determine the cutting speedcutting speed and and spindle speedspindle speed
�� For For MillingMilling applications the applications the Diameter of the ToolDiameter of the Tool is used to determine the is used to determine the
cutting speed and spindle speedcutting speed and spindle speed
Speed and FeedsSpeed and Feeds
FeedrateFeedrate
FeedrateFeedrate is the velocity at which the is the velocity at which the tool is fed into the tool is fed into the workpieceworkpiece
FeedratesFeedrates are expressed in two ways:are expressed in two ways:
�� inches per minute of inches per minute of spindle travelspindle travel
�� Inches per revolution of the Inches per revolution of the spindlespindle
�� For For millingmilling applications applications feedratesfeedrates are generally given in are generally given in inches per inches per
minute (minute (ipmipm)) of spindle travelof spindle travel
FeedrateFeedrate
FeedrateFeedrate is the velocity at which the is the velocity at which the tool is fed into the tool is fed into the workpieceworkpiece
FeedratesFeedrates are expressed in two ways:are expressed in two ways:
�� inches per minute of inches per minute of spindle travelspindle travel
�� Inches per revolution of the Inches per revolution of the spindlespindle
�� For For millingmilling applications applications feedratesfeedrates are generally given in are generally given in inches per inches per
minute (minute (ipmipm)) of spindle travelof spindle travel
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
minute (minute (ipmipm)) of spindle travelof spindle travel
�� For For turningturning applications applications feedratesfeedrates are given in are given in inches per revolution (inches per revolution (ipripr))
of the spindleof the spindle
WHY Feed Rates are critical for the effectiveness of a job?WHY Feed Rates are critical for the effectiveness of a job?
�� Too heavyToo heavy a federate will result in premature burning of the toola federate will result in premature burning of the tool
�� Too lightToo light a federate will result in tools chipping which rapidly leads to a federate will result in tools chipping which rapidly leads to
tool burning and breakagetool burning and breakage
minute (minute (ipmipm)) of spindle travelof spindle travel
�� For For turningturning applications applications feedratesfeedrates are given in are given in inches per revolution (inches per revolution (ipripr))
of the spindleof the spindle
WHY Feed Rates are critical for the effectiveness of a job?WHY Feed Rates are critical for the effectiveness of a job?
�� Too heavyToo heavy a federate will result in premature burning of the toola federate will result in premature burning of the tool
�� Too lightToo light a federate will result in tools chipping which rapidly leads to a federate will result in tools chipping which rapidly leads to
tool burning and breakagetool burning and breakage
Speed and FeedsSpeed and Feeds
TURNINGTURNING FeedratesFeedrates�� The vast majority of tools used with NC are inserted toolsThe vast majority of tools used with NC are inserted tools
�� The feed rates vary with:The feed rates vary with:
��Material typeMaterial type
��Insert TypeInsert Type
�� Tables of manufacturers’ catalogs and machining data handbooks are the Tables of manufacturers’ catalogs and machining data handbooks are the
best sources for turning feedrates best sources for turning feedrates
TURNINGTURNING FeedratesFeedrates�� The vast majority of tools used with NC are inserted toolsThe vast majority of tools used with NC are inserted tools
�� The feed rates vary with:The feed rates vary with:
��Material typeMaterial type
��Insert TypeInsert Type
�� Tables of manufacturers’ catalogs and machining data handbooks are the Tables of manufacturers’ catalogs and machining data handbooks are the
best sources for turning feedrates best sources for turning feedrates
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
WHY the values given in tables are starting points?WHY the values given in tables are starting points?
�� Conditions which are also affect CS and feedrates are the following:Conditions which are also affect CS and feedrates are the following:
��Part geometryPart geometry
��Machine rigidity Machine rigidity
��Machine setupMachine setup
�� The actual CS and feedrate used during the run will ultimately be The actual CS and feedrate used during the run will ultimately be
determined determined when the first piece is run during the job setupwhen the first piece is run during the job setup
WHY the values given in tables are starting points?WHY the values given in tables are starting points?
�� Conditions which are also affect CS and feedrates are the following:Conditions which are also affect CS and feedrates are the following:
��Part geometryPart geometry
��Machine rigidity Machine rigidity
��Machine setupMachine setup
�� The actual CS and feedrate used during the run will ultimately be The actual CS and feedrate used during the run will ultimately be
determined determined when the first piece is run during the job setupwhen the first piece is run during the job setup
Speed and FeedsSpeed and Feeds
DrillingDrilling FeedratesFeedrates�� DrillingDrilling feedratesfeedrates dependdepend onon thethe drilldrill diameterdiameter
�� ValuesValues forfor HSSHSS drillsdrills fromfrom tablestables inin machinists’machinists’ handbookshandbooks
DrillingDrilling FeedratesFeedrates�� DrillingDrilling feedratesfeedrates dependdepend onon thethe drilldrill diameterdiameter
�� ValuesValues forfor HSSHSS drillsdrills fromfrom tablestables inin machinists’machinists’ handbookshandbooks
MATERIALMATERIAL CUTTING SPEEDCUTTING SPEED
Tool steelTool steel 5050
Cast ironCast iron 6060
Mild steelMild steel 100100
Brass, soft bronzeBrass, soft bronze 200200
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
iprrpmipm ×=
WhereWhere :: ipmipm == thethe requiredrequired feedratefeedrate expressedexpressed inin inchesinches perper minuteminute
rpm=rpm= thethe programmedprogrammed spindlespindle speedspeed inin revolutionsrevolutions perper minuteminute
ipripr == thethe drilldrill feedratefeedrate toto bebe usedused expressedexpressed inin inchesinches perper revolutionrevolution
WhereWhere :: ipmipm == thethe requiredrequired feedratefeedrate expressedexpressed inin inchesinches perper minuteminute
rpm=rpm= thethe programmedprogrammed spindlespindle speedspeed inin revolutionsrevolutions perper minuteminute
ipripr == thethe drilldrill feedratefeedrate toto bebe usedused expressedexpressed inin inchesinches perper revolutionrevolution
Brass, soft bronzeBrass, soft bronze 200200
Aluminum, magnesiumAluminum, magnesium 300300
Speed and FeedsSpeed and Feeds
MILLINGMILLING FeedratesFeedrates
�� FeedsFeeds usedused inin millingmilling notnot onlyonly dependdepend onon thethe spindlespindle rpmrpm butbut alsoalso onon thethe
numbernumber ofof teethteeth onon thethe cuttercutter
�� TheThe millingmilling feedratefeedrate isis calculatedcalculated toto produceproduce aa desireddesired chipchip loadload onon eacheach
toothtooth ofof thethe cuttercutter
MILLINGMILLING FeedratesFeedrates
�� FeedsFeeds usedused inin millingmilling notnot onlyonly dependdepend onon thethe spindlespindle rpmrpm butbut alsoalso onon thethe
numbernumber ofof teethteeth onon thethe cuttercutter
�� TheThe millingmilling feedratefeedrate isis calculatedcalculated toto produceproduce aa desireddesired chipchip loadload onon eacheach
toothtooth ofof thethe cuttercutter
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
�� ExampleExample:: InIn endend millingmilling chipchip loadload shouldshould bebe 00..002002 inchinch toto 00..006006 inchinch
�� TheThe recommendedrecommended chipchip loadsloads forfor variousvarious millmill cutterscutters areare givengiven inin
machinists’machinists’ handbookshandbooks
�� ForFor insertedinserted cutterscutters manufacturers’manufacturers’ catalogcatalog willwill listlist recommendedrecommended chipchip
loadsloads forfor aa givengiven insertinsert
�� ExampleExample:: InIn endend millingmilling chipchip loadload shouldshould bebe 00..002002 inchinch toto 00..006006 inchinch
�� TheThe recommendedrecommended chipchip loadsloads forfor variousvarious millmill cutterscutters areare givengiven inin
machinists’machinists’ handbookshandbooks
�� ForFor insertedinserted cutterscutters manufacturers’manufacturers’ catalogcatalog willwill listlist recommendedrecommended chipchip
loadsloads forfor aa givengiven insertinsert
Speed and FeedsSpeed and Feeds
MillingMilling FeedratesFeedrates�� ToTo calculatecalculate thethe feedratefeedrate forfor aa millmill cutcut thethe followingfollowing formulaformula isis usedused
MillingMilling FeedratesFeedrates�� ToTo calculatecalculate thethe feedratefeedrate forfor aa millmill cutcut thethe followingfollowing formulaformula isis usedused
rpmTRF ××=
WhereWhere :: FF == thethe millingmilling feedratefeedrate expressedexpressed inin inchesinches perper minuteminute
RR == thethe chipchip loadload perper toothtooth
WhereWhere :: FF == thethe millingmilling feedratefeedrate expressedexpressed inin inchesinches perper minuteminute
RR == thethe chipchip loadload perper toothtooth
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
RR == thethe chipchip loadload perper toothtooth
TT == thethe numbernumber ofof teethteeth onon thethe cuttercutter
rpmrpm == thethe spindlespindle speedspeed inin revolutionsrevolutions perper minuteminute
�� MillingMilling feedratesfeedrates areare alsoalso affectedaffected byby::
��MachineMachine rigidityrigidity
��SetSet upup
��PartPart geometrygeometry
RR == thethe chipchip loadload perper toothtooth
TT == thethe numbernumber ofof teethteeth onon thethe cuttercutter
rpmrpm == thethe spindlespindle speedspeed inin revolutionsrevolutions perper minuteminute
�� MillingMilling feedratesfeedrates areare alsoalso affectedaffected byby::
��MachineMachine rigidityrigidity
��SetSet upup
��PartPart geometrygeometry
Speed and FeedsSpeed and Feeds
MillingMilling FeedratesFeedrates�� InIn thethe casecase ofof insertedinserted millingmilling cutterscutters ChipChip ThicknessThickness affectsaffects feedratesfeedrates tootoo
�� ThisThis isis notnot thethe chipchip loadload onon thethe toothtooth butbut thethe actualactual thicknessthickness ofof thethe chipchip
producedproduced atat aa givengiven feedratefeedrate
�� ChipChip thicknessthickness willwill varyvary withwith thethe geometrygeometry ofof thethe cuttercutter::
��PositivePositive RakeRake
��NegativeNegative RakeRake
��NeutralNeutral RakeRake
MillingMilling FeedratesFeedrates�� InIn thethe casecase ofof insertedinserted millingmilling cutterscutters ChipChip ThicknessThickness affectsaffects feedratesfeedrates tootoo
�� ThisThis isis notnot thethe chipchip loadload onon thethe toothtooth butbut thethe actualactual thicknessthickness ofof thethe chipchip
producedproduced atat aa givengiven feedratefeedrate
�� ChipChip thicknessthickness willwill varyvary withwith thethe geometrygeometry ofof thethe cuttercutter::
��PositivePositive RakeRake
��NegativeNegative RakeRake
��NeutralNeutral RakeRake
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
��NeutralNeutral RakeRake
NoteNote:: RakeRake AngleAngle isis thethe angleangle thethe chipschips flowflow awayaway fromfrom thethe cuttingcutting areaarea
�� ChipChip thicknessthickness valuesvalues:: 00..004004 inchinch toto 00..008008 inchinch
�� ChipChip thicknessthickness lessless thanthan oror greatergreater thanthan thesethese valuesvalues willwill placeplace eithereither tootoo
littlelittle oror tootoo greatgreat pressurepressure onon thethe insertinsert forfor efficientefficient machiningmachining
�� OnceOnce aa feedratefeedrate isis calculatedcalculated thethe chipchip thicknessthickness itit producesproduces shouldshould bebe
derivedderived
�� IFIF thethe chipchip thicknessthickness isis outout ofof thethe recommendedrecommended rangerange THENTHEN thethe feedratefeedrate
shouldshould bebe adjustedadjusted toto bringbring itit inin toto acceptableacceptable limitslimits
��NeutralNeutral RakeRake
NoteNote:: RakeRake AngleAngle isis thethe angleangle thethe chipschips flowflow awayaway fromfrom thethe cuttingcutting areaarea
�� ChipChip thicknessthickness valuesvalues:: 00..004004 inchinch toto 00..008008 inchinch
�� ChipChip thicknessthickness lessless thanthan oror greatergreater thanthan thesethese valuesvalues willwill placeplace eithereither tootoo
littlelittle oror tootoo greatgreat pressurepressure onon thethe insertinsert forfor efficientefficient machiningmachining
�� OnceOnce aa feedratefeedrate isis calculatedcalculated thethe chipchip thicknessthickness itit producesproduces shouldshould bebe
derivedderived
�� IFIF thethe chipchip thicknessthickness isis outout ofof thethe recommendedrecommended rangerange THENTHEN thethe feedratefeedrate
shouldshould bebe adjustedadjusted toto bringbring itit inin toto acceptableacceptable limitslimits
Speed and FeedsSpeed and Feeds
RD
WCT ×=
MillingMilling FeedratesFeedrates�� ChipChip ThicknessThickness cancan bebe calculatedcalculated byby thethe followingfollowing formulaformula::
MillingMilling FeedratesFeedrates�� ChipChip ThicknessThickness cancan bebe calculatedcalculated byby thethe followingfollowing formulaformula::
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
WhereWhere :: CTCT == thethe chipchip thicknessthickness
WW == thethe widthwidth ofof thethe cutcut
DD == thethe diameterdiameter ofof thethe cuttercutter
RR == thethe feedfeed perper toothtooth
WhereWhere :: CTCT == thethe chipchip thicknessthickness
WW == thethe widthwidth ofof thethe cutcut
DD == thethe diameterdiameter ofof thethe cuttercutter
RR == thethe feedfeed perper toothtooth
Speed and FeedsSpeed and Feeds
CTW
Df ×=
MillingMilling FeedratesFeedrates�� IFIF thethe ChipChip ThicknessThickness isis tootoo smallsmall aa modificationmodification ofof thethe precedingpreceding formulaformula
cancan bebe usedused toto determinedetermine anan acceptableacceptable feedratefeedrate
MillingMilling FeedratesFeedrates�� IFIF thethe ChipChip ThicknessThickness isis tootoo smallsmall aa modificationmodification ofof thethe precedingpreceding formulaformula
cancan bebe usedused toto determinedetermine anan acceptableacceptable feedratefeedrate
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
W
WhereWhere :: ff == thethe feedfeed perper toothtooth beingbeing calculatedcalculated
DD == thethe diameterdiameter ofof thethe cuttercutter
CTCT == thethe desireddesired chipchip thicknessthickness
�� TheThe newnew calculatedcalculated valuevalue ofof thethe FeedFeed perper ToothTooth cancan bebe thenthen
substitutedsubstituted backback intointo thethe feedratefeedrate formulaformula andand aa newnew FeedrateFeedrate
calculatedcalculated
WhereWhere :: ff == thethe feedfeed perper toothtooth beingbeing calculatedcalculated
DD == thethe diameterdiameter ofof thethe cuttercutter
CTCT == thethe desireddesired chipchip thicknessthickness
�� TheThe newnew calculatedcalculated valuevalue ofof thethe FeedFeed perper ToothTooth cancan bebe thenthen
substitutedsubstituted backback intointo thethe feedratefeedrate formulaformula andand aa newnew FeedrateFeedrate
calculatedcalculated
Speed and FeedsSpeed and Feeds
SpeedSpeed andand FeedFeed ExampleExample�� AnAn aluminiumaluminium workpieceworkpiece isis toto bebe milledmilled usingusing aa carbidecarbide insertedinserted millmill cuttercutter
�� TheThe cuttercutter isis 11..750750 inchinch diameterdiameter xx 44 fluteflute
What should be the appropriate Spindle rpm and Milling Feedrate?What should be the appropriate Spindle rpm and Milling Feedrate?
�� StepStep 11:: CalculateCalculate SpindleSpindle SpeedSpeed (rpm)(rpm) withwith thethe followingfollowing formulaformula::
SpeedSpeed andand FeedFeed ExampleExample�� AnAn aluminiumaluminium workpieceworkpiece isis toto bebe milledmilled usingusing aa carbidecarbide insertedinserted millmill cuttercutter
�� TheThe cuttercutter isis 11..750750 inchinch diameterdiameter xx 44 fluteflute
What should be the appropriate Spindle rpm and Milling Feedrate?What should be the appropriate Spindle rpm and Milling Feedrate?
�� StepStep 11:: CalculateCalculate SpindleSpindle SpeedSpeed (rpm)(rpm) withwith thethe followingfollowing formulaformula::
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
183,21416.375.1
12000,1rpm =
×
×
=
π×
=
D
12xCSrpm
�� StepStep 22:: SelectSelect CSCS == 11,,000000 sfmsfm (surface(surface feetfeet perper minute)minute) forfor AluminumAluminum�� StepStep 22:: SelectSelect CSCS == 11,,000000 sfmsfm (surface(surface feetfeet perper minute)minute) forfor AluminumAluminum
Speed and FeedsSpeed and Feeds
004.04183.2F ××= min/inches91.34F =
SpeedSpeed andand FeedFeed ExampleExample�� StepStep 33:: CalculateCalculate FeedrateFeedrate withwith thethe followingfollowing formulaformula::
SpeedSpeed andand FeedFeed ExampleExample�� StepStep 33:: CalculateCalculate FeedrateFeedrate withwith thethe followingfollowing formulaformula::
rpmTRF ××=
�� StepStep 44:: SelectSelect RR == 00..004004 (chip(chip loadload perper tooth)tooth) –– valuesvalues areare 00..002002 toto 00..006006�� StepStep 44:: SelectSelect RR == 00..004004 (chip(chip loadload perper tooth)tooth) –– valuesvalues areare 00..002002 toto 00..006006
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
004.0750.1
000.1CT ×= 00302.0CT =
�� StepStep 55:: CalculateCalculate thethe chipchip thicknessthickness toto insureinsure thatthat thethe insertsinserts willwill notnot breakbreak
downdown prematurelyprematurely:: ItIt isis assumedassumed WidthWidth ofof thethe CutCut == 11..000000 inchinch widewide
�� StepStep 55:: CalculateCalculate thethe chipchip thicknessthickness toto insureinsure thatthat thethe insertsinserts willwill notnot breakbreak
downdown prematurelyprematurely:: ItIt isis assumedassumed WidthWidth ofof thethe CutCut == 11..000000 inchinch widewide
�� StepStep 66:: CTCT isis lessless thanthan thethe recommendedrecommended minmin ofof 00..004004 andand thethe feedfeed perper
toothtooth mustmust bebe calculatedcalculated
�� StepStep 66:: CTCT isis lessless thanthan thethe recommendedrecommended minmin ofof 00..004004 andand thethe feedfeed perper
toothtooth mustmust bebe calculatedcalculated
RD
WCT ×=
Speed and FeedsSpeed and Feeds
0.0081.000
1.75f ×= 010.0f =
SpeedSpeed andand FeedFeed ExampleExample�� StepStep 77:: CalculateCalculate FeedFeed perper toothtooth withwith thethe followingfollowing formulaformula andand CTCT == 00..008008
SpeedSpeed andand FeedFeed ExampleExample�� StepStep 77:: CalculateCalculate FeedFeed perper toothtooth withwith thethe followingfollowing formulaformula andand CTCT == 00..008008
CTW
Df ×=
�� StepStep 33:: TheThe newnew valuevalue forfor thethe chipchip loadload perper toothtooth isis substitutedsubstituted inin thethe
feedratefeedrate formulaformula andand recalculaterecalculate FeedrateFeedrate::
�� StepStep 33:: TheThe newnew valuevalue forfor thethe chipchip loadload perper toothtooth isis substitutedsubstituted inin thethe
feedratefeedrate formulaformula andand recalculaterecalculate FeedrateFeedrate::
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
010.042138F ××= min/inches32.87F =
feedratefeedrate formulaformula andand recalculaterecalculate FeedrateFeedrate::feedratefeedrate formulaformula andand recalculaterecalculate FeedrateFeedrate::
ConclusionConclusion::
�� TheThe 22,,813813 rpmrpm spindlespindle speedspeed andand 8787..3232 inchesinches perper minmin feedratefeedrate areare
“book“book value”value” ratesrates
�� TheyThey willwill havehave toto bebe adjustedadjusted upup oror downdown dependingdepending onon thethe
machine,machine, fixturefixture andand workpieceworkpiece
ConclusionConclusion::
�� TheThe 22,,813813 rpmrpm spindlespindle speedspeed andand 8787..3232 inchesinches perper minmin feedratefeedrate areare
“book“book value”value” ratesrates
�� TheyThey willwill havehave toto bebe adjustedadjusted upup oror downdown dependingdepending onon thethe
machine,machine, fixturefixture andand workpieceworkpiece
SummarySummary
�� ProcessProcess planningplanning isis thethe termterm usedused toto describedescribe thethe stepssteps thethe
programmerprogrammer usesuses toto developdevelop andand implementimplement aa partpart
programmingprogramming
�� TheThe stepssteps inin processprocess planningplanning areare:: determinedetermine thethe machine,machine,
determinedetermine thethe workholding,workholding, determinedetermine thethe machiningmachining
strategy,strategy, selectselect thethe toolstools toto bebe usedused
�� ProcessProcess planningplanning isis thethe termterm usedused toto describedescribe thethe stepssteps thethe
programmerprogrammer usesuses toto developdevelop andand implementimplement aa partpart
programmingprogramming
�� TheThe stepssteps inin processprocess planningplanning areare:: determinedetermine thethe machine,machine,
determinedetermine thethe workholding,workholding, determinedetermine thethe machiningmachining
strategy,strategy, selectselect thethe toolstools toto bebe usedused
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
�� ToolTool selectionselection isis importantimportant toto thethe efficiencyefficiency ofof thethe NCNC
programprogram
�� CuttingCutting toolstools forfor NCNC areare mademade inin highhigh--speedspeed steel,steel, tungstentungsten
carbide,carbide, andand ceramicceramic
�� InsertedInserted cutterscutters areare thethe preferredpreferred toolstools forfor NCNC useuse
�� ToolTool selectionselection isis importantimportant toto thethe efficiencyefficiency ofof thethe NCNC
programprogram
�� CuttingCutting toolstools forfor NCNC areare mademade inin highhigh--speedspeed steel,steel, tungstentungsten
carbide,carbide, andand ceramicceramic
�� InsertedInserted cutterscutters areare thethe preferredpreferred toolstools forfor NCNC useuse
SummarySummary
�� InsertsInserts areare manufacturedmanufactured inin differentdifferent gradesgrades withwith differentdifferent
applicationsapplications intendedintended
�� CuttingCutting speedspeed isis thethe edgeedge speedspeed ofof thethe tooltool;; itit isis aa functionfunction onon
thethe spindlespindle rpmrpm andand thethe tooltool diameterdiameter
�� FeedratesFeedrates thatthat areare tootoo heavyheavy willwill resultresult inin excessexcess tooltool wearwear
andand prematurepremature tooltool failurefailure
�� InsertsInserts areare manufacturedmanufactured inin differentdifferent gradesgrades withwith differentdifferent
applicationsapplications intendedintended
�� CuttingCutting speedspeed isis thethe edgeedge speedspeed ofof thethe tooltool;; itit isis aa functionfunction onon
thethe spindlespindle rpmrpm andand thethe tooltool diameterdiameter
�� FeedratesFeedrates thatthat areare tootoo heavyheavy willwill resultresult inin excessexcess tooltool wearwear
andand prematurepremature tooltool failurefailure
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
andand prematurepremature tooltool failurefailure
�� FeedratesFeedrates thatthat areare tootoo lightlight willwill resultresult inin chippedchipped toolstools andand
prematurepremature tooltool failurefailure
�� WhenWhen calculatingcalculating millingmilling feedrates,feedrates, chipchip thicknessthickness mustmust bebe
consideredconsidered
andand prematurepremature tooltool failurefailure
�� FeedratesFeedrates thatthat areare tootoo lightlight willwill resultresult inin chippedchipped toolstools andand
prematurepremature tooltool failurefailure
�� WhenWhen calculatingcalculating millingmilling feedrates,feedrates, chipchip thicknessthickness mustmust bebe
consideredconsidered
Vocabulary Introduced in this chapterVocabulary Introduced in this chapter
�� ChipChip thicknessthickness
�� CuttingCutting speedspeed (CS)(CS)
�� FeedrateFeedrate
�� HighHigh speedspeed steelsteel (HSS)(HSS)
�� MethodizingMethodizing
�� ChipChip thicknessthickness
�� CuttingCutting speedspeed (CS)(CS)
�� FeedrateFeedrate
�� HighHigh speedspeed steelsteel (HSS)(HSS)
�� MethodizingMethodizing
Laboratory for Manufacturing Systems and Automation Laboratory for Manufacturing Systems and Automation Dr. Dimitris MourtzisDr. Dimitris Mourtzis
�� MethodizingMethodizing
�� ProcessProcess planningplanning
�� NCNC setupsetup sheetsheet
�� TungstenTungsten carbidecarbide
�� MethodizingMethodizing
�� ProcessProcess planningplanning
�� NCNC setupsetup sheetsheet
�� TungstenTungsten carbidecarbide
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