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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:


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




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


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:


�� 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?



The collaboration between CAM, CAPP and CAD systems (Ming et al. 2008)



Role of CAM in a typical product lifecycle (Zeid 1991)



Manufacturing information flow in the state-of-the-art CAD/CAM/CNC chain (Newman et al. 2008)



CAD/CAM links and flow of a computer-aided system (Rehg and Kraebber 2005)

Evolution of turning machinesEvolution of turning machines


‘‘‘‘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



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 machinesmachines areare available?available?





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


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


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)


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


XY

Z

BC

XZ

C







XY

Z

BC

XZ

C








(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


(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



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?


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



�� WhatWhat isis thethe shapeshape ofof thethe partpart

�� WhatWhat isis thethe blueprintblueprint tolerancetolerance??

�� WhatWhat toolingtooling isis available?available?



�� WhatWhat isis thethe shapeshape ofof thethe partpart

�� WhatWhat isis thethe blueprintblueprint tolerancetolerance??

�� WhatWhat toolingtooling isis available?available?



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


�� WhatWhat toolstools areare availableavailable??

�� WhatWhat machiningmachining strategystrategy isis toto bebe used?used?


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?


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?


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


�� TheThe programmerprogrammer mustmust

communicatecommunicate toto thethe

setupsetup personnelpersonnel inin thethe

shopshop whatwhat toolstools andand

fixturesfixtures areare toto bebe usedused

inin thethe NCNC programprogram


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



�� SpecialSpecial instructionsinstructions toto

thethe setupsetup personnelpersonnel oror

machinemachine operatorsoperators

shouldshould bebe includedincluded


�� SpecialSpecial instructionsinstructions toto

thethe setupsetup personnelpersonnel oror

machinemachine operatorsoperators



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


�� SpecialSpecial notesnotes regardingregarding

toolingtooling shouldshould alsoalso bebe

includedincluded


�� SpecialSpecial notesnotes regardingregarding

toolingtooling shouldshould alsoalso bebe

includedincluded

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


MaterialsMaterials

High Speed High Speed SteelSteel

TUNGSTEN TUNGSTEN CarbideCarbide

CeramicCeramic


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


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


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


Carbide ToolsCarbide Tools

Solid CarbideSolid CarbideToolsTools

Brazed Brazed CarbideCarbideToolsTools

Inserted Inserted CarbideCarbide

ToolingTooling


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::


�� 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




�� 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


�� 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 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 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




�� Carbide is Carbide is harder to resharpenharder to resharpen and requires diamond grinding wheelsand requires diamond grinding wheels


�� Carbide is Carbide is harder to resharpenharder to resharpen and requires diamond grinding wheelsand requires diamond grinding wheels


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


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


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




��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


��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


Tooling for Tooling for Hole Hole

OperationsOperations

DrillingDrilling ReamingReaming BoringBoring TappingTapping


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



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


�� DrillsDrills alsoalso produceproduce triangulartriangular-- shapedshaped holesholes


�� DrillsDrills alsoalso produceproduce triangulartriangular-- shapedshaped holesholes

FIGURE 3FIGURE 3--4 Center drill 4 Center drill FIGURE 3FIGURE 3--4 Center drill 4 Center drill


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


FIGURE 3FIGURE 3--5 Spade drill 5 Spade drill FIGURE 3FIGURE 3--5 Spade drill 5 Spade drill


�� 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


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))


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))


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


�� StraightStraight flutedfluted reamersreamers (Fig(Fig.. 33--77))�� StraightStraight flutedfluted reamersreamers (Fig(Fig.. 33--77))


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


FIGURE 3FIGURE 3--8 Spiral flute chucking reamers 8 Spiral flute chucking reamers


FIGURE 3FIGURE 3--8 Spiral flute chucking reamers 8 Spiral flute chucking reamers


��SolidSolid carbidecarbide��SolidSolid carbidecarbide


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


�� 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


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



FIGURE 3FIGURE 3--9 Machining screw tap9 Machining screw tapFIGURE 3FIGURE 3--9 Machining screw tap9 Machining screw tap


Aluminum)Aluminum)


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 allowsallows thethe contouringcontouring capabilitiescapabilities ofof thethe NCNC machinemachine toto bebe usedused toto

efficientlyefficiently performperform operationsoperations thatthat wouldwould requirerequire specialspecial toolingtooling ifif donedone

manuallymanually



Solid Milling Solid Milling CuttersCutters

Inserted Inserted Milling CuttersMilling Cutters



CanCan alsoalso bebe furtherfurther classifiedclassified inin::


CanCan alsoalso bebe furtherfurther classifiedclassified inin::

Milling Milling CuttersCutters


CuttersCutters

End MillsEnd Mills Face MillsFace Mills


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


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)


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::


�� 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:




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


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)


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


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)


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


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)


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



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)


patternpattern

�� CycloCyclo MillMill cancan removeremove largelarge

amountamount ofof materialmaterial atat highhigh speedsspeeds

�� CycloCyclo MillMill waswas developeddeveloped forfor NCNC

useuse


patternpattern

�� CycloCyclo MillMill cancan removeremove largelarge

amountamount ofof materialmaterial atat highhigh speedsspeeds

�� CycloCyclo MillMill waswas developeddeveloped forfor NCNC

useuse


FaceFace MillsMills�� FaceFace MillsMills areare designeddesigned toto removeremove largelarge amountsamounts ofof materialmaterial fromfrom thethe faceface

ofof thethe workpieceworkpiece

�� FaceFace MillsMills areare manufacturedmanufactured inin::


�� 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::


�� BrazedBrazed CarbideCarbide

�� InsertedInserted CarbideCarbide (the(the mostmost commoncommon typetype ofof facingfacing tool)tool)



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)


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


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�� 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


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)


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



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)


betweenbetween EndEnd MillMill andand FaceFace

MillMill


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




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


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



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


�� 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


�� aa machinemachine taptap inin aa taptap holderholder withwith


�� 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)


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




�� tooltool bodiesbodies

�� boringboring headsheads

�� arborsarbors


�� tooltool bodiesbodies

�� boringboring headsheads

�� arborsarbors


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


CommonCommonInsertInsert

SHAPESSHAPES

TriangularTriangular 8080oo DiamondDiamond 5555oo DiamondDiamond RoundRound


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


�� 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))



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)


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



FIGUREFIGURE 33--2626 CarbideCarbide insertinsert gradesgradesFIGUREFIGURE 33--2626 CarbideCarbide insertinsert gradesgrades


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


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



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



FIGUREFIGURE 33--2929 PartPart drawingdrawingFIGUREFIGURE 33--2929 PartPart drawingdrawing


�� 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 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


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


�� 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



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


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




�� TheThe designdesign isis easyeasy toto loadload


�� TheThe designdesign isis easyeasy toto loadload


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



FIGUREFIGURE 33--3131 FixtureFixture conceptconceptFIGUREFIGURE 33--3131 FixtureFixture conceptconcept


borebore

�� TheThe partpart willwill bebe clampedclamped withwith

44 swivellingswivelling clampsclamps

�� TheThe swivellingswivelling clampsclamps areare

purchasedpurchased fromfrom thethe toolingtooling

suppliersupplier


borebore

�� TheThe partpart willwill bebe clampedclamped withwith

44 swivellingswivelling clampsclamps

�� TheThe swivellingswivelling clampsclamps areare

purchasedpurchased fromfrom thethe toolingtooling

suppliersupplier



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



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


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




�� 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


�� 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


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)




Cast ironCast iron 6060

Mild steelMild steel 100100

Brass, soft bronze Brass, soft bronze 200200

Aluminum, magnesiumAluminum, magnesium 300300




Brass, soft bronze Brass, soft bronze 200200



Cutting Speed DataCutting Speed DataCutting Speed DataCutting Speed DataCutting Speed for DRILLSCutting Speed for DRILLS

MATERIALMATERIAL CUTTING SPEED CUTTING SPEED

(sfm) (sfm)




Brass, soft bronzeBrass, soft bronze 200200



Cutting speeds for MILLINGCutting speeds for MILLING

MATERIALMATERIAL CUTTING SPEED CUTTING SPEED

(sfm)(sfm)







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


�� 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::



�� TheThe spindlespindle necessarynecessary rpmrpm toto achieveachieve aa givengiven CSCS cancan bebe calculatedcalculated byby

thethe formulaformula::


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


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×

=


�� 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

×

=



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


Important NoteImportant Note

�� For For TurningTurning applications the applications the Diameter of the WorkpieceDiameter of the Workpiece rather than the rather than the




�� 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


�� 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


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




�� 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


�� 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


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


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


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






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




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


�� 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


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




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


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


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




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


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


RD

WCT ×=

MillingMilling FeedratesFeedrates�� ChipChip ThicknessThickness cancan bebe calculatedcalculated byby thethe followingfollowing formulaformula::

MillingMilling FeedratesFeedrates�� ChipChip ThicknessThickness cancan bebe calculatedcalculated byby thethe followingfollowing formulaformula::


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


RR == thethe feedfeed perper toothtooth


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


W

WhereWhere :: ff == thethe feedfeed perper toothtooth beingbeing calculatedcalculated


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


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


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::


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


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


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 ×=


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::


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


�� 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




�� FeedratesFeedrates thatthat areare tootoo lightlight willwill resultresult inin chippedchipped toolstools andand

prematurepremature tooltool failurefailure

�� WhenWhen calculatingcalculating millingmilling feedrates,feedrates, chipchip thicknessthickness mustmust bebe

consideredconsidered


�� 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)




�� ProcessProcess planningplanning

�� NCNC setupsetup sheetsheet

�� TungstenTungsten carbidecarbide


�� ProcessProcess planningplanning

�� NCNC setupsetup sheetsheet

�� TungstenTungsten carbidecarbide

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