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Copyright © 1997 Society of Manufacturing Engineers

FUNDAMENTAL MANUFACTURING PROCESSES

CUTTING TOOL MATERIALS

SCENE 1. CG: FBI warning

SCENE 2. tape 40, 01:00:00-01:00:12 ANI: SME logo

SCENE 3. tape 25, 01:01:06-01:01:20 series opening title: FUNDAMENTAL MANUFACTURING PROCESSES tape 63, 12:06:32-12:09:06 opening music

MUSIC UP AND UNDER

NARRATION (VO):

THE FUNDAMENTAL MANUFACTURING PROCESSES VIDEO

SERIES. EXAMINING THE TOOLS AND TECHNIQUES OF

PRECISION METALWORKING.

SCENE 4. program title, CG: CUTTING TOOL MATERIALS white text centered on black

NARRATION (VO):

THIS PROGRAM IS AN INTRODUCTION TO CUTTING TOOLS

AND TOOL MATERIALS.

SCENE 5. tape 36, 00:01:12-00:01:25 cutting tool on lathe tape 4, 00:03:45-00:03:48 cutting tool milling tape 79, 02:03:52-02:03:55 drill, drilling tape 1, 00:06:33-00:06:36 boring on lathe tape 3, 00:07:03-00:07:05 milling cutter, spinning

NARRATION (VO):

TOOLING INCORPORATES THOUSANDS OF DIFFERENT

CUTTING TOOLS AND TOOLHOLDERS FOR DISCRETE PARTS

MANUFACTURING.

SCENE 6. tape 56, 01:23:20-01:23:31 cutting tool on lathe tape 217, 00:09:30-00:09:36 milling cutter, spinning tape 33, 02:26:30-02:26:42 drill, drilling tape 59, 02:28:38-02:28:42 reamer, reaming tape 80, 03:27:27-03:27:39 tap, starting to tap

NARRATION (VO):

PRINCIPAL CATEGORIES WITHIN “CUTTING TOOLS”

INCLUDE:

SINGLE POINT CUTTING TOOLS, SUCH AS LATHE TOOLS,

MULTI-POINT CUTTING TOOLS, SUCH AS MILLING


CUTTERS...,

DRILLS...,

REAMERS...,

AND TAPS.

SCENE 7. tape 4, 00:06:24-00:06:28 milling of part tape 237, 02:14:32-02:14:39 flipping through catalog of standard tools tape 235, 01:01:14-01:01:23 pull back, special tools

NARRATION (VO):

CUTTING TOOLS ARE EITHER STANDARD TOOLS, WHICH

ARE PURCHASED AS CATALOG ITEMS...,

OR SPECIAL TOOLS, WHICH ARE DESIGNED AND BUILT

FOR A SPECIAL MACHINING JOB--OFTEN TO SUIT A

PARTICULAR WORKPIECE.

--- FTB ---

SCENE 8. tape 210, 03:20:34-03:20:40 c.u. cutting tool on lathe tape 225, 02:03:34-02:03:46 ANI: triangular insert

NARRATION (VO):

THE MAIN OBJECTIVE IN THE SELECTION AND

APPLICATION OF CUTTING TOOLS IS TO SAFELY MACHINE

A WORKPIECE IN THE SHORTEST POSSIBLE TIME, WHILE

MEETING THE PART’S QUALITY REQUIREMENTS.

SCENE 9. tape 210, 03:21:25-03:21:38 c.u. cutting tool on lathe

NARRATION (VO):

FURTHERMORE, THE SPECIFIED TOOLING SHOULD BE THE

LEAST COSTLY AND LEAST COMPLEX TOOLING AVAILABLE

TO SATISFACTORILY FULFILL THE QUALITATIVE AND

QUANTITATIVE WORKPIECE DEMANDS.

SCENE 10. tape 235, 01:07:35-01:07:45 part being milled tape 92, 01:00:07-01:00:25 lathe holemaking using hss drill tape 92, 01:01:27-01:01:35 lathe holemaking using carbide drill

NARRATION (VO):

IT IS ESTIMATED THAT NEARLY FIFTY PERCENT OF ALL

CUTTING TOOLS ARE USED INCORRECTLY. ADDITIONALLY,

THE NUMBER ONE ERROR WHEN FORMULATING TOOLING

SELECTIONS IS CALCULATING MONETARY SAVINGS BASED


ON LOWEST COST PER TOOL, RATHER THAN ON MAXIMIZED

PRODUCTIVITY AND EXTENDED TOOL LIFE.

--- FTB ---

SCENE 11. tape 5, 00:08:43-00:08:52 4 shots, tool placed in spindle, cutting tape 225, 02:01:00-02:02:30 blue background CG: WORKPIECE STARTING & FINISHED SHAPE WORKPIECE HARDNESS WORKPIECE TENSILE STRENGTH MATERIAL ABRASIVENESS tape 5, 00:08:53-00:09:02 2 shots, part being milled

NARRATION (VO):

TO EFFECTIVELY SELECT TOOLS FOR MACHINING A PART,

A MACHINIST MUST HAVE SPECIFIC INFORMATION ABOUT

THE WORKPIECE, SUCH AS THE STARTING AND FINISHED

SHAPE,

THE HARDNESS,

THE TENSILE STRENGTH,

AND ABRASIVENESS OF THE MATERIAL. THESE FACTORS

ALL INFLUENCE THE INTERACTION BETWEEN THE TOOL

AND THE WORK.

SCENE 12. tape 216, 01:04:53-01:05:00 c.u. small chips produced on lathe tape 210, 03:06:46-03:06:56 c.u. long stringy chips snarling cutting tool

NARRATION (VO):

THE MACHINIST ALSO NEEDS TO KNOW WHETHER THE

WORKPIECE MATERIAL BREAKS INTO SHORT CHIPS EASILY

OR WHETHER IT TENDS TO FLOW INTO LONG, HARD-TO-

BREAK STRINGY CHIPS.

SCENE 13. tape 204, 01:04:42-01:04:56 workholding, machining of part

NARRATION (VO):

ALSO IMPORTANT IS THE PART’S WORKHOLDING SETUP

WHICH PROPERLY ORIENTATES AND HOLDS THE

WORKPIECE, AND THE POWER AND SPEED CAPACITY OF

THE MACHINE TOOL.

SCENE 14. tape 225, 02:01:00-02:02:30 blue background CG: CHANGES IN WORKPIECE MATERIAL PART TOLERANCES PART GEOMETRIES

NARRATION (VO):

CHANGES IN THE WORKPIECE MATERIAL, PART

TOLERANCES, GEOMETRIES, AND QUANTITIES REQUIRED,


REQUIRED QUANTITIES CHANGES IN TOOL MATERIALS TOOL GEOMETRIES

OFTEN DEMAND CORRESPONDING CHANGES IN THE TOOL

MATERIALS, AND OR TOOL GEOMETRIES SELECTED.

--- FTB ---

SCENE 15. CUTTING TOOL MATERIALS white text on black

SCENE 16. tape 2, 00:10:11-00:10:13 slot milling tape 3, 00:03:44-00:03:47 contour turning tape 5, 00:09:15-00:09:20 die milling tape 1, 00:06:09-00:06:17 cast iron turning

NARRATION (VO):

FOR THE WIDE VARIETY OF MACHINING APPLICATIONS

THERE IS A CORRESPONDING NECESSITY FOR DIFFERENT

CUTTING TOOL MATERIALS.

SCENE 17. continue previous shot tape 225, 02:01:00-02:02:30 blue background CG: HARDER THAN WORKPIECE RETAIN HARDNESS RESIST WEAR/THERMAL SHOCK IMPACT RESISTANT CHEMICALLY INERT

NARRATION (VO):

THE IDEAL CUTTING TOOL MATERIAL SHOULD BE:

HARDER THAN THE WORKPIECE IT IS CUTTING,

BE ABLE TO RETAIN ITS HARDNESS AND STABILITY AT

HIGH TEMPERATURES,

RESIST WEAR AND THERMAL SHOCK,

BE IMPACT RESISTANT, TO WITHSTAND THE MECHANICAL

SHOCKS OF MILLING,

AND ALSO BE CHEMICALLY INERT TO THE WORK MATERIAL

AND THE CUTTING FLUID.

SCENE 18. tape 187, 00:05:30-00:05:46 milling operation tape 225, 02:07:40:-02:07:52 ANI: balance of qualities CG, SUPER: CERAMICS CHEMICAL/THERMAL STABILITY MECHANICAL/THERMAL SHOCK

NARRATION (VO):

NO SINGLE CUTTING TOOL MATERIAL INCORPORATES ALL

THESE QUALITIES. INSTEAD, TRADE-OFFS OCCUR AMONG

THE VARIOUS TOOL MATERIALS. FOR EXAMPLE,

MATERIALS WITH EXCELLENT CHEMICAL AND THERMAL

STABILITY, SUCH AS CERAMICS, TEND TO BE BRITTLE,


WITH LIMITED RESISTANCE TO MECHANICAL AND THERMAL

SHOCK.

SCENE 19. tape 237, 02:00:53-02:01:09 pan of carbide classifications tape 235, 02:01:19-02:01:26 ANI: hss/carbide half screen, changes to carbide/ceramic half screen

NARRATION (VO):

THESE VARIABLE PROPERTIES TAKE PLACE BOTH WITHIN

A MATERIAL CLASS--SUCH AS DIFFERENT GRADES OF

CARBIDE--AS WELL AS WHEN COMPARING DIFFERENT

CLASSES OF TOOL MATERIALS, SUCH AS HIGH-SPEED

STEEL AND CARBIDE, OR CARBIDE AND CERAMICS.

SCENE 20. tape 187, 00:17:47-00:17:56 carbide insert milling tape 216, 01:10:38-01:10:46 ceramic insert turning tape 13, 03:07:33-03:07:43 hss milling

NARRATOR (VO):

EVERY NEW AND ESTABLISHED TOOL MATERIAL HAS AN

APPLICATION AREA IN WHICH IT OUTPERFORMS THE

OTHER CUTTING TOOL MATERIALS. NEWER MATERIALS

TEND TO MINIMIZE, BUT NOT ELIMINATE THE

APPLICATION OF OLDER MATERIALS, SUCH AS HIGH

SPEED STEEL.

SCENE 21. tape 238, 01:05:02-01:05:20 slow cut with hss end mill tape 5, 00:09:53-00:10:01 fast cut with carbide end mill tape 225, 02:09:04-02:09:13 ANI: illustrating development of hss, carbide, ceramic, superhard materials

NARRATOR (VO):

THE DEVELOPMENT OF CUTTING TOOL MATERIALS HAS

OFFERED STEADY ADVANCEMENT IN THE RATE OF METAL

REMOVAL, AND CONSEQUENTLY IN THE NEED FOR MORE

HEAT-RESISTANT MATERIALS. SO THERE HAS BEEN A

PROGRESSION FROM HIGH SPEED STEEL,

TO CARBIDE,

TO CERAMICS,

AND ONTO OTHER SUPERHARD CUTTING TOOL MATERIALS.

--- FTB ---

SCENE 22. CG, SUPER: HIGH SPEED STEEL tape 238, 01:02:32-01:02:42

NARRATION (VO):


hss machining part tape 13, 03:05:58-03:06:24 hss end mill, milling

HIGH SPEED STEEL TOOLS WERE INTRODUCED AROUND

1900, AND GRADUALLY REPLACED THE CARBON STEEL

TOOLS OF THE 19TH CENTURY. HIGH SPEED STEEL CUTS

ABOUT FOUR TIMES FASTER THAN THE CARBON STEEL

TOOLS THEY REPLACED, HENCE THE NAME “HIGH SPEED

STEEL.” IT OPERATES AT TEMPERATURES UP TO 600

DEGREES CENTIGRADE.

SCENE 23. tape 238, 01:03:03-01:03:10 hss machining tape 225, 02:01:00-02:02:30 blue background CG: HIGH SPEED STEEL CATEGORIES TUNGSTEN-BASED MOLYBDENUM-BASED MOLYBDENUM-COBALT-BASED

NARRATION (VO):

THERE ARE OVER 30 GRADES OF HIGH SPEED STEEL, IN

THREE MAIN CATEGORIES: TUNGSTEN-BASED,

MOLYBDENUM-BASED, AND MOLYBDENUM-COBALT-BASED.

SCENE 24. tape 234, 02:02:21-02:02:30 pm/hss drill being milled tape 234, 01:03:24-01:03:29 pm/hss form tool being milled tape 234, 01:12:52-01:12:59 pm/hss form tool being ground

NARRATION (VO):

SINCE THE 1960’S A FORM OF HIGH SPEED STEEL

CALLED POWDER METALLURGY HIGH SPEED STEEL HAS

ALLOWED TOOLS SUCH AS DRILLS, MILLING CUTTERS,

AND FORM TOOLS, TO BE MADE TO NEAR-NET SHAPES

THAT OFFER SUPERIOR GRINDABILITY.

SCENE 25. tape 238, 01:06:31-01:06:42 hss drill with titanium nitride coating, drilling

NARRATION (VO):

THE USE OF COATINGS, PARTICULARLY TITANIUM

NITRIDE, ALLOWS HIGH SPEED STEEL TOOLS TO CUT

FASTER AND LAST LONGER.

SCENE 26. tape 238, 01:07:28-01:07:44 c.u. hss reamer with titanium nitride coating, reaming

NARRATION (VO):

TITANIUM NITRIDE PROVIDES A HIGH SURFACE

HARDNESS, IS RESISTANT TO CORROSION, AND

MINIMIZES FRICTION.


SCENE 27. tape 187, 00:18:00-00:18:15 carbide tooling tape 11, 01:22:55-01:23:02 toolroom hss operation tape 79, 02:18:13-02:18:19 hss drill, drilling tape 197, 01:19:33-01:19:36 hss tap, tapping tape 238, 01:04:52-01:04:59 hss end mill starting to spin

NARRATION (VO):

IN INDUSTRY TODAY, HIGH SPEED STEEL TOOLS HAVE

BEEN REPLACED BY CARBIDE TOOLING IN MANY AREAS.

BUT HIGH SPEED STEEL TOOLS ARE STILL PREFERRED

FOR SOME TOOLROOM AND LOW-CUTTING SPEED

OPERATIONS...,

AND FOR CERTAIN TOOL TYPES SUCH AS SMALL DIAMETER

DRILLS...,

TAPS...,

AND END MILLS.

--- FTB ---

SCENE 28. CG, SUPER: CARBIDE tape 187, 00:17:12-00:17:25 carbide insert machining today

NARRATION (VO):

CARBIDE TOOLS WERE INTRODUCED FROM GERMANY IN THE

1930’S, AND TODAY ARE THE MOST WIDELY USED

CUTTING TOOL MATERIALS.

SCENE 29. tape 187, 00:13:18-00:13:32 fast carbide machining

NARRATION (VO):

CARBIDE AND COATED CARBIDE TOOLS, IN GENERAL, CUT

ABOUT THREE TO FIVE TIMES FASTER THAN HIGH SPEED

STEEL, AND OPERATES AT TEMPERATURES UP TO ABOUT

1200 DEGREES CENTIGRADE.

SCENE 30. tape 1, 00:06:44-00:06:52 carbide insert being produced tape 225, 02:01:00-02:02:30 blue background CG: PRIMARY CARBIDE CATEGORIES TUNGSTEN CARBIDE TITANIUM CARBIDE TANTALUM CARBIDE NIOBIUM CARBIDE tape 236, 01:02:46-01:02:56 photomicrography of carbide substrate

NARRATION (VO):

CEMENTED CARBIDE IS A POWDER METAL PRODUCT MADE

UP OF FINELY GROUND HARD CARBIDE PARTICLES,

CEMENTED TOGETHER BY A BINDER. THE MAJOR

CATEGORIES OF HARD CARBIDES ARE TUNGSTEN CARBIDE,

TITANIUM CARBIDE, TANTALUM CARBIDE, AND NIOBIUM


tape 236, 01:00:42-01:00:52 photomicrography of carbide substrate tape 236, 01:02:04-01:02:14 photomicrography of carbide substrate

CARBIDE. THE HARD CARBIDE PARTICLES ARE FROM ONE

TO TEN MICRONS IN SIZE AND MAKE UP FROM 60 TO 95%

OF THE MATERIAL. THE BINDER IS MOSTLY COBALT.

SCENE 31. tape 225, 02:01:00-02:02:30 blue background CG: CARBIDE PROPERTY VARIABLES PARTICLE SIZE BINDER METALLURGY MANUFACTURING TECHNIQUES tape 227, 02:11:38-02:11:48 turning, using carbide insert

NARRATION (VO):

VARIATIONS IN PARTICLE SIZE, BINDER, METALLURGY,

AND MANUFACTURING TECHNIQUES CAUSE THE PROPERTIES

OF THE CARBIDE TOOLS TO VARY WIDELY, PARTICULARLY

IN THE BALANCE OF HARDNESS AND TOUGHNESS.

SCENE 32. tape 225, 02:07:40-02:07:52 ANI: balance of qualities CG, SUPER: CARBIDE TUNGSTEN CONTENT WEAR RESISTANCE STRENGTH tape 233, 06:08:06-06:08:16 ANI: balance of qualities CG, SUPER: CARBIDE COBALT CONTENT WEAR RESISTANCE STRENGTH

NARRATION (VO):

FOR EXAMPLE, A HIGHER TUNGSTEN CONTENT INCREASES

THE WEAR RESISTANCE OF A CARBIDE INSERT, BUT

REDUCES STRENGTH. A HIGHER PERCENTAGE OF COBALT

BINDER INCREASES STRENGTH, BUT LOWERS THE WEAR

RESISTANCE.

SCENE 33. tape 225, 02:07:40-02:07:52 ANI: balance of qualities CG, SUPER: CARBIDE TANTALUM CONTENT HEAT RESISTANCE STRENGTH

NARRATION (VO):

ADDITIONS OF AN ALLOYING AGENT, SUCH AS TANTALUM,

CAN INCREASE A CARBIDE GRADE’S RESISTANCE TO

HEAT, BUT REDUCES IT’S STRENGTH.

SCENE 34. tape 5, 00:09:35-00:09:42 solid carbide end mill tape 226, 01:01:42:00 freeze, insert in holder tape 226, 01:03:02-01:03:08 dissolve to, insert being indexed to new position

NARRATION (VO):

CARBIDE IS UTILIZED FOR SOLID ROUND TOOLS, SUCH

AS END MILLS AND DRILLS...,

OR IN THE FORM OF INSERTS CLAMPED TO A SHANK OR

HOLDER. INSERTS MAY BE INDEXED TO ANOTHER

POSITION WHEN AN EDGE HAS WORN.

SCENE 35. tape 226, 01:09:40-01:09:47

NARRATION (VO):


c.u. worn insert, taken out tape 232, 04:22:39-04:22:43 insert bin

WHEN ALL THE TOOL EDGES ON AN INSERT ARE DULL,

THE INSERT IS GENERALLY THROWN AWAY...,

OR RECYCLED.

SCENE 36. tape 228, 03:09:59-03:10:03 single sided insert, held, turned over tape 228, 03:10:25-03:10:29 double sided insert, held, turned over

NARRATION (VO):

SOME INSERTS ARE SINGLE-SIDED...,

OTHERS DOUBLE-SIDED.

SCENE 37. tape 237, 02:05:54-02:06:03 mfg. carbide grade range chart tape 246, 02:12:37-02:12:40 still, carbide grade range chart tape 237, 02:08:44-02:08:53 mfg. carbide grade range chart

NARRATION (VO):

EVERY MANUFACTURER OF CARBIDE TOOLS HAS A VARIETY

OF CARBIDE GRADES FOR SPECIFIC WORK MATERIALS AND

TYPES OF MACHINING APPLICATIONS.

SCENE 38. tape 187, 00:16:33-00:16:43 high speed carbide milling

NARRATION (VO):

CHOOSING THE CORRECT GRADE OF CARBIDE CAN DOUBLE

TOOL LIFE, OR DOUBLE THE CUTTING SPEED FOR THE

SAME TOOL LIFE.

SCENE 39. tape 233, 05:01:49-05:01:59 interrupted face milling tape 56, 01:17:30-01:17:41 high-speed turning shot tape 227, 02:16:50-02:17:00 machining superalloy

NARRATION (VO):

TOUGH, SHOCK-RESISTANT GRADES ARE NEEDED FOR

INTERRUPTED CUTTING...,

HARDER AND CHEMICALLY-STABLE GRADES ARE NEEDED

FOR FINISHING STEEL AT HIGH SPEED...,

HEAT-RESISTING GRADES ARE NEEDED FOR MACHINING

THE SUPERALLOYS, SUCH AS INCONEL AND HASTELLOY.

SCENE 40. tape 237, 02:03:29-02:03:36 c.u. looking at chart of carbide grades on computer tape 187, 00:06:59-00:07:07 workpiece on mill tape 216, 01:09:45-01:09:54 cast part being turned tape 56, 01:07:47-01:07:58 c.u. heavy cut

NARRATION (VO):

THERE ARE MANY CONSIDERATIONS WHEN SELECTING A

CARBIDE GRADE FOR METALCUTTING, SUCH AS:

THE TYPE OF WORKPIECE MATERIAL, ESPECIALLY ITS

HARDNESS.


tape 56, 01:08:36-01:08:49 c.u. light cut tape 187, 00:09:41-00:09:53 rigid machine with part

THE CONDITION OF THE WORKPIECE’S OUTER SKIN. IF

IT IS A FORGED OR CAST WORKPIECE, A TOUGHER

INSERT SHOULD BE SELECTED.

IS THE CUT HEAVY?...,

OR IS THE CUT LIGHT?

IS THE MACHINE TOOL AND WORKHOLDING SETUP RIGID,

OR LOOSE? IF LOOSE, THEN A STRONGER, MORE DURABLE

CARBIDE GRADE SHOULD BE SELECTED.

SCENE 41. tape 237, 02:11:44-02:11:53 pull back, carbide grade information from supplier tape 246, 02:08:23-02:08:31 carbide grade information from supplier tape 237, 02:10:08-02:10:15 pan, carbide grade information from supplier

NARRATION (VO):

BECAUSE THERE ARE NOT EFFECTIVE U.S. OR

INTERNATIONAL STANDARDS FOR CARBIDE GRADE

SPECIFICATIONS, IT IS THE CARBIDE SUPPLIERS WHO

RECOMMEND WHICH GRADES THEY BELIEVE ARE SUITABLE

FOR GIVEN APPLICATIONS.

SCENE 42. tape 235, 02:02:38-02:03:15 ANI: two carbide grades with same iso coding, image grays out, cg appears CG: ISO 513-1991 STANDARD DIFFERING COMPOSITIONS MICROSTRUCTURES COATINGS PROPERTIES PERFORMANCE

NARRATION (VO):

TWO CARBIDE GRADES FROM DIFFERENT SUPPLIERS, WITH

IDENTICAL CODING IN THE INTERNATIONAL “ISO” 513-

1991 STANDARD, WILL LIKELY HAVE DIFFERENT

COMPOSITIONS,

MICROSTRUCTURES,

COATINGS,

PROPERTIES,

AND, MOST IMPORTANTLY, PERFORMANCE.

SCENE 43. tape 17, 10:34:59-10:35:08 cutting with insert tape 228, 04:00:40-04:01:00 ANI: c.u. carbide insert, ansi seven-digit code, CNMG-432-MR7

NARRATION (VO):

ALTHOUGH CARBIDE INSERTS ARE NOT STANDARDIZED BY

APPLICATION, THEY DO CARRY THEIR OWN SEVEN-

CHARACTER “ANSI” CODE, WHICH IS USED FOR THEIR


IDENTIFICATION.

SCENE 44. tape 233, 06:01:47-06:02:00 ANI: shape chart appears, highlights “C” CG, SUPER: INSERT SHAPE

NARRATION (VO):

THE FIRST CHARACTER REPRESENTS THE INSERT’S

SHAPE.

SCENE 45. tape 228, 04:02:22-04:02:35 ANI: front clearance angle appears, highlights “N” CG, SUPER: INSERT RELIEF ANGLE

NARRATION (VO):

THE SECOND CHARACTER REPRESENTS THE INSERT’S

RELIEF ANGLE, WHICH MAY BE FROM ZERO TO 30

DEGREES.

SCENE 46. tape 233, 06:02:50-06:03:10 ANI: tolerance class appear, highlights “M” CG, SUPER: INSERT TOLERANCE

NARRATION (VO):

THE THIRD CHARACTER REPRESENTS THE INSERT’S

TOLERANCE CLASS. MOLDED INSERTS USUALLY HAVE A

CODE “M” TOLERANCE, AND ARE THE MOST COMMON.

SCENE 47. tape 228, 04:03:26-04:03:40 ANI: clamping, chip control shape chart appears, highlights “G” CG, SUPER: INSERT TYPE

NARRATION (VO):

THE FOURTH CHARACTER REPRESENTS THE TYPE OF

INSERT WITH REGARDS TO IT’S REQUIRED CLAMPING

SYSTEM.

SCENE 48. tape 233, 06:04:00-06:04:15 ANI: cutting edge length chart, highlights “4” CG, SUPER: INSERT SIZE tape 228, 04:04:32-04:04:45 ANI: inscribed circle appears along with highlighted “4” CG, SUPER: INSCRIBED CIRCLE

NARRATION (VO):

THE FIFTH CHARACTER DESIGNATES INSERT SIZE BY THE

LARGEST CIRCLE WHICH CAN BE INSCRIBED WITHIN THE

PERIMETER OF THE INSERT, KNOWN AS THE “INSCRIBED

CIRCLE” OR “IC” SIZE.

SCENE 49. tape 233, 06:05:01-06:05:20 ANI: insert thickness chart, highlights “3” CG, SUPER: INSERT THICKNESS

NARRATION (VO):

THE SIXTH CHARACTER REPRESENTS THE INSERT

THICKNESS. HARDER MATERIALS AND HIGHER FEED RATES

REQUIRE THICKER INSERTS TO WITHSTAND THE CUTTING

FORCES.


SCENE 50. tape 228, 04:05:35-04:05:50 ANI: corner radius chart, highlights “2” CG, SUPER: INSERT CORNER RADIUS

NARRATION (VO):

THE SEVENTH CHARACTER REPRESENTS THE CORNER

RADIUS ON TURNING INSERTS. ON MILLING INSERTS

THIS CHARACTER REPRESENTS THE WIPER EDGE ANGLE.

SCENE 51. tape 233, 06:00:45-06:01:00 ANI: c.u. carbide insert, nothing highlighted tape 228, 04:06:33-04:06:47 ANI: c.u. carbide insert, three character code highlighted, outline of chipbreaker appears

NARRATION (VO):

THIS “ANSI” CLASSIFICATION SYSTEM DOES NOT

CATEGORIZE EVERYTHING. FOR EXAMPLE, THE VARIETIES

OF CHIPBREAKER GEOMETRIES IN CARBIDE TURNING

INSERTS ARE NOT REQUIRED TO BE COVERED, BUT MANY

MANUFACTURER’S DO ADD A CHIPBREAKER CODE.

--- FTB ---

SCENE 52. tape 226, 01:08:54-01:09:06 coated carbide tool, turning

NARRATION (VO):

TWO-THIRDS OF ALL CARBIDE TOOLS USED ARE COATED.

AND A COATED CARBIDE SHOULD BE THE FIRST TOOL

MATERIAL CONSIDERED FOR MOST OPERATIONS.

SCENE 53. tape 187, 00:15:49-00:16:03 coated carbide tool, milling

NARRATION (VO):

IN GENERAL, A COATED CARBIDE TOOL MAY HAVE OVER

THREE TIMES THE TOOL LIFE OF AN UNCOATED GRADE,

OR MAY OPERATE AT CUTTING SPEEDS TWO TO FOUR

TIMES HIGHER FOR THE SAME TOOL LIFE.

SCENE 54. tape 226, 01:19:39-01:19:44 coated carbide tool, cutting tape 225, 02:07:40-02:07:52 ANI: balance of qualities CG, SUPER: CARBIDE’S PRIMARY LIMITATION FRACTURE RESISTANCE WEAR RESISTANCE tape 226, 01:07:32-01:07:50 coated carbide tool, cutting

NARRATION (VO):

THESE COATINGS HELP OVERCOME CARBIDE’S PRIMARY

LIMITATION - THAT AS FRACTURE RESISTANCE OR

TOUGHNESS INCREASES, WEAR RESISTANCE OR HARDNESS

DECREASES. THESE WEAR-RESISTANT COATINGS PROVIDE

CARBIDE GRADES WITH BROAD APPLICATION RANGES--


OFFERING A COMBINATION OF CHARACTERISTICS NOT

OBTAINABLE WITH CARBIDE ALONE.

SCENE 55. tape 235, 02:07:33-02:07:43 photomicrograph of multilayers tape 235, 02:11:50-02:12:00 photomicrograph of multilayers tape 235, 02:09:12-02:09:22 photomicrograph of multilayers

NARRATION (VO):

MOST COATINGS ARE UNDER ONE-THOUSANDTH OF AN INCH

THICK, AND HAVE SEVERAL LAYERS. EACH LAYER HAS A

PARTICULAR BENEFIT, SUCH AS RESISTING HEAT OR

DECREASING FRICTION.

SCENE 56. tape 235, 02:11:00-02:11:10 photomicrograph of multilayers tape 225, 02:01:00-02:02:30 blue background CG: PRIMARY CUTTING TOOL COATING MATERIALS TITANIUM CARBIDE TITANIUM NITRIDE ALUMINUM OXIDE TITANIUM CARBONITRIDE tape 226, 01:18:25-01:18:30 aluminum oxide coated carbide tool, cutting tape 226, 01:04:12-01:04:20 titanium nitride coated carbide tool, cutting

NARRATION (VO):

THE MAIN INSERT AND CUTTING TOOL COATING

MATERIALS ARE TITANIUM CARBIDE, TITANIUM NITRIDE,

ALUMINUM OXIDE, AND TITANIUM CARBONITRIDE.

ALUMINUM OXIDE AND TITANIUM CARBIDE ARE VERY HARD

AND CHEMICALLY INERT...,

AND TITANIUM NITRIDE MINIMIZES FRICTION.

SCENE 57. tape 225, 01:12:03-01:12:18 coated carbide tools

NARRATION (VO):

FOR AN APPROPRIATE COATING, THE COATING MATERIAL

MUST ADHERE OR BOND STRONGLY TO THE CARBIDE TOOL

SURFACE.

SCENE 58. continue previous shot tape 225, 02:01:00-02:02:30 blue background CG: PRIMARY CARBIDE COATING METHODS CHEMICAL VAPOR DEPOSITION PHYSICAL VAPOR DEPOSITION tape 237, 01:04:55-01:05:10 still, cvd parts in oven tape 237, 01:06:50-01:07:05 still, c.u. cvd inserts tape 225, 01:09:19-01:09:30 pvd process

NARRATION (VO):

THE TWO MAJOR COATING METHODS ARE CHEMICAL VAPOR

DEPOSITION AND PHYSICAL VAPOR DEPOSITION. THE

CHEMICAL VAPOR DEPOSITION PROCESS TAKES PLACE AT

ABOUT 1000 DEGREES CENTIGRADE AND IS TYPICALLY

REQUIRED FOR THE MULTI-LAYER COATINGS. THE

PHYSICAL VAPOR DEPOSITION METHOD TAKES PLACES AT


TEMPERATURES AROUND 500 DEGREES CENTIGRADE AND IS

USED FOR SINGLE-LAYER OR DUAL-LAYER COATINGS.

SCENE 59. tape 226, 01:06:03-01:06:10 c.u. coated carbide insert tape 227, 02:10:54-02:11:00 c.u. uncoated carbide insert tape 226, 01:21:54-01:22:04 coated carbide insert, cutting

NARRATION (VO):

COATED CARBIDES ARE MORE COSTLY ON A PER INSERT

BASIS THAN UNCOATED INSERTS, BUT THEY ACHIEVE

GREATER PRODUCTIVITY. IN TERMS OF PARTS-PER-EDGE,

THE COATED CARBIDES HAVE THE ADVANTAGE.

--- FTB ---

SCENE 60. CG, SUPER: CERAMIC tape 227, 02:02:21-02:02:36 machining with ceramic tool tape 226, 01:26:08-01:26:16 ceramic tool cutting cast iron

NARRATION (VO):

CERAMIC TOOLS ARE HARDER AND MORE HEAT-RESISTANT

THAN CARBIDE TOOLS, BUT ALSO MORE BRITTLE. THEY

HAVE BEEN SUCCESSFUL IN MACHINING CAST IRON, HARD

MATERIALS, AND SUPERALLOYS. BEST RESULTS ARE AT

HIGH SPEEDS, WHICH MEAN HIGH CUTTING

TEMPERATURES.

SCENE 61. continue previous shot tape 225, 02:01:00-02:02:30 blue background CG: ALUMINA-BASED SILICON NITRIDE-BASED

NARRATION (VO):

CERAMIC CUTTING TOOLS CAN BE DIVIDED INTO

ALUMINA-BASED CERAMICS...,

AND SILICON NITRIDE-BASED CERAMICS.

SCENE 62. tape 227, 02:03:10-02:03:33 alumina-based high speed finishing operation

NARRATION (VO):

ALUMINA-BASED CERAMICS ARE USED FOR HIGH SPEED

SEMI-FINISHING AND FINISHING OF FERROUS AND SOME

NON-FERROUS MATERIALS. THESE TOOLS ARE NOT GOOD

WITH ALUMINUM BECAUSE OF AN AFFINITY BETWEEN THE

MATERIALS.

SCENE 63. tape 239, 07:01:18-07:01:37

NARRATION (VO):


alumina-based turning operation ALUMINA-BASED CERAMICS OFFER MECHANICAL AND

CHEMICAL WEAR RESISTANCE, BUT LACK TOUGHNESS AND

THERMAL SHOCK RESISTANCE. THUS THEY ARE GENERALLY

NOT USED FOR MILLING, ROUGH TURNING, OR FOR

INTERRUPTED CUTS.

SCENE 64. tape 226, 01:24:27-01:24:46 silicon nitride-based machining

NARRATION (VO):

SILICON NITRIDE-BASED CERAMICS, ALSO CALLED

SIALONS, OFFER GREATER TOUGHNESS AND THERMAL

SHOCK RESISTANCE THAN ALUMINA-BASED CERAMICS.

THEY ARE USED IN HIGH SPEED ROUGHING

APPLICATIONS, AND HAVE EXCELLENT ABRASION

RESISTANCE.

SCENE 65. tape 226, 01:25:14-01:25:25 silicon nitride-based machining of grey cast iron

NARRATION (VO):

SILICON NITRIDE-BASED CERAMICS ARE USED FOR HIGH

SPEED MACHINING OF GRAY CAST IRON, AS WELL AS ON

SUPERALLOYS, SUCH AS NICKEL AND COBALT-BASED WORK

MATERIALS.

SCENE 66. tape 235, 02:04:18-02:04:36 ANI: photomicrograph of whisker-reinforced ceramics, arrow(s) points out reinforcing whiskers photomicrograph of whisker-reinforced ceramics

NARRATION (VO):

WHISKER-REINFORCED CERAMICS, WITH SILICON CARBIDE

REINFORCING “WHISKERS” IN AN ALUMINUM OXIDE

MATRIX, ARE STRONGER THAN THE BRITTLE CERAMIC

MATRIX ALONE. THE WHISKERS ACT LIKE REBAR IN

CONCRETE, ADDING MECHANICAL STRENGTH AND THERMAL

CONDUCTIVITY.

--- FTB ---

SCENE 67. CG, SUPER: CERMET tape 226, 01:13:20-01:13:45

NARRATION (VO):


c.u. cermets being used in machining tape 226, 01:11:48-01:12:04 cermet used in machining

CERMET TOOLS ARE COMPOSED OF MATERIALS COMMONLY

APPLIED AS COATINGS TO CARBIDE TOOLS--TITANIUM

CARBIDE AND TITANIUM NITRIDE. THE SOLID CERMET

INSERT OFFERS EXCELLENT RESISTANCE TO VARIOUS

CAUSES OF WEAR IN MACHINING, ESPECIALLY CHEMICAL

RESISTANCE.

SCENE 68. tape 226, 01:14:40-01:14:58 zoom in, cermets being used in rough turning tape 233, 05:12:43-05:13:04 cermets being used in milling

NARRATION (VO):

INITIALLY USED ONLY FOR SEMI-FINISH AND FINISH

TURNING AND BORING, SOME CERMET GRADES ARE NOW

TOUGH ENOUGH TO HANDLE ROUGH TURNING AS WELL AS

MILLING APPLICATIONS ON CARBON STEELS, STAINLESS

STEELS AND SOME DUCTILE IRONS.

--- FTB ---

SCENE 69. tape 227, 02:21:58-02:22:07 superhard machining tape 225, 02:01:00-02:02:30 blue background CG: CUBIC BORON NITRIDE POLYCRYSTALLINE DIAMOND tape 232, 04:24:14:00 still, insert with superhard tip

NARRATION (VO):

SUPER HARD TOOL MATERIALS ARE DIVIDED INTO TWO

CATEGORIES, CUBIC BORON NITRIDE,

AND POLYCRYSTALLINE DIAMOND.

TYPICALLY A SMALL TIP OF ONE OF THESE SUPER HARD

MATERIALS IS BONDED TO A CARBIDE INSERT BASE.

SCENE 70. tape 227, 02:15:28-02:15:40 superhard insert machining

NARRATION (VO):

SUPERHARD INSERTS MAY COST 30 TIMES MORE THAN A

CARBIDE INSERT, SO THEIR USE IS LIMITED TO WELL-

CHOSEN, COST EFFECTIVE APPLICATIONS.

SCENE 71. CG, SUPER: CUBIC BORON NITRIDE tape 227, 02:23:47-02:24:27 cbn machining alloy steels

NARRATION (VO):

CUBIC BORON NITRIDE OR “CBN”, THE SECOND HARDEST

MATERIAL AFTER DIAMOND, IS USED TO PROVIDE LONG


TOOL LIFE IN MACHINING VERY HARD, TOUGH FERROUS

MATERIALS, HARDENED DIE STEELS, ALLOY STEELS, AND

HARD-FACING MATERIALS.

SCENE 72. continue previous shot tape 228, 03:04:51-03:05:13 machining with round cbn insert

NARRATION (VO):

“CBN” IS A HARD, BRITTLE MATERIAL REQUIRING

CUTTING EDGE PREPARATIONS TO SUIT APPLICATION

NEEDS. OTHER TECHNIQUES ARE UTILIZED TO PROTECT

THE CUTTING EDGE, SUCH AS THE USE OF A LEAD ANGLE

WHERE POSSIBLE, AND A STRONG SHAPE SUCH AS ROUND

OR SQUARE ARE RECOMMENDED.

SCENE 73. CG, SUPER: POLYCRYSTALLINE DIAMOND tape 226, 01:27:52-01:28:03 pcd insert tape 227, 02:07:52-02:08:10 pcd insert machining non-ferrous metal

NARRATION (VO):

POLYCRYSTALLINE DIAMOND OR “PCD” IS COMPOSED OF

MICRO-SIZED DIAMOND PARTICLES IN A METALLIC

BINDER, AND IS OVER 50 TIMES HARDER THAN COMMON

CARBIDE.

SCENE 74. continue previous shot tape 243, 01:10:25-01:10:33 pcd furniture manufacturing operation

NARRATION (VO):

“PCD” IS USED FOR NON-FERROUS APPLICATIONS, AND

ALSO CUTS ABRASIVE MATERIALS SUCH AS GLASS,

REINFORCED PLASTICS, AND HARDWOODS FOR FURNITURE

MANUFACTURING.

SCENE 75. tape 232, 04:24:49-04:25:03 pcd insert machining

NARRATION (VO):

IN SOME HIGH VOLUME APPLICATIONS, “PCD” INSERTS

HAVE MACHINED PARTS FOR SIX MONTHS BEFORE HAVING

TO BE REPLACED, OUTLASTING CARBIDE BY UP TO 100

TIMES.

--- FTB ---


SCENE 76. CG, SUPER: DIAMOND-COATED INSERTS tape 237, 01:08:05-01:08:19 tilt of still, diamond coated inserts tape 237, 01:04:27-01:04:39 zoom of still, diamond-coated ceramic insert, machining

NARRATION (VO):

DIAMOND-COATED CARBIDE AND CERAMIC INSERTS ARE A

RECENT ADDITION TO CUTTING TOOL MATERIALS. THEY

OFFER A GREATER VARIATION IN GEOMETRIES, THAN DO

“PCD” INSERTS, BUT LIKE “PCD” CAN ONLY BE USED

FOR MACHINING NON-FERROUS MATERIALS.

--- FTB ---

SCENE 77. CG: TOOL FAILURE MODES white text on black

SCENE 78. tape 209, 02:07:46-02:08:00 cutting tool, cutting tape 235, 01:13:14:19, freeze broken cutting tool tape 228, 03:08:12-03:08:20 toolholder with broken cutting tool

NARRATION (VO):

ALL CUTTING TOOLS HAVE A WORKING LIFE AND THEN

THEY DULL, FAIL, OR FRACTURE. FOR THIS REASON

THEY ARE CALLED “PERISHABLE” TOOLS.

SCENE 79. tape 232, 04:15:07-04:15:17 indexing insert to new edge tape 78, 01:05:30-01:05:50 resharpening drill

NARRATION (VO):

THE CUTTING TOOL LIFE CYCLE MAY BE A SINGLE USE,

OR INVOLVE INDEXING TO MULTIPLE EDGES AS WITH AN

INSERT...,

OR MULTIPLE RESHARPENING, SUCH AS WITH DRILLS,

END MILLS, AND TAPS.

SCENE 80. tape 116, 01:23:59-01:24:08 tapping tool breaking in cut tape 235, 01:11:56-01:12:06 c.u. broken cutting edges tape 227, 02:25:33-02:25:40 cutting tool machining part

NARRATION (VO):

IT IS A SAFETY HAZARD TO RUN ANY CUTTING TOOL

UNTIL IT BREAKS. THIS CREATES SCRAP, IMPACTS TOOL

AND PART COSTS, AND REDUCES PRODUCTIVITY. ASIDE

FROM BREAKAGE, CUTTING TOOLS WEAR IN MANY

DIFFERENT WAYS.


SCENE 81. CG, SUPER: EDGE WEAR tape 236, 01:03:25-01:03:40 photomicrography still of edge wear CG, SUPER: FLANK WEAR tape 247, 01:04:30-01:04:50 photomicrography still of flank wear tape 236, 01:05:25-01:05:45 photomicrography still of flank wear

NARRATION (VO):

EDGE WEAR...,

AND FLANK WEAR ARE BOTH A NORMAL AND SLOW TYPE OF

TOOL WEAR. IN CARBIDE TURNING OF STEEL, IT OFTEN

OCCURS AFTER 15 TO 30 MINUTES OF CUTTING.

SCENE 82. tape 216, 01:12:11-01:12:33 cutting tool insert machining cast iron

NARRATION (VO):

IF THE WORK MATERIAL IS HIGHLY ABRASIVE, SUCH AS

WITH CERTAIN CAST-IRONS, THIS TYPE OF WEAR WILL

ACCELERATE. TO CORRECT THIS PROBLEM, SELECT

ANOTHER MORE ABRASION-RESISTANT TOOL GRADE.

SCENE 83. CG, SUPER: CRATERING tape 236, 01:06:14-01:06:34 photomicrography still of cratering tape 247, 01:07:05-01:07:25 photomicrography still of early cratering tape 248, 01:01:46-01:01:55 ANI: arrow showing cratering

NARRATION (VO):

CRATERING, OR TOP WEAR, BEHIND THE CUTTING EDGE,

OCCURS COMMONLY IN MACHINING LONG-CHIPPING STEELS

-- FROM ABRASION AND DIFFUSION WEAR. IF THE

CRATER GROWS LARGE ENOUGH AND CONTACTS THE

CUTTING EDGE, THE TOOL FAILS IMMEDIATELY.

SCENE 84. tape 226, 01:18:31-01:18:48 c.u. carbide insert, machining

NARRATION (VO):

TO COMBAT CRATERING USE HARD GRADES OF CARBIDE,

WITH TANTALUM CARBIDE OR TITANIUM CARBIDE, AND

HARD COATINGS, SUCH AS ALUMINUM OXIDE, OR OTHER

MATERIALS SUCH AS CERMETS, OR CERAMICS.

SCENE 85. CG, SUPER: CHIPPING tape 236, 01:18:46-01:18:56 ANI: arrows pointing out chipping tape 247, 01:08:23-01:08:45 photomicrography still of chipping

NARRATION (VO):

CHIPPING ON A TOOL EDGE IS AN UNPREDICTABLE FORM

OF TOOL FAILURE. IT IS SOMETIMES STARTED WHEN A

HIGH-POINT ON AN EDGE BREAKS AWAY. A STRONGER


CARBIDE GRADE, DIFFERENT EDGE PREPARATION, OR

LEAD ANGLE CHANGE MAY ELIMINATE CHIPPING.

SCENE 86. CG, SUPER: BUILT-UP EDGE tape 236, 01:09:50-01:10:10 photomicrography still of built-up edge tape 247, 01:22:08-01:22:20 ANI: deposit building up on edge, breaking away with insert material tape 236, 01:10:35-01:10:50 photomicrography still of built-up edge

NARRATION (VO):

A BUILT-UP EDGE IS A DEPOSIT OF WORKPIECE

MATERIAL ADHERING TO THE RAKE FACE OF THE INSERT.

CHIPS WELD THEMSELVES TO A CUTTING EDGE. SOME

TIME LATER THE DEPOSIT BREAKS OFF AND PULLS SMALL

PIECES OF CARBIDE OUT OF THE EDGE. THIS OCCURS AT

OR JUST BEHIND THE EDGE. DUCTILE MATERIALS SUCH

AS LOW CARBON STEEL, SOFT ALUMINUM, AND COPPER

CAUSE THIS DAMAGE.

SCENE 87. tape 216, 01:04:13-01:04:26 machining of part with cutting fluid

NARRATION (VO):

HIGHER RAKE ANGLES, FASTER CUTTING SPEED, AND

HIGHER PRESSURE CUTTING FLUID ALL HELP ELIMINATE

BUILT-UP EDGE.

SCENE 88. CG, SUPER: DEFORMATION tape 236, 01:11:18-01:11:38 photomicrography still of deformation tape 247, 01:12:59-01:13:20 photomicrography still of deformation tape 236, 01:12:10-01:12:30 photomicrography still of deformation

NARRATION (VO):

DEFORMATION TAKES PLACE AT VERY HIGH

TEMPERATURES, 1800 TO 2000 DEGREES FAHRENHEIT.

THESE TEMPERATURES CAUSE THE INSERT BINDER

MATERIAL TO SOFTEN, DEPRESSING THE TOP SURFACE

AND MUSHROOMING THE SIDES OUT INTO THE CLEARANCE

ANGLE, WHERE IT IS ABRADED AWAY. DEFORMATION IS

DIFFICULT TO DETECT WITHOUT THE USE OF A

MICROSCOPE.

SCENE 89. tape 227, 02:22:37-02:22:50 machining of high heat workpiece

NARRATION (VO):

A DEFORMATION-RESISTANT GRADE AND/OR HIGH-HOT

HARDNESS COATING IS REQUIRED; OR ELSE REDUCE THE


OPERATION’S SPEED TO REDUCE THE HEAT.

SCENE 90. CG, SUPER: THERMAL CRACKING tape 236, 01:20:28-01:20:43 ANI: arrows pointing out thermal cracking

NARRATION (VO) :

THERMAL CRACKING OCCURS WHEN INSERTS GO THROUGH A

RAPID HEAT/COOL CYCLE, SUCH AS IN EITHER

INTERRUPTED CUTTING, OR WHEN THE COOLANT IS

IMPROPERLY APPLIED, SUDDENLY COOLING A HOT

INSERT.

SCENE 91. CG, SUPER: NOTCHING tape 247, 01:13:38-01:13:58 photomicrography still of notching tape 236, 01:14:23-01:14:45 photomicrography still of notching tape 247, 01:15:14-01:15:34 photomicrography still of notching

NARRATION (VO):

A NOTCH AT THE DEPTH OF CUT LINE MAY OCCUR IN

MACHINING HIGH-TEMPERATURE ALLOYS OR WITH ANY

VERY HARD OUTER LAYER, SUCH AS IN A CASTING OR

FORGING. THIS IS CAUSED BY THE “PULL-OUT” OF

SMALL PARTICLES OF TOOL MATERIAL AT THE FLANK,

FACE, AND CUTTING EDGE BY THE PRESSURE-WELDING OF

WORK MATERIAL TO THE TOOL MATERIAL. AN EDGE

PREPARATION ON THE INSERT AND AN INCREASED LEAD

ANGLE MAY DECREASE NOTCHING.

SCENE 92. tape 236, 01:04:30-01:04:50 still of edge wear/flank wear tape 247, 01:06:14-01:06:34 still of cratering tape 236, 01:08:23-01:08:45 still of chipping tape 247, 01:09:50-01:10:10 still of built-up edge tape 236, 01:11:18-01:11:38 still of deformation tape 247, 01:20:18-01:20:25 still of thermal cracking tape 236, 01:13:38-01:13:58 still of notching

NARRATION (VO):

THESE ARE ONLY SOME OF THE “NATURAL CAUSES” OF

TOOL WEAR. MAXIMUM TOOL LIFE CAN BE ACHIEVED

THROUGH SELECTING THE PROPER INSERT OR TOOL

MATERIAL OR ALTERING THE CUTTING CONDITIONS.

--- FTB ---

SCENE 93. CG: REVIEW white text on black tape 63, 12:00:15-12:03:49

NARRATION (VO):

LET'S REEXAMINE THE MATERIAL CONTAINED IN THIS


review music VIDEOTAPE.

SCENE 94. tape 56, 01:23:20-01:23:31 cutting tool on lathe tape 217, 00:09:30-00:09:38 milling cutter, spinning

NARRATION (VO):

THE MAIN OBJECTIVE IN THE SELECTION AND

APPLICATION OF CUTTING TOOLS IS TO SAFELY MACHINE

A WORKPIECE IN THE SHORTEST POSSIBLE TIME, WHILE

MEETING THE PART’S QUALITY REQUIREMENTS.

SCENE 95. tape 225, 02:09:04-02:09:13 ANI: illustrating development of hss, carbide, ceramic, superhard materials

NARRATION (VO):

THERE IS NO IDEAL CUTTING TOOL MATERIAL, BUT THE

RAPID EVOLUTION OF TOOL MATERIALS HAS GIVEN US A

WIDE CHOICE TO MEET ANY NEED.

SCENE 96. CG, SUPER: HIGH SPEED STEEL tape 11, 01:22:55-01:23:02 toolroom hss operation tape 79, 02:18:13-02:18:19 hss drill, drilling tape 197, 01:19:33-01:19:36 hss tap, tapping tape 13, 03:05:58-03:06:04 hss end mill, milling

NARRATION (VO):

HIGH SPEED STEEL TOOLS ARE COMMONLY USED IN

TOOLROOMS AND IN LOW-SPEED OPERATIONS. ROUND

TOOLS SUCH AS DRILLS...,

TAPS...,

AND END MILLS ARE COMMONLY MADE OF HIGH SPEED

STEEL.

SCENE 97. tape 238, 01:06:31-01:06:42 hss drill with titanium nitride coating, drilling

NARRATION (VO):

COATINGS HAVE EXTENDED THE APPLICATIONS AND

CUTTING LIFE OF HIGH SPEED STEEL TOOLS.

SCENE 98. CG, SUPER: CARBIDE tape 233, 05:01:49-05:01:59 interrupted face milling tape 226, 01:03:02-01:03:08 insert being indexed to new position tape 5, 00:09:35-00:09:42 solid carbide end mill

NARRATION (VO):

CARBIDE TOOLS, PARTICULARLY COATED CARBIDES, ARE

TODAY’S MOST COMMON CUTTING TOOL MATERIAL. THERE

ARE A GREAT VARIETY OF CARBIDE COMPOSITIONS AND

COATING TYPES. CARBIDE TOOLS MAY BE INDEXABLE

INSERTS...,


OR SOLID ROUND TOOLS SUCH AS SMALL DIAMETER END

MILLS OR DRILLS.

SCENE 99. tape 226, 01:07:32-01:07:50 coated carbide tool, cutting tape 235, 02:07:33-02:07:43 photomicrograph of multilayers tape 235, 02:11:50-02:12:00 photomicrograph of multilayers tape 235, 02:09:12-02:09:22 photomicrograph of multilayers

NARRATION (VO):

COATED CARBIDE INSERTS ARE THE FIRST TOOL

MATERIAL TO CONSIDER FOR MOST PRODUCTION

OPERATIONS. MOST INSERT COATINGS HAVE MULTIPLE

LAYERS TO PROTECT THE TOOL AGAINST ABRASION AND

CHEMICAL WEAR.

SCENE 100. CG, SUPER: CERAMIC tape 227, 02:02:21-02:02:36 machining with ceramic tool tape 226, 01:26:08-01:26:16 ceramic tool cutting cast iron

NARRATION (VO):

CERAMIC INSERTS MAY BE ALUMINA-BASED OR SILICON-

NITRIDE-BASED. THEY WITHSTAND HIGHER HEAT THAN

CARBIDE, HAVE GOOD RESISTANCE TO ABRASION, AND

THEY CUT VERY FAST. BUT CERAMIC INSERTS ARE LESS

SHOCK RESISTANT THAN CARBIDE TOOLS, SO THEIR

APPLICATIONS ARE LIMITED.

SCENE 101. CG, SUPER: CERMET tape 226, 01:13:20-01:13:45 c.u. cermets being used in machining

NARRATION (VO):

CERMETS ARE COMPOSED OF TITANIUM CARBIDE OR

TITANIUM NITRIDE, WITH EXCELLENT RESISTANCE TO

VARIOUS FORMS OF WEAR. BUT CERMETS DO NOT

WITHSTAND HIGH HEAT WELL.

SCENE 102. CG, SUPER: CUBIC BORON NITRIDE tape 227, 02:23:47-02:24:27 cbn machining alloy steels CG, SUPER: POLYCRYSTALLINE DIAMOND tape 227, 02:15:28-02:15:40 superhard insert machining tape 232, 04:24:49-04:25:03 pcd insert machining

NARRATION (VO):

THE SUPERHARD MATERIALS ARE CUBIC BORON NITRIDE

“CBN”, FOR FERROUS APPLICATIONS...,

AND POLYCRYSTALLINE DIAMOND OR “PCD”, FOR NON-

FERROUS APPLICATIONS. BOTH MATERIALS ARE

EXPENSIVE BUT CAN OUTLAST CARBIDES BY TEN TO ONE

HUNDRED TIMES.


SCENE 103. tape 209, 02:07:46-02:08:00 cutting tool, cutting tape 235, 01:12:20-01:12:30 broken cutting tool tape 228, 03:08:12-03:08:20 toolholder with broken cutting tool tape 227, 02:25:33-02:25:40 cutting tool machining part tape 247, 01:03:25-01:03:20 still of edge wear tape 236, 01:04:30-01:04:50 still of flank wear tape 247, 01:06:14-01:06:34 still of cratering tape 236, 01:08:23-01:08:45 still of chipping tape 247, 01:11:18-01:11:38 still of deformation tape 236, 01:09:50-01:10:10 still of built-up edge tape 247, 01:20:18-01:20:25 still of thermal cracking tape 236, 01:13:38-01:13:58 still of notching

NARRATION (VO):

ALL CUTTING TOOLS HAVE A FINITE PERFORMANCE LIFE,

THEN THEY WEAR OUT OR FAIL; HENCE THEY ARE CALLED

“PERISHABLE” TOOLS. THE VARIETIES OF CUTTING TOOL

WEAR INCLUDE:

EDGE WEAR...,

FLANK WEAR...,

CRATERING OR TOP WEAR...,

CHIPPING OF THE TOOL EDGE...,

DEFORMATION...,

AND THE EDGE DAMAGE CAUSED BY THE PULLING AWAY OF

MATERIAL ON A BUILT-UP EDGE.

TWO OTHER TYPES OF TOOL WEAR ARE

THERMAL CRACKING...,

AND NOTCHING.

--- FTB ---

SCENE 104. CREDITS:

Produced by:

The Society of Manufacturing Engineers

Executive Producer:

Steven Bollinger

Producer/Director/Cameraman:

Jerome T. Cook

Written By:

Frederick Mason

Graphics By:

Jerome T. Cook


Equipment access and organizational support

provided by:

Valenite Inc.

Additional equipment access provided by:

Adaptive Technologies Corp.

Balzers Tool Coating Inc.

Bitner Brothers Tool Co., Inc.

William D. Ford Vocational/Technical Center

Video footage provided by:

Autoblok Corp.

Buck Chuck Co.

Carboloy Inc.

The Colchester Lathe Co., Ltd.

Cool Jet Systems

Crucible Materials Corp.

Fadal Engineering Co., Inc.

Focus: HOPE

GE Superabrasives

Greenleaf Corp.

Ingersoll Cutting Tools

Iscar Ltd.

Jergens Inc.

Kennametal Inc.

Makino Inc.

The Monarch Machine Tool Co.

Pratt Burnerd America

Sandvik Coromant

Ti-Coating, Inc.

T. M. Smith Tool International Corp.

Technical assistance provided by:

Terry Ashley, Kennametal Inc.

Kevin Mayer, Sandvik Coromant

Ann Meister, Servo Products Co.

Additional camerawork:


Steven Bollinger

Video editing:

James P. Slayden

Some Machinery In This Program Had Safety

Equipment Removed To Allow Better Recording Of

Certain Processes.

Always Read The Safety Information Provided In

The Manufacturers Manual Before Operating Any

Machine

SCENE 105. tape 40, 01:00:00-01:00:12 ANI: SME logo

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