Sandvik Metal Cutting Technology Training Handbook

Sandvik Coromant Academy
Metal Cutting Technology
Training Handbook
n
x
D
m
x
1000
vc =
Content
Turning
Theory
Selection procedure
System overview
Choice of inserts
Choice of tools
- External
- Internal
Code keys
Troubleshooting
Drilling
A
A
A
A
4
12
16
22
A
A
A
A
50
56
66
70
Parting & Grooving

Theory
Selection procedure
System overview
Parting & grooving - how to apply
- Parting off
- General grooving
- Circlip grooving
- Face grooving
- Profiling
- Turning
- Undercutting
Troubleshooting
B
B
B
B
B
B
B
B
B
B
B
B
4
7
11
15
22
25
27
28
31
33
35
36
Threading
Theory
Selection procedure
System overview
How to apply
Troubleshooting
E
E
E
E
E
E
6
15
20
26
37
42
F
F
F
F
F
F
4
9
14
16
21
26
G
G
G
G
G
G
4
7
15
23
29
33
H
H
H
H
4
18
29
44
H
H
H
H
55
68
75
84
Boring
Theory
Selection procedure
System overview
Choice of tools
How to apply
Troubleshooting
Tool holding
History and background
Why modular tooling
Turning centers
Machining centers
Multi-task machines
Chucks
Machinability
C
C
C
C
C
4
9
13
19
25
Workpiece materials
The cutting edge
Cutting tool materials
Manufacturing of cemented carbide
Other information
Milling
Theory
Selection procedure
System overview
Choice of insert how to apply
Choice of tools how to apply
Troubleshooting
Theory
Selection procedure
System overview
How to apply
Hole quality and tolerances
Troubleshooting
D
D
D
D
D
D
4
9
13
24
29
36
Machining economy
Maintenance & tool wear
Formulas and definitions
Cutting data calculator
A2
Turning
Turning generates cylindrical and rounded forms with a
single-point tool. In most cases the tool is stationary with
the workpiece rotating.
Theory
A4
Selection procedure
A 12
System overview
A 16
Choice of inserts how to apply
A 22
C
hoice of tools how to apply
- External
- Internal
A 50
A 56
Code keys
A 66
Troubleshooting
A 70
A3
Theory
Turning is the combination of two movements rotation of

the workpiece and feed movement of the tool.
Parting and
grooving
Turning
General turning operations
The feed movement of the tool can be along the axis of

the workpiece, which means the diameter of the part will
be turned down to a smaller size. Alternatively, the tool
can be fed towards the center (facing off), at the end of
the part.
Often feeds are combinations of these two directions,
resulting in tapered or curved surfaces.
Threading
Milling
Turning and facing as axial and radial tool movements.
Drilling
Boring
Three common turning operations:
G
Tool holding
- Longitudinal turning
- Facing
- Profiling.
Machinability
Other information
A4
Theory
Turning
Definitions of terms
Spindle speed
The spindle speed rpm (revolution per

minute) is the rotation of the chuck and
workpiece.
Parting and
grooving
n (rpm)
Threading
vc (ft/min)
(m/min)
The cutting speed is the surface speed,

ft/min (m/min), at which the tool moves
along the workpiece in feet (meters) per
minute.
Milling
Cutting speed
Definition of cutting speed
vc = cutting speed, ft/min (m/min)
Boring
The definition of cutting speed as the result

of the diameter, pi () and spindle speed in
revolutions per minute (rpm). The circumference (C) is the distance the cutting edge
moves in a revolution.
Drilling
Dm = machined diameter, inch (mm)
G
Tool holding
n = spindle speed, rpm

Circumference, C = x Dm inch (mm)
Metric
vc =
Dm n
12
ft/min
vc =
Dm n
1000
m/min
A5
Machinability
Other information
Inch
Theory
Turning
Calculation of the circumference

C
ircumference = x diameter (inch)

(mm)
B
Parting and
grooving
(pi) = 3.14
Example:
Dm2 = 3
.937 inch (100 mm)
Circumference = 3.14 x 3.937
= 12.362 inch
C
Threading
Circumference = 3.14 x 100

= 314 mm
Dm1 = 1
.969 inch (50 mm)
Circumference = 3.14 x 1.969
= 6.183 inch
Milling
Circumference = 3.14 x 50
= 157 mm
Example of cutting speed fluctuations
The cutting speed differs depending on the workpiece diameter.

Given:
Drilling
Spindle speed, n = 2000 rpm

Diameter, Dm1 = 1.969 inch (50 mm)
Diameter, Dm2 = 3.150 inch (80 mm)
Boring
Inch
G
Tool holding
vc =
vc1 =
H
Machinability
Other information
Metric
vc2 =
A6
Dm n
12
ft/min
3.14 1.969 2000

12
3.14 3.150 2000
12
vc =
= 1030
ft/min
vc1 =
= 1649
ft/min
vc2 =
Dm n
1000
m/min
3.14 50 2000
1000
3.14 80 2000
1000
= 314
m/min
= 502
m/min
Theory
Feed
fn = cutting feed (inch/r) (mm/r)

ap = depth of cut (inch) (mm)
r = entering angle
r = lead angle
Depth of cut
Boring
Lead angle = 0
Entering angle = 90
The cutting depth (ap) in inch (mm) is half

of the difference between the un-cut and
cut diameter of the workpiece. The cutting
depth is always measured at right angles
to the feed direction of the tool.
Lead (entering) angle

The cutting edge approach to the workpiece is expressed through the lead angle
(r), which is the angle between the cutting edge and the workpiece plane. It can
also be expressed as the entering angle
(r), the angle between the cutting edge
and the direction of feed. The lead angle
is important in the basic selection of the
correct turning tool for an operation.
A7
G
Tool holding
vc = cutting speed (ft/min) (m/min)
The cutting feed (fn) in inch/r (mm/r) is

the movement of the tool in relation to the
revolving workpiece. This is a key value
in determining the quality of the surface
being machined and for ensuring that the
chip formation is within the scope of the
tool geometry. This value influences, not
only how thick the chip is, but also how the
chip forms against the insert geometry.
H
Machinability
Other information
n = spindle speed (rpm)
Parting and
grooving
The cutting speed (vc) in ft/min (m/min) at

which the periphery of the cut workpiece
diameter passes the cutting edge.
Threading
Surface/cutting speed
Milling
The workpiece rotates in the lathe, with

a certain spindle speed (n), at a certain
number of revolutions per minute (rpm).
Drilling
Spindle speed
Turning
Theory
Turning
Calculating cutting data

Example of how to calculate the spindle speed (n) from cutting speed (vc).
Parting and
grooving
Cutting speed
Given:
Cutting speed, vc = 1312 ft/min (400 m/min)
C
Threading
Diameter Dm = 3.937 inch (100 mm)
Inch
Metric
Milling
n=
n=
Drilling
vc 12
Dm
1312 12
3.14 3.937
r/min
= 1274 r/min
n=
Dm
400 1000
3.14 100
r/min
= 1274 r/min
Inclination and rake angles

Rake angle
Boring
The rake angle gamma () is a measure

of the edge in relation to the cut. The rake
angle of the insert itself is usually positive
and the clearance face is in the form of
a radius, chamfer or land and affects tool
strength, power consumption, finishing ability of the tool, vibration tendency and chip
formation.
Tool holding
Inclination angle
The inclination angle lamda () is the angle the insert is mounted in the tool holder.
When mounted in the tool holder, the
insert geometry and inclination in the tool
holder will determine the resulting cutting
angle with which the cutting edge cuts.
H
Machinability
Other information
vc 1000
n=
A8
Theory
Turning
Cutting depth and chip formation

B
ap
r
Parting and
grooving
ap
The cutting depth (ap) is the length the

edge goes into the workpiece.
Chip formation varies with depth of cut,

lead (entering) angle, feed, material and
insert geometry.
Threading
Milling
Feed rate and the effective cutting edge length
Drilling
The effective cutting edge length (la) relates to cutting

depth and lead (entering) angle.
G
Tool holding
Cutting edge length
The feed rate (fn) is the

distance the edge moves
along the cut per revolution.
A9
Machinability
Other information
Feed rate
Boring
Turning
Parting and
grooving
Theory
Insert shape selection, lead (entering) angle and chip

thickness
The lead angle, r (entering angle r), of the tool and the
nose radius (re) of the insert affect the chip formation in
that the chip cross-section changes. The chip thickness is
reduced and the width increased with a larger lead angle
(smaller entering angle).
The direction of chip flow is also changed.
Threading
Milling
Lead angle r:
-5, 15
Entering angle r:
95, 75
Lead angle r:
-17.5, -3, 27.5
Entering angle r:
107.5, 93, 62.5
TNMG
Lead angle r:
45, 15
Entering angle r:
45, 75
Lead angle r:
Variable
Entering angle r:
Variable
Lead angle r:
-3, -1, 30
Entering angle r:
93, 91, 60
VNMG
Lead angle r:
-27.5, -17.5, 17.5
Boring
Entering angle r:
117.5, 107.5, 72.5
Lead angle r (Entering angle r)

Is defined by the holder tip seat in
combination with insert shape
selected.
Tool holding
Machinability
Other information
Lead angle r:
-5
Entering angle r:
95
RCMT
WNMG
SNMG
Drilling
DNMG
CNMG
Maximum chip thickness hex
r = 45
hex fn x 0.71
A 10
hex fn
R
educes relative to the feed rate as
the lead angle increases (entering
angle reduces).
Theory
Turning
The effect of lead angle (entering angle) on chip thickness

Maximum chip thickness hex reduces relative to the feed
rate as the lead angle increases (entering angle reduces).
Parting and
grooving
Lead angle r
Entering angle r
5
95
15
75
30
60
45
45
0 min
90 max
Chip thickness
compared to feed,
inch (mm)
.039 (1)
.038 (0.96)
.034 (0.87)
.028 (0.71)
Variable
D
.082 (2.08)
.091 (2.3)
.111 (2.82)
Variable
Milling
.079 (2)
Calculating power consumption

fn = cutting feed (inch/rev) (mm/rev)
Drilling

ap = depth of cut (inch) (mm)
kc = s
pecific cutting force (lbs/in2)
(N/mm2)
Pc = net power (HP) (kW)
Boring
For information about the kc value, see

page H 16.
G
Pc =
Pc =
vc ap fn kc
33 103
vc ap fn kc
60 103
HP
Tool holding
The net power (Pc) in HP (kW) required for

metal cutting is mainly of interest when
roughing, where it is essential to ensure
that the machine has sufficient power for
the operation. The efficiency factor of the
machine is also of great importance.
kW
A 11
Machinability
Other information
Contact length la,

inch (mm) at ap
.079 inch (2 mm)
C
Threading
Turning
Selection procedure
Production planning process
Parting and
grooving
Selection procedure
Dimension and type of

operation
C
Component
Threading
Workpiece material and

quantity
Milling
Machine parameters
Machine
Drilling
Choice of tool
Type of turning tool:

- External/internal
- Longitudinal
- Profiling
- Facing
Boring
How to apply
Troubleshooting
Cutting data, tool

path, etc.
Tool holding
Machinability
Other information
A 12
Remedies and solutions
Selection procedure
Turning
1. Component and the workpiece material

Parameters to be considered
C
Threading
A
nalyze the dimensions and quality demands of the
surface to be machined.
Type of operation (longitudinal, profiling and facing).
External, internal
Roughing, medium or finishing
Tool paths
Number of passes
Tolerances
Parting and
grooving
Component
D
Material
achinability
M
Cast or pre-machined
Chip breaking
Hardness
Alloy elements
Milling
Drilling
2. Machine parameters
Condition of the machine
Boring
Some important machine considerations:

- Stability, power and torque, especially for
larger diameters
- Component clamping
- Tool position
- Tool changing times/number of tools in turret
- Spindle speed (rpm) limitations, bar feed magazine
- Sub spindle, or tail stock available?
- Use all possible support
- Easy to program
- Cutting fluid pressure.
Tool holding
A 13
Machinability
Other information
P M K
N S H
Selection procedure
Turning
3. Choice of tools
Turning with rhombic inserts
Parting and
grooving
Different ways to optimize turning

Advantages
Operational versatility.
Small lead angle.
For turning and facing.
Good roughing strength.
Disadvantages
Can cause vibration
when turning slender
components.
Advantages
Increase feed and gain
productivity.
Use normal feed rate and
gain surface quality.
Productivity booster.
Disadvantages
In back turning and profiling the wiper edge is not
effective.
Threading
Turning with wiper inserts
Milling
Drilling
New ways in profile turning
Boring
Advantages
productivity.
Use normal feed rate and
Productivity booster
Tolerance
Setup time
Tool holding
G
Rigid insert location with
T-rails.
Machinability
Other information
A 14
Selection procedure
Turning
4. How to apply
Important application considerations
The tool path has a significant impact on
the machining process.
Parting and
grooving
It influences:
- Chip control
- Insert wear
- Surface quality
- Tool life.
In practice, the tool holder, insert geometry,

grade, workpiece material and tool path
influences the cycle time and productivity
considerably.
Threading
Milling
5. Troubleshooting
Some areas to consider
E
Insert style
Positive style
O
ptimize the chip breaking by changing the
depth of cut, the feed or the insert geometry.
T he depth of cut should be no less than 2/3

of the nose radius (re).
Insert wear
G
Tool holding
ake sure that the flank wear does not

M
exceed the general recommendation of .012
inch (0.3 mm).
Boring
Nose radius
ap
re
A 15
Machinability
Other information
Negative style
Chip breaking
Drilling
U
se positive inserts for lower cutting forces in
general and for internal turning.
Turning
System overview
External turning, negative inserts

1. Longitudinal turning
2. Profiling
Parting and
grooving
3. Facing
C
Threading
2
3
Milling
Drilling
Overview of tool holders
Boring
Tool holding
G
N
egative insert
Rigid clamping system
Modular/shank tools
Machinability
Other information
A 16
N
egative insert
Lever clamping system
Modular/shank tools
System overview
Turning
External turning, positive inserts
2. Profiling
Parting and
grooving
3. Facing
C
1
Threading
2
3
Milling
Drilling
Boring
N
egative/positive
insert
All clamping systems
Cutting heads
Modular/shank
tools
P
ositive insert
Screw clamping
system
Modular/shank
tools
G
Tool holding
Positive insert
Screw clamping
system
T-rail interface
Modular/shank
tools
A 17
Machinability
Other information
P
ositive insert
Screw clamping
system
Modular/shank
tools
Turning
System overview
Internal turning, negative/positive inserts

B
Parting and
grooving
2. Profiling
Mini bars
Threading
Overview of internal tool holders
Milling
Drilling
E
N
egative insert
Min. hole .984 inch
(25 mm)
Modular/boring bars
egative insert
N
Min. hole .787 inch
(20 mm)
Modular/boring bars
ositive insert
P
Screw clamping system
Cutting heads
Min. hole .236 inch
(6 mm)
Modular/boring bars
D
ampened boring bars
Min. hole .512 inch
(13 mm)
Boring bars
Boring
N
egative/positive inserts
Dampened boring bars
Min. hole 1.575 inch
(40 mm)
Boring bars
Tool holding
Machinability
Other information
egative/positive insert
N
All clamping systems
Cutting heads
Min. hole .787 inch
(20 mm)
Dampened modular/
boring bars
A 18
System overview
Turning
Tools for small part machining

2. External turning
(Sliding head machines)
3. Internal turning
(Exchangeable inserts)
4. Internal turning
Threading
5. Internal turning
(Carbide rods)
B
Parting and
grooving
1. External turning
Milling
External tools
P
ositive insert
Shank tools
Quick change tools

Positive insert
P
ositive insert
Drilling
Boring
Internal tools
P
ositive insert
Min. hole .394 inch
(10 mm)
P
ositive insert
Carbide rods
Min. hole .012 inch
(0.3 mm)
Machine adapted bars
A 19
H
Machinability
Other information
P
ositive insert
Min. hole .236 inch
(6 mm)
Tool holding
System overview
Turning
Overview of insert clamping systems

Clamping of negative basic-shape inserts
Parting and
grooving
Threading
Clamping of positive basic-shape inserts
Milling
Drilling
Boring
Clamping of positive T-rail inserts
Tool holding
T-rails
Machinability
Other information
H
A 20
5/7
System overview
Turning
Modern insert clamping for turning tools

Rigid clamping
Negative inserts
Parting and
grooving
Excellent clamping
Easy indexing
Negative inserts
Threading
Lever clamping
Free chip flow
Milling
Easy indexing
Screw clamping
Drilling
Positive inserts
S
ecure clamping of
the insert
Boring
Free chip flow
Screw clamping system, T-rail
G
Tool holding
Positive inserts
Very secure clamping
High accuracy
A 21
Machinability
Other information
Choice of inserts
Choice of inserts
Turning
Parting and
grooving
Threading
Milling
Drilling
Boring
Tool holding
Machinability
Other information
A 22
Basic factors
A 23
Insert geometries
A 32
Insert grades
A 39
Insert shape, size, nose radius
A 42
Cutting data effect on tool life
A 48
Choice of inserts basic factors
Turning
The complex world of metal cutting

Getting metal cutting processes right means knowing
the workpiece material, then choosing the correct insert
geometry and grade to suit the specific application.
T hese three main basic

factors must be carefully
considered and adapted
for the machining operation in question.
Grade
Parting and
grooving
Drilling
T he knowledge and
understanding of how
to work with and employ
these factors is of vital
importance.
C
Threading
T he interaction between
an optimized insert
geometry and grade for a
certain workpiece material is the key to successful machining.
Milling
Workpiece material
Geometry
Boring
The machining starts at the cutting edge
Tool holding
A 23
Machinability
Other information
H
Typical chip breaking
sequences with high speed
imaging.
Turning
Six material groups
Parting and
grooving
In the metal cutting industry there is an

incredibly broad range of component
designs made from different materials.
Each material has its own unique characteristics influenced by the alloying elements, heat treatment, hardness, etc. This
strongly influences the selection of cutting
tool geometry, grade and cutting data.
Workpiece materials are divided into 6

major groups in accordance with the ISOstandard, where each group has unique
properties regarding machinability.
Threading
Steel
Stainless
steel
Milling
Workpiece material groups
Drilling
ISO P Steel is the largest material

group in the metal cutting area, ranging
from unalloyed to high-alloyed material
including steel castings and ferritic and
martensitic stainless steels. The machinability is normally good, but differs
a lot depending on material hardness,
carbon content, etc.
Boring
Tool holding
Machinability
Other information
ISO M Stainless steels are materials

alloyed with a minimum of 12% chromium; other alloys are, e.g., nickel and
molybdenum. Different conditions such
as ferritic, martensitic, austenitic and
austenitic-ferritic (duplex), makes this an
extensive material group. Common for
all these types are that they expose cutting edges to a great deal of heat, notch
wear and built-up edge.
A 24
Cast iron
ISO K Cast iron is, contrary to steel, a

short-chipping type of material. Gray cast
iron (GCI) and malleable cast irons (MCI)
are quite easy to machine, while nodular
cast iron (NCI), compact cast iron (CGI)
and austempered cast iron (ADI) are
more difficult. All cast irons contain silicon carbide (SiC) which is very abrasive
to the cutting edge.
Turning
B
Parting and
grooving
Aluminum
ISO N Non-ferrous metals are softer

types of metals such as aluminum, copper, brass, etc. Aluminum with a silicon
content (Si) of 13% is very abrasive.
Generally high cutting speeds and long
tool life can be expected for inserts with
sharp edges.
Milling
Threading
Drilling
E
ISO S Heat Resistant Super Alloys
include a great number of high-alloyed
iron, nickel, cobalt and titanium-based
materials. They are sticky, create built-up
edge, workharden and generate heat,
very similar to the ISO M-area, but they
are much more difficult to cut, leading to
shorter tool life for the cutting edges.
Boring
Heat resistant
alloys
ISO H This group covers steels with a

hardness between 45-65 HRc and also
chilled cast iron around 400-600 HB.
The hardness makes them all difficult to
machine. The materials generate heat
during cutting and are very abrasive to
the cutting edge.
A 25
G
Tool holding
Hardened
steel
H
Machinability
Other information
Turning
Cutting forces
Parting and
grooving
Another expression of the differences

in the six material groups is through the
force (FT) needed to shear off a specific
chip cross-section in certain conditions.
tion of how much power is needed for an

operation.
kc1 = specific cutting force for average
chip thickness .039 inch (1 mm).
This value, the specific cutting force value

(kc), is indicated for various types of workpiece materials and used in the calcula-
Steel
Threading
Milling
P
materials have a kc1 variation of:
217,500-449,500 lbs/inch2
(1500-3100 N/mm2).
Stainless steel
Drilling
Boring
Cast iron
Tool holding
M materials have a kc1 variation of:

261,000-413,250 lbs/inch2
(1800-2850 N/mm2).
K
114,550-195,750 lbs/inch2
(790-1350 N/mm2).
Machinability
Other information
A 26
Turning
Aluminum
Parting and
grooving
N
50,750-195,750 lbs/inch2
(350-1350 N/mm2).
Threading
Heat resistant super alloys
Hardened material
Boring
H materials have a kc1 variation of:

369,750-706,150 lbs/inch2
(2550 4870 N/mm2).
Tool holding
A 27
Machinability
Other information
Drilling
S materials have a kc1 variation of:

- 348,000-449,500 lbs/inch2
(2400-3100 N/mm2) for HRSA
- 188,500-203,000 lbs/inch2
(1300-1400 N/mm2) for titanium alloys
Milling
Turning
Chip formation
There are three patterns for a chip to break
after it has been cut.
B
Against the tool
Against the workpiece
Self-breaking, where the

material, in combination with how the chip is
curved, leads to the chips
being parted as they come
off the insert.
Chips breaking against the

tool, where the chip curves
around until it makes
contact with the clearance
face of the insert or tool
holder, and the resulting
strain snaps it. Although
often accepted, this
method can in some cases
lead to chip hammering,
where the chip damages
the insert.
Chips breaking against the

workpiece, where the chip
snaps when making contact with the surface that
has just been machined.
This type of chip breaking
is usually not suitable in
applications where a good
surface finish is needed,
because of possible
damage caused to the
component.
Parting and
grooving
Self-breaking
Threading
Milling
Drilling
Boring
Tool holding
Machinability
Other information
A 28
Turning
Chip formation varies with different parameters

Chip formation varies with depth of cut, feed, material
and tool geometry.
Self-breaking
ap
Against the tool
ap
Against the workpiece
Parting and
grooving
C
Threading
Milling
Insert rake angle

The rake angle () can be either negative or positive.
Based on this, there are negative and positive inserts,
where the clearance angles are either zero or several degrees plus. This determines how the insert can be tilted
in the tool holder, giving rise to a negative or positive
cutting action.
Drilling
F
Negative cutting action
Boring
Positive cutting action
Tool holding
A 29
Machinability
Other information
Turning
Insert rake angle
Parting and
grooving
Negative style
Threading
There is a distinction in cutting edge geometry between negative and positive insert
geometry:
- A negative insert has a wedge angle of
90 seen in a cross-section of the basic
shape of the cutting edge.
-A
positive insert has an wedge angle of
less than 90.
The negative insert has to be inclined
negatively in the tool holder so as to
provide a clearance angle tangential to the
workpiece while the positive insert has
this clearance built in.
ouble/single sided
D
Edge strength
Zero clearance
External/internal machining
Heavy cutting conditions
ingle sided
S
Low cutting forces
Side clearance
Internal/external machining
Slender shafts, small bores
Note: The clearance

angle is the angle
between the front
face of the insert
and the vertical axis
of the workpiece.
Milling
Positive style
Insert geometries
Metal cutting is very much the science of removing

chips from the workpiece material in the right way.
Chips have to be shaped and broken off into lengths
that are manageable in the machine.
Boring
Drilling
In milling and drilling a lot of parameters influence the

chip formation compared to turning.
Turning is a single-cut operation with a stationary tool
and a rotating workpiece.
The insert rake angle, geometry and feed play an
important role in the chip formation process.
Removing heat from the cutting zone through the chip
(80%) is a key issue.
Tool holding
Machinability
Other information
A 30
Choice of inserts geometries
Turning
The design of a modern insert

Definitions of terms and geometry design
Nose cutting edge design
Main cutting edge design

.010 in.
(0.25 mm)
20
Parting and
grooving
Macro geometry with

chip breaker
C
utting edge reinforcement .010 inch
(0.25 mm)
Rake angle 20
Geometry for small

cutting depths
Threading
Primary land 5
Milling
.008 in. (0.2 mm)
The reinforcement of the cutting edge

Drilling
The ER-treatment (Edge Roundness) gives the cutting

edge the final micro-geometry.
G
Tool holding
T he relationship between W/H is what

makes inserts suitable for different
applications.
Boring
E
R-treatment is done before coating, and
gives the final shape of the cutting edge
(micro-geometry).
A 31
Machinability
Other information
Turning
The working area of an insert geometry

A chip breaking diagram for an insert
geometry is defined by acceptable chip
breaking for feed and depth of cut.
Parting and
grooving
Cutting depth,
ap inch (mm)
C
utting depth (ap) and feed (fn) must be
adapted to the chipbreaking area of the
geometry to get acceptable chip control.
C
hip breaking which is too hard can lead
to insert breakage.
Threading
C
hips which are too long can lead to
disturbances in the machining process
and bad surface finish.
Milling
Feed, fn inch/r (mm/r)
Drilling
Three main application areas in turning

R
M
F
= Roughing
Roughing
= Medium machining
aximum stock removal and/or severe

M
conditions.
= Finishing
L arge cutting depth and feed rate combinations.
Cutting depth,
ap inch (mm)
High cutting forces.

Medium machining
Boring
Most applications general purpose.

Medium operations to light roughing.
G
Tool holding
W
ide range of cutting depth and feed
rate combinations.
Finishing
Small cutting depths and low feed rates.
Machinability
Other information
A 32
Low cutting forces.
Turning
Chip breaking application areas
CNMG 432 (CNMG 120408)

.236 (6.0)
Medium M
Wide range of depth of cut and feed rate
combinations.
.157 (4.0)
.079 .(2.0)
Chip breaking area:
P R
ap = 5.0 (1.0 - 7.5 )

fn = 0.5 (0.25 - 0.7)
Drilling
ap = .197 (.039 - .295) inch

fn = .020 (.010 - .028) inch/r
CNMM 432-PR
(CNMM 120412-PR)
Cutting depth,
ap inch (mm)
Milling
Chip breaking diagram

Roughing of low alloy
steel
mm
mm/r
F
The area marked
in red indicates the
area which gives
acceptable chip
breaking.
.236 (6.0)
.118 (3.0)
Boring
(0.1)
.004
Finishing F
Operations at light depths of cut and low
(0.4)
(0.8)
feed rates.
.016
.031
Feed, fn inch/r (mm/r) Operations requiring low cutting forces.
B
Parting and
grooving
Roughing R
High depth of cut and feed rate combinations. Operations requiring the highest
edge security.
Cutting depth,
ap inch (mm)
Threading
Turning of low alloy steel
G
Tool holding
.059 (1.5)
.039 (1.0)
.020 (0.5)
(0.2)
.008
(0.3)
.012
(0.4)
.016
(0.5)
.020
(0.6)
.024
(0.7)
.028
A 33
Machinability
Other information
H
(0.1)
.004
Turning
Medium machining of
low alloy steel
Parting and
grooving
Chip breaking area:
P M
ap = .118 (.020 - .217) inch

fn = .012 (.006 - .020) inch/r
ap = 3.0 (0.5 - 5.5)
fn = 0.3 (0.15 - 0.5)
CNMG 432-PM
(CNMG 120408-PM)
Cutting depth,
ap inch (mm)
mm
mm/r
.236 (6.0)
C
Threading
.118 (3.0)
.059 (1.5)
.039 (1.0)
.020 (0.5)
Milling
(0.1)
.004
(0.2)
.008
(0.3)
.012
(0.4)
.016
Drilling
Finishing of low alloy

steel
Cutting depth,
ap inch (mm)
(0.5)
.020
Chip breaking area:
P F
ap = .016 (.010 - .059) inch

fn = .006 (.003 - .012) inch/r
ap = 0.4 (0.25 - 1.5)
fn = 0.15 (0.07 - 0.3)
CNMG 434-PF
(CNMG 120404-PF)
mm
mm/r
Boring
.059 (1.5)
.049 (1.25)
.039 (1.0)
Tool holding
.030 (0.75)
.020 (0.5)
.010 (0.25)
Machinability
Other information
(0.1)
.004
A 34
(0.15)
.006
(0.2)
.008
(0.25)
.010
(0.3)
.012
(0.35)
.014
It is important to select the correct insert

size, insert shape, geometry and insert
nose radius to achieve good chip control.
S
elect the largest possible point angle
on the insert for strength and economy.
S
elect the largest possible nose radius
for insert strength.
B
Parting and
grooving
Considerations when selecting inserts
Turning
Selection of inserts
re
Threading
S
elect a smaller nose radius if there is a
tendency for vibration.
l = cutting edge length (insert size)

re = nose radius
Milling
Dedicated inserts for the ISO P, M and K area
Finishing
Medium
Roughing
F
.008 in.
(0.2 mm)
.013 in.
(0.32 mm)
Boring
.003 in.
(0.07 mm)
.004 in.
(0.1 mm)
.013 in.
(0.32 mm)
G
Tool holding
.012 in.
(0.29 mm)
.010 in.
(0.25 mm)
A 35
Machinability
Other information
Workpiece
material
Drilling
The different micro and macro-geometries are adapted to the

various requirements in the applications.
Turning
Geometry description
Parting and
grooving
Every insert has a working area with optimized chip control.

A geometry description and application information are also
available.
Geometry working
area
Geometry
description
Application
-PM
CNMG 432-PM
(CNMG 12 04 08-PM)
ap = .020 .217 inch
fn = .006 .020 inch/r
-PM for medium turning

with broad capability for steel.
Feed: .004 .026 inch/r (0.1 0.65 mm/r)
Depth of cut: .016 .339 inch (0.4 8.6 mm)
Operations: turning, facing and profiling.
Advantages: all-purpose, reliable, with problemfree machining.
Components: axles, shafts, hubs, gears, etc.
Limitations: depth of cut and feed, risk of
overloading the cutting edge.
General recommendations: Combine with
a wear resistant grade (GC4225) for best
productivity.
Possible optimization: geometry WMX.
Threading
ap = 0.5 5.5
fn = 0.15 0.5
ap inch (mm)
.236 (6.0)
.010 in.
(0.25 mm)
.197 (5.0)
.157 (4.0)
.008 in.
(0.20 mm)
.118 (3.0)
Milling
.079 (2.0)
.039 (1.0)
(0.1) (0.2) (0.3) (0.4) (0.5) (0.6) (0.7) (0.8) (0.9)
.004 .008 .012 .016 .020 .024 .028 .031 .035
mm
mm/r
fn inch (mm)
Drilling
From universal to optimized turning inserts
Universal inserts
Universal geometry.
Optimizing with grades.
Boring
Performance compromised.
Application area
Optimized inserts
O
ptimized performance
according to workpiece
machinability.
Machinability
Other information
Tool holding
D
edicated geometries
and grades.
A 36
Application area
Dedicated turning inserts

Turning
For steel, stainless, cast iron, aluminum, heat resistant

super alloys and hardened steel.
Negative basic-shape inserts

ISO
Finishing
Medium
Roughing
Positive basic-shape inserts

Finishing
Medium
Roughing
Parting and
grooving
C
Threading
Milling
Drilling
Boring
G
Tool holding
A 37
Machinability
Other information
Turning
Inserts for general turning
Threading
A
negative insert has a
wedge angle of 90 seen in
a cross-section of the basic
shape of the cutting edge.
Negative, double/single-sided inserts

Plain inserts
Parting and
grooving
The choice of different insert concepts
Double
sided
Single
sided
Without
hole
With hole
A positive insert has a

wedge angle less than 90.
Positive, single-sided inserts
Milling
Drilling
A
vailable as double/singlesided inserts with P-hole or
plain.
A
vailable with 7 or 11
clearance angle.
Positive
11
Positive
7
Positive T-rail
clamping
The

positive T-rail inserts
have a clearance angle of
5 or 7.
Chip forming at high pressure and temperatures

The choice of cutting material and grade is critical
for success
The ideal cutting tool material should:
Boring
e hard to resist flank wear and

-b
deformation.
- be tough to resist bulk breakage.
G
Tool holding
-n
ot chemically interact with the workpiece
material.
-b
e chemically stable to resist oxidation
and diffusion.
Temperatures given
in Celsius
Machinability
Other information
A 38
-h
ave good resistance to sudden thermal
changes.
Choice of inserts grades
Turning
The main range of cutting tool materials

The most common cutting tool materials are divided into
the following main groups:
HT U
ncoated cermet containing
primarily titanium carbides (TiC)
or titanium nitrides (TiN) or both
HC Cermet as above, but coated
CC Ceramics as above, but coated.

- Cubic boron nitrides (BN)
Parting and
grooving
- Cermets (HT, HC)
itride ceramics containing prima CN N

rily silicon nitride (Si3N4).
- Polycrystalline diamonds (DP, HC)

HC P
olycrystalline diamonds, but
coated.
Threading
- Coated cemented carbides (HC)
- Ceramics (CA, CM, CN, CC)

CA O
xide ceramics containing primarily aluminum oxide (Al2O3).
Milling
CM M
ixed ceramics containing
primarily aluminum oxide (Al2O3)
but containing components other
than oxides.
Drilling
Boring
Tool holding
A 39
Machinability
Other information
- Uncoated cemented carbide (HW)
Turning
How to select insert geometry and grade

Select the geometry and grade according to the application.
Machining conditions
Build up of a grade chart
Parting and
grooving
Wear resistance
Good
C
Threading
Average
Difficult
Milling
Good conditions
Continuous cuts
High speeds
Pre-machined workpiece
Excellent component clamping
Small overhangs
Drilling
Good
Boring
Average conditions
Profiling cuts
Moderate speeds
Forged or cast workpiece
Good component clamping
Tool holding
Difficult conditions
Interrupted cuts
Low speeds
Heavy cast or forged skin on workpiece
Poor component clamping
Machinability
Other information
A 40
Average
Difficult
Turning
Dedicated grades for ISO P, M and K

Dedicated grades minimize tool wear development
B
Parting and
grooving
The workpiece material influences the wear during the

cutting action in different ways. Therefore dedicated
grades have been developed to cope with the basic wear
mechanisms, e.g.:
- Flank wear, crater wear and plastic deformation in steel
- Built-up edge and notch wear in stainless steel
C
Threading
- Flank wear and plastic deformation in cast iron.
Milling
Select geometry and grade depending on the type of the

workpiece material and type of application.
Drilling
Boring
G
GC 4200
ISO
GC 2000
ISO
GC 3200
Tool holding
A 41
Machinability
Other information
ISO
Choice of inserts shape
The influence of large and small point angle
The insert shape and point angle varies

considerably from the smallest, at 35, to
the round insert.
Parting and
grooving
Turning
Selection of the insert shape
-o
thers give the best profiling
accessibility.
Threading
Each shape has unique properties:

- some provide the highest roughing
strength
Each shape also has unique limitations.

For example:
- high edge accessibility during machining
leads to a weaker cutting edge.
Round
90
80
80
60
55
35
Milling
Drilling
E
Accessibility
Vibration
tendency
Power
consumption
Large point angle
Small point angle
Stronger cutting edge
Weaker cutting edge
Higher feed rates
Increased accessibility
Increased cutting forces
Decreased cutting forces
Increased vibration
Decreased vibration
Tool holding
Boring
Cutting edge
strength
Machinability
Other information
A 42
Turning
Factors affecting choice of insert shape

Insert shape should be selected relative to the lead
(entering) angle accessibility required of the tool. The
largest possible point angle should be applied to give
insert strength and reliability.
B
= Most suitable
Parting and
grooving
= Suitable
Finishing
Longitudinal turning
Profiling
Operational versatility
Limited machine power

Vibration tendencies
Hard material
Intermittent machining
Small lead angle

Large lead angle
Milling
Drilling
Facing
Boring
Light roughing/semifinishing
Tool holding
A 43
Machinability
Other information
Roughing strength
Threading
Insert shape
Turning
Number of cutting edges
Parting and
grooving
Number of edges,
negative inserts
4/8
2/4
3/6
3/6
2/4
2/4
Number of edges,
positive inserts
ISO (first letter)
Threading
Insert shape
Selection of the nose radius
Milling
Effect of small and large nose radius

re
re
Drilling
re
Boring
Small nose radius
Large nose radius
Ideal for small cutting

depth
Heavy feed rates
Tool holding
Reduces vibration
Weak cutting edge
Machinability
Other information
A 44
Large depths of cut
Rule of thumb
Strong edge security
The depth of cut

should be no less
than 2/3 of the nose
radius r.
Increased radial
pressures
Choice of inserts nose radius
Turning
A small nose radius should be first choice

With a small nose radius, the radial cutting forces can
be kept to a minimum, while utilizing the advantages of a
larger nose radius leads to a stronger cutting edge, better
surface texture and more even pressure on the cutting
edge.
Parting and
grooving
C
DOC
Threading
DOC
DOC
Milling
T he relationship between nose radius and DOC (depth

of cut) affects vibration tendencies.
It is often an advantage to choose a nose radius which
is smaller than the DOC.
Boring
However with a round insert, radial pressure will never stabilize because the
theoretical nose radius is half the insert
diameter (iC).
Tool holding
A 45
Machinability
Other information
The radial force exerted on the workpiece

grows linearly until the nose radius of the
insert is less than the depth of cut where
it stabilizes at the maximum value.
Drilling
Effect of nose radius and DOC
Turning
High feed turning with wiper inserts

Wiper General information
Why use a wiper

productivity.
Parting and
grooving
Wiper insert
rWiper
Rmax
se normal feed rate and

U
When to use wipers
Use wipers as a first
choice where its possible.
Threading
Conventional insert
Rmax
isually, surfaces can

V
look different even
though the measured
surface is great.
Milling
rISO
Limitations
General limitation is
vibration.
Wiper Technical solution

Drilling
O
ne wiper cutting edge is based on
3-9 radii.
C
ontact surface between insert and
component is longer with wipers.
L onger contact surface makes a better

surface finish.
Boring
L onger contact surface increases cutting

forces which makes a wiper insert more
sensitive to vibration when machining
unstable components.
Tool holding
Machinability
Other information
H
A conventional nose radius compared
with a wiper nose radius.
A 46
Turning
Wiper Surface finish

Traditional
insert
T wo times feed with a wiper will

generate as good surface as conventional geometries with normal
feed.
T he same feed with a wiper will

generate twice as good surface
compared with conventional
geometries.
Threading
Wiper insert
Twice the
feed, same Ra
Parting and
grooving
Rule of thumb
Rt = Maximum value peak-to-valley height

Ra = A
rithmetic average height of the
profile
Milling
D
Wiper insert
Same feed,
half Ra
Drilling
Achieved surface traditional ISO inserts and wipers
Ra
157 (4.00)
Standard -PM
118 (3.00)
Wiper -WM
79 (2.00)
Wiper -WMX
0 (0.00)
(0.20)
.008
(0.35)
.014
(0.50)
.020
(0.65) Feed, fn inch/r (mm/r)

.026
A 47
Machinability
Other information
39 (1.00)
G
Tool holding
Insert geometry
197 (5.00)
Boring
(m)
236 (6.00)
Choice of inserts speed and tool life
Turning
Cutting data parameters affect tool life

B
Parting and
grooving
Use the potential of:

- ap to reduce number of cuts
- fn for shorter cutting time
- vc for best tool life
Threading
Cutting speed
Tool life
vc large effect on tool life.
Milling
Adjust vc for best economy.
Boring
Cutting speed vc
Feed
Tool life
Drilling
fn less effect on tool life than vc.
Feed fn
Cutting depth
Tool life
Tool holding
ap little effect on tool life.
Machinability
Other information
H
Cutting depth ap
A 48
Choice of inserts speeds and tool life
Turning
Effects of cutting speed

The single largest factor determining tool life
Too low
Rapid flank wear
Built-up edge
Poor finish
Uneconomical
B
Parting and
grooving
Too high
Rapid cratering
Plastic deformation
Threading
Effects of feed rate
Too high
Too low
Loss of chip control
Stringers
Poor surface finish
Uneconomical
Milling
The single largest factor determining productivity
ratering, plastic deforC

mation
Chip hammering
Boring
Chip welding
Drilling
High power consumption
Effects of depth of cut

High power consumption
Loss of chip control
Insert breakage
Vibrations
Increased cutting forces
Excessive heat
G
Tool holding
Too small
Uneconomical
A 49
Machinability
Other information
Too deep
Turning
Choice of tools external turning
External turning
Tool selection and how to apply
B
Parting and
grooving
General guidelines
S
ecure insert and tool holder clamping is
an essential factor for stability in turning.
T ool holder types are defined by the lead
(entering) angle, the shape and size of
the insert used.
C
Threading
T he selection of tool holder system is

mainly based on the type of operation.
A
nother important selection is the use of
negative versus positive inserts.
Milling
W
henever possible choose modular
tools.
Drilling
Definitions of key figures
Boring
22 Max in copy angle
Lead angle r 3
(Entering angle r = 93)
Feed directions
Tool holding
Machinability
Other information
H
Insert point angle
A 50
60
Insert shape
Turning
Four main application areas

Longitudinal turning/facing
Rhombic shape C-style (80) insert is frequently used.
Holders with lead angles of 5 and 3 (entering angles of
95 and 93) are commonly used.
C
Threading
Alternatives to the C-style insert are D-style (55), W-style (80)

and T-style (60).
Parting and
grooving
The most common turning operation.
Profiling
Versatility and accessibility is the determining factor.
The effective lead angle (r ) (entering angle (kr)) should be
considered for satisfactory machining.
M
ost commonly used lead angle is 3 (entering angle = 93)
because it allows an in-copying angle between 22-27.
Milling
T he most frequently used insert shapes are D-style (55),

V-style (35) and T-style (60) inserts.
E
Facing
P
ay attention to the cutting speed which will change progressively when feeding towards the centre.
Drilling
The tool is fed in towards the center.
L ead angles of 15 and 5/1 (entering angles of 75 and

95/91) are commonly used.
Boring
C-style (80), S-style (90), and T-style (60) inserts are frequently used.
Plunging
R
ound inserts are very suitable for plunge turning as they can
be used for both radial and axial feeds.
Neutral 90 holders for round inserts are commonly used.
Tool holding
A method to produce or widen shallow grooves.
A 51
Machinability
Other information
Turning
Small lead angle

Features / Benefits
Cutting forces directed towards chuck.
Can turn against a shoulder.
Parting and
grooving
Higher cutting forces at entrance and exit of cut.
Tendency to notch in HRSA and hard materials.
Threading
Large lead angle
Milling
Features / Benefits
Produces a thinner chip
- Increased productivity.
Reduced notch wear.

Cannot turn against a shoulder.
Drilling
45
Boring
Tool holding
Machinability
Other information
A 52
Turning
The lead angle

Important consideration in profile turning
Out-copying
Parting and
grooving
In-copying
r
r
T he maximum in-copying angle beta () is recommended for each tool type and is specified in the catalogs.
Milling
T he effective lead angle (r) should also be considered

for satisfactory machining when the operation involves
profiling.
Threading
Axial and radial cutting forces

Large lead angle
Drilling
Small lead angle
F
Ff = axial
Fp = radial
Boring
Fp = radial
Ff = axial
Higher cutting forces especially at

entrance and exit of cut.
Reduced load on the cutting edge.

F orces are directed both axially and
radially.
- Vibration tendencies.
A 53
Machinability
Other information
Forces are directed both axially and

radially.
Tool holding
G
Forces directed toward the chuck. Less
tendency for vibration.
++
++
++
Wedge
clamp
design
Screw
clamp
design
++
++
++
++
++
=R
ecommended tool
holder system
= Alternative system
Plunging
++
+
Facing
Tooling system
Profiling
Parting and
grooving
Longitudinal
turning
Turning
Define the suitable clamping system
Milling
Rigid clamp
design
Negative inserts
Threading
Boring
Positive inserts
Drilling
Lever
design
Screw
clamp
design
T-rail
++
Machinability
Other information
Ceramic and CBN

inserts
Tool holding
A 54
Rigid clamp
design
Top clamp
design
++
Alternative shape
Rhombic 80
++
Rhombic 55
++
Round
Square
Triangular
Trigon 80
Rhombic 35
Rhombic 55
++
Threading
B
Parting and
grooving
Plunging
Recommended insert shape
Facing
++
+
Drilling
Milling
++ =
+=
Profiling
Insert shape
Longitudinal
turning
Turning
Insert recommendation depending on operation
+
+
Screw clamping
Screw clamping,
T-rail
G
Tool holding
P lever style
A 55
Machinability
Other information
Rigid clamping
Boring
Modern insert clamping for turning tools
Turning
Choice of tools - internal turning
Internal turning
Tool selection and how to apply
B
Parting and
grooving
General guidelines
In internal turning (boring operations)
the choice of tool is very much restricted
by the components hole diameter and
length.
hip evacuation is a critical factor for

-C
successful boring.
- T he clamping method has a decisive effect on the performance and result.
Milling
Threading
-C
hoose the largest possible bar diameter and the smallest possible overhang.
Drilling
Boring
Tool holding
Selection factors
Tool and insert geometry
Chip evacuation
Tool requirements
Chip size
Reduced length
Insert shape, negative/

positive
Chip control
Increased diameters
Techniques
Optimized shape
Insert geometry
Nose radius
Machinability
Other information
A 56
Different tool materials

Clamping
Choice of tools internal turning
Turning
Effect of cutting forces on internal turning

Radial and tangential cutting forces deflect the boring bar
Tangential cutting force, Ft
Parting and
grooving
F orces the tool down, away from the

center line.
Gives a reduced clearance angle.
Alters cutting depth and chip thickness.

ives out of tolerance dimension and
G
risk of vibration.
Fr
Directed along the feed of the tool.

Milling
Ft
Feed force, Fa
Fa
Threading
Radial cutting force, Fr
If possible, do not choose a lead angle

more than 15 (entering angle less than
75), since this leads to a dramatic
increase of the radial cutting force Fr.
- L ess force in radial direction = less
deflection.
Boring
S
elect a lead angle close to 0 (entering
angle close to 90).
G
Tool holding
Lead angle and cutting forces
Drilling
Selecting lead (entering) angles
A 57
Machinability
Other information
Turning
Four main application areas

Longitudinal turning/facing
The most commonly used internal turning operation.
Parting and
grooving
Rhombic shape C-style (80) insert is frequently used.

Boring bars with lead angles of 5 and 3 are
commonly used.
D
-style (55), W-style (80) and T-style (60) insert shapes
are also frequently used.
Threading
Profiling
Versatility and accessibility is the determining factor.
The effective lead angle (r) should be considered.
Bars with lead angle of 3, allowing an in-copying angle between 2227, are commonly used.
Milling
-style (55), V-style (35) and T-style (60) inserts are

D
frequently used.
A lead angle of close to 0 is recommended.
C
-style (80), S-style (90) and T-style (60) inserts are frequently used.
Boring
Drilling
Boring operations are performed to open up existing holes.
Back boring
Back boring is a boring operation with reverse feed.
It is used for turning shoulders less than 90.
Tool holding
Use smallest possible overhang.
B
oring bars with 3 lead angles and D-style (55) inserts are
commonly used.
Machinability
Other information
A 58
Longitudinal
turning
Insert shape
Facing
B
Parting and
grooving
Recommended insert shape

Alternative shape
Rhombic 80
Rhombic 55
Round
Square
Triangular
++
Trigon 80
Rhombic 35
++
++
+
Threading
+
+
Milling
++ =
+=
Profiling
Turning
Insert recommendation depending on operation
Drilling
Selecting the insert basic shape
Inserts with clearance angle 11

- First choice when small cutting forces
and long overhangs are required.
F or best economy
- Use negative inserts in stable conditions and with short overhang.
7, positive,
single sided
inserts
Negative,
double sided
inserts
A 59
Machinability
Other information
11, positive,
single sided
inserts
Boring
Inserts with clearance angle 7

- First choice for small and medium holes
from .236 inch (6 mm) diameter.
Tool holding
Positive inserts generate lower cutting force and tool deflection
Turning
Insert point angle
Parting and
grooving
Small point angle:

Use the smallest
angle giving acceptable strength and
economy
- Increases accessibility
- Decreases vibration
- Decreases cutting forces.
Round
90
80
80
60
55
35
Threading
Milling
Cutting edge
strength
Accessibility
Vibration tendency
Power consumption
Drilling
Chip area and nose radius

Cutting forces and cutting tool deflection
Boring
Rule of thumb!
Tool holding
Machinability
Other information
B
oth small and large
chip areas can cause
vibration:
- Large due too high
cutting forces
- Small due too high
friction between the tool
and the workpiece.
A 60
The relationship between

r (nose radius) and ap
(depth of cut) affects
vibration tendencies.
L ess force in radial direction = less deflection.
Choose a nose
radius which is somewhat less than the
cutting depth.
Turning
Clamping the boring bar
M
aximum contact between tool and tool
holder (design, dimensional tolerance).
dmm
lamping length 3 to 4 times bar diamC

eter (to balance cutting forces).
Holder strength and stability.
B
Parting and
grooving
Critical stability factors for optimized performance
C
Threading
3-4 x dmm
Milling
Tool requirements for clamping
Drilling
Maximum contact between tool and tool holder
Best choice
Coromant Capto coupling
Boring
Acceptable
G
Tool holding
Not recommended
Not recommended
A 61
Machinability
Other information
Choice of tools - how to apply
Turning
EasyFix sleeves
For correct clamping of cylindrical bars
B
Parting and
grooving
Guarantees correct center height
Benefits:
Cutting edge in right position
Best cutting action gives better surface finish
Threading
Reduced setup time

Even insert wear.
Silicon sealer
Milling
Drilling
Groove
Boring
A spring plunger mounted in the sleeve clicks into a

groove in the bar and guarantees correct center height.
Tool holding
Spring plunger
The slot in the cylindrical sleeve is filled with a silicon

sealer which allows the existing coolant supply system to
be used.
Machinability
Other information
A 62
Turning
Factors that affect vibration tendencies

Vibration tendencies grow towards the right
Parting and
grooving
Lead (entering)
angle
Threading
Nose radius
Micro and
macro geometry
Milling
Edge design
Inserts with thin coatings, or uncoated

inserts, are to be preferred as they
normally give lower cutting forces.
Micro and macro geometry

Use a positive basic-shape insert, as
these give lower cutting forces compared to negative inserts.
Drilling
Insert wear changes the clearance

between the insert and the hole wall.
This can affect the cutting action and
lead to vibration.
Boring
Nose radius
Choose a nose radius which is somewhat smaller than the cutting depth.
Edge design
Tool holding
A 63
Machinability
Other information

Choose a lead angle as close to 0
(entering angle as close to 90) as possible, never more than 15 (less than
75 for entering angle).
Turning
Chip evacuation
Chip evacuation is a critical factor for successful boring
B
Parting and
grooving
C
entrifugal force presses the chips to
the inside wall of the bore.
T he chips can damage the inside of the
bore.
- Internal coolant can help with chip
evacuation.
C
Threading
-B
oring upside down helps to keep chips
away from the cutting edge.
Chip evacuation and chip control

Milling
Hard breaking of chips, short chips

Power demanding and can increase the
vibration.
Drilling
C
an cause excessive crater wear and
result in poor tool life and chip jamming.
Long chips
Can cause chip evacuation problems.
Boring
Causes little vibration tendency, but can

in automated production cause problems due to chip evacuation difficulties.
Tool holding
G
Short and spiral chips
To be preferred. Easy to transport and
do not cause a lot of stress on the cutting edge during chip breaking.
Machinability
Other information
A 64
Turning
Recommended tool overhang

Maximum overhang for different types of bars
B
Parting and
grooving
Steel bar
up to 4 x dmm
Carbide bar
up to 6 x dmm
Short, dampened bar
up to 7 x dmm
C
Threading
Long, dampened bar

up to 10 x dmm
Carbide reinforced, dampened bar
up to 14 x dmm
14
10
Clamping
length:
4 x dmm
Milling
Overhang: ... x dmm
Eliminate vibrations
Increase productivity in deep bores
Minimize vibration
Coolant tube
M
achining performance can be maintained or improved
Oil
D
ampened boring bars are available
in diameters from .394 inch (10 mm)
High density mass
- F or max overhang 14 x dmm (carbide

reinforced)
Boring
Rubber damper
Drilling
Internal machining with dampened boring bars
G
Tool holding
Cutting head
Steel bar
Dampened bar
A 65
Machinability
Other information
Turning
Code key for inserts and toolholders - INCH

Extract from ISO 18321991
INSERT
Tolerances
Insert thickness
Nose radius
Parting and
grooving
Code keys
C N M G
C
Threading
4 3 2 - PF
5
1. Insert shape
5. Insert size
Milling
2. Insert clearance angle
TOOL HOLDERS
External
D C L N R 16 4 D
Drilling
E

B 1 C 2 D
Boring
Internal
S 16 T S C L C R
Tool holding
Machinability
Other information
C3 A
4
5
Bar diameter
Coromant Capto
coupling size
A 66
S = Solid steel bar

A = Steel bar with coolant supply
E = Carbide shank bar
F = Dampened, carbide shank bar
Holder lead angle
Code keys
55
4. Insert type
35
80
5. Insert size
Inscribed circle is indicated in 1/8"
B
Parting and
grooving
80
Turning
1. Insert shape
C
7. Nose radius
r
r
r
r
r
r
=
=
=
=
=
=
.008
1/64
1/32
3/64
1/16
3/32
First choice nose radius recommendations:

Finishing
Medium
Roughing
T-MAX P
CoroTurn 107
2
2
3
1
2
2
Threading
0
1
2
3
4
6
Milling
8. Geometry manufacturers option

The manufacturer may add a further two symbols to the code describing the
insert geometry e. g.
-PF = ISO P Finishing

-MR = ISOMRoughing
Drilling
B. Clamping system
Right-hand style
L
Left-hand style
Bars:
Boring
E. Shank or bar size

Shanks: height
and width
Neutral
Rigid clamping (RC) Top and hole clamping Hole clamping Screw clamping
D. Hand of tool
G. Tool length
External, l1 in inch
Internal, l1 in inch
A = 4.000
B = 4.500
C = 5.000
D = 6.000
M = 4.000
M = 6.000
R = 8.000
S = 10.000
T = 12.000
U = 14.000
A 67
G
Tool holding
Top clamping
M,W
H
Machinability
Other information
Turning
Code key for inserts and toolholders - METRIC

Extract from ISO 18321991
INSERT
Tolerances
Insert thickness
Nose radius
Parting and
grooving
Code keys
C N M G 09 03 08 - PF
C
Threading
1. Insert shape
5. Insert size = cutting edge length
Milling
TOOL HOLDERS
External
D C L N R 16 16 H 09
Drilling
E

B 1 C 2 D
Boring
Internal
A 25 T S C L C R 09
Tool holding
Machinability
Other information
C3 A
Bar diameter
Coromant Capto
coupling size
A 68
S = Solid steel bar

A = Steel bar with coolant supply
E = Carbide shank bar
F = Dampened, carbide shank bar
Holder style
Code keys
55
4. Insert type
35
80
5. Insert size = Cutting edge length
l mm: 0625
0715
0632
0925
0627
1116
0608
B
Parting and
grooving
80
Turning
1. Insert shape
C
7. Nose radius
=
=
=
=
=
=
First choice nose radius recommendations:
0.2
0.4
0.8
1.2
1.6
2.4
Finishing
Medium
Roughing
T-MAX P
CoroTurn 107
08
08
12
04
08
08
Threading
02 r
04 r
08 r
12 r
16 r
24 r
Milling
8. Geometry manufacturers option

The manufacturer may add a further two symbols to the code describing the
insert geometry e. g.
-PF = ISO P Finishing

-MR = ISOMRoughing
Rigid clamping (RC)
D. Hand of tool
Top and hole clamping
E. Shank height
Hole clamping
Screw clamping
G. Tool length
Boring
Drilling
B. Clamping system
Tool length
F. Shank width
L
Left-hand style
N
Neutral
H = 100
K = 125
M = 150
P = 170
Q = 180
R = 200
S = 250
T = 300
U = 350
V = 400
W = 450
Y = 500
A 69
H
Machinability
Other information
Right-hand style
Tool holding
= l1 in mm
Turning
Parting and
grooving
Troubleshooting
Troubleshooting
Chip control
Problem
Long unbroken snarls winding
around the tool or workpieces.
Cause
F eed too low for the chosen
geometry.
Solution
Increase the feed.
elect an insert geometry
S
with better chip breaking
capabilities.
se a tool with high presU
sure coolant.
Threading
D
epth of cut too shallow for
the chosen geometry.
Increase the depth of cut or

select a geometry with better chip breaking capability.
Nose radius too large.
S
elect a smaller nose
radius.
Unsuitable lead angle
S
elect a holder with as small
a lead angle as possible
(r =0 [r =90]).
Feed too high for the chosen

geometry
C
hoose a geometry
designed for higher feeds,
preferably a single-sided
insert.
Milling
Drilling
Boring
Very short chips, often sticking

together, caused by too hard
chip breaking. Hard chip breaking often causes reduced tool
life or even insert breakages
due to too high chip load on
the cutting edge.
Unsuitable lead angle.
Select a holder with as small

a lead angle as possible
(r =4515 [r=4575]).
Nose radius too small.
Select a larger nose radius.
Tool holding
Reduce the feed.
Machinability
Other information
A 70
Troubleshooting
The surface looks and feels

hairy and does not meet the
tolerance requirements
Cause
The chips are breaking
against the component
and marking the finished
surface.
Solution
Select a geometry which
guides the chips away.
Change lead angle.

Reduce the depth of cut.
S
elect a positive tool system
with a neutral angle of
inclination.
Parting and
grooving
Problem
Turning
Surface finish
Reduce the cutting speed.
Too high feed in combination

with too small nose radius
generates a rough surface.
Select a wiper insert or a

larger nose radius.
Reduce the feed.
Burr formation
The cutting edge is not
sharp enough.
Boring
The feed is too low for the

edge roundness.
U
se inserts with sharp
edges:
- PVD coated inserts
- ground inserts at small
feed rates, < .004 inch/r
(< 0.1 mm/r).
U
se a holder with a large
lead angle.
E
nd the cut with a chamfer
or a radius when leaving the
workpiece.
A 71
G
Tool holding
Notch wear at depth of cut,

or chipping.
H
Machinability
Other information
Burr formation at the end of

the cut when the cutting edge
is leaving the workpiece.
Milling
Select a grade with better

resistance to oxidation wear,
e.g., a cermet grade.
Drilling
Hairy surface caused by

excessive notch wear on the
cutting edge.
Threading
Troubleshooting
Turning
Vibration
Parting and
grooving
High radial cutting forces due

to:
Cause
- Unsuitable lead angle.
Nose radius too large.

Vibrations or chatter marks
which are caused by the
tooling or the tool mounting.
Typical for internal machining
with boring bars.
S
elect as small lead
angle as possible (r = 0)
elect a smaller nose

S
radius.
elect a grade with a thin

S
coating, or an uncoated
grade.
xcessive flank wear on cut-E

ting edge.
elect a more wear resistant

S
grade or reduce speed.
- Insert geometry creating high

cutting forces.
S
elect a positive insert
geometry.
hip-breaking is too hard

-C
giving high cutting forces.
educe the feed or select a

R
geometry for higher feeds.
-V
arying or too low cutting
forces due to small depth
of cut.
Increase the depth of cut

slightly to make the insert
cut.
- Tool incorrectly positioned.
Check the center height.
Milling
Solution
nsuitable edge rounding, or

-U
negative chamfer.
Threading
Problem
High tangential cutting forces

due to:
Drilling
Boring
Tool holding
Machinability
Other information
A 72
- Instability in the tool due to

long overhang.
Solution
Reduce the overhang
se the largest bar

U
diameter.
Use a Silent Tool or a carbide bar.
Parting and
grooving
Cause
Threading
E
xtend the clamping length
of the boring bar.
Milling
U
se EasyFix for cylindrical
bars.
Drilling
Boring
G
Tool holding
nstable clamping offers

-U
insufficient rigidity.
A 73
Machinability
Other information
Problem
Turning
B2
Parting & Grooving

Parting and grooving is a category of turning. It has a
wide range of machining applications requiring dedicated
tools.
These tools can be used, to some extent, for general
turning.
Theory
B4
Selection procedure
B7
System overview
B 11
Parting & grooving how to apply
B 15
Troubleshooting
B 36
B3
Turning
Parting and
grooving
Parting & grooving theory

Parting off
Chip evacuation is essential
Chip evacuation is a critical factor in parting operations.
There is little opportunity to break chips in the confined
space as the tool moves deeper. The cutting edge is
designed largely to form the chip so it can be evacuated
smoothly. Consequences of poor chip evacuation are chip
obstruction, which leads to poor surface quality, and chip
jamming, leading to tool breakdown.
Threading
Theory
C
hip evacuation is a critical factor in
parting operations.
Milling
C
hip breaking is difficult in the confined
slots created as tools cut deep into the
workpiece.
T ypical chips are clock-spring shaped,
narrower than the groove.
Drilling
T he insert geometry shrinks the chip

width.
Parting off definition of terms

Boring
n
Tool holding
fnx = radial cutting feed (inch/r) (mm/r)

ar = depth of groove (inch) (mm)
(outer dia. to center or bottom of
groove)
Machinability
Other information
B4
Theory
Turning
Cutting speed value

Feed rate reduction is often advantageous for performance
when machining towards the center to minimize the pressure
on the cutting edge.
Parting and
grooving
C
utting speed declines to zero at the
center.
Threading
Milling
100 0% of vc
Feed reduction towards center
Drilling
To reduce pip size, the feed should be reduced by up to

75% when approaching the center, around .079 inch
(2 mm) before the part comes off.
educe feed by 75% when approaching

R
the center, around .079 inch (2 mm)
before the part comes off.
Boring
Feed reduction reduces pip size.
Tool holding
F eed reduction reduces vibration and

increases tool life.
B5
Machinability
Other information
.079
(2mm)
Theory
Turning
Grooving definition of terms
Parting and
grooving
The tool movement in directions X and Z is called feed

rate (fn), or fnx/fnz, inch/r (mm/r). When feeding towards
center (fnx), the rpm will increase until it reaches the
rpm limit of the machine spindle. When this limitation
is passed, the cutting speed (vc) will decrease until it
reaches 0 ft/min (m/min) at the component center.
n
Threading

fnz = axial cutting feed (inch/r) (mm/r)
(outer dia. to center or bottom of
groove)
Milling
ap = depth of cut in turning
Drilling
Face grooving definition of terms
Boring
The feed has a great influence on chip formation, chip

breaking, and thickness, and also influences how chips
form in the insert geometry. In sideways turning or profiling (fnz), the depth of the cut (ap) will also influence chip
formation.
Tool holding

H
Machinability
Other information
fnz = axial cutting feed (inch/r) (mm/r)
B6
Selection procedure
Turning
Tool selection procedure

<.0004 (.01 mm)
Dimension and quality

of the groove or face
Parting and
grooving
C
Component
Workpiece material,
chip evacuation
Threading
Milling
Machine parameters
Machine
Choice of tool
Drilling
Type of tool:
- Spring-clamp
- Screw-clamp
- Insert type
How to apply
Boring
Cutting data, method,

cutting fluid, etc
Troubleshooting
Remedies and
solutions
B7
Machinability
Other information
Tool holding
Selection procedure
Turning

Component
Parting and
grooving
A
nalyze the dimensions and quality
demands of the groove or face to be
machined.
Threading
T ype of operation: parting, grooving

Cutting depth
Cutting width
Corner radius
Milling
P M K
N S H
achinability
M
Clamping
Chip breaking
Hardness
Alloy elements
Drilling
Material
Boring
tability, power and torque especially for

S
larger diameters
Component clamping
Tool changing times/number of tools in
turret
Chip evacuation
Cutting fluid and coolant
Tool holding
Machinability
Other information
B8
Selection procedure
Turning
3. Choice of tools
Multiple grooving
M
ultiple grooving is the best method for
rough grooving when the depth is bigger
than the width.
M
ake a fork. This will improve chip flow
and increase tool life.
B
Parting and
grooving
Example of different machining methods
C
Threading
Good chip control.
Drilling
P
lunge turning is the best choice when
machining steel and stainless steel and
when the width of the groove is larger
than the depth.
Milling
Plunge turning
R
amping avoids vibration and minimizes
radial forces.
Boring
R
ound inserts are the strongest inserts
available.
Double the number of cuts/passes.
Tool holding
Ramping
F irst choice in heat resistant super alloys

(HRSA). Reduces notch wear.
B9
Machinability
Other information
Selection procedure
Turning
4. How to apply
C
enter height is important, .004 inch
(0.1 mm).
B
Parting and
grooving
educe feed by up to 75% around .079

R
inch (2 mm) before center.
.079
Max .004 inch

(0.1 mm)
se shortest possible overhang, ar inch

U
(mm).
L argest height dimension on blade for
bending stiffness.
Threading
Use coolant to improve chip flow.
Milling
ar

Insert wear and tool life
Check the wear pattern and if necessary
adjust cutting data accordingly.
Drilling
5. Troubleshooting
To improve chip formation & tool wear

Use recommended chip former.
Use neutral front angle.
Check center height.
Use cutting fluid.
Boring
General recommendation parting off

Neutral inserts (insert without front
angle).
To save material, use smallest possible
insert width.
Largest possible tool holder.
Shortest possible overhang, ar.
Tool holding
Machinability
Other information
B 10
System overview
Turning
System overview
External parting and grooving

4. Shallow to deep grooving
2. Turning and recessing
5. Face grooving
3. Undercutting
6. Profiling
B
Parting and
grooving
1. Parting-off solid bars and tubes
C
Threading
Milling
Drilling
Internal grooving
1. Grooving and pre-parting

Boring
2. Face grooving
3. Profiling
B 11
H
Machinability
Other information
Tool holding
System overview
Turning
Different systems
Insert type
B
Parting and
grooving
Application
Threading
CoroCut2
CoroCut1
CoroCut3
Q-Cut
151.2
Medium
Deep
Shallow
Deep
Q-Cut
151.3
U-Lock
154.0
Parting
(Cut off)
Grooving
Internal,
small dia.
Face grooving
Milling
Turning
Profiling
Drilling
Undercutting
Circlip grooving
Boring
First choice
Tool holding
Medium parting 1.575 inch (40 mm)

Second
choice
H
Machinability
Other information
Deep parting 4.409 inch (112 mm)
B 12
Shallow parting .472 inch (12 mm)
System overview
Turning
Internal parting and grooving
Different systems
.472
(12)
.394
(10)
.984
(25)
C
Threading
.165
(4.2)
Parting and
grooving
Internal grooving min hole diameter
.165 .394
(4.2)
(10)
.472 .984
(12)
(25)
Min. hole
diameter,
inch (mm)
Milling
Drilling
Face grooving min/max first cut diameter
F
.472
(12)
.906
(23)
Boring
.244
(6.2)
1.339
(34)
.472 1.181
(12 30)
.906 2.756
(23 70)
1.339
(34 )
First cut
diameter,
inch (mm)
B 13
Machinability
Other information
.244 .709
(6.2 18)
Tool holding
Turning
System overview
Inserts
Overview
B
Parting and
grooving
Application
Threading
Milling
Machining
condition
Parting
(Cut off)
Grooving
Turning
Finishing
CF
GF
TF
Medium
CM
GM
TM
Roughing
CR
Profiling
RM
RO
Drilling
Optimizer
Sharp
Boring
ER treated
Tool holding
Machinability
Other information
B 14
RS
CS
GE
RE
Profiling
AM
Turning
Parting and grooving how to apply
Parting & grooving and how to apply
B 16
Parting off and how to apply
B 22
General grooving and how to apply
B 25
Threading
Parting and
grooving
Parting & grooving

and how to apply
Circlip grooving and how to apply
B 27
Face grooving and how to apply
B 28
Profiling and how to apply
B 31
Turning and how to apply
B 33
Undercutting and how to apply
B 35
Milling
Drilling
Boring
Tool holding
B 15
Machinability
Other information
Turning
Tool overhang & workpiece deflection
Parting and
grooving
The tool overhang should always be minimized for

improved stability. In parting and grooving operations
consideration must be given to the depth of cut and the
width of the groove, which means that stability must often
be compromised to meet the demands of accessibility.
Threading
C
Best stability
O
verhang (ar) should be as small as
possible.
Largest seat size should be used.
Milling
ar = 8 x la max
Drilling
Internal machining
Shank type:
Dampened steel bars 5 x dmm
Steel bars 3 x dmm

Carbide bars 5 x dmm
Boring
C
arbide reinforced dampened bars, up
to 7 x dmm.
Tool holding
G
Inserts:
Use smallest possible width
Use light cutting geometries.
Machinability
Other information
B 16
Turning
Tool holder selection parameters

System considerations
Medium parting 1.575 inch (40 mm)
C
Threading
Shallow parting .472 inch (12 mm)
Parting and
grooving
Deep parting 4.409 inch (112 mm)
Deep parting
Medium parting
Shallow parting
F irst choice are springclamp blades with singleedge inserts.
First choice for medium

parting are screw-clamp
holders with 2-edge
inserts.
U
se the 3-edge insert
for economic parting in
mass production.
Milling
Drilling
General tool holder considerations

Tool block with spring-clamp tool blade for
tool overhang adjustment.
Boring
Shortest possible overhang, ar inch (mm)

Maximum tool holder shank
Largest height dimension
Tool holding
B 17
Machinability
Other information
ar
Maximum blade width
Turning
Spring-clamp design blades

Features/Benefits
Quicker insert change
Cut off larger diameter

Parting and
grooving
Adjustability
Deep grooving
Double ended
Threading
Radial feed only
Screw-clamp design holders
Features/Benefits
Milling
Smaller diameters
Shallow grooving
Increased rigidity
Radial & axial feed
Drilling
Single ended
Screw-clamp design holders

Boring
Features/Benefits
E
xtremely small insert widths
- grooving down to .020 inch (0.5 mm)
- parting down to .039 inch (1 mm).
G
Tool holding
Cutting depths up to .236 inch (6 mm).

One holder for all insert widths.
Very tight insert indexing tolerance.
Machinability
Other information
The productivity choice, 3 cutting edges.
B 18
Overhang should not exceed 8 x la (width

of insert).
Use as narrow an insert as possible:

- To save material
- Minimize cutting force
- Minimize environmental pollution.
Parting and
grooving
Max ar = 8 x la
(width of insert)
Turning
Parting-off bars
Threading
Milling
Material savings
Drilling
Positioning of the tool
Boring
Use maximum deviation of .004 inch

(0.1 mm) from center line.
Too high cutting edge
Clearance will decrease.
Cutting edge will rub (break).
Tool holding
Too low cutting edge

Tool will leave material in center (PIP).
B 19
Machinability
Other information
Max .004 inch (0.1 mm)
Turning

90 mounting of tool holder
P
erpendicular surface
Reduce vibrations
Parting and
grooving
Hand of insert
Threading
Hand of insert
Milling
Three types of insert with different entering

angles:
- Right hand (R)
- Neutral (N)
- Left hand (L)
Right hand (R)
Insert geometry
Drilling
Neutral entering angle
laa
r = 0
Increases strength
Higher feed/productivity
Better surface finish
Straighter cut
Pip stays on part falling off.
Boring
Tool holding
Small/large corner radius

r
Machinability
Other information
B 20
Small corner radius

Smaller PIP
Better chip control
Lower feed rate
Large corner radius
Increased feed rate
Longer tool life
Turning
Recommendations for boring bar solutions

EasyFix sleeves
B
Parting and
grooving
Use EasyFix clamping sleeves for

accurate machining with less
vibration and precise height.
Threading
Milling
Recommended overhang
dmm
Drilling
Carbide reinforced
dampened bars
l <7 x dmm
dmm
Dampened steel bars
Boring
Carbide bars
l 5 x dmm
G
Tool holding
dmm
Solid steel bars
l 3 x dmm
B 21
Machinability
Other information
Parting off how to apply
Pip reduction by using different front angles
C
hoose left or right hand front angle to
control the pip or burr.
Parting and
grooving
Turning
Parting off
When

the front angle is:
- increased, the pip/burr is decreased
- decreased, the chip control and tool life
are improved.
C
entrifugal force will always push away
the parted off component
- Tool will leave material in center (PIP).
Threading
R
L
Milling
Drilling
Example of front angles on

1-, 2- and 3-edge inserts:
5, 10, 8, 12, 15, 20
Note!
A front-angled insert will give reduced
chip control due to the direction of the
chip flow. (A neutral insert directs the chip
straight out of the groove).
Tool selection - Review
Boring
Tool holding
Machinability
Other information
B 22
General recommendations:
Consider:
-N
eutral inserts
- Smallest possible
insert width
- Largest possible
tool holder.
utting depth
C
Insert width
Front angle
Corner radius.
Turning
Parting-off tubes
Use insert with the smallest possible

width (la) to save material, minimize cutting
force and environmental impact.
B
Parting and
grooving
Parting-off tubes
Parting-off thin walled tubes
Milling
Make sure that the lowest possible cutting

forces are generated. Use inserts with the
smallest possible width and sharpest cutting edges.
Threading
C
enter height is important, .004 inch (0.1
mm).
If subspindle is used,
pull away the component
approximately .040 inch
(1 mm) before center.
.040 inch
(1
0.1 mm)
R
educe feed by up to
75%, approximately
.079 inch (2 mm) before
center also for tube
parting.
G
Tool holding
0.25 x fn
Boring
Max .004 inch

(0.1 mm)
Drilling
Practical hints
fn
.079
(2mm)
B 23
Machinability
Other information
Turning
Use cutting fluid
Parting and
grooving
Cutting fluid has an important function since the space

often is restricted and obstructed by the chips. It is
therefore important that coolant always is used in large
amounts and directed at the cutting edge throughout the
whole operation.
Use large amounts.
Direct at the cutting edge.

Threading
Use coolant adapter.

Has positive effect on chip formation.
Prevents chip jamming.
Milling
Drilling
Boring
Example of external coolant supply in

addition to internal coolant channels.
Tool holding
Machinability
Other information
B 24
Grooving how to apply
Turning
General grooving
S
ingle cut grooving is the most
economic and productive method to
produce grooves.
A
screw-clamp tool holder should be
selected for grooving operations.
C
Threading
If the depth of the groove is bigger than

the width, multiple grooving is the best
method for rough grooving.
Parting and
grooving
Milling
Single cut grooving
Drilling
E
conomic and productive method to
produce grooves.
W
iper inserts give extremely high quality
surface on the side of the groove.
Boring
F inishing geometry has width tolerance

of .0008 inch (0.02 mm) and works
well in low feeds.
Tool holding
B 25
Machinability
Other information
Grooving how to apply
Turning
Multiple grooving
T he best method for rough grooving
when depth is bigger than width.
B
Parting and
grooving
U
se the insert width to produce full
grooves and then remove the rings.
Threading
Milling
Practical hints
When producing high quality grooves, there is often a
need for chamfered corners.
E
One way is to use the corners on the insert, for example, of a finishing grooving
insert, to chamfer; see illustration A.
A better way to make grooves with

chamfer in mass production is to order a
Tailor Made insert with the exact chamfer form; see illustration B.
Drilling
Boring
Tool holding
Machinability
Other information
B 26
Circlip grooving how to apply
C
irclip grooving can be performed with
three-edge inserts or two-edge grooving
inserts.
F or internal grooving there is also a wide
choice of inserts and boring bars.
B
Parting and
grooving
Circlips on shafts and axle components

are very common.
Turning
Circlip grooving
Threading
Systems to choose from
r 2-edge inserts in widths

O
.059 - .236 inch (1.50 - 6.00 mm).
Internal inserts are available for min.

hole diameter .394 inch (10 mm) and
with circlip widths .043 - .163 inch (1.10
- 4.15 mm).
in hole diameter for carbide rod inserts
M
is .165 inch (4.2 mm) and circlip widths
are .031 - .079 inch (0.78 - 2.00 mm).
internal
Internal/external
Milling is an alternative for non-rotating

components
T he circlip widths for diameters
.382 - 1.366 inch (9.7 34.7 mm) cutters are .028 - .203 inch (0.70 - 5.15
mm).
Cutter diameter
.382 - 1.366 inch
(9.7 34.7 mm)
Cutter diameter
1.535 - 2.480 inch
(39 80 mm)
T he circlip widths for diameters

1.535 - 2.480 inch (39 80 mm) cutters
are .043 - .203 inch (1.10 - 5.15 mm).
B 27
Drilling
Carbide rod inserts
Boring
internal inserts
Milling
D
F or best economy, use 3-edge inserts
in widths .039 - .125 inch (1.00 - 3.18
mm).
G
Tool holding
2-edge inserts
H
Machinability
Other information
3-edge inserts
Face grooving how to apply
Turning
Face grooving
Making grooves axially on the faces on a
component requires tools dedicated to the
application.
B
Parting and
grooving
T he correct curve on the tool is dependent on the radius of the workpiece.

T he inner and outer diameters of the
groove need to be taken into account in
order to select the tool.
Threading
Milling
Tools for face grooving
Drilling
Boring
C
urved tool for face
grooving, shank 0 style.
Tool holding
Machinability
Other information
B 28
urved tool for face

C
grooving, shank 90
style.
E
xchangable cutting
blades make it possible
to make a special tool
from standard tools.
T ool must be adapted to

the bending radius of the
groove.
achine largest diameter
M
and work inwards for
best chip control.
B
Parting and
grooving
T ool is fed axially towards

the end surface of the
part.
Turning
Choice of R and L tools depending on rotation
C
Threading
Left hand (L) tool
Milling
Right hand (R) tool
Choice of A and B curve, right or left hand tool
Drilling
Choose the correct tool A or B curve, right or left hand

style depending on machine setup and workpiece rotation.
Boring
Tool holding
B 29
Machinability
Other information
Turning
First cut consederation

1 If the insert support rubs workpiece
inside dia:
- maybe the dia. range is wrong
- tool is not parallel to axis
- check center height
- lower the tool below center line.
Parting and
grooving
1
2
2 If the insert support rubs workpiece
Threading
outside dia:
- maybe the dia. range is wrong
- tool is not parallel to axis
- check center height
- lift the tool above center line.
Milling
Roughing
Finishing
Drilling
Roughing and finishing
2
3
Boring
Tool holding
Machinability
Other information
First cut (1) always starts

on the largest diameter
and works inwards. The
first cut offers chip control
but less chip breaking.
Cuts two (2) and
three (3) should be
0.50.8 x width of the insert. Chip breaking will now
be acceptable and the feed
can be increased slightly.
B 30
Machine the first cut (1) within the given

diameter range.
Cut two (2) finishes the diameter. Always start outside
and turn inwards.
Finally, cut three (3) finishes the inner diameter to the
correct dimensions.
Profiling how to apply
Turning
Profiling
When machining components with complex
shapes, profiling inserts offer great opportunities for rationalization.
B
Parting and
grooving
M
odern parting and grooving tool systems can also perform turning.
A
screw-clamp tool holder should be
selected for turning and profiling
operations in view of achieving maximum
stablility.
C
Threading
A
neutral tool holder is suitable for both
opening up or completing a recess.
T he round shape inserts have dedicated
geometries for these operations.
Milling
Drilling
Boring
Ramping
U
se round inserts for outstanding chip control and good
surface finish.
In unstable setups, use ramping to avoid vibrations.
Tool holding
B 31
Machinability
Other information
Turning how to apply
Turning
Profile turning
Insert radius < component radius
Recommended
L arge area of insert creates high cutting pressure so

feed should be reduced.
Parting and
grooving
If possible, use an insert radius that is smaller than the

component radius.
If you must have the same insert radius as the component radius, use micro-stops to make the chip short
and avoid vibrations.
Threading
Insert radius component radius is not

recommended
Milling
Drilling
fn1 = parallel cuts max. chip thickness .006 - .016 inch (0.150.40 mm).
fn2 = radius plunging 50% max. chip thickness.
Boring
Tool holding
Machinability
Other information
B 32
Turning
Turning
The most common applications for wide
grooves or turning between shoulders
are multiple grooving, plunge turning or
ramping. All three methods are roughing
operations and have to be followed by
a separate finishing operation. A rule of
thumb is that if the width of the groove is
smaller than the depth multiple grooving
should be used and vice versa for plunge
turning. However, for slender components,
the ramping method may be used.
Parting and
grooving
Threading
U
se holders with smallest possible overhang, screw clamping and insert with rail
shape if possible.
U
se a stable, modular tooling system if
possible.
Milling
Drilling
Reinforced blade will increase stability.
Roughing
Boring
Tool holding
G
1. Radially infeed to required depth +.008 inch (+0.2 mm) (max 0.75 x insert width).
2. Retract radially .008 inch (0.2 mm).
3. Turn axially to opposite shoulder position.
B 33
Machinability
Other information
4. Retract radially .020 inch (0.5 mm).
Turning
Finishing
Parting and
grooving
As the insert contours around the radius, most of the movement is in the Z direction. This produces an extremely thin
chip along the front cutting edge which can result in rubbing
and hence vibration.
Threading
T he axial and radial cutting depth should

be .020.039 inch (0.51.0 mm).
Milling
Axial turning
Surface finish
Drilling
T his wiper effect generates high quality

surface finish.
Ra max
Boring
R
a value below 20RA (0.5 m) will be
generated with high bearing.
Tool holding
H
Machinability
Other information
Y
ou get the best wiper effect when you
find the right combination between
feed (fn) and blade deflection.
B 34
Undercutting how to apply
Turning
Undercutting
T hese applications require dedicated inserts with round
cutting edges that are sharp and accurate.
T he tolerance of these inserts is high: .0008 inch
(0.02 mm).
B
Parting and
grooving
When a clearance is needed.
Threading
Tools for undercutting

Angled 20
Angled 45
Milling
Angled
7 ,45 and 70
Drilling
Boring
H
older for external undercutting. Insert with one
cutting edge.
G
Tool holding
H
older for internal undercutting. Insert with two
cutting edges.
B 35
Machinability
Other information
H
older for external undercutting. Insert with two
cutting edges.
Turning
Troubleshooting
Troubleshooting
Tool wear
Parting and
grooving
Problem
Flank wear
Plastic deformation
Crater wear
Chipping
Fracture
Built-up
edge
Threading
Solution
More positive
geometry
++
++
Milling
Tougher grade
Drilling
More wear
resistant grade
++
Increase cutting
speed
Boring
Decrease cutting speed
Tool holding
Reduce feed
rate
Choose stronger
geometry
+
++
++
+
++
Machinability
Other information
H
+ + = Best possible remedy
B 36
+ = Possible remedy
Troubleshooting
Bad surface
U
se a short and stable
tool.
Take away the chips
use geometry with good
chip control.
C
heck speed/feed guidelines.
Use wiper geometry.
Check tool setup.
Turning
Solution
B
Parting and
grooving
Problem
S
elect a special soluble
oil for the material.
Milling
Select the sharpest

geometry.
Use geometry with good
chip control.
Bad chip breaking

hange geometry.
C
Select a higher feed.
Use dwelling (pecking).
Increase coolant.
Drilling
Threading
Bad surface on aluminum
Vibration
C
heck tool condition.
Check tool setup.
Boring
U
se a stable setup.
Check speed/feed guidelines.
Use shorter overhang.
Change geometry.
C
heck center height.
Check angle between
tool and component.
C
heck condition of blade.
If blade is old, the insert
could be unstable in the
tip seat.
B 37
H
Machinability
Other information
Poor tool life
Tool holding
F2
Threading
Thread turning is the process of an indexable insert tool
making a number of passes along the section of a workpiece requiring a screw thread.
By dividing the full cutting depth of the thread into a
series of small cuts, the sensitive thread-profile point of
the cutting edge is not overloaded.
Theory
C4
Selection procedure
C9
System overview
C 13
How to apply
C 19
Troubleshooting
C 25
C3
Turning
Parting and
grooving
Threading
Theory
Threading theory
The threading methods
The prime functions of a thread are:
- to form a mechanical coupling
- to transmit motion by converting rotational movement
into linear and vice-versa
- to obtain a mechanical advantage; using a small force to
create a larger one.
Different ways of making threads

Grinding
Rolling
Milling
Molding
Drilling
Metal cutting threading methods
Boring
Thread turning
Tool holding
Machinability
Other information
C4
Milling
Tapping
Theory
Turning
= spindle speed (rpm)
ap = total depth of thread (inch) (mm)

nap = number of passes
Parting and
grooving
Threading
itch, mm or threads
P = p
per inch (t.p.i.)
= angle of the thread

Milling
d1 = minor diameter external

D1 = minor diameter internal
d2 = pitch diameter external
D2 = pitch diameter internal

d = major diameter external
Drilling
D = major diameter internal
= helix angle of the thread
Boring
Tool holding
C5
Machinability
Other information
Theory
Turning
1. Root
The bottom surface joining the two
adjacent flanks of the thread crest.
B
Parting and
grooving
2. Flank
The side of a thread surface connecting the crest and the root.
3. Crest
The top surface joining the two sides,
or flanks.
C
Threading
Helix angle
The helix angle ()is dependent on and
related to the diameter and pitch (P) of
the thread.
Milling
B
y changing the shim, the flank clearance of the insert is adjusted.
T he angle of inclination is lambda ().
The most common angle of inclination is
1 which is the standard shim in the tool
holder.
Drilling
Boring
Cutting forces in and out of the thread

The highest axial cutting force in the
threading operation occurs during the
entrance and exit of the cutting tool.
Tool holding
A
ggressive cutting data can lead to
movement of insecurely clamped inserts.
Machinability
Other information
C6
Theory
Turning
Inclining the insert for clearance

Selecting shims for inclination
The inclination angle can be set using shims under the
insert in the tool holder. The choice of which shim to use
can be made by referring to a chart in the catalog.
As standard, all tool holders are delivered with the shim
set at 1.
Parting and
grooving
Threading
D
tan =
d2
Milling
Standard shim = 1
E
Threads/inch
Drilling
Pitch, mm
Boring
Tool holding
Workpiece
diameter
mm
inch
C7
Machinability
Other information
Theory
Turning
Selecting shims for inclination
Parting and
grooving
Threading
The diameter and pitch influence the inclination angles.

Example of how to use the diagram.
1. The workpiece diameter is 40 mm
(1.575 inch) with a thread with a pitch
of 6 mm (.236 inch). From the diagram
we can see that the required shim
must have an angle of inclination of 3
(standard shim can be used).
2. T he workpiece diameter is 4 inches

(102 mm) with a thread with a pitch of
5 threads. From the diagram we can
see that the required shim must have
an angle of inclination of 1.
Pitch, mm
Threads/inch
D
3
Milling
Drilling
Boring
Workpiece
diameter
mm
inch
Marking of threading inserts and shims

How to read and understand markings.
Tool holding
Machinability
Other information
Angle of shim
inclination
Thread profile
Pitch
Internal (O)
External, no marking
C8
Carbide grade
Tool selection
Turning

Parting and
grooving
Dimension and
quality of the
thread
Component
Workpiece material, thread profile

and quantity
Threading
Milling
Machine parameters
Machine
Choice of tool
Drilling
Type of tool:
- Full profile
- V-profile
- Multi-point
How to apply
Boring
Cutting data,
in-feed etc.
Troubleshooting
Remedies and
solutions
C9
Machinability
Other information
Tool holding
Tool selection
Turning

B
A
nalyze the dimensions and quality
demands of the thread to be machined.
Parting and
grooving
Component
Type of operation (external or internal)

Right- or left-hand thread
Type of profile (metric, UN, etc.)
Pitch size
Threading
Number of thread starts

Tolerance (profile, position)
P M K
N S H
Milling
Material
Machinability
Chip breaking
Drilling
Hardness
Alloy elements
Boring
Tool holding
Machinability
Other information
C 10
pindle interface
S
Machine stability
The spindle speed
Coolant supply
Clamping of the workpiece
Horizontal or vertical spindle
Power and torque
Tool magazine
Tool selection
Turning
3. Choice of tools
Different ways to make threads
Full profile inserts
The insert can only cut one pitch.
Disadvantages
Each insert can only cut
one pitch.
C
Threading
As the insert is generating both the root and

the crest, the tool pressure increases, putting
high requirements on setup and overhang.
B
Advantages
Better control over the
thread form.
Less deburring.
Parting and
grooving
The thread is cut by the insert with good

control over the geometrical properties as the
distance between the root and the crest is
controlled.
In setups prone to vibrations, a non-topping

insert can often prove to be a solution due to
the reduction of cutting pressure.
Advantages
Flexibility, one insert
can be used for several
pitches.
Disadvantages
Can result in burr formation that needs to be
taken away.
Drilling
The insert can accommodate a range of

pitches thus reducing stock. The root and
flanks are being formed by the insert.
The crest is controlled in a prior turning operation, resulting in high tolerances.
Milling
V-profile inserts
The tool pressure increases exponentially,

requiring stable setups and shortened overhangs. Sufficient room behind the last thread
is also needed.
Advantages
Reduced number of
infeeds.
Very high productivity.
Disadvantages
Requires stable setups.
Needs sufficient room
behind the last thread.
G
Tool holding
A full profile (topping) insert with several teeth

reduces the number of required in-feeds and
generates high productivity, e.g. a multi-point
insert with two teeth reduces the number of
in-feeds to half.
C 11
Machinability
Other information
Multi-point inserts
Boring
Tool selection
Turning
4. How to apply
The infeed method can have a significant
impact on the thread machining process.
B
Parting and
grooving
It influences:
- chip control
- insert wear
- thread quality
- tool life
C
Threading
In practice, the machine tool, insert

geometry, workpiece material and thread
pitch influence the choice of infeed
method.
Milling
5. Troubleshooting
Drilling

Check the wear pattern and if necessary
adjust the cutting data accordingly.
Boring
Infeed type
Optimize infeed method, number and
size of pass.
G
Tool holding
Insert geometry
Make sure the right insert geometry is
used (all-purpose, F or C geometries).
H
Machinability
Other information
Insert inclination
Ensure there is sufficient and even
clearance (insert inclination shims).
C 12
System overview
External threading
Turning
System overview
1. Small part threading
2. Conventional threading
Parting and
grooving
3. Oil pipe threading
Threading
3
0.5 8 mm
32 3 t.p.i
10 5 t.p.i
Milling
0.2 2 mm
Internal threading
10 5 t.p.i
Min hole: .157 inch

(4 mm)
Min hole: .394 inch

(10 mm)
Boring
0.5 3 mm
56 16 t.p.i
Min hole: .472 inch

(12 mm)
2. Threading mini-bars
Tool holding
3. Conventional threading
1. Carbide rods
4. Oil pipe threading
C 13
Machinability
Other information
0.5 2.5 mm
32 10 t.p.i
Min hole: 2.374

inch (60.3 mm)
Drilling
0.5 8 mm
32 3 t.p.i
System overview
Turning
External threading assortment
Inserts
Parting and
grooving
Choose from an extensive program
Threading
Milling
Drilling
Pitch
0.2
32
2.0
10
5.0
mm
t.p.i
8.0
3
Three standard geometries

F our insert sizes:
1/4, 3/8, 1/2 and
5/8 inch (11, 16, 22
and 27 mm)
1/4
(11)
3/8
(16)
1/2
(22)
5/8
(27)
Boring
Tool holders
1. Coromant Capto cutting units
2. Shank tools
Tool holding
3. Boring bars
4. Exchangable cutting heads
5. Cartridges
Machinability
Other information
C 14
System overview
Turning
Internal threading assortment

Choose from an extensive program and several systems
Conventional bars
New system
Mini-bars
.157 inch
(4 mm)
Bars for oil pipe

threading
.394 inch
(10 mm)
.984 inch
(25 mm)
.472 inch
(12 mm)
C
2.362 inch
(60 mm)
Threading
Conventional bars
Old system
Carbide rods
Parting and
grooving
.394
(10)
.472
(12)
.984
(25)
2.362
(60)
Min. hole diameter, inch (mm)
Drilling
.157
(4)
Milling
For high precision, internal threading of small components
Boring
Inserts for mini-bars
Tool holding
C 15
Machinability
Other information
Carbide rods
System overview
Turning
Thread forms
Thread type
Code
General use
ISO metric
American UN
MM
UN
Pipe thread
Whitworth, NPT
British Standard (BSPT), NPTF
American National Pipe Threads
WH, NT
PT, NF
Food and fire
Round DIN405
RN
Aerospace
MJ
UNJ
MJ
NJ
Oil and gas
API Rounded
API V form 60
RD
V38, 40,
50
Oil and gas
Buttress, VAM
BU
Motion
General use
Trapezoidal
ACME
Stub ACME
TR
AC
SA
Application
Insert/thread form
Parting and
grooving
Threading
Milling
Drilling
General usage
Good balance between load bearing
capacity and volume of material.
Boring
Pipe Threads
Ability to bear loads.
Tool holding
Machinability
Other information
A
ble to form leak-proof connections
(threads are often conical).
Food & Fire
Same as for pipe threads but round, for
easy cleaning for food.
Easily repeated connecting/disconnecting for fire.
Aerospace
High precision and minimized risk for
stress concentration and breakage.
C 16
Oil & Gas

Extreme load bearing and leak proof requirements, with limitations of thin wall
thickness of pipe.
Motion
Symmetrical form.
Large contact surface.
Sturdy form.
System overview
Turning
Insert types
Three different types of threading inserts
B
Full profile inserts
Parting and
grooving
For high productivity in threading.
C
V-profile inserts - 60 and 55
Threading
F or threading with minimum tool

inventory.
F or highly productive, economic threading

in mass production.
Milling
Multi-point inserts
Drilling
Three different geometries

F-geometry
C-geometry
First choice in most

operations.
Sharp geometry.
Chip breaking geometry.
Boring
All-purpose geometry
Gives clean cuts in sticky

and work hardening
materials.
Optimized geometry for low

carbon, low alloy and easily
machined stainless steel.
C 17
H
Machinability
Other information
Good chip forming in a

wide range of materials.
Tool holding
System overview
Turning
A new, modern threading solution

Ultra-rigid threading tool
B
Parting and
grooving
U
ltra-rigid threading with fixed position
inserts.
T he insert locates in the correct position
with guidance of the rail.
C
Threading
T he screw forces the insert on the rail

back to a radial stop at one contact
face in the insert seat. (The red contact
faces).
Milling
Quick change
coupling
Boring bar
Coromant
Capto coupling
Drop head
Drilling
A variety of tool holder solutions
Boring
Tool holding
Machinability
Other information
H
CoromantCapto
coupling
C 18
Shank tool
Exchangable
cutting head
How to apply
Turning
How to apply
In practice, the machine tool, insert
geometry, workpiece material and thread
pitch influence the choice of infeed
method.
B
Parting and
grooving
Three different types of infeed
Threading
Modified flank infeed

M
ost newer CNC machines can be programmed for
modified flank.
U
sed with C-geometry as the chip breaker will not
function with radial infeed.
Axially directed cutting forces reduce the risk of vibrations.
Controlled chip direction.
Milling
The infeed method can have a significant

impact on the thread machining process.
It influences:
- chip control
- insert wear
- thread quality
- tool life.
Used by all manual machines and most canned CNC

programs.
Boring
F irst choice for work hardening materials and suitable

for fine pitches.
Drilling
Radial infeed
ormally used with very large profiles and pitches, long

N
work threading cycles where tool life needs to match
the length of the thread.
Requires special programming.
Tool holding
Incremental infeed
C 19
Machinability
Other information
How to apply
Turning
Modified flank infeed

M
ost CNC machines have a programmed cycle using
this infeed.
Chip is similar to that in conventional turning - easier to
form and guide.
Chip is thicker, but has contact with only one side of the
insert.
Less heat is transferred to the insert.
First choice for most threading operations.
Parting and
grooving
Threading
C
Feed direction
Chip flow
Chip flow
Milling
Feed direction
Feed direction
Drilling
C-geometry
insert
B
etter chip control.
Better surfaces.
For C-geometry insert, modified flank
infeed is the only suitable infeed.
Radial infeed
Boring
M
ost commonly used method - and only method possible on older non-CNC lathes.
Makes a stiff V chip.
Even insert wear.
Insert tip exposed to high temperatures, which restricts
depth of infeed.
Suitable for fine pitches.
Vibration possible and poor chip control in coarse
pitches.
First choice for work hardening materials.
Tool holding
Machinability
Other information
C 20
How to apply
Turning
Incremental infeed
E
ven insert wear and longest tool life in
very coarse threads.
C
hips are directed both ways, making
control difficult.
Parting and
grooving
Recommended for large profiles.
C
Threading
Programming methods
Ways of improving the machining result
Decreasing depth per pass (Constant chip area)
Milling
T he deepest pass is the

first pass.
Follows recommendation on infeed tables in
catalog.
More balanced chip
area.
Last pass actually
around .0028 inch (0.07
mm).
Drilling
Allows for constant chip

area.
This is the most common
method in CNC programs.
G
Tool holding
M
uch more demanding
on the insert.
Offers best chip control.
Should not be used for
pitches larger than 1.5
mm or 16 t.p.i.
C 21
Machinability
Other information
Each pass is of an equal

depth, regardless of the
number of passes.
Boring
Constant depth per pass
How to apply
Use extra stock/material for topping the thread
For topping inserts, .001 .003 inch (0.03 - 0.07 mm) material should be
left from prior turning operations to allow for proper forming of the crest.
Parting and
grooving
Turning
Threading with full profile inserts
Threading
~.005
Infeed values recommendations

ISO inch, external
Drilling
Boring
Tool holding
H
Machinability
Other information
A
dd extra stock/material on the workpiece
diameter, .002 .006 inch (0.06 - 0.14 mm)
for topping the finish diameter of the thread.
Number of infeeds and total depth of thread.
Milling
T he blank does not need to be turned to the

exact diameter prior to the threading.
+.004
0
C 22
How to apply
Use maximum deviation of .004 inch

(0.1 mm) from centerline.
Max .004 inch ( 0.1 mm)
Turning

B
Too high cutting edge
Parting and
grooving
Clearance will decrease.

Cutting edge will rub (break).
Too low cutting edge
Method of threading
Threading
The thread profile can be incorrect.
Right and left hand threads and inserts
Internal
Right hand threads
Left hand threads
Right hand threads
Left hand threads
Milling
External
Left hand
tool/insert
Right hand
tool/insert
Left hand
tool/insert
Drilling
Right hand
tool/insert
Left hand
tool/insert
Right hand
tool/insert
Left hand
tool/insert
Right hand
tool/insert
Right hand
tool/insert
Boring
Left hand
tool/insert
G
Tool holding
Left hand
tool/insert
Left hand
tool/insert
A negative shim must be used.
C 23
Machinability
Other information
Right hand
tool/insert
Right hand
tool/insert
Troubleshooting
Turning
Thread turning application hints
Parting and
grooving
Threading
Milling
C
heck the workpiece diameter for correct working allowance before threadturning (add .006 inch (0.14 mm) as
crest allowance).
osition the tool accurately in the
P
machine.
heck the setting of the cutting edge in
C
relation to pitch diameter.
M
ake sure the correct insert geometry
is used (all-purpose, F or C).
Ensure there is sufficent and even
clearance (insert-inclination shims)
to achieve correct flank clearance by
selecting the appropriate shim.
ptimize infeed method, number and

O
size of passes.
nsure the correct cutting speed for the
E
demands of the application.
In case of pitch error on component
thread, check to see if machine pitch is
correct.
It is recommended that the tool should
start a minimum distance of 3 times
the thread pitch before engaging the
workpiece.
If threads are rejected, check entire

setup, including machine tool.
heck the available CNC program for
C
thread turning.
Drilling
Some vital factors to consider to achieve success
Boring
Tool holding
Machinability
Other information
C 24
Troubleshooting
Problem
Cause
Solution
1. Excessive temperature in
cutting zone.
educe the cutting speed,

1. R
increase the number of
infeeds.
Plastic deformation
Starts as plastic deformation

(A).
2. Inadequate supply of
coolant.
3. Wrong grade.
Reduce the largest infeed

depth, check the diameter
before threading.
2. Improve coolant supply.
which leads to edge chipping

(B).
3. C
hoose a grade with better
resistance to plastic deformation.
Built-up edge (BUE)

ften occurs in stainless
-O
material.
BUE (A) and edge spalling (B)

often occur in combination.
Accumulated BUE is then
ripped away together with
small amounts of insert
material, which leads to
spalling.
ften occurs in low carbon

-O
steel.
- Increase cutting speed.

-C
hoose an insert with good
toughness, preferably PVD
coated.
- Unsuitable grade.
-C
utting edge temperature
too low.
Drilling
C
Threading
Parting and
grooving
Milling
Turning
Troubleshooting
3. Wrong grade.
4. Poor chip control.
5. Center height incorrect.
2. Increase number of infeeds.

Reduce size of the largest
infeeds.
3. Choose a tougher grade.
4. C
hange to C-geometry and
use modified flank infeed.
5. Correct center height.
C 25
G
Tool holding
2. Infeed series too tough.
1. Turn to correct diameter

before threading operation,
.001 .003 inch (0.03
0.07 mm) radially larger
than max. diameter for
thread.
H
Machinability
Other information
1. Wrong turned diameter prior

to threading.
Boring
Insert breakage
Troubleshooting
Turning
Problem
Cause
Solution
1. Highly abrasive material.
1. W
rong grade. Choose a
more wear resistant grade.
Rapid flank wear
2. Cutting speed too high.
Parting and
grooving
3. Infeed depths too shallow.

4. Insert is above center line.
2. Reduce cutting speed.

3. Reduce number of infeeds.
4. Correct center height.
Threading
C
Abnormal flank wear
1. Incorrect method for flank
infeed.
2. Insert inclination angle
does not agree with the
lead angle of the thread.
hange shim to obtain

2. C
correct angle of inclination.
Milling
Poor surface on one flank of

thread.
1. C
hange method of flank
infeed for F-geometry and
standard geometry; 3 - 5
from flank, for C-geometry;
1 from flank.
E
Vibration
Drilling
1. Incorrect clamping of the

workpiece.
2. Incorrect setup of the tool.
3. Incorrect cutting data.

4. Incorrect center height.
1. Use soft jaws.

2. O
ptimize center hole and
check pressure of face
driver.
Minimize overhang of tool.
Boring
Check that the clamping

sleeve for bars is not worn.
Use 570-3 anti-vibration
bars.
G
Tool holding
3. Increase cutting speed; if

this does not help, lower
the speed dramatically.
Try F-geometry.
4. Adjust center height.
Machinability
Other information
C 26
Solution
1. Cutting speed too low.
1. Increase cutting speed.
2. The insert is above the

center height.
Poor surface finish
3. Uncontrolled chips.
3. U
se C-geometry and modified flank infeed.
1. Incorrect method of infeed.
1. Modified flank infeed 3 - 5.
2. Incorrect thread geometry.
2. U
se C-geometry with modified flank infeed 1.
1. Wrong center height.
2. Insert breakage.
Excessive wear.
2. Change cutting edge.
1. Unsuitable thread profile

(angle of thread and nose
radius) external inserts
used for internal operation
or vice versa.
1. C
orrect tool, shim and
insert combination.
3. Adjust to 90.
2. Wrong center height.
4. Correct the machine.
Poor chip control
Turning
Cause
Shallow profile
Threading
Problem
Parting and
grooving
Troubleshooting
Milling
Incorrect thread profile
Drilling
3. Holder not 90 to center

line.
Boring
4. Pitch error in machine.
1. R
educe the number of
infeeds.
2. Excessive pressure on cutting edge.
2. Change to a tougher grade.
3. Profile with too small thread

profile angle.
Change to F-geometry.
3. Use modified flank infeed.
C 27
H
Machinability
Other information
1. Work hardening material

in combination with infeed
depths which are too shallow.
Tool holding
Excessive edge pressure
D2
Milling
Milling is performed with a rotating, multi-edge cutting tool which performs programmed feed movements
against a workpiece in almost any direction.
Milling is mostly applied to generate flat faces, but with
the development of machines and software there are increasing demands to produce other forms and surfaces.
Theory
D4
Selection procedure
D9
System overview
D 13
D 24
D 29
Troubleshooting
D 36
D3
Turning
Milling theory
Spindle speed, cutting speed and cutter diameter
Parting and
grooving
Theory
n = S
pindle speed, rpm
(revolutions per minute)
vc = Cutting speed (ft/min) (m/min)
Threading
ve = E
ffective cutting speed (ft/min)
(m/min)
Dc = Cutter diameter (inch) (mm)
De = Dcap = C
utting diameter (inch)
(mm) [at cutting depth]
Milling
Drilling
Boring
Cutting speed (vc) in ft/min (m/min) indicates the surface

speed at which the cutting edge machines the workpiece.
Specified cutter diameter (Dc), having an effective cutting
diameter (De), which is the basis for the cutting speed vc
or ve.
Tool holding
Spindle speed (n) in rpm is the number of revolutions the

milling tool on the spindle makes per minute.
Machinability
Other information
D4
Theory
Turning
Feed, number of teeth and spindle speed
B
Parting and
grooving
fz = F eed per tooth (inch/tooth) (mm/

tooth)
vf = Table feed (inch/min) (mm/min)
zn = Number of cutter teeth (pcs)
zc = E
ffective number of teeth (pcs)
[in engagement]
Threading
fn = F eed per revolution (inch/rev)

(mm/rev) [fz x zc]
n = Spindle speed (rpm)
vf = fz zc n
Milling
inch/min (mm/min)
Drilling
Feed per tooth, fz inch/tooth (mm/tooth), is a value in

milling for calculating the table feed. The feed per tooth
value is calculated from the recommended maximum chip
thickness value.
Boring
Feed per minute, vf inch/min (mm/min), also known as

the table feed, machine feed or feed speed is the feed
of the tool in relation to the workpiece in distance per
time-unit related to feed per tooth and number of teeth in
the cutter.
G
Tool holding
The number of available cutter teeth in the tool (zn) varies

considerably and is used to determine the table feed
while the effective number of teeth (zc) is the number of
effective teeth in cut.
Feed per revolution (fn) in inch/rev (mm/rev) is a value
used specifically for feed calculations and often to determine the finishing capability of a cutter.
D5
Machinability
Other information
Theory
Turning
Depth of cut
ae = R
adial depth of cut (inch) (mm)
[working engagement]
B
Parting and
grooving
ap = Axial depth of cut (inch) (mm)
Threading
Axial depth of cut, ap inch (mm), is what

the tool removes in metal on the face of
the workpiece. This is the distance the
tool is set below the unmachined surface.
Radial cutting width, ae inch (mm), is the

width of the component engaged in cut by the
diameter of the cutter. It is the distance across
the surface being machined or, if the tool diameter is smaller, that is covered by the tool.
Net power, torque and specific cutting force

ap = Axial depth of cut (inch) (mm)
Milling
ae = Radial depth of cut (inch) (mm)

[working engagement]
vf = Table feed (inch/min) (mm/min)
kc = Specific cutting force (lbs/inch2)

(N/mm2)
Drilling
Pc = Net power (Hp) (kW)
Boring
Tool holding
Machinability
Other information
Mc = Torque (lbf ft) (Nm)
The net power (Pc) is the power the

machine must be able to provide to
the cutting edges in order to drive the
cutting action. The efficiency of the machine must be taken into consideration
when selecting cutting data.
The torque (Mc) is the torque value
produced by the tool during cutting action, which the machine must be able
to provide.
The specific cutting force value (kc) is

a material constant, expressed in
lbs/inch2 (N/mm2). The values can be
found in our main ordering catalog and
technical guide.
D6
Inch
Pc =
ap ae vf kc
396 103
Hp
Metric
Pc =
ap ae vf kc
60 106
kW
Inch
Mc =
Pc 16501
n
lbf ft
Metric
Mc =
Pc 30 103
n
Nm
Theory
Turning
Climb or conventional milling

Climb milling preferred method
In climb milling, the insert starts its cut with a
large chip thickness.
B
Parting and
grooving
Using climb milling (also

referred to as down milling), the burnishing effect
is avoided, resulting in less
heat and minimal workhardening tendency.
Always use climb milling

for best cutting conditions.
Boring
The position of the cutter in relation to the

workpiece engagement, and the contact
which the cutter teeth have, are vital factors for a successful operation.
Drilling
Cutter diameter and position
C
utter diameter should be 20 50% larger than the
width of cut.
2
/3 rule (i.e., 5.906 inch (150 mm) cutter)
- 2/3 in cut, 3.937 inch (100 mm)
- 1/3 out of cut, 1.969 inch (50 mm).
y moving the milling cutter off the center, a more
B
constant and favorable direction of cutting forces will be
obtained.
D7
Tool holding
The selection of milling cutter diameter is

usually made on the basis of the workpiece width with the availability of the machine power also being taken into account.
Milling
In conventional milling

(also referred to as up
milling) the chip thickness starts at zero and
increases to the end of
the cut.
H
Machinability
Other information
The feed direction of the

workpiece is opposite to
that of the cutter rotation
at the area of cut.
Threading
Conventional milling
Theory
Turning
Chip formation through cutter position
Parting and
grooving
The cutting edge in a radial direction engages with the

workpiece in three different phases:
1. Entrance into cut
2. Arc of engagement in cut
3. Exit from cut
Dc = Cutter diameter
ae = working engagement
Threading
The centerline of the cutter is well inside the workpiece

width, ae >75% of Dc.
M
ost favorable cutting conditions and optimized use of
the cutter diameter.
Milling
T he initial impact at the entry of cut is taken up further

along the cutting edge, away from the sensitive tip.
The insert leaves the cut gradually.
T he centerline of the cutter is well outside the workpiece

width, ae <25% of Dc.
The angle of entry is positive
Drilling
T he impact at the entry is taken up by the outermost tip

of the insert and the load is gradually taken up by the
the tool.
Boring
The centerline of the cutter is in line with the workpiece

edge, ae = 50% of Dc.
Not recommended.
G
Tool holding
T he shock loads at the cutting edge are very high at

entry.
= Recommended cutter position.
Machinability
Other information
= Alternative cutter position.

= Not recommended cutter position.
D8
Selection procedure
Turning
Selection procedure
Parting and
grooving
Type of operation and

method
Component
Threading
Workpiece material and

quantity
Machine
Milling
Machine parameters
Choice of tool
Select type of cutter
Drilling
How to apply
Boring
Cutting data, method etc.
Troubleshooting
Remedies and solutions
D9
Machinability
Other information
Tool holding
Selection procedure
Turning

Geometric shape
Parting and
grooving
Flat surface
Deep cavities
Thin walls/bases
Slots
Threading
P M K
N S H
Milling
Material
Tolerances
Machinability
Dimensional accuracy
Chip forming
Surface finish
Hardness
Part distortion
Alloy elements
Surface integrity
Drilling
Boring
Tool holding
Available power
Long overhang
Age/condition stability
Poor holding
Horizontal/vertical
Axial/radial runout
Spindle type and size
Tool holding
N
umber of axes/configuration
Workpiece clamping
H
Machinability
Other information
Material
D 10
Selection procedure
Turning
3. Choice of tools
Different ways to optimize milling
Cutters with round inserts
Disadvantages
Robust milling cutters.
R
ound inserts require
more stable machines.
V
ery flexible for face milling and profiling.
Parting and
grooving
B
Advantages
C
Threading
H
igh performance multipurpose cutters.
45 face mill
Disadvantages
G
eneral choice for face
milling.
Max cutting depth

.236-.394 inch
(6-10 mm).
Drilling
Smooth entry into cut.
90 square shoulder face mill
Disadvantages
Great versatility.
F eed per tooth is relatively low while fz = hex.
Large depth of cut.
Boring
Advantages
L ow axial cutting forces

(thin workpieces).
G
Tool holding
Light-cutting inserts with

true four edges.
D 11
Machinability
Other information
B
alanced radial and axial
cutting forces.
Milling
Advantages
Selection procedure
Number of cutting
edges/pitch
Parting and
grooving
Turning
4. How to apply
S
electing the right
number of edges or pitch
is very important.
It affects both productivity and stability.
Insert geometry
Threading
S
elect between a geometry for Light, Medium or
Heavy machining.
C
hoose largest possible
spindle size or outer
diameter.
Chip formation through cutter positioning
A
lways use climb milling.
Move the cutter off the
center.
Use a cutter with a diameter 2050% larger than
the cut.
Milling
Stability
Drilling
5. Troubleshooting
Boring
C
heck the wear pattern
and if necessary adjust
the cutting data accordingly.

Vibration
Tool holding
Machinability
Other information
D 12
eak fixture.
W
Long tool overhang.
Weak workpiece.
Size of spindle taper.
Unsatisfactory surface
finish
C
heck spindle runout.
Use wiper inserts.
Decrease feed per tooth.
System overview
Turning
System overview
Face milling
Cutters for general use
Parting and
grooving
Face milling cutter with round inserts

for tough conditions
Face and square shoulder

milling cutter for light face
milling operations
C
Threading
General purpose face milling

cutter with 45 lead (entering)
angle
Milling
High feed face milling
Drilling
Dedicated cutters
Face milling cutters for cast iron machining
Boring
Heavy duty face milling
Tool holding
Face milling cutters for aluminum

machining
D 13
Machinability
Other information
Selection procedure
Turning
Shoulder milling
Face and shoulder milling for light
shoulder milling operations
B
Parting and
grooving
Face and shoulder milling

cutter for heavy machining
Threading
Side and face milling cutter

used for shoulder milling operation
Milling
End mills and long edge cutters
Indexable insert end

mill
Drilling
End mill with exchangeable, solid carbide head
F
Long edge milling cutter
Boring
Solid carbide end mill
Dedicated cutters
Edging with square shoulder milling cutters
Tool holding
Deep shoulder milling
Machinability
Other information
D 14
System overview
Turning
Profiling
Cutters for general use roughing
Round insert cutter
Parting and
grooving
Round insert end mill
Threading
Cutters for general use finishing

Milling
End mill with exchangeable, solid carbide head

Solid carbide
ball nose end mill
Drilling
Boring
Other methods
G
Tool holding
Blade milling
D 15
Machinability
Other information
Turn milling
System overview
Turning
Slot milling
Side and face mill for slot
milling
Parting and
grooving

radial slot milling
Slitting cutter for grooving

and parting off
Threading
Cutter for external, shallow grooving and slotting

axial slot milling
Milling
End mill for internal shallow

grooving and slotting
End mill with exchangeable,

solid carbide head
Indexable insert end mill
Long edge milling

cutter
Drilling
Boring
Thread milling
G
Tool holding
Indexable insert
cutter
Indexable insert
end mill
Machinability
Other information
D 16
System overview
Face milling
High-feed milling
B
Parting and
grooving
Tooling developments have also contributed to the new possibilities, along with the
gains in productivity, reliablity and quality
consistency that have been made in indexable insert and solid carbide technology.
C
Shoulder milling
Slot milling
Threading
Modern milling is a very universal machining method. During the past few years,
hand-in-hand with machine tool developments, milling has evolved into a method
that machines a very broad range of
configurations. The choice of methods
in multi-axis machinery makes milling a
strong contender for producing holes,
cavities, surfaces that used to be turned,
threads, etc.
Turning
Overview of milling operations
Cutting off
Chamfering
Profile milling
Milling
Turn milling
Drilling
Trochoidal milling
Circular milling
Linear ramping
Boring
Plunge milling
G
Tool holding
Thread milling
D 17
Machinability
Other information
Circular ramping
System overview
Milling machines may be manually operated, mechanically

automated, or digitally automated via computer numerical
control (CNC).
Parting and
grooving
Turning
Milling methods
Conventional milling methods

Vertical milling machines
In conventional 3-axis machines, milling
most frequently entails the generation of
flat faces, shoulders and slots.
Threading
Surfaces and forms, other than those

described below, are increasing steadily as
the number of five-axis machining centers
and multi-task machines grows.
Milling
Drilling
Face milling
High-feed milling
Shoulder milling
Cutting off
Chamfering
Plunge milling
Boring
Tool holding
Machinability
Other information
D 18
Slot milling
System overview
Turning
Advanced milling methods

Modern 4/5-axis machining center or multi-task machine
Today, machines are developing in all directions. Turning
centers now have milling capability through driven tools,
and machining centers have turning capability via turnmill
or mill-turn machines. CAM developments mean that
5-axis machines are increasing.
Parting and
grooving
Threading
Increased flexibility
Fewer machines/setups to
complete a component
Reduced stability
Longer tool lengths
Lower depth of cut.
Milling
The results of these trends

and the development of methods put new demands and
opportunities on the tooling,
such as:
Turn milling
Trochoidal milling
Circular milling
Boring
Profile milling
Drilling
G
Thread milling
Tool holding
Circular ramping
D 19
Machinability
Other information
Linear ramping
System overview
Turning
Positioning of cutters for face milling

Type of milling
cutter
Parting and
grooving
Threading
Milling
Considerations
Round inserts
10
45
90
ISO 40, 50
ISO 40, 50
ISO 40, 50
ISO 30, 40, 50
High
High
Medium
Low
Roughing
Very good
Good
Very good
Acceptable
Finishing
Acceptable
Acceptable
Very good
Good
Medium
Small
Medium
High
Versatility
Very good
Good
Good
Very good
Productivity
Very good
Very good
Very good
Good
Machine/spindle
size
Stability
requirement
Drilling
Cutting depth ap
Boring
Tool holding
Machinability
Other information
D 20
System overview
Turning
Positioning of cutters for shoulder milling

Type of milling
cutter
Parting and
grooving
90
90
ISO 40, 50
ISO 30, 40, 50
ISO 40, 50
ISO 30, 40, 50
High
High
Medium
Low
Roughing
Very good
Good
Acceptable
Good
Finishing
Acceptable
Acceptable
Very good
Good
Large
Medium
Small
Large
All
All
Aluminum
Aluminum
Very good
Very good
Acceptable
Good
Machine/spindle
size
Stability
requirement
Drilling
Cutting depth ap
Milling
90
Threading
90
Considerations
Boring
G
Tool holding
Versatility
D 21
Machinability
Other information
Material
System overview
Turning
Positioning of cutters for profile milling

Type of milling
cutter
Parting and
grooving
Threading
Milling
Round inserts
Ball nose
Ball nose
Ball nose
ISO 40, 50
ISO 40, 50
ISO 30, 40
ISO 30, 40
High
Medium
Medium
Low
Roughing
Very good
Good
Acceptable
Acceptable
Finishing
Acceptable
Acceptable
Very good
Very good
Medium
Medium
Small
Small
Versatility
Very good
Very good
Very good
Very good
Productivity
Very good
Good
Good
Good
Considerations
Machine/spindle
size
Stability
requirement
Drilling
Cutting depth ap
Boring
Tool holding
Machinability
Other information
D 22
System overview
Turning
Positioning of cutters for slots and grooves

Type of milling cutter
Parting and
grooving
Slot open
Slot closed
Cutting width
Cutting depth ap inch (mm)
Versatility
Grooving
Long edge
ISO 50
ISO 40, 50
ISO 40, 50
Open
Open
Open
Threading
Machine/spindle size
Side and face
Small
Small
Very good
4.508 (114.5)
.256 (6.5)
Good
Limited
Good
Good
Milling
Considerations
Drilling
Type of milling cutter
Indexable insert
end mill
Exchangablehead end mill
Solid carbide end

mill
Machine/spindle size
ISO 30, 40, 50
ISO 30, 40, 50
ISO 30, 40, 50
Open
Open
Open
Closed
Closed
Closed
Good
Small
Small
Cutting depth ap
Very good
Small
Large
Versatility
Very good
Very good
Very good
Slot closed
Cutting width
D 23
Machinability
Other information
Slot open
Boring
Considerations
Tool holding
Turning
Choice of inserts and how to apply
Parting and
grooving
Modern milling inserts for

face milling operations.
Threading
Milling
The design of a modern milling insert

E
Drilling
Corner design
Main cutting edge

design
.005
.005
Boring
Tool holding
C
utting edge reinforcement .005 inch (0.13
mm).
Rake angle 30.
Corner reinforcement
H
Machinability
Other information
Rake angle 30.

Primary land 17.
Primary land 11.
Chip former
D 24
C
utting edge reinforcement
.005 inch (0.13 mm).
Main cutting edge

design
Turning
Making the tool choice in milling

First choice
High
Cutter pitch
L
Close pitch (-M)
Extra close pitch (-H)
Light (-L)
Medium (-M)
Heavy (-H)
C
Threading
Coarse pitch (-L)
Parting and
grooving
Operation stability
Low
Toughness
Milling
Machining conditions/
Grades
Wear resistant
E
Good conditions
Drilling
Average conditions
Type of application
Tool holding
Medium milling
Most applications general purpose milling.
Medium depth of cut and feed rate.
Light milling
Operations at small depth of cut and low feed rates.
Operations requiring low cutting forces.
H
fn
Feed, inch/tooth (mm/tooth)
D 25
Machinability
Other information
Heavy milling
Operation for maximum stock removal and/or severe
conditions.
Larger depth of cut and feed rate.
Operations requiring highest edge security.
Boring
ap Depth of cut,
inch (mm)
Turning
Selecting the insert geometry
Parting and
grooving
Light (-L)
Extra positive.
Threading
Light machining.
Low cutting forces.
Low feed rates.
Medium (-M)
G
eneral purpose
geometry.
Medium feed rates.
M
edium operations to
light roughing.
Heavy (-H)
Reinforced cutting edge.
Heavy machining.
Highest edge security.
High feed rates.
Milling
Achieving good surface finish in milling
Drilling
Surface
roughness
Standard
insert
U
se wiper inserts for
higher productivity and
improved surface finish.
One wiper
insert
L imit the feed to 60% of

the parallel land.
Boring
M
ount the wiper inserts
correctly.
fn1 = .031 x bs1
(fn1 = 0.8 x bs1)
Machinability
Other information
fn
Feed, inch/tooth
(mm/tooth)
bs2
Tool holding
bs1
fn1 = .024 x bs2

(fn1 = 0.6 x bs2)
bs, inch .079

(mm) (2.0)
D 26
.323
(8.2)
.002 inch
(0.05 mm)
S
et the wiper inserts
below other inserts.
Turning
How to select insert grade

Select the geometry and grade according to the application.
Parting and
grooving
Build-up of a grade chart

Good
Average
C
Threading
Difficult
Average
Difficult
Milling
Good
Define machining conditions
Drilling
C
utting depth 25% of
max ap or less.
C
utting depth 50% of
max ap or more.
C
utting depth 50% of
max ap or more.
Overhang under two

times cutter diameter.
O
verhang two to three
O
verhang over three
Continuous cuts.
Interrupted cuts.
Interrupted cuts.
Wet or dry machining.
Boring
G
Tool holding
Average conditions
D 27
Machinability
Other information
Good conditions
Choice of inserts and to apply
Turning
Dedicated grades for ISO P, M and K
Parting and
grooving
Dedicated grades minimize tool wear development

The workpiece material influences the wear during the
cutting action in different ways. Therefore dedicated
grades have been developed to cope with the basic wear
mechanisms, e.g.:
- Flank wear, crater wear and plastic deformation in steel
- Built-up edge and notch wear in stainless steel
Threading
- Flank wear and plastic deformation in cast iron.
Milling
Select geometry and grade depending on the type of

workpiece material and type of application.
Drilling
Boring
G
ISO
Tool holding
Machinability
Other information
D 28
GC 4200
ISO
GC 2000
ISO
GC 3200
Turning
Choice of cutter and how to apply
Parting and
grooving
High performace face milling

cutters for small to medium
cutting depths.
Threading
Milling
Making the tool choice in milling

First choice
Operation stability
Low
High
Close pitch (-M)
Boring
Coarse pitch (-L)
Drilling
Cutter pitch
Wear resistant
Medium (-M)
Machining conditions/
Grades
Heavy (-H)
Tool holding
Light (-L)
Toughness
Good conditions
Average conditions
D 29
Machinability
Other information
Turning
Selecting cutter pitches

First choice
Operation stability
Low
High
Parting and
grooving
Cutter pitch
Threading
Coarse pitch (-L)

R
educed number of
inserts.
Limited stability.
Milling
Long overhang.
S
mall machines/limited
horsepower.
Close pitch (-M)

General purpose
S
uitable for mixed
production.
S
mall to medium
machines
H
igh number of inserts
for maximum productivity.
Stable conditions.
Short chipping materials.
Heat resistant materials.
Usually first choice.
D
eep, full slotting
operations.
Drilling
Differential pitch.
Limited stability
Stable
conditions
Boring
First choice
G
Tool holding
Long overhang
Limited
horsepower
Machinability
Other information
D 30
Cast iron
(CMC 08)
Heat
resistant
alloys
(CMC 20)
Turning
Cutting forces and entering angle

45 entering angle
Round insert cutters
B
Parting and
grooving
90 entering angle
Threading
Milling
General purpose cutter.
C
hip thinning effect allows increased productivity.
Increased chip thinning

effect for heat resistant
alloys.
Drilling
educed vibration on
R
long overhang.
Boring
here 90 form is
W
required.
S
trongest cutting edge
with multiple indexes.
G
Tool holding
eak-fixtured compoW
nents.
G
eneral purpose first
choice.
D 31
Machinability
Other information
Thin-walled components
Turning
Axial and radial cutting forces

Effect of entering angle (90)
Thin-walled components.
Parting and
grooving
Axially weak fixtured components.

Square shoulder
hex = fz (In case ae > 50% x Dc)
Threading

General purpose 1st choice.
Reduced vibration on long tool overhang.
Milling
C
hip thinning effect allows increased
productivity.
fz = 1.41 x hex (Compensating for entering angle).
Drilling

On round inserts, the chip load and entering angle vary with the
depth of cut.
S
trongest cutting edge with multiple
indexes.
Boring
General purpose cutter.
G
Tool holding
Increased chip thinning effect for heat

resistant alloys.
hex = depends on ap.
Machinability
Other information
D 32
Turning
Formulas for cutters with round inserts

Max. cutting diameter at a
specific depth (inch).
iC2 (iC 2 ap)2
Parting and
grooving
Facemilling round insert

(ap<iC/2) (inch).
hex iC
2 ap iC ap 2
Threading
fz =
Slide milling (ae<Dcap/2) and round insert

(ap<iC/2) (inch).
hex iC Dcap
4 ap iC ap 2 Dcap ae ae 2
Drilling
Feed compensation for different entering angles

90 = (fz or hex) 1.0
Boring
45 = (fz or hex) 1.41
Tool holding
Round = depends on ap
D 33
Machinability
Other information
fz =
Milling
Dcap = Dc +
Turning
Calculating cutting data
Parting and
grooving
Example in face milling

Need:
Given:
Spindle speed, n (rpm)
Cutting speed, vc =
738 ft/min (225 m/min)
.157
(4 mm)
Table feed, vf
(inch/min) (mm/min)
Feed per tooth, fz =

.0082 inch (0.21 mm)
Metal removal rate, Q

(inch3/min) (cm3/min)
Number of cutter teeth, zn = 5
Power consumption (Hp) (kW)
Cutter diameter, Dc =
4.921 inch (125 mm)
3.346
(85 mm)
Threading
Cutting depth, ap =
.157 inch (4 mm)
Working engagement, ae =
3.346 inch (85 mm)
Milling
Spindle speed
Inch
n=
Drilling
Metric
n=
Given: vc = 738 ft/min (225 m/min)
vc 12
Dc
738 12
3.14 4.921
Table feed
(rpm)
= 575 rpm
n=
n=
Boring
Tool holding
3.14 125
= 575 rpm
vf = n fz zn (mm/min)
vf = 575 .0082 5 = 23.6 inch/min
Metal removal rate
Given vf = 23.6 inch/min (600 mm/min)
Inch
Q = ap ae vf
vf = 575 0.21 5 = 600 mm/min
Metric
(inch3/min)
Q=
H
Machinability
Other information
225 1000
(rpm)
Metric
vf = n fz zn (inch/min)
Q = .157 3.346 23.6 = 12.4 inch3/min

D 34
Dc
Given: n = 575 rpm
Inch
vc 1000
Q=
ap ae vf
1000
4 85 600
1000
(cm3/min)
= 204 cm3/min
Turning
Net power consumption

Given: Material CMC 02.1
Metric
Pc =
ae ap vf kc
396 103
(Hp)
Pc =
B
ae ap vf kc1
(kW)
60 106
Parting and
grooving
Inch
C Cutting
Specific
cutting force
kc 1
02.1
02.2
03.11
03.13
03.21
03.22
06.1
06.2
06.3
Low alloyed (alloying elements d 5%)

Non-hardened
Hardened and tempered
High alloyed (alloying elements > 5%)
Annealed
Hardened tool steel
Castings
Unalloyed
Low alloyed (alloying elements d 5%)
High alloyed (alloying elements > 5%)
N/mm2
HB
mc
1500
1600
1700
1800
2000
125
150
170
210
300
0.25
0.25
0.25
0.25
0.25
43039050
38535015
36533000
31529060
23521095
1700
1900
175
300
0.25
0.25
30027545
19518060
1950
2150
2900
3100
200
200
300
380
0.25
0.25
0.25
0.25
23020585
19017055
16515035
1059585
1400
1600
1950
150
200
200
0.25
0.25
0.25
30528050
24522000
18016045
mc
CT530
Max chip thickness
0.1 0.15 0.2
Cutting speed vc, m
Specific
cutting force
kc 1
CMC
ISO No.
Material
Stainless steel
Ferritic/martensitic
Hp
= 7.7
Pc =
05.11 Non-hardened
396 103
05.12
05.13
05.21
05.22
PH-hardened
Hardened
Austenitic
Non-hardened
PH-hardened
Austenitic-ferritic (Duplex)
Non-weldable t 0.05%C
Weldable < 0.05%C
Stainless steel Cast
Ferritic/martensitic
Non-hardened
PH-hardened
Hardened
Austenitic
PH-hardened
Austenitic-ferritic (Duplex)
Non-weldable t 0.05%C
Weldable < 0.05%C
The calculation above is approximate05.51and valid for an

05.52 inch (0.1 mm).
maximum chip thickness (hex) of .0039
For a more accurate value of power consumption
(Pc) the
15.11
15.12
kc value should be calculated accordingly.
15.13
15.21
15.22
Inch
kc = kc1 hm-mc 1
100
Metric
( )
o
kc = kc1 hm-mc 1
100
15.51
15.52
60 106
HB
= 5.8 kW
200
0.21
1800
2850
2350
330
330
0.21
0.21
285 255 230

205 185 165
215 190 170
1950
2850
200
330
0.21
0.21
265 240 215

200 175 160
2000
2450
230
260
0.21
0.21
260 235 210

230 205 185
1700
2450
2150
1800
2450
200
330
330
200
330
0.25
0.25
0.25
0.25
0.25
255 230 205

180 160 145
195 175 155
255 225 205
180 160 145
230
260
0.25
0.25
245 220 195

215 190 170
1800
2250
Specific
cutting force
kc 1
Hardness
Brinell
CB50
hm = Average chip thickness
Max chip thickness
0.1 0.15 0.2
CMC
ISO No.
Material
mc
N/mm
HB
Cutting speed v , m
o = Insert rake angle
Malleable cast iron
K
07.1
Ferritic (short chipping)
790
130
0.28
=
C

hip
thickness
compensation
factor
m
c
07.2
Pearlitic (long chipping)
900
230
0.28
Grey cast iron
08.1
Low tensile k
strength
180
0.28
850 720 620
c = Specific cutting force 890
08.2
High tensile strength
1100
245
0.28
910 780 670
Nodular cast
iron =
S
pecific
cutting
force
for
average
chip
k
c1
09.1
Ferritic
900
160
0.28
09.2
0.28
495 420 360
thickness .039 inch1350
(1 mm)250
2) Pearlitic
(N/mm
H
45-60q entering
angle. Positive cutting geometry and coolant should be used.
(lbs/inch2)
Tool holding
( )
o
N/mm2
85 4 600 1700
1)
100 mm
125 mm
D 35
MILLING Cutting data
Machinability
Other information
Pc =
3.346 .157 23.6 246500

M
Hardness
Brinell
Milling
01.1
01.2
01.3
01.4
01.5
Material
Steel
Unalloyed
C = 0.10 0.25%
C = 0.25 0.55%
C = 0.55 0.80%
Drilling
CT530
Max chip thickness
0.1 0.15 0.2
Cutting speed vc, m
Boring
CMC
ISO No.
Hardness
Brinell
Threading
Milling with large engagement Metric
Condit
Cutter,
over the
engage
Troubleshooting
Turning
Application hints for milling

Power capacity
Check power capability and machine
rigidity, making sure that the machine
can handle the cutter diameter required.
Parting and
grooving
Overhang
Machine with the shortest possible tool
overhang on the spindle.
C
Threading
Select correct cutter pitch

Use the correct cutter pitch for the
operation to ensure that there are not
too many inserts engaged in cut, as this
may cause vibration.
Milling
Cutting engagement
Ensure there is sufficient insert engagement with narrow workpieces or when
milling over voids.
Drilling
Up to .020 inch (0.50 mm)

Use correct feed
Ensure that the right feed per insert is
used to achieve the right cutting action
by use of the recommended maximum
chip thickness.
Boring
Cutting direction
Use climb (down) milling whenever possible.
Tool holding
Machinability
Other information
D 36
Choice of insert geometry

Use positive geometry indexable inserts
whenever possible for smooth cutting
action and lowest power consumption.
Turning
Dampened milling tools
Entering angle
Select the most suitable entering angle.
C
Threading
For longer overhang of more than 4 times

the tool diameter, vibration tendencies
can become more apparent, and dampened cutters can improve the productivity
radically.
Cutter diameter
Select the right diameter in relation to
the workpiece width.
Cutter position
Position the milling cutter correctly.
Milling
Boring
Coolant
Only use coolant if considered necessary. Milling is generally performed better
without.
Drilling
G
Tool holding
Maintenance
Follow tool maintenance recommendations and monitor tool wear.
D 37
Machinability
Other information
Parting and
grooving
Troubleshooting
Drilling
Drilling covers methods of making cylindrical holes in a
workpiece with metal cutting tools
Theory
E6
Selection procedure
E 15
System overview
E 20
How to apply
E 26
E 37
Troubleshooting
E 42
E3
Turning
Theory
The drilling process

T he drill is always engulfed in the workpiece, leaving no view of the operation.
B
Parting and
grooving
Chips must be controlled.

hip evacuation is essential; it affects
C
hole quality, tool life and reliability.
Threading
Milling
Four common drilling methods
E
Drilling
Trepanning
Drilling
Drilling is classified into

four common methods:
- Drilling
- Trepanning
- Chamfer drilling
Boring
- Step drilling
Chamfer drilling
Tool holding
Machinability
Other information
E4
Step drilling
Theory
Turning
The most common holes
Parting and
grooving
Threading
1 2 3 4 5
Milling
The most common holes are:
1 Holes with clearance for bolts
2 Holes with a screw thread

3 Countersink holes
6 Holes to remove weight for balancing.
Boring
5 Holes that form channels
Drilling
4 Holes that have a good fit
Tool holding
E5
Machinability
Other information
Theory
Turning
Maximum hole depth
B
Parting and
grooving
Chip evacuation
Maximum hole depth is a function of hole

diameter Dc and hole depth (l4).
Example: max hole depth l4 = 3 x Dc.
Threading
Milling
Drilling
Boring
Tool holding
H
Machinability
Other information
Hole depth (l4) determines the choice of

tool.
E6
Theory
Turning
Drilling theory
C
utting speed (vc) for indexable drills
declines from 100% at the periphery to
zero at the center.
T he central insert operates from cutting
speed zero to approx. 50% of vc max.
The peripheral insert works from 50% of
vc max up to 100% of vc max.
C
Threading
vc = 0
B
Parting and
grooving
Cutting speeds for indexable drills
0.5 x vc max
vc max
Milling
Cutting speeds for solid and brazed carbide drills

Drilling
T wo effective cutting edges, from the

center to the periphery.
Two edges/rev: z = 2.
Boring
G
Tool holding
vc max
E7
Machinability
Other information
vc = 0
Theory
Turning
Solid carbide drill (SCD) vs. high speed drills (HSS)
Solid carbide drill

C
hisel edge is practically
eliminated with the solid
carbide drill.
Parting and
grooving
Point angle and chisel edge
C
Threading
140 point angle

Chisel edge
HSS drill
T his results in better

centering features and
cuts chips close to the
center of the drill point.
This eliminates the need
for a center drill.
Milling
T he axial cutting force

is reduced considerably,
because the chisel edge
is eliminated on solid
carbide drills.
118 point angle
Drilling
2 Chisel edge
3 Primary clearance
1 Main cutting edge
4 Secondary clearance
Boring
5 Flute
Tool holding
6 Margin
7 First split
8 Negative chamfer
9 Clearance surface
Machinability
Other information
E8
6
9
7
5
C
hisel edge is practically
eliminated.
The main cutting edge
reaches the center point.
Gives longer life and
productivity.
Lower thrust and torque.
Better tolerances.
Theory
Cutting speed
Turning
Parting and
grooving
fn = feed per revolution (inch/r) (mm/r)

vf = penetration rate (inch/min) (mm/
min)
Dc = drill diameter (inch) (mm)
C
Inch
Dc n
12
ft/min
Threading
vc =
Metric
Productivity in drilling is strongly

related to the penetration rate, vf.
Dc n
1000
D
m/min
Milling
vc =
vf = fn n inch/min (mm/min)
E
Cutting speeds for indexable drills
vc = 0
vc max
2
Drilling
Cutting speed (vc) for indexable drills declines from 100 % at the periphery to zero
at the center.
vc max
Boring
The central insert operates from cutting

speed zero to approx. 50% of vc max.
The peripheral insert works from 50%
of vc max up to 100% of vc max.
G
vc = 0
Tool holding
Two edges, from the center to the periphery.
vc = max
Two edges/rev: z = 2.
E9
Machinability
Other information
Cutting speeds for solid and brazed carbide drills
Theory
Turning
Parting and
grooving
Effects of cutting speed vc (ft/min) (m/min)

Affects the power Pc (Hp) (kW) and torque Mc (lbf-ft) (Nm).
The largest factor determining tool life.
igher speed generates higher temperature and inH
creased flank wear, especially on the peripheral corner.
H
igher speed is beneficial for chip formation in long chipping, soft materials, i.e., low carbon steel.
Threading
Milling
Drilling
Too high cutting speed causes:

- rapid flank wear
- plastic deformation
- poor hole quality
- bad hole tolerance.
Too low cutting speed causes:
- built-up edge
- bad chip evacuation
- longer time in cut.
Boring
Cutting speed (vc) affects:

- tool life
- power consumption.
Tool holding
Machinability
Other information
E 10
Theory
Effects of feed rate fn (inch/r) (mm/r)

A
ffects the feed force Ff (N), power Pc (Hp) (kW) and
torque Mc (lbf-ft) (Nm).
Turning
Feed rate
B
Parting and
grooving
Controls chip formation.

Contributes to hole quality.
Primarily influences surface finish.
Contributes to mechanical and thermal stress.
Threading
fn = fz 2 inch/r (mm/r)
Milling
Feed rate (fn) affects:

- chip formation
- power consumption
- feed force
- mechanical and thermal stress on the drill.
Drilling
High feed rate:

- harder chip breaking
- reduced time in cut.
Boring
Low cutting speed:

- higher risk of drill breakage
- reduced hole quality.
Low feed rate:
- longer, thinner chips
- quality improvement
- accelerated tool wear
- longer time in cut.
Tool holding
E 11
Machinability
Other information
Theory
Turning
Approximate calculation of power consumption

CoroDrill 880
CoroDrill Delta-C
vc = c utting speed (ft/min) (m/min)
fn = feed per revolution (inch/rev)
(mm/rev)
vf = penetration rate (inch/min)
(mm/min)
Dc = drill diameter (inch) (mm)
fz = feed per edge (inch) (mm)
kc1 = specific cutting force (lbf ft/
inch2) (N/mm2)
Pc = power consumption (Hp) (kW)
Ff = feed force (N)
Mc = torque (lbf ft) (Nm)
Parting and
grooving
Threading
Milling
Inch
fn vc Dc kc1
132 103
Hp
Drilling
Pc =
Metric
Boring
Tool holding
For information about the kc value, see page H16.
Machinability
Other information
E 12
Pc =
fn vc Dc kc1
240 103
kW
Theory
CoroDrill Delta-C
B
Parting and
grooving
CoroDrill 880
Turning
Accurate calculation of power consumption
Pc =
Metric
fn vc Dc kc
132 103
Pc =
Hp
fn vc Dc kc
kW
240 103
r)-mc
100
Drilling
kc = kc1 (fz sin
Milling
Inch
C
Threading
0 = 30
Boring
Tool holding
For information about the kc value, see page H16.
E 13
Machinability
Other information
Theory
Turning
Calculation of torque and feed force
Parting and
grooving
n = Spindle speed (rpm)

fn = F eed per revolution (inch/rev)
(mm/rev)
Dc = Drill diameter (inch) (mm)
Power
consumption
(Hp) (kW)
kc1 = S
pecific cutting
force (lbf ft/inch2) (N/mm2)
Ff = Feed force (N)
Threading
Mc = Torque (lbf ft) (Nm)
Torque (lbf ft)

(Nm)
Milling
Feed force (N)
Drilling
Mc =
Boring
Inch
Tool holding
Machinability
Other information
E 14
Ff 0.5 kc
Dc
2
fn sin r (N)
Metric
Pc 16501
n
(lbf ft)
Mc =
Pc 30 103
n
(Nm)
Tool selection
Turning
Parting and
grooving
Hole dimension
and quality
C
Component
Workpiece material, shape

and quantity
Threading
Machine
Milling
Machine parameters
Choice of tool
Type of tool
Drilling
How to apply
Cutting data, coolant,

etc.
Boring
Troubleshooting
Remedies and
solutions
E 15
Machinability
Other information
Tool holding
Tool selection
Turning

Component:
B
Parting and
grooving
- Is the component rotation symmetric

around the hole, i.e., can the hole be
machined with a stationary drill?
-C
lamping, clamping forces and cutting
forces. Is the component sensitive to
vibrations?
C
Threading
- Is a tool extension needed to reach the

surface where the hole will be drilled, i.e.,
long tool overhangs?
D
Material:
Milling
Drilling
achinability
m
chip breaking
hardness
alloy elements.
2. Important machine considerations

Condition of the machine:
Boring
Tool holding
Machinability
Other information
E 16
achine stability
m
spindle speed
coolant supply
coolant pressure
clamping of the workpiece
horizontal or vertical spindle
power and torque
tool magazine.
Tool selection
Turning
3. Choice of drilling tools

The basic parameters are:
diameter
depth
quality (tolerance, surface finish,
straightness).
The hole type, and the required precision

affect tool choice.
Drilling can be affected by irregular or
angled entry/exit surfaces and by cross
holes.
B
Parting and
grooving
Different ways to make a hole
Drilling and boring
Step drilling
Threading
Milling, helical
interpolation
Milling
Advantages
Advantages
Advantages
Simple standard tools.
Simple Tailor Made tools.
Simple standard tools.
Relatively flexible.
F astest way to make a

hole.
Very flexible.
Drilling
Low cutting forces.
Disadvantages
Disadvantages
Boring
Requires more power and

stability.
Longer cycle times.
Less flexibility.
Tool holding
R
equires two tool
positions.
Disadvantages
E 17
Machinability
Other information
T wo tools, adapters and

basic holders.
Turning
Tool selection
4. How to apply
B
Parting and
grooving
Tool holding
lways use shortest possible drill and
A
overhang.
F or best stability and hole quality, use
modular tools, hydro-mechanical or
hydraulic holding tools.
Threading
D
Tool runout
Milling
M
inimum tool runout is essential for
successful drilling.
Drilling
Chip evacuation and cutting fluid

hip formation and evacuation is the
C
dominant factor in drilling and affects
hole quality.
Boring
Cutting
speed
Thicker and
stiffer chips
Tool holding
G
More open due to
less friction
Machinability
Other information
H
Feed
E 18
Tool selection
Turning
5. Troubleshooting
B
-C
heck the wear pattern and if necessary adjust cutting
data accordingly.
Chip evacuation
Parting and
grooving

-C
heck clamping of drill/workpiece, feed rate, machine
conditions and chip evacuation.
-C
orrect cutting speed and feed rate is essential for high
productivity and tool life.
Milling
Cutting data
Drilling
Boring
Tool holding
E 19
Machinability
Other information
.984 in.
(25mm)
Threading
- Check chip breaking and cutting fluid supply.
Turning
Parting and
grooving
System overview
Drilling tools
Drilling tools covering diameters from .0118 inch up to
4.331 inch (0.30 mm 110 mm) and even larger as
engineered products.
Conventional drilling
C
Threading
Irregular surface and

cross-hole drilling
Milling
Drilling
Deep hole drill
Solid carbide drill

Brazed carbide drill
Short hole drill
L/Dc
Boring
Large diameter drill

15xDc
Trepanning drill
Tool holding
10xDc
5xDc
Machinability
Other information
E 20
.394
(10)
.787
(20)
1.181
(30)
1.575
(40)
1.969
(50)
2.362 2.756 3.150

(60) (70) (80)
4.331
(110)
Drill
diameter, Dc
inch
(mm)
System overview
Turning
Choice of drilling tools

Step and chamfer drilling
Parting and
grooving
Chamfer drilling
Step or step and chamfer

drilling
Threading
Milling
Other methods
Drilling
Trepanning
Boring
Helical interpolation
G
Tool holding
Radial adjusted
drilling
Plunge drilling
E 21
Machinability
Other information
Solid drilling
System overview
Positioning of short hole drills
Indexable insert drills
Parting and
grooving
Turning
Diameter and hole depth
Always to be considered
as the first choice due to
lower cost per hole. They
are also very versatile
tools.
M
edium and large
diameter holes.
Medium tolerance
demands.
Blind holes requiring a
flat bottom.
Plunge drilling or boring
operations.
First choice for smaller

diameters and when closer
hole tolerance is required.
S
mall diameter.
Close or precision
tolerance holes.
Short to relatively deep
holes.
An alternative choice to a
solid carbide drill for larger
diameters and when stability is bad (due to the less
sensitive steel body).
Complement to solid carbide for larger diameters or

when process stability is
poor the steel part of the
drill provides toughness.
Threading
Application areas
Solid carbide drills
Milling
Drilling
Brazed carbide drills
Boring
Tool holding
Machinability
Other information
E 22
System overview
Turning

The basic drill
For all workpiece materials.

S
tandard, Tailor Made and special drills
available.
A
versatile tool that can do more than
just drilling.
C
Threading
T he most economical way to

produce a hole.
Parting and
grooving
Milling
Mounting options
Drilling
Different mounting options are available, which enables

the user to mount the drill to almost all machine configurations. Today, machine tool manufacturers are offering
mounting options integrated to the spindle.
F
Coromant Capto coupling
Cylindrical with flat
Boring
Cylindrical shank
Whistle Notch
Other modular systems
E 23
Machinability
Other information
P-shank
Tool holding
System overview
Turning

The basic choice
Material-optimized drills
Parting and
grooving
Threading
Milling
Special tools
Application-optimized drills
Precision
drill for
hard steel
Chamfer drill
P M K
N S H
P
H
Drilling
P M K
N S H
Short hole drills ISO material groups

ISO material group
Solid carbide
drills
Brazed carbide
drills
Indexable
insert drills
Boring
Tool holding
Machinability
Other information
E 24
Selection procedure
Turning
Large hole diameters

Large diameter drill
B
Parting and
grooving
Indexable insert drills are available in diameters

up to 3.150 inch (80 mm).
Threading
Trepanning drill
Milling
Trepanning is used for larger hole diameters and where

machine power is limited, because it is not as power consuming as solid drilling. Trepanning drills are available up
to diameter 4.331 inch (110 mm) as standard.
Drilling
A milling cutter with helical or circular interpolation can be

used instead of drills or boring tools. The method is less
productive but can be an alternative when chip breaking
is a problem.
Boring
Milling, helical interpolation
Tool holding
E 25
Machinability
Other information
Turning
How to apply
Setup routine
Use the shortest possible drill.
Parting and
grooving
How to apply
Check programming length.

S
tart drilling with a mid-range recommended feed rate
to a depth of .125 inch (3.2 mm).
Check chip formation and measure hole size.

Threading
Inspect the drill to make sure no drill-to-hole rubbing is

taking place.
Increase or decrease feed rate according to chip
formation, vibration, hole-surface quality, etc.
Milling
Drilling
Chip control
Improved chip evacuation is initially achieved by improving chip formation.
Long chips may cause chip jamming in the drill flutes.

Excellent
Boring
Rectification involves selecting the correct insert

geometry and adjusting cutting data.
G
Tool holding
Acceptable
Not acceptable
H
Machinability
Other information
A
lso the surface finish may be affected and the insert
or tool may be at risk.
E 26
CoroDrill 880 has three insert geometries to suit

different materials and cutting conditions.
How to apply
Turning
Rotating drill
If over- or under-sized holes are produced
or if the center insert tends to chip, it is
often because the drill is off center.
T urning the drill 180 in its holder may
solve this problem.
C
Threading
B
ut it is important to ensure that the
center axis of the drill and the axis of
rotation are parallel in order to achieve
accurate holes.
B
Parting and
grooving
Alignment
T he machine spindle and the holder

must be in good condition.
Milling
Radial adjustment
It may be necessary to reduce the

feed/rev (fn) due to longer tool overhang
and less balanced cutting forces created
by the offsetting.
leeves are used to adapt various ISO
S
shank sizes for one holder.
E 27
Boring
G
Tool holding
R
adial adjustment -.008 /+.028 inch
(-0.2 /+0.7 mm). Note that the adjustment range for the drill should not be
exceeded. (Maximum adjustment can
be seen on the ordering pages in the
catalog).
H
Machinability
Other information
S
etting is achieved by turning the scale
ring surrounding the holder, marked in
increments of .002 inch (0.05 mm),
indicating a diametrical movement of the
tool.
Drilling
Adjustable holder
How to apply
Turning
Adjustable sleeve for drills with ISO 9766 shanks
Parting and
grooving
C
Threading
Rotating drill eccentric sleeve

Drill diameter can be adjusted for closer
hole tolerance. The adjustment range is
approx. .012 (0.3 mm), but adjustment
in the negative direction should be made
only if the drill produces an oversized hole
(not in order to achieve undersized holes).
Milling
O
ne dot increases/decreases the diameter by .004 inch (0.10 mm).
Increase the diameter by turning the
sleeve clockwise.
Drilling
D
ecrease the diameter by turning the
sleeve counterclockwise.
U
se both screws to clamp the drill in the
fixture and make sure the bolts in the
holder are long enough.
Boring
Tool holding
Machinability
Other information
E 28
How to apply
Turning
Non-rotating drill
.001 inch
T he total runout between the center line

of the machine and the workpiece must
not exceed .001 inch (0.03 mm).
C
Threading
T he drill should be mounted so that the

top face of the peripheral insert is parallel to the machines transverse movement (usually X-axis).
B
Parting and
grooving
Alignment
Milling
Misalignment also has the effect of

radial offsetting, which produces either
an over- or under-sized hole.
T esting can be carried out with a dial
indicator together with a test bar.
Drilling
Dial indicator and test bar
M
ake holes with the drill mounted in
each of the four flat positions. Hole
measurement will indicate the state of
machine alignment.
G
Tool holding
Another way is by making a drill with four

flats equally positioned around the drill
shank.
Boring
Drill with four flats
3
E 29
Machinability
Other information
How to apply
Turning
Deflection of turret
Problem solving
D
eflection of the turret on a CNC lathe
can be caused by the feed force.
Parting and
grooving
Feed force
Threading
F irst, check if you can minimize torque

by mounting the tool differently.
Position B is preferable to position A.
Milling
B
A
Drilling
T o avoid wear on the drill body and

retraction marks in the hole, mount the
drill with the peripheral insert as shown
in the picture.
Boring
Peripheral insert
Tool holding
Feed force
Machinability
Other information
E 30
F inally, a reduction of the feed/revolution

(fn) can be made to minimize the feed
force.
How to apply
N
on-rotating indexable insert drills can also be used to
generate tapered holes.
A
lso chamfering and reliefs can be machined
with the drill.
C
Threading
hole which is to be threaded can be prepared in one

A
pass along with chamfering.
B
Parting and
grooving
H
oles can be drilled larger than the nominal size of the
drill as well as enlarged and finished with a subsequent
boring pass.
Turning
Radial offset
Milling
Entering non-flat surfaces

A
When entering non-flat surfaces there is

a risk of drill deflection. To avoid this, the
feed can be reduced when entering.
Drilling
A. Convex surface
Normally no feed reduction needed.
F
B. Concave surface
Boring
to 1/3 of original feed rate.

C. Inclined surface
W
ith entering angle of 289, reduce
feed to 1/3 of original feed rate.
Tool holding
D. Curved surface
Reduce feed 1/3 of original feed rate.
E 31
Machinability
Other information
How to apply
Turning
Irregular surfaces and pre-drilled holes

When entering or exiting an irregular surface there is a risk of the inserts chipping.
B
Parting and
grooving
T he feed rate should therefore be

reduced.
pre-drilled hole should be small rather
A
than large - not more than 25% of the
drill diameter - to avoid drill deflection.
C
Threading
H
owever, reduced feed does allow broad
machining of pre-drilled holes.
Milling
Coolant supply
Internal coolant supply
Drilling
A
lways to be preferred especially in longchipping materials and when drilling
deeper holes (4-5 x Dc).
External coolant supply
C
an be used when chip formation
is good and when the hole depth is
shallow.
Boring
Compressed air, minimal lubrication or dry

drilling
C
an be successful in favorable conditions, but is generally not recommended.
Tool holding
Machinability
Other information
E 32
How to apply
Turning
Coolant Important for successful performance

Coolant supply is essential in drilling and influences:
- chip evacuation
- hole quality
- tool life.
C
Threading
The cubic capacity of the coolant tank should be

between 5-10 times larger than the volume of coolant
that the pump supplies per minute.
The volume capacity can be checked using a stopwatch
and a suitably-sized bucket.
Parting and
grooving
Milling
The cutting fluid

Soluble oil (emulsion)
5 to 12% oil (10-25% for stainless steels).
EP (extreme pressure) additives.
Mist cutting fluid or minimal lubrication

can be used with good performance especially at high
cutting speeds.
Boring
Neat oil
always with EP additives.
to be preferred for stainless steels.
both solid carbide and indexable insert drills work well
with neat oil.
Drilling
G
Tool holding
Dry drilling, without any coolant

can be performed in short-chipping materials.
hole depths up to 3 times the diameter.
preferably in horizontal applications.
tool life will be influenced negatively.
E 33
Machinability
Other information
How to apply
Turning
Brazed and solid carbide drills
Rotating drill
.0008 inch (0.02 mm)
Parting and
grooving
Tool runout
Minimum tool runout is one of the main
criteria for successful use of solid carbide
drills.
The runout should not exceed .0008 inch
(0.02 mm) in order to achieve:
- close hole tolerance
C
Threading
- good surface finish

- long and consistent tool life.
Stationary drill
.0008 inch (0.02 mm)
Milling
Tool holding
collet and tool shank in bad condition
A
will ruin an otherwise perfect setup.
Drilling
M
ake sure that the TIR (Total Indicator
Readout) is within .0008 inch (0.02
mm).
Boring
A
n unacceptable runout can be temporarily reduced by turning the drill or the
collet 90 or 180 to find lowest TIR.
Tool holding
For best performance use

hydro-mechanical, hydraulic or
shrink fit chuck.
Machinability
Other information
E 34
How to apply
Turning
Coolant
Internal or external
S
hould always be used at hole depths above 3 times
the diameter.
A
horizontal drill should have a flow of coolant coming
out of the drill without any downward drop for at least
12 inches (30 cm).
C
Threading
Parting and
grooving
Is always to be preferred to avoid chip jamming.
T o improve chip evacuation at least one coolant nozzle

(two if drill is stationary) should be directed close to the
tool axis.
C
an sometimes help to avoid built-up edge formation
due to a higher edge temperature.
Milling
Can be acceptable in short-chipping materials.
Drilling
Boring
Tool holding
E 35
Machinability
Other information
How to apply
Turning
Safety precautions
Safety against
dangerous discs
uarding against through-hole discs is

G
important to avoid damage or injury,
especially when using non-rotating drills.
Rotating stop
is an important
measure
A
rotation stop may be necessary for
rotating drills.
Parting and
grooving
Threading
Milling
If the coolant contains chip particles, the

slit seatings may seize and as a result
the housing will rotate.
Drilling
If the rotating connector has not been

used for a long time, check that the
holder rotates in the housing before the
machine spindle is started.
Boring
Tool holding
Machinability
Other information
E 36
Hole quality and tolerance
Turning
Steps to ensure good hole quality in drilling
T ool holding influences hole quality and

tool life.
se the shortest possible drill for maxiU
mum stability.
C
hip breaking and chip evacuation must
always be satisfactory.
Milling
C
oolant supply and coolant pressure is
important.
C
Threading
The

machine tool should be in good
condition.
Parting and
grooving
- nominal

value (the theoretical exact
value)
- tolerance

width (a number), e.g., IT 7 according to ISO
G
Tool holding
- position

of the tolerance (designated by
capital letters according to ISO).
Boring
Dmin
Hole dimensions are characterized by

three parameters:
Dmax minus Dmin is the tolerance width,

also called, e.g., IT 7.
E 37
Machinability
Other information
Dmax
Drilling
Hole and hole tolerance
Turning
Hole tolerance according to ISO

Diameter range, inch/mm
Parting and
grooving
Threading
Milling
Tolerance
Drilling
Boring
.709
1.181
1830
1.181
1.969
3050
1.969
3.150
5080
3.150
4.724
80120
IT7

.0005 .0006 .0007 .0008 .0010 .0012 .0014

0.012 0.015 0.018 0.021 0.025 0.030 0.035
IT8

.0007 .0009 .0011 .0013 .0015 .0018 .0021

0.018 0.022 0.027 0.033 0.039 0.046 0.054
IT9

.0012 .0014 .0017 .0020 .0002 .0029 .0034

0.030 0.036 0.043 0.052 0.062 0.074 0.087
IT10

.0019 .0022 .0028 .0033 .0039 .0047 .0055

0.048 0.058 0.070 0.084 0.100 0.120 0.140
IT11

.0030 .0035 .0043 .0051 .0062 .0074 .0089

0.075 0.090 0.110 0.130
0.160 0.190 0.220
IT12

.0047 .0059 .0071 .0083 .0098 .0118 .0138

0.120 0.150 0.180 0.210 0.250 0.300 0.350
IT13

.0071 .0087 .0106 .0130 .0154 .0181 .0213

0.180 0.220 0.270 0.330 0.390 0.460 0.540
Examples

Bearings
1)
Holes for
threading
Normal tap
holes
Holes for threading with fluteless taps (rolled threads)
The lower the IT-number, the closer the tolerance.

The tolerance for one IT-class grows with larger diameters.
+.003 inch
(0.07 mm)
+0.00
Example:
.591 inch (15.00 mm)

H10
Nominal value:
.591 inch (15.00 mm)
Tolerance width: .003 inch (0.07 mm)

(IT 10 acc. to ISO)
Position:
H
Machinability
Other information
.394
.709
1018
.0003 .0004 .0004 .0005 .0006 .0007 .0009

0.008 0.009 0.011 0.013 0.016 0.019 0.022
Tool holding
.236
.394
610
IT6

1)
.118
.236
36
E 38
0 to plus
(H acc. to ISO)
Turning
Hole
.787 inch
(20 mm) H7
Axle
.787 inch
(20 mm) h7
The hole tolerance is often

connected to the tolerance
of an axle, that should fit
the hole.
B
Parting and
grooving
Hole tolerances according to ISO
Threading
Hole and axle tolerance according to ISO
Milling
Axle tolerance position is denominated by lower case letters corresponding to the hole tolerance. The figure below
gives a complete picture.
Drilling
Most common
Axle larger than

hole
Boring
Hole larger
than axle
G
Drive fit
Interface
Tool holding
Play
(bearings)
Slide fit
Grip = negative play

(fix joints)
E 39
Machinability
Other information
Running fit
Turning
Hole and tool tolerance

Obtainable hole tolerance with different tools
B
Parting and
grooving
Threading
R844
Tolerance
Brazed carbide drill
Indexable insert drill
R840
R842
R850
IT6
IT7
IT8
IT9
With pre-setting
Milling
IT10
IT11
IT12
IT13
Drilling
Solid carbide and brazed drills

Drill diameter Dc tolerance
Boring
T he drill is ground to a certain diameter tolerance,

designated by lower case
letters according to ISO.
Dc tolerance for a solid carbide drill and a brazed carbide drill
H
Machinability
Other information
The hole tolerance

F or modern solid carbide
or brazed carbide drills
like CoroDrill Delta-C and
Coromant Delta, the hole
tolerance is very close to
the drill tolerance.
Tool holding
Drill tolerance
E 40
Hole tolerance
T he diameter tolerance of an indexable

insert drill is a combination of the tip
seat tolerance in the drill body and the
insert tolerance.
Indexable insert drills give an optimal

cutting force balance and a plus tolerance (oversized) hole, because most
holes are with H-tolerance.
B
Parting and
grooving
Drill tolerance
Turning
Threading
Drill depth 2-3 x Dc
Hole tolerance, inch (mm)
.472 1.732
(12.00 43.99)
0/+.0098
(0/+0.25)
1.732 2.086
(44.00 52.99)
0/+.0110
(0/+0.28)
2.087 2.500
(53.00 63.50)
0/+.0118
(0/+0.30)
0/+.0079
(0/+0.20)
0/+.0098
(0/+0.25)
0/+.0110
(0/+0.28)
Tolerance Dc, inch (mm)
Milling
Drill diameter, inch (mm)
2.087 2.500
(53.00 63.50)
0/+.0177
(0/+0.45)
+.0016/+.0094
(+0.04/+0.24)
+.0016/+.0114
(+0.04/+0.29)
+.0016/+.0126
(+0.04/+0.32)
How to improve the hole tolerance
.9876 in (25.084 mm)

.9843 in (25 mm)
One way of eliminating the manufacturing

tolerance of the drill body and inserts is to
preset the drill.
This can be done in a lathe or with an adjustable holder/sleeve, see page E27.
.9843 inch
(25 mm) H10
A tolerance width (IT) inside .004 inch

(0.10 mm) can then be obtained.
Boring
Tolerance Dc, inch (mm)
1.732 2.086
(44.00 52.99)
0/+.0169
(0/+0.43)
G
Tool holding
Hole tolerance, inch (mm)
.472 1.732
(12.00 43.99)
0/+.0157
(0/+0.40)
E 41
Machinability
Other information
Drill diameter, inch (mm)
Drilling
Drill depth 4-5 x Dc
Turning
Parting and
grooving
Troubleshooting
Troubleshooting
Indexable insert drill
Problem
Solution
Oversized holes
Rotating drill
1. Increase coolant flow, clean
filter, clear coolant holes
in drill.
2. Try a tougher geometry on
peripheral side (keep center
insert).
Non-rotating drill
1. Check alignment on lathe.
2. Rotate drill 180.
peripheral side (keep center
insert).
Undersized holes
Rotating drill
in drill.
center side and a light cutting geometry on peripheral
side.
Non-rotating drill
1. Stationary:
Check alignment on lathe.
2. Stationary:
Rotate drill 180.
3. Try a tougher geometry
on peripheral side (keep
center).
Pin in hole
Rotating drill
in drill.
2. Try a different geometry on
peripheral side and adjust
feed rate within recommended cutting data.
3. Shorten drill overhang.
Non-rotating drill
1. Check alignment on lathe.
in drill.
3. Shorten drill overhang.
4. Try a different geometry on
peripheral side and adjust
feed rate within recommended cutting data.
Vibrations
1. Shorten drill overhang, Improve the workpiece stability.

2. Reduce cutting speed.
3. Try a different geometry on peripheral side and adjust feed
rate within recommended cutting data.
Insufficient machine torque
1. Reduce feed.
2. Choose a light cutting geometry to lower the cutting force.
Threading
Milling
Drilling
Boring
Tool holding
Machinability
Other information
H
Mc lbf-ft (Nm)
E 42
Troubleshooting
Solution
Insufficient machine power
1. Reduce speed.
2. Reduce feed.
3. Choose a light cutting geometry to lower the cutting force.
Pc HP (kW)
Hole widens at bottom (due to chip jam on center insert)
1. Increase coolant flow, clean filter, clear coolant holes in drill.
2. Try a different geometry on peripheral side and adjust feed
rate within recommended cutting data.
3.Shorten drill overhang.
C
Threading
Hole not symmetrical
B
Parting and
grooving
Problem
Turning
1. Reduce feed.
2. Choose a light-cutting geometry to lower the cutting force.
Broken insert screws
1. Use torque wrench to fasten the screw together, apply

Molykote.
Milling
Poor tool life
Drilling
Bad surface finish
1. Important to have good chip control.

2. Reduce feed (if it is important to keep vf, increase speed as
well).
4. Shorten drill overhang, improve the workpiece stability.
Boring
Caused by long chips

1. Check geometry and cutting data recommendations.
3. Reduce feed within recommended cutting data.
4. Increase cutting speed within recommended cutting data.
E 43
Machinability
Other information
Chip jamming in the

drill flutes
Tool holding
Troubleshooting
Turning
Tool wear Indexable insert drill

Cause
Solution
a) C
utting speed too high.
b) Insufficiently wear resistant
grade.
a) R
educe cutting speed.
b) Choose a more wear resistant
grade.
Peripheral insert
Diffusion wear caused by temperature too high on rake face.
Peripheral insert
Select GC4024 or GC4014 with
Al2O3 coating against oxidation.
Reduce speed.
Flank wear
Parting and
grooving
Problem
C
Threading
Crater wear
Central insert:
Abrasive wear caused by built-up
edge and smearing.
Milling
General:
Choose a more positive geometry.
Plastic deformation (peripheral insert)
Drilling
Boring
utting temperature (cutting

a) C
speed) too high, combined with
high pressure (feed, hardness of
workpiece).
b) As a final result of excessive
flank wear and/or crater wear.
ab) S
elect a more wear resistant
grade with better resistance
to plastic deformation, i.e.,
GC4014 or GC4024.
ab) Reduce cutting speed.
a) Reduce feed.
a) Insufficent toughness of grade.

b) Insert geometry too weak.
c) Built-up edge (BUE).
d) Irregular surface.
e) Bad stability.
f) Sand inclusions (cast iron).
a) S
elect a tougher grade, i.e.,
GC4044.
b) Select a stronger geometry,
i.e., -GT.
c) Increase cutting speed or select
a more positive geometry.
d) Reduce feed at entrance. Choose
geometry -GT.
e) Improve stability.
f) Choose a stronger geometry, i.e.,
-GR or -GT. Reduce feed.
Chipping
Tool holding
H
Machinability
Other information
Central insert:
Choose GC1044, if H13A is used.
Reduce feed.
E 44
Troubleshooting
Cause
Solution
a) L ow cutting speed (temperature

too low at the cutting edge).
b) Cutting geometry too negative.
c) Very sticky material, such as
certain stainless steels and pure
aluminum.
d) Percent of oil mixture in cutting
fluid too low.
a) Increase cutting speed or change

to a coated grade.
b) Select a more positive geometry.
c-d) Increase oil mixture and
volume/pressure in cutting
fluid.
Built-up edge (BUE)
B
Parting and
grooving
Problem
Turning
Threading
Checkpoints and remedies

1. M
ake sure the right cutting data and
drill geometry are used.
Milling
Chip evacuation - general recommendations
4. Inspect the cutting edges. Chipping on

the edge can cause long chips because
the chip is divided.
6. A
djust feed and speed. See diagram on
page E 18.
G
Tool holding
5. C
heck if the machinability has changed
due to a new batch of workpiece
material. Cutting data may need to be
adjusted.
Boring
heck if the cutting fluid flow and pres3. C

sure can be increased.
Drilling
2. Inspect chip form (compare with picture

on page E 26).
E 45
Machinability
Other information
Troubleshooting
Turning
Peck drilling solid carbide / brazed drills
Parting and
grooving
Peck drilling can be used if no other solution can be

found.
There are two different ways to perform a peck drilling
cycle:

1 2 3 4 5 6 7 8
Do not retract the drill more than

approx. .012 inch (0.3 mm) from the
hole bottom. Alternatively, make a
periodical stop, while the drill is still
rotating, before continuing to drill.
C
Threading
- Method 1 for best productivity

1 2 3 4 5 6 7 8
- Method 2 for best chip evacuation
Milling
After each drilling cycle, retract the

drill out from the hole to ensure that
no chips are stuck onto the drill.
Drilling
Tool wear solid carbide / brazed drills
1. C
utting speed too low and edge
temperature too high.
2. Negative land too large.
3. No coating.
4. Percentage of oil in the cutting
fluid too low.
1. Increase cutting speed or use

external cutting fluid.
2. Sharper cutting edge.
3. Coating on the edge.
4. Increase the percentage of oil in
the cutting fluid.
Boring
Chipping on the edge corner
Tool holding
1. Unstable fixturing.
2. TIR too large.
3. Intermittent cutting.
4. Insufficient cutting fluid (thermal
cracking).
5. Unstable tool holding.
H
Machinability
Other information
Solution
Built-up edge
Cause
1.
2.
3.
4.
5.
heck fixture.
C
Check radial runout.
Decrease the feed.
Check cutting fluid supply.
Check the tool holder.
E 46
Troubleshooting
Solution
1.
2.
3.
4.
Large wear on the cutting edge

1. Cutting speed too high.
2. Feed too low.
3. Grade too soft.
4. Lack of cutting fluid.
ecrease the cutting speed.

D
Increase the feed.
Change to harder grade.
Check for proper cutting fluid
supply.
Chipping on the cutting edge
1. C
heck the setup.
2. Replace drill sooner.
3. Change to softer grade.
Threading
1. Unstable conditions.
2. Maximum allowed wear
exceeded.
3. Grade too hard.
Wear on the circular lands

1. C
heck the radial runout.
2. Use neat oil or stronger
emulsion.
3. Decrease cutting speed.
4. Change to harder grade.
Milling
1. TIR too large.

2. Cutting fluid too weak.
3.Cutting speed too high.
4. Abrasive material.
Parting and
grooving
Cause
Turning
E
Wear on the chisel edge
1. Increase cutting speed.
2. Decrease feed.
3. Check dimensions.
Drilling
1. Cutting speed too low.

2. Feed too high.
3. Chisel edge too small.
Thermal cracks (notches)

1. Inconsistent cutting fluid
G
Tool holding
1. D
ecrease the cutting speed
and/or feed.
2. Increase cutting fluid pressure.
3. Use a harder grade.
1. Check cutting fluid supply

2. Fill cutting fluid tank
E 47
Machinability
Other information
1. C
utting speed and/or feed too
high.
2. Not enough cutting fluid supply.
3. Unsuitable drill/grade.
Boring
Wear due to plastic deformation
F2
Boring
Boring operations involving rotating tools are applied to
machine holes that have been made through methods
such as pre-machining, casting, forging, extrusion,
flame-cutting, etc.
Theory
F4
Selection procedure
F9
System overview
F 14
How to apply
F 21
Troubleshooting
F 25
F3
Turning
Parting and
grooving
Boring theory
The boring process
T ypically, boring operations are performed in machining centers and
horizontal boring machines.
T he rotating tool is fed axially through
the hole.
M
ost holes are through-holes, often in
prismatic components such as housings
and casings.
Threading
Theory
Three different basic boring methods

Boring with a
stationary tool
Milling
Boring with a
rotating tool
Milling, helical
interpolation
Drilling
Boring
Tool holding
F or unsymmetrical components machined in a

machining center.
P
rofiling can be carried
out with standard boring
bars.
F lexible tool solutions

with adjustable diameters.
ery flexible tool soluV

tions with interchangeable cutting heads.
V
ery productive in roughing operations.
G
ood solution when chip
breaking is a problem.
H
igh quality hole tolerance and surface (for
finishing).
H
igh quality demands of
the machine (for finishing).
H
Machinability
Other information
V
ery flexible solution
where one milling cutter
can be used for different
diameters.
T o be used only for symmetrical components in a

turning lathe.
F4
S
aves space in the tool
magazine.
Theory
Turning
Definitions of cutting data terms

ap = radial depth of cut (inch) (mm)
Parting and
grooving

fn = feed per revolution (inch/r) (mm/r)
Dc = boring diameter (inch) (mm)
vf = penetration rate (inch/min) (mm/min)

fz = feed per tooth (inch/rev) (mm/rev)
Dc n
12
(ft/min)
Milling
vc =
Metric
1000
E
(m/min)
Drilling
vc =
Dc n
Feed
vf = fn n (inch/min) (mm/min)
Boring
The axial tool movement is called feed rate

(fn) and is measured in inch/revolution
(mm/rev). The feed rate is obtained by multiplying the feed per tooth, inch/rev (mm/
rev), by the number of effective teeth (zc).
The feed rate is the key value in determining
the quality of the surface being machined
and for ensuring that the chip formation is
within the scope of the insert geometry.
fn = zc fz (inch/r) (mm/r)
Penetration rate
Cutting depth
The penetration rate (vf) is the speed of

the axial movement and is strongly related
to productivity.
The cutting depth (ap) is the difference

between the uncut and the cut hole radius.
F5
Tool holding
The boring tool rotates at a certain number

of revolutions (n) per minute generating a
certain diameter (Dc). This gives a specific
cutting speed (vc) measured in ft/min
(m/min) at the cutting edge.
Inch
H
Machinability
Other information
Cutting speed
Threading
zc = effective number of teeth that machine the final surface
Theory
Turning
Calculating power consumption and torque

B
Parting and
grooving

Pc Hp (Nm)
Dc = boring diameter (inch) (mm)
C
Threading
fn = feed per revolution (inch/r)

(mm/r)
kc = specific cutting force (lbs/inch2)
(N/mm2)
Mc lbf ft (Nm)
Pc = power consumption (Hp) (kW)

Mc = torque (lbf ft) (Nm)
Milling
Drilling
Boring
Tool holding
Machinability
Other information
Torque
The torque (Mc) is the torque value produced by the boring tool during cutting
action, which the machine must be able to
provide.
Net power
The net power (Pc) is the power the
machine must be able to provide to the
cutting edges in order to drive the cutting
action. The mechanical and electrical
efficiency of the machine must be taken
into consideration when selecting cutting
data.
Specific cutting force

Cutting force/area for a given chip thickness in tangential direction.
The kc value indicates the machinability
of a certain material and is expressed
in lbs/inch2 (N/mm2).
F6
Inch
Mc =
Pc 16501
(lbf ft)
Metric
Mc =
Pc =
Pc 30 103
ap fn kc vc
60 103
(Nm)
( )
1
ap
Dc
(Hp)
(kW)
Theory
Turning
Tools for roughing and finishing
R
ough boring operations are performed to open up the
existing hole to prepare for fine boring.
B
Parting and
grooving
Rough boring tool with multiple edges
Single-edge fine boring tool

F ine boring operations are performed to make the hole
within final hole tolerance, position and surface finish
limits.
Milling
T he diameter of a fine boring tool can be adjusted

within microns.
Threading
.9843 in
(25 mm) H7
Drilling
.9843 in (25 mm)

.9851 in (25.021 mm)
Hole tolerance of boring and reaming tools

Single-edge fine
boring tool
Multi-edge
reamer for high
feed finishing
Boring
Rough boring
tool with multiple edges
G
Tool holding
IT6
IT7
IT8
IT9
F7
Machinability
Other information
Theory
Turning
Hole making methods

Single-edge boring
Usually applied for finishing operations and for roughing
in materials where chip control is demanding, or when
machine tool power is limited.
Parting and
grooving
Threading
C
Multi-edge boring
Involves two or three cutting edges and is employed for
roughing operations where metal removal rate is the first
priority.
Milling
Step boring
Performed in roughing by a boring tool having the inserts
set at different axial heights and diameters. Employed
where large stock removal is required or to get improved
chip control. Good choice for off-center holes.
Drilling
Boring
Reaming
A light finishing operation performed with a multi-edge
reamer at high feeds.
Tool holding
Machinability
Other information
F8
Tool selection
Turning

Component
Workpiece
material, shape
and quantity
Parting and
grooving
.9843 in
(25 mm) H7
.9843 in (25 mm)

.9851 in (25.021 mm)
Threading
Hole dimension
and quality
Machine
Machine
parameters
Milling
Choice of tool
Drilling
Type of tool
How to apply
Cutting data,
coolant, etc.
Boring
Troubleshooting
Remedies and
solutions
Machinability
Other information
Tool holding
Tool selection
Turning

Component
Parting and
grooving
Identify the type of operation and note

characteristics regarding the hole to
be machined, limitations, material and
machine.
C
lamping, clamping forces and cutting
forces. Is the component sensitive to
vibrations?
C
Threading
S
elect the tool that covers the boring
diameter range and depth for the
operation, surface finish and tolerance.
Milling
Material
Drilling
achinability
M
Chip breaking
Hardness
Alloy elements
pindle interface
S
Machine stability
The spindle speed
Coolant supply
Clamping of the workpiece
Horizontal or vertical spindle
Power and torque
Tool magazine
Boring
Tool holding
Machinability
Other information
F 10
Tool selection
Turning
3. Choice of tools
Finishing
Roughing
Parting and
grooving
C
Single-edge
boring
Single-edge
boring
Reaming
Threading
Step boring
Multi-edge boring
Step-boring
Single-edge boring
High metal removal rate.
F or rough boring with

large stock removal.
For general fine boring.
Productive boring.
Improved chip control.
Single-edge boring
Tolerance capability IT6.
Reaming
V
ery good surface finish
at high penetration rates.
L ess machine-power
demanding.
Milling
Multi-edge
boring
Drilling
uitable for mass

S
production.
Boring
Special boring operations
Engineered tools
Tool holding
Many operations in one tool.

T he operations can be completed during one
feed motion.
F 11
Machinability
Other information
Tool selection
Turning
4. How to apply
Tool holding
B
Parting and
grooving
lways use the strongest coupling and

A
aim for the shortest tool overhang.
F or best stability and hole quality use
Coromant Capto, dampened tools and
tapered shanks.
C
Threading
Tool considerations
onsider lead (entering) angle, insert
C
geometry and grade.
Chip evacuation and cutting fluid
Milling
hip formation and evacuation are imC

portant factors in boring and affect hole
quality and hole tolerance.
Cutting data
Cutting speed,
vc ft/min (m/min)
orrect cutting speed and feed rate is

C
essential for high productivity, tool life
and hole quality.
Drilling
Boring
Feed, inch/r
(mm/r)
Tool holding
Machinability
Other information
F 12
Tool selection
Turning
5. Troubleshooting
C
heck the chip breaking and cutting fluid
supply.
.9843 in
(25 mm) H7
heck clamping of boring tool/workC

piece, feed rate, machine conditions and
chip evacuation.
C
Threading
Chip evacuation
Parting and
grooving
C
orrect geometry, grade and cutting data
is essential in boring operations.

Drilling
orrect cutting speed, feed rate and

C
cutting depth is essential for high productivity, tool life and to avoid vibrations.
Boring
Tool holding
F 13
Machinability
Other information
.9843 in (25 mm)

.9851 in (25.021 mm)
Milling
Cutting data
Turning
Parting and
grooving
System overview
System overview
Rough boring tools
Rough boring operations are performed to open up an
existing hole to prepare for finishing.
Heavy duty tool with two
inserts
Tool with two inserts
Tool with one insert
Threading
Tool with three inserts
Milling
Tool with dampened adapter
Fine boring tools
Drilling
Fine boring operations are performed to finalize hole within

tolerance and surface finish limits.
Single-edge tool with

dampened adapter
Single-edge tool with

modular adapter
Single-edge tools
Boring
Multi-edge reamer
G
Tool holding
Fine boring head for

fine boring bars
Machinability
Other information
F 14
Turning
System overview
Rough boring tool with three inserts

Diameter range 1.378 - 12.047 inch (35 - 306 mm)
Parting and
grooving
Rough boring tool with two inserts

Diameter range .984 - 10.630 inch (25 - 270 mm)
C
Diameter range 5.906 - 21.654 inch (150 - 550 mm)
Milling
Diameter
inch 0 1.969 3.937 5.906 7.874 9.843 11.811 13.780 15.748 17.717 19.685 21.654
mm
0 50 100 150 200 250 300 350 400 450 500 550
Threading
Heavy duty rough boring tool with two inserts
Multi-edge reamer
Diameter range .394 - 1.250 inch (10 - 31.75 mm)
Drilling
Fine boring head

Diameter range .118 - 1.654 inch (3 - 42 mm)
F
Single-edge boring tool with integrated adapter
Boring
Diameter range .906 - 6.953 (23 - 176.6 mm)
G
Diameter range 5.906 - 38.646 inch (150 - 981.6 mm)
Diameter
Tool holding
Single-edge boring tool with modular adapter
F 15
Machinability
Other information
inch 0 .984 1.969 5.906 7.874 9.843 11.811 19.685 21.654 23.622 35.433 39.370
mm
0 25 50 150 200 250 300 500 550 600 900 1000
Turning
Choice of tool
Choice of tools
Roughing
Multi-edge boring
B
Parting and
grooving
H
igh metal removal rate.
Productive boring.
Single-edge boring
Less machine-power demanding.
C
Threading
Step-boring
F or rough boring with large stock
removal.
Milling
Finishing
Single-edge boring
F or general fine boring.

Tolerance capability IT6.
Drilling
Reaming
V
ery good surface finish at high penetration rates.
Suitable for mass production.
Boring
Special boring operations
Tool holding
Engineered tools
M
any operations in one tool.
The operations can be completed during
one feed motion.
Machinability
Other information
F 16
Choice of tool
Rough boring tool with three inserts
B
Parting and
grooving
First choice recommendation for medium and high power

machines is a rough boring tool with three cutting edges
for optimized productivity.
Turning
Rough boring tools
Rough boring tool with two inserts

A rough boring tool with two cutting edges is first choice
for low to medium power machines, unstable operations
or large diameters.
Threading
Milling
Dampened rough boring tool for long overhangs

Choose dampened rough boring tools for overhangs
longer than 4 times the coupling diameter.
Drilling
Boring tool setup
Single-edge boring
Multi-edge boring
Boring
All rough boring tools can be set up in three different

ways.
Step boring
Tool holding
F 17
Machinability
Other information
All rough boring tools can be ordered and assembled, adapted to

the chosen type of rough boring method.
Choice of tool
Turning
Slides for rough boring tools

Slides with negative inserts
F or stable conditions, choose negative
shape inserts for better insert economy.
B
Parting and
grooving
se negative inserts in tough applicaU

tions that require strong inserts and
improved process security.
Slides with positive inserts

In rough boring, it is an advantage to use
positive basic-shape inserts as they give
lower cutting forces compared to negative inserts.
Threading
Milling
Lead (entering) angle and insert shape
Drilling
A small nose angle and small nose

radius also contribute to keeping the
cutting forces down.
The lead (entering) angle of boring tools affects the direction and magnitude of axial and radial forces. A small
lead (large entering) angle produces a large axial force,
while a large lead (small entering) angle results in a large
radial cutting force.
Positive inserts
Negative inserts
Boring
- For interrupted cuts, sand

15/6
(75/84) inclusions, stack boring etc.
Through holes only.
6
(84)
G
Tool holding
0
(90)
- F irst choice for general

operations, step boring and for
shoulder operations.
0
(90)
0
(90)
5
(95)
H
Machinability
Other information
6
(84)
15
(75)
-5
(95)
F 18
- F or high feeds or improved

surface finish with Wiper
inserts in stable conditions.
-5
(95)
Choice of tool
Turning
Fine boring tools

Single-edge fine boring tool
B
Parting and
grooving
A single-edge fine boring tool is the first choice for fine

boring operations.
For small diameters a fine boring head with fine boring

bars is required.
Threading
Fine boring head with fine boring bars
Milling
Silent Tools for long overhangs
Drilling
Silent Tools (dampened) are the first choice for overhangs

longer than 4 times the coupling diameter.
G
Tool holding
Multi-edge reamers are suitable for high feeds in mass

production.
Boring
Multi-edge reamer
F 19
Machinability
Other information
Choice of tool
Turning
Cartridges for fine boring tools

General recommendations
In fine boring, positive basic-shape inserts are used, as they give lower cutting
forces compared to negative inserts.
Parting and
grooving
Positive inserts
7 clearance angle
P
ositive basic-shape inserts with 7
clearance angle are the first choice
L ight-cutting insert geometries, thin
coatings and a small nose radius
(maximum .016 inch (0.4 mm)) also contribute to keep the cutting forces down.
Threading
Positive inserts
11 clearance angle
Milling
Adapters
Choose the shortest possible adapter length.
Choose the largest possible diameter/size of adapter.
If possible, use a tapered adapter to increase the static

stiffness and to reduce the deflection.
F or long overhangs, ensure rigid clamping with flange

contact to spindle if possible.
Boring
Drilling
F or long overhangs (larger than 4 x coupling diameter)

use dampened adapters.
Tool holding
Machinability
Other information
F 20
How to apply
Adjustable fine boring mechanism
B
Single-edge fine boring tools have adjustment possibilities to accurately pre-set the
cutting edge within microns.
Parting and
grooving
Fine boring tools
Turning
How to apply
Threading
B
oring tools for finishing, with one cutting edge, will experience some degree
of radial deflection during machining due
to the cutting forces.
T he depth of cut and length of overhang

influence the radial deflection of the
boring tool.
Milling
Tool deflection
A
measuring cut is normally needed,
followed by a final adjustment of the tool.
Drilling
T he deflection might cause undersized

holes or vibrations.
Boring
Tool holding
F 21
Machinability
Other information
How to apply
Turning
Boring tools general

Chip evacuation, cooling and lubrication between the
tool and the workpiece material are primary functions
of cutting fluid.
Parting and
grooving
Cutting fluid supply
A
pply cutting fluid for optimized chip
evacuation, cooling and lubrication.
Affects hole quality and tool life.
C
Threading
Internal cutting fluid is recommended in

order to direct the fluid to the cutting
zone.
Milling
Chip control and chip evacuation
Drilling
Chip formation and chip evacuation are critical issues in

boring operations, especially in blind holes.
Ideally, chips should be in the form of defined commas
or spirals.
Cutting depth,
ap inch (mm)
Factors that have an influence on chip

breaking are:
- the insert micro and macro geometry
- nose radius
- lead (entering) angle
- cutting depth
- feed
- cutting speed
- material.
Boring
G
Tool holding
Feed, inch/r (mm/r)
Machinability
Other information
F 22
How to apply
Turning
Cutting data recommendations

The cutting data for the insert geometry and grade
chosen can generally be followed with the following
exceptions:
B
Parting and
grooving
- Rough boring
Max start value vc = 656 ft/min (200 m/min).
- Fine boring with fine boring adapters:
Max start value vc = 787 ft/min (240 m/min).
- Fine boring with fine boring bars:
Max start value vc = 295 394 ft/min
(90 120 m/min).
- Fine boring:
Max ap = .020 inch (0.5 mm).
If the cutting depth is too small, the insert will tend to
ride on the pre-machined surface, only scratching and
rubbing it, leading to poor results.
When rough boring, make sure the machine can provide

sufficient power and torque.
Boring
Important parameters are:

- feed
- number of inserts
- diameter
- depth of cut.
Drilling
Power and torque consumption
Tool holding
F 23
Machinability
Other information
M
Mcc lbf-ft (Nm)
Milling
Cutting speed is mainly limited by:

- vibration tendencies
- chip evacuation
- long overhangs.
Threading
How to apply
Turning
Tool maintenance and use of torque wrench

A
lways use a torque wrench and apply the recommended torque on screws for insert and tool assembly.
Check inserts and insert seats regularly.
Parting and
grooving
Replace worn or exhausted screws and washers.

Clean all assembly items before assembly.
L ubricate all assembly items with oil at least
once a year.
C
Threading
L ubricate the fine adjustment mechanism for fine boring

regularly.
Milling
How to apply reaming tools

T he reamer should not be expected to correct any
positional or straightness errors in the pre-machined
hole.
Drilling
T he straightness of the pre-machined hole should be

less than .0020 inch (0.05 mm).
A small runout is very important for reaming operations.

Boring
Maximum recommended runout is 5 microns.

M
ake sure the reamer is concentric with the pre-machined hole.
Choose the shortest possible tool holder and shank.
Tool holding
E
mulsion as cutting fluid generates better tool life
than oil.
Use recommended cutting data.
Machinability
Other information
F 24
Troubleshooting
Turning
Troubleshooting
Factors that affect vibration tendencies

Vibration tendencies grow towards the right.
Parting and
grooving
Threading
D
.008 (0.2)
.016 (0.4)
.031-.047 (0.8-1.2)
Milling
inch (mm)
Drilling
Apply step boring.

Choose a 2-edge rough boring tool.
C
hoose a light-cutting geometry and
grade.
Use a smaller nose radius.
C
heck that all units in the tool assembly
are assembled correctly with the correct
torque.
Reduce feed or increase feed.

Use the largest tool diameter possible.
Use the shortest tool overhang possible.
Boring
Decrease cutting speed.
G
Tool holding
Check workpiece clamping.

C
heck machine spindle, wear, clamping,
etc.
Increase depth of cut (finishing).
Use dampened tools if long overhang.

F 25
Machinability
Other information
Decrease depth of cut (roughing).
Troubleshooting
Turning
Insert wear
Insert wear patterns and remedies in boring are generally
very similar to turning.
Parting and
grooving
Chip breaking
Cause
Too short, hard
Solution
Increase cutting speed
Decrease feed
Threading
C
hange geometry to a more
open chip breaker
Too long
Increase feed
Decrease cutting speed
Milling
C
hange geometry to a more
closed chip breaker
Surface
Drilling
Tool vibration
Boring
Too high feed
Decrease feed
Too high speed
Decrease speed
Too large cutting depth
Apply step boring
Too high cutting forces
Decrease depth of cut

Use positive inserts
Use smaller nose radius
Tool holding
G
Feed marks
C
hoose knife edge wiper
insert
Use larger nose radius
Machinability
Other information
Too high feed
Decrease feed
F 26
Troubleshooting
Turning
Solution
Wrong cutting data
C
hange cutting edge and
investigate reason for wear
pattern cutting data, insert
geometry and insert grade.
Chips scratching surface

Bad chip breaking
B
Parting and
grooving
Insert wear
Change cutting data

Change insert geometry
Threading
Cause
Increase speed
Use coolant
Drilling
Use a cermet grade
Machine power limitation

Decrease cutting data
Boring
Apply step boring
G
Tool holding
Limited machine power
F 27
Machinability
Other information
Bad surface finish
Milling
Surface finish
Tool holding
The clamping of a cutting tool can influence the productivity and performance of the cutting tool dramatically.
Therefore it is important to choose the right holding tools.
This chapter will simplify the decision process and give
guidelines how to apply and maintain the holding products.
G4
Why modular tooling
G7
Turning centers
G 15
Machining centers
G 23
Multi-task machines
G 29
Chucks
G 33
G3
Turning
Parting and
grooving
Tool holding systems

T he tool holding interface with the
machine plays a very important part in
the cutting process.
S
tability, time for tool changing, accuracy,
flexibility, modularity, handling and storing is of vital importance for successful
machining.
C
ompared to conventional shank tools,
a quick change system can increase the
effective cutting time by 25% in turning
centers.
Threading
Milling
Tool holding systems today

T ooling has evolved through the necessity to produce new types of machine
manufacturing standards.
Drilling
These tools have generally followed the

spindle interface design of MTMs, without any standardization controls.
Boring
There are over 35 types of spindle

interface on machines today, with as
many tooling options to support, hence
exchangeability and assortment availability decreases dramatically.
Tool holding
Machinability
Other information
G4
Turning
History of machine tapers
T he taper was the basis of most

machine tool spindles, due to the long
taper, giving secure contact and stability.
C
Threading
It is still popular today, in various sizes,

using taper 7/24, but it is not a modular
tooling solution.
B
Parting and
grooving
T his style of taper was introduced 40

years ago.
Milling
Quick change systems
U
nfortunately, these systems are not
interchangeable with each other, and are
very limited in their flexibility between
machining centers and CNC lathes.
Boring
M
ost of these systems are not suitable
for multi-task machining operations.
Drilling
T here is an ever increasing supply of

quick change and modular tooling systems on the market today.
Tool holding
G5
Machinability
Other information
Turning
Coromant Capto
A multi-purpose, quick-change modular tooling system
Parting and
grooving
Threading
Capto is Latin and means to grab.
Milling
The history of the Coromant Capto system

Machining center / Rotating tools
Drilling
Solid holders
Boring
Varilock
1980
Coromant Capto/
Basic holders
1990
Turning center / Turning tools
Standard
G
Tool holding
ISO 26623
Shank holders
Machinability
Other information
G6
Block Tool
System
Coromant Capto/
Clamping units
Why modular tooling
Turning
A dramatic development of the machines

Machining centers
Parting and
grooving
Threading
Turning centers
Milling
Multi-task machines
Trends
Machines and machining methods

Drilling
ulti-task machines requiring one holder system for

M
both spindle and turrets.
everal turrets on multi-task machines and turning
S
centers.
More multi-function tools for multi-task machines.
owerful interfaces in the machine control system for

P
higher degrees of automation.
Boring
-D models of tools and holders to virtually check the

3
machine process.
Integration of various manufacturing technologies into

fewer machine types.
Tool holding
Driven tools in turning centers.
High pressure coolant.
G7
Machinability
Other information
Why modular tooling
Turning
When to use quick change tooling

M
achine requires frequent setup
changes.
B
Parting and
grooving
M
easuring cuts are necessary to get
correct size.
M
achining is performed with high cutting
data and relatively short tool life.
O
ne operator services more than one
machine.
Threading
Milling
Reduce downtime in your turning centers
E
Only 36% of the machine time is used for metal cutting
Drilling
-S
ervice and maintenance
- Insert change and tool
change
Boring
-M
easuring of the tool
and workpiece
25%
Tool holding
G
Conventional shank
tools
Coromant Capto
quick- change system
- Effective cutting time
Quick change tooling offers a productivity increase of 25%
H
Machinability
Other information
- Change of workpiece
G8
Why modular tooling
Turning
A true modular tooling system

One system! One solution! For the entire workshop
Coromant Capto is a flexible tooling system, suitable
for all types of machining. This makes it possible to
standardize on one system in your entire workshop.
Parting and
grooving
Vertical lathes
Threading
Turning centers
Milling
Drilling
Boring
Multi-task machines
Tool holding
G9
Machinability
Other information
Machining centers
Why modular tooling
Turning
Minimize tool holder inventory
Parting and
grooving
Threading
By combining basic holders, adapters and (when needed)

extensions or reductions, many different assemblies for
different machines can be built.
The below examples represent a customer that has four
different spindles resulting in:
- taper 40, taper 50, HSK 63 and HSK 100,
- two extensions
- 30 different adapters for milling, drilling, tapping, etc.
- 10 different boring tools.
ISO 40
ISO 50
HSK 100
HSK 63
Milling
Solid
Modular
Drilling
Boring
F
Number of items with modular tools:
4 + 2 + 30 + 10 = 46 items
Number of items with solid tools:

4 x 3 x (30 + 10) = 480 items
Tool holding
Modular tools give access to a very

large number of tooling solutions,
with very few items!
Machinability
Other information
G 10
Why modular tooling
- T he ground flange contact

face in relation to the
ground taper polygon
gives maximum stability
due to two-face contact
and interference fit.
- T here are four gripper
grooves for the automatic
tool changer.
Milling
Flange contact
-C
oolant supply through
center
-C
oolant channel in the
coupling.
Drilling
Coolant through center
There are two options for

coolant supply:
Boring
Coolant channel in
coupling
G
Tool holding
Slot for angular

positioning
- T here is one slot for

angular positioning of the
cutting tool.
B
Parting and
grooving
The unique Coromant

Capto coupling has some
very specific features:
Threading
Gripper groove
G 11
Machinability
Other information
Taper polygon
Turning
The Coromant Capto coupling
Why modular tooling
1. The radial centering is taken care of by

the conical part of the polygon.
Parting and
grooving
The main feature of the coupling is the positive 3-way locking
2. T he low taper angle makes it possible

to transmit the full force into the flange
contact. The strength of the polygon
coupling makes it possible to clamp
with higher force than other systems.
This is very important for the bending
stiffness.
Threading
3. A
polygon shape is self centering and
takes care of the orientation without
the need for a driving slot, therefore
there is no play in the coupling.
The polygon shape is also unique due
to its capability to transmit high torque
due to three contact areas.
Milling
Due to the above features - radial and

axial contact and self centering ability - the
coupling has extremely good repeatability,
within .00008 inch (2 microns).
1.4
Turning
Coupling features and benefits
Drilling
3
2
3
3-way locking
Boring
Tool holding
Machinability
Other information
H
C3 C10
G 12
Why modular tooling
Turning
Six different coupling sizes

C3 = D 1.260 inch (32 mm)
C4 = D 1.575 inch (40 mm)
C5 = D 1.969 inch (50 mm)
Parting and
grooving
C6 = D 2.480 inch (63 mm)

C8 = D 3.150 inch (80 mm)
C10 = D 3.937 inch (100 mm)
Threading
Three different methods of clamping

One coupling offers 3 methods of clamping.
Center bolt clamping
Front clamping
Milling
Segment clamping
Clamping method for quickchange and automatic tool

changing.
For modular clamping solutions, e.g., when using extensions and basic holders.
Machine interface for quick

change in machines.
Drilling
Boring
Excellent repetitive accuracy and guaranteed

center height
B
C
F ew or no measuring cuts needed if

pre-measuring is used (first component
right).
G 13
G
Tool holding
H
Machinability
Other information
T he repeatable accuracy is .00008 inch

(2 microns [m]) of the center height,
length and the radial measurement
(A),(B),(C).
Why modular tooling
Turning
Transmission of torque
The polygon shape transmits torque without any loose parts such as pins or keys.
No pins, keys, etc.
Parting and
grooving
No play in the coupling.

Symmetrical loads.
Two face contact/high clamping force.
Threading
Milling
In internal machining the Coromant Capto coupling is an

outstanding solution to clamp the boring bar, with a firm
secure grip around the entire polygon.
Drilling
Less vibration with stable coupling
Boring
G
Tool holding
The boring bar is very often clamped with

2-3 screws. This causes problems with
vibration, bad surface finish, inserts worn
out quickly and production disturbances,
with downtime spent on adjusting cutting
data and measuring the component.
Machinability
Other information
G 14
Turning centers
Turning
Quick change tooling for turning centers
Machining centers
Parting and
grooving
Threading
Turning centers
Milling
Multi-task machines
What is a turning center?
Boring
T he cutting tool moves parallel and

perpendicular to the workpiece axis to
provide the desired finished shape.
hen a cutting tool is applied to

W
the workpiece, it can be shaped to
produce a component which has
rotational symmetry.
Drilling
T he principle of lathes and turning centers is to cut a rotating component with a

stationary cutting tool.
The turning center has a choice of configurations
G
Tool holding
Horizontal and vertical design.

Sub-spindle for two-sided machining.
Driven tools.
Y-axis for eccentric boring and milling.
G 15
Machinability
Other information
Turning centers
Turning
Configuration of a turning center

Spindle rotation and definitions of axis
B
Parting and
grooving
S
everal multi-axis machine tool programs can provide turning results from
roughing and grooving to threading and
finishing.
Threading
Milling
Quick change tooling for turning centers

A quick-change system offers:
- faster and efficient tool changing
Drilling
- inserts which can be changed outside the

machine
- pre-setting possibilities.
The most economical system for:
Boring
-s
mall batch production, quicker setup
times
- operations with frequent insert changes.
G
Tool holding
Less than 180 for clamp and unclamp
Machinability
Other information
G 16
Turning centers
Square shank
Camshaft activated
Automatic unit
Hydraulically operated
B
Parting and
grooving
VDI angled
Camshaft activated
Turning
Typical clamping units for turning centers
VDI straight
Camshaft activated
Round shank
Segment clamping
Special applications
Segment clamping
Threading
Milling
Drilling
Methods of installing quick change
G
Tool holding
Coromant Capto directly integrated in

turrets is the best solution to get maximum performance out of the Coromant
Capto coupling.
Boring
Directly integrated into the turret
G 17
Machinability
Other information
Turning centers
Turning
Conversion of a turret by using standard clamping units

Turning lathes can easily be converted to
Coromant Capto quick-change tools using
standard clamping units. No modification
to the turret, and no special adapters
required.
Parting and
grooving
Threading
Milling
Drilling
Boring
Tool holding
Machinability
Other information
G 18
Turning centers
Turning
Machine adapted clamping units

Coromant Disc Interface (CDI)
Same interface for static and driven tool

holders. Static and driven tool holders can be
used in all positions.
Higher cutting performance.
Parting and
grooving
F lexible and symmetrical interface, 180

mountable.
Longer cutting tool life.
M
ore available tool length for radial drilling
operations.
Increased production.
Threading
Better workpiece quality.
Rationalized tooling.
Milling
Reduction in tooling costs.
Driven drill/milling unit,

straight
Drilling
Static clamping unit,

straight
Driven drill/milling unit,

right angle
Tool holding
G 19
Machinability
Other information
Static clamping unit,

right angle
Boring
Turning centers
Turning
A quick change system

Insert change by using sister tools
Less downtime.
B
Parting and
grooving
F ew or no measuring cuts. Improved

profitability.
N
o risk of losing insert screws in the
chip conveyer.
1.
2.
Ergonomic.
E
asy to clean the tip seat outside the
machine.
Threading
0.5 min
1.5 min
Milling
Drilling
Boring
Changing to a sister tool with a quick

change system is faster than changing
the insert inside the machine.
Tool holding
Machinability
Other information
G 20
Turning centers
Turning
Different ways how to install quick change
A Hydraulically operated clamping units

Manual push-button tool changing
F ully automatic tool changing
possibilities.
B
Parting and
grooving
Tooling alternatives in conventional turrets
B Shank type clamping units

quare and round shank tools as
S
well as cutting units for external and
internal operations.
Threading
A
ngled and straight clamping units for
external and internal operations.
Milling
C Clamping units for VDI turrets
Drilling
Boring
Tool holding
Example of installations.
G 21
Machinability
Other information
Turning centers
Turning
Coromant Capto driven tool holders
Parting and
grooving
Driven tool holders provide the key to dramatic improvements in machining economy by allowing milling, turning
and drilling operations to be carried out in a single setup.
V
arious licensed manufacturers of these
units are available.
C
Threading
S
pindle dimensions
- Machine type and model
- Maximum turret swing diameter
- Maximum tool length.
Milling
Drilling
Boring
Tool holding
Machinability
Other information
H
Example of installations.
G 22
Machining centers
Turning
Modular tooling for machining centers
B
Parting and
grooving
Machining centers
Threading
Milling
Turning centers
Multi-task machines
A
machining center is a multi-function
machine that typically combines boring,
drilling and milling tasks.
5
-axis machining centers add two more
axes in addition to the three normal
axes (X/Y/Z).
Drilling
What is a machining center?

F
Boring
Machining centers could be in horizontal

design as well as vertical design.
Tool holding
G 23
Machinability
Other information
Machining centers
Turning

Configuration of a vertical machining center
Parting and
grooving
Threading
Configuration of a horizontal machining center
Milling
Drilling
What is a basic holder?

A basic holder is an adapter
which connects the modular tools
to the machine interface.
Boring
Basic holders with front clamp

solution offer quick change in machines that do not have automatic
tool changing.
Tool holding
Front clamping
Machinability
Other information
G 24
Center bolt clamping
Machining centers
Turning
Commonly used tool holding range

Milling machines, machining centers, multi-task machines
Basic holders
Cat V-Flange
DIN 69871
Form B
40
50
ISO 7388/1 DIN 96871

Form B
ISO 30
ISO 40
ISO 40
ISO 50
ISO 50
ISO 60
ISO 7388/1
BIG-PLUS
ISO 40
ISO 50
MAS BT
ISO 30
ISO 40
ISO 50
MAS BT
Form B
ISO 40
ISO 50
MAS BT
BIG-PLUS
ISO 40
ISO 50
HSK
50-A/C
63-A/C
100-A/C
125-A/C
80-F
Parting and
grooving
DIN 2080
ISO 40
ISO 50
C
Threading
Cat V-Flange Cat V-Flange

BIG-PLUS/
40
90 rotated
45
50
40
60
50
Milling
Chucks and adapters
Drilling
Modular tooling for machining centers
- one single system in the machine
-m
aximum power of the machine can be
utilized thanks to the rigidity of the coupling
-e
asier handling as modular tools are relatively small in size and weight.
Tool holding
A modular tooling system integrated into

machining centers gives many advantages:
Boring
G 25
Machinability
Other information
Machining centers
Turning
Spindle integration in machining centers

Integration of the female coupling in the spindles
An integrated clamping mechanism could
be used in most of the machines on the
market today and gives many advantages:
Parting and
grooving
- standardization in the workshop

- better torque transmission and stability
- shorter tools due to integration tools
Threading
- more space in the machine

- no need for basic holders.
Milling
Drilling
Directly integrated in the spindle or via basic holder
Boring
G
Tool holding
Integrated in the spindle
Machinability
Other information
G 26
Basic holder solution
Machining centers
Turning
Right combination for best possible rigidity

Extension adapters
It is important that the minimum length

is used, particularly when long overhangs
are required.
W
ith modular tools it is always possible
to use optimal cutting data for best
productivity!
Threading
Parting and
grooving
Extended tools for machining centers are frequently

required to be able to reach the surface to be machined.
With Coromant Capto modular system it is possible to
build an assembly, so the right length can be achieved.
odular tools are built together

M
in minutes!
Milling
Get closer tolerances.
Minimize tool holder inventory in machining centers
Solid
Boring
Modular
Drilling
Modular tools give access to a very large number of

tooling solutions, with very few items!
Tool holding
Number of items solid tools:

4 x 3 x (30 + 10) = 480 items.
G 27
Machinability
Other information
Number of items with modular tools:

4 + 2 + 30 + 10 = 46 items.
Turning
Multi-task machines
Modular tooling for multi-task machines
B
Parting and
grooving
Machining centers
Threading
D
Turning centers
Milling
Multi-task machines
Drilling
What is a multi-task machine?
Boring
Tool holding
M
ulti-task machines come in a variety of
configurations:
- horizontal or vertical design
- two spindles (main and sub) and a
B-axis spindle enable milling and turning operations on both front and back
face of the workpiece
- each spindle acts as a workpiece
holder allowing multi-axis machining
on either front or back face of the
workpiece.
Machinability
Other information
G 28
In a multi-task machine, the workpiece

can be completed in a single machine
setup, e.g., turning, milling, contouring and milling of angled surfaces, and
grinding.
M
ulti-task machines are a combination
of a turning center and a machining
center.
Multi-task machines
Turning
Definitions of the spindle directions

The program language for defining the spindle direction
lockwise spindle
M03 = C
direction
C
Threading
ounterclockwise
M04 = C
spindle direction
Parting and
grooving
Milling
Configuration of a multi-task machine

Drilling
Boring
Tool holding
G 29
Machinability
Other information
Multi-task machines
Turning
Definitions of the spindle directions
Parting and
grooving
Therefore multi-task machine tools needed

a tooling system with unsurpassed rigidity
and repetitive accuracy both radially and
axially, like Coromant Capto.
Multi-task machine tools are often used in

done-in-one applications in which operations run from roughing to finishing in one
machine tool setup.
Threading
The milling spindle in a multi-task machine

tool should be able to carry both rotating
and non-rotating tools. Coromant Capto is
the only tooling system that can fulfill this
demand without compromise.
Milling
Drilling
The Coromant Capto tooling

system is directly integrated in
the spindle.
Boring
Tool holding
Machinability
Other information
Turret with Coromant Capto

tooling system
Multi-task machine tool with Coromant Capto integrated tool
spindle and lower turning turret with Coromant Capto clamping
units.
G 30
Multi-task machines
Turning
New multifunctional tools for multi-task machines

For taking advantage of versatile multi-task machine tools
and to optimize their efficiency, there is sometimes a
demand for running them with dedicated tooling. These
tools are only available with Coromant Capto and have been
invented for multi-task machine tools, offering:
Parting and
grooving
- accessibility, stability and higher productivity

- reduced tool changing time
- saved tool pocket in tool magazine
Threading
- cost reduction - one tool replaces many tools.
Milling
Twin tools
two turning tools in one
Boring
Tool holding
Mini-turrets
four turning tools in one
G 31
H
Machinability
Other information
Multifunctional tools
one milling and four turning tools in one
Drilling
Multi-task machines
Turning
Build your own mini-turret

Four cutting heads applied to one tool holder
B
Parting and
grooving
Radial
Pick and choose from a large number of

exchangeable cutting heads for turning,
threading, parting and grooving operations for building an optimized tool for the
component.
educe tool changing time
R
Save tool pockets in tool magazine
For both external and internal use
C
Threading
Axial
Milling
Tool adapters for shank tools

Turning tool adapters for
- shanks
- bars
- blades
- mini-turrets
to make it possible to use shank tools
also in a multi-task machine with an integrated modular tool system in the spindle.
Drilling
Use of shank tools in a multi-task machine
Boring
Tool holding
G
Tool adapter with blade for
parting off
Machinability
Other information
G 32
Tool adapter for boring bar
Chucks
Turning
Chucks
Chucks are mechanical, hydro-mechanical and hydraulic

chucks respectively, for holding end mills and drills.
Parting and
grooving
Choice of chucks and adapters

Hydromechanical
chuck
Shrink fit
adapter
Collet
chuck
Endmill
(Weldon)
adapter
Drill
adapter
C
Threading
Hydraulic
chuck
D
1
6
Milling
Rank
Clamping
area
+++
+++
< .787 in.

( <20 mm)
+++
+++
Runout
+++
Balance
Balanced
by rotational testing
+++
+++
+++
++
+++
+++
+++
+++
Balanced
by rotational testing
Balanced
by design
(C4-C5)
Balanced
by design
(C3-C5)
Balanced
by design
(C3-C5)
No
Tool holding
G 33
H
Machinability
Other information
< .787 in.

( <20 mm)
Boring
Clamping
force
Drilling
Chucks
Turning
Hydraulic chucks
igh clamping forces.

H
Large assortment of collets.
High accuracy, runout max .00024 inch (6 m) at 3xD.
Large assortment of tools.
For drilling, reaming and milling.
Fast tool changing time.
Can damage hydraulic membrane if not used properly.
Any shank type can be used, but recommended to use
solid round-shank cutting tools.
High speed capability
Parting and
grooving
Threading
Milling
Drilling
Clamping
part
Pressure
screw
Boring
Collet
Tool holding
Machinability
Other information
G 34
Piston
Chucks
Parting and
grooving
S
mall collapsibility.
High clamping forces for small diameters - low clamping
force for large diameters.
No collets.
Tools can be made slender - narrow.
High accuracy, low runout.
Expensive heating systems.
Long tool changing time.
Heavy investment in tools and machinery.
Low tool lifetime.
Can only clamp solid round-shank cutting tools.
Milling
Shrink fit adapters
h6 shank
Threading
igh clamping force.

H
Any shank type can be used.
High accuracy, runout max .00024 inch (6 m) at 3xD.
Medium tool changing time.
Minimum investment compared to shrink fit.
Better reliability than power chucks or shrink fit.
Any shank type can be used, but recommended to use
solid round-shank cutting tools.
Drilling
h6 shank
Turning
Hydro-mechanical chucks
Large collapsing range.

h
6 or h7 tolerance shanks can be used due to large
collapsibility.
Boring
Collet chuck adapter ER type

G
Tool holding
Low to medium clamping force.

General purpose clamping system.
Industry standard.
G 35
Machinability
Other information
h6/h7
shank
Chucks
Turning
Drill adapter for drills, screw type

Screw type adapter for drills.
Good general purpose tool.
Limited clamping area, typically less than 10%.
Parting and
grooving
R
unout typically is around .0016 inch (40 m) at the
surface of the chuck.
Can cause vibration problems.
Threading
Endmill (Weldon) holders

Screw type holders.
Good general-purpose tool.

Limited clamping area, typically less than 10%.
Milling
unout typically is around .0016 inch (40 m) at the

R
surface of the chuck.
Can cause vibration problems.
Drilling
Low-cost solution for holding tools.
Try to minimize the gauge length

It is important to maintain as short a
gauge length as possible to increase
stability and reduce deflection.
Boring
Overhang
G
Tool holding
(20%)
Machinability
Other information
Tool protrusion
(50%)
G 36
L ength reduction as little as 20% can

have a significant reduction in deflection
(-50%).
Chucks
Turning
Influence of runout on tool life
F or every .0004 inch (0.01 mm) runout

- up to 50% decrease in tool life.
M
ore critical as tool diameter gets
smaller.
Parting and
grooving
R
unout should be < .001 inch
(< 0.025 mm).
C
Threading
Tool holding requirements

Application - Roughing and semi-finishing
Main criteria = clamping force.
High torque capability.
Milling
F or best performance use cylindrical

shanks.
Versatility of collets.
Main criteria = runout.
Boring
Influence on tool life and component

- finish and accuracy.
Unbalance in tool holders
G
Tool holding
Unbalance in tool holders causes:

- poor surface finish
- poor part tolerances
- reduction in tool life
- premature machine-spindle wear.
G 37
Machinability
Other information
Max runout .00024 inch (6 m)
Drilling
Application - Finishing
Machinability
Matching the most suitable cutting tool material (grade)
and insert geometry with the workpiece material to be
machined is important for a trouble-free and productive
machining process.
Workpiece materials
H4
The cutting edge
H 18
H 29
Manufacturing of cemented carbide
H 44
Other information
Machining economy
H 55
Maintenance and tool wear
H 68
H 75
H3
Turning
Parting and
grooving
Workpiece materials
Six main groups
The ISO standard material groups are divided into six
different types. Each type has unique properties regarding
machinability and setups that make different demands on
the tool.
ISO
Steel
ISO
Stainless steel
ISO
Cast iron
Threading
Workpiece materials
ISO
Aluminum
ISO
Heat Resistant Super Alloys
ISO
Hardened material
Milling
E
The largest variety of different types of
components is probably in the P-area
as it covers several different sectors in
the industry.
The aircraft industry and manufacturers of aluminum automotive wheels

dominate the N-area.
In the M-area, a big part of the application is in gas and oil, tubes, flanges,
process industry and the pharmaceutical business.
Difficult to machine S-area materials

are found in the aerospace, gas turbine
and power generator industries.
The K-area is dominated by automotive

components, the machine builders and
the iron works production.
Hardened materials in the H-area are

seen in a variety of industries such as
automotive and their subcontractors, as
well as in machine builders and the die
and mold business.
Drilling
Boring
Tool holding
Machinability
Other information
H4
Workpiece materials
-C
lassification, metallurgical/mechanical,
of the workpiece material.
- The cutting edge micro- and macro geometry to be used.
ISO
Steel
ISO
The selections will have a great influence

on the machinability of the material at
hand.
Stainless steel
ISO
Cast iron
C
Threading
- T he cutting tool material (grade), e.g.

coated cemented carbide, ceramic, CBN,
PCD, etc.
Parting and
grooving
Factors that must be identified in order to

determine a materials machinability:
Turning
Characteristics for chip formation and removal
ISO
Aluminum
ISO
ISO
S Heat resistant and super alloys H
Hardened material
Milling
N
M
ISO-M forms a lamellar, irregular chip formation where the cutting forces are higher
compared to normal steel. There are many
different types of stainless steels.
Chip breaking varies depending on the
alloying properties and the heat treatment,
from easy to almost impossible-to-break
chips.
Chip formation for ISO-K materials varies

from near-powderlike chips to a long chip.
The power needed to machine this material
group is generally low.
Note that there is a big difference between
gray cast iron (often near-powder) and
ductile iron, which many times has a chip
breaking more similar to steel.
Low power needed per inch3 (mm3), but due
to the high metal removal rate, it is still a
good idea to calculate the maximum power
required.
The range is wide, but in general high cutting forces are present.
Often a continuous, red-glowing chip. This

high temperature helps to lower the kc1
value and is important to help out with the
application.
H5
Boring
G
Tool holding
ISO-P materials are generally long chipping

and have a continuous, relatively even
flow of chip formation. Variations usually
depend on carbon content.
Low carbon content = tough sticky
material.
High carbon content = brittle material.
Cutting force and power needed varies
very little.
H
Machinability
Other information
Drilling
Workpiece materials
Turning
The complex world of metal cutting

Many parameters influence the cutting process
Parting and
grooving
Steel
Stainless steel
Cast iron
Aluminum
Milling
Threading
Turning
Application
Workpiece material
Condition
Cutting conditions
Milling
Milling
Drilling
Clamping conditions
Heat resistant alloys
Hardened steel
R
Boring
M
F
Tool holding
G
The ISO material groups
are divided into 6 different
types where each type has
unique properties regarding
machinability.
Machinability
Other information
Roughing/
Heavy
Medium
Finishing/
Light
There are three major types of

application, all requiring different tools, inserts and grades.
These also depend on the
load on the cutting edge, from
finishing to roughing.
All components are different

in look, need various setups,
and require special attention
and demands from the tool.
H6
Workpiece materials
Turning
Parting and
grooving
Hardness
Cutting environment
C
Threading
Component
Hardness Brinell
Milling
Coolant
Drilling
Carbide performs best when

machining at high, constant
temperatures. Dry conditions
should therefore be the first
choice. Some grades are, however, developed for wet conditions; for example, grades for
cast iron machining.
G
Tool holding
Usually there is a relation between material hardness and

tool life, as well as machining
data and type of geometry and
grade. The higher the hardness, the shorter the tool life,
with more rapid wear on the
cutting edge.
H7
Machinability
Other information
Depending on the size, type

of material, setup and machining method, a different
choice of tooling is required
(turning, milling, drilling, etc).
Boring
Dry machining
Turning
Workpiece materials
The interaction between workpiece material, geometry

and grade
Workpiece material
T he interaction between an optimized

geometry and grade for a certain workpiece material is the key for a successful machining process.
Parting and
grooving
T hese three basic factors must be considered carefully and adapted for each
machining operation.
C
Threading
T he knowledge and understanding of

how to work with and adjust these factors is of vital importance.
Insert grade
Insert geometry
Milling
Workpiece materials, main groups
Materials are classified using MC codes
Drilling
Steel
Boring
Heat resistant super

alloys and titanium
Cast iron
Stainless steel
Aluminum
Tool holding
Within each material group there are subgroups

depending on the hardness of the material, kc1 value,
and metallurgical and mechanical properties.
Machinability
Other information
H
* MC = A new material classification that replaces the CMC
(Coromant Material Classification) codes.
H8
Hardened material
Workpiece materials
Turning
MC code structure
The structure is set up so that the MC code can represent a variety of workpiece
material properties and characteristics using a combination of letters and numbers.
P = ISO code for steel
Parting and
grooving
Example 1:
1 = material group: unalloyed steel
The code P1.2.Z.AN is interpreted this way:
2 = material subgroup: carbon content ?0.25% 0.55% C

Threading
Z = manufacturing process: forged/rolled/cold drawn

AN = heat treatment: annealed, supplied with hardness values
Milling
Example 2:
The code N1.3.C.AG is interpreted this way:
N = ISO code for non-ferrous metals
1 = material group: aluminum

2 = material subgroup: aluminum with Si content 1-13%
Drilling
Z = manufacturing process: casting

AN = heat treatment: aging
Boring
By describing not only the material composition, but also the manufacturing process
and heat treatment, which influences the mechanical properties, a more exact description is available, which can be used to generate improved cutting data recommendations.
Tool holding
H9
Machinability
Other information
Workpiece materials
Turning
Steel ISO P main characteristics
Parting and
grooving
Threading
Milling
What is steel?
- Long-chipping material
-S
teel is the largest group in the metal
cutting area.
- Relatively easy, smooth chip control

- Low carbon steel is sticky and needs
sharp cutting edges
- Specific cutting force kc:
217,500449,500 lbs/inch2
(15003100 N/mm2)
- Cutting force, and the power needed to
machine ISO P materials, stays within a
limited range.
-S
teels can be non-hardened or hardened
and tempered with hardness up to
400 HB.
teel is an alloy with the element iron
-S
( Fe) as the major component. It is produced through a melting process.
-U
nalloyed steels have a carbon content
lower than 0,8 %, and only Fe, with no
other alloying elements.
-A
lloyed steels have a carbon content
which is lower than 1,7 % and alloying
elements like Ni, Cr, Mo, V, W.
Drilling
Machining characteristics:
Boring
ISO
Tool holding
Material
P1
Unalloyed steel
P2
Low-alloyed steel
(5% alloying elements)
P3
High-alloyed steel
(>5% alloying elements)
P4
Sintered steels
H
Machinability
Other information
MC
See Technical Guide Chapter H

for detailed MC code listing
H 10
Workpiece materials
Turning
Stainless steel ISO M main characteristics
Parting and
grooving
What is stainless steel?
tainless steels are materials alloyed

-S
with min 1112% chromium.
-C
hip control is fair in ferritic, to difficult in
- T he carbon content is often low (down to
austenitic and duplex
max 0.01%).
- Specific cutting force:
- Alloys are mainly Ni (Nickel), Mo
261,000413,250 lbs/inch2
(Molybdenum), and Ti (Titanium).
(18002850 N/mm2)
Milling
- T he formed Cr2O3 layer on the steel

surface makes it non-corrosive.
Drilling
achining creates high cutting forces,

-M
built-up edge, heat and deformation
hardening.
Threading
Material
P5
Ferritic/Martensitic stainless
steel
M1
Austenitic stainless steels
M2
Super-austenitic, Ni20%
Tool holding
MC
M
H
M3
Duplex (austenitic/ferritic)
H 11
Machinability
Other information
ISO
Boring
Workpiece materials
Turning
Cast iron ISO K main characteristics
Parting and
grooving
Threading
Milling
What is cast iron?
- Short chipping material
- T here are 3 main forms of cast iron:

gray (GCI), nodular (NCI) and compacted
graphite (CGI).
- Good chip control in all conditions

-S
pecific cutting force:
114,550195,750 lbs/inch2
(7901350 N/mm2)
-C
ast iron is an Fe-C composition with
relatively high content of Si (13%).
- Machining at higher speeds creates

abrasive wear
-C
arbon content is over 2% which is the
max solubility of C in the Austenitic
phase.
- Moderate cutting forces.
Drilling
-C
r (Chromium), Mo (Molybdenum), and
V (Vanadium) form carbides which increase strength and hardness, but lower
machinability.
ISO
MC
Material
K1
Malleable cast iron
K2
Gray cast iron
K3
Nodular SG iron
K4
CGI
K5
ADI
Boring
G
Tool holding
Machinability
Other information

H 12
Workpiece materials
Turning
Non-ferrous materials ISO N main characteristics
Parting and
grooving
What is Non-ferrous material?
- T his group contains non-ferrous, soft

metals with hardness under 130 HB.
-A
luminum (Al) is sticky and needs sharp
cutting edges
50,750101,500 lbs/inch2
(350700 N/mm2)
-A
luminum (Al) alloys with up to 22%
silicon (Si) make up the largest part.
- Copper, bronze, brass

- Plastic
Milling
- Relatively easy chip control if alloyed
Threading
- Composites (Kevlar)
- Cutting force, and the power needed to

machine ISO N materials, stays within a
limited range.
Drilling
ISO
MC
Material
N1
Aluminum-based alloys
Boring
N2
Magnesium-based alloys
N3
Copper-based alloys
N4
Zinc-based alloys
Tool holding
H 13
Machinability
Other information

Turning
Workpiece materials
Heat resistant super alloys and titanium

ISO S main characteristics
Parting and
grooving
Threading
Milling
Drilling
What are Heat Resistant Super Alloys?

Resistant Super Alloys (HRSA)
-- Heat
include a great number of high alloyed
iron, nickel, cobalt or titanium based
materials.
- Difficult chip control (segmented chips)

-N
egative rake angle is required with
ceramics, a positive rake angle with
carbide
For HRSA:
348,000449,500 lbs/inch2
(24003100 N/mm2)
For titanium:
188,500203,000 lbs/inch2
(13001400 N/mm2)
- Cutting forces, and power required are
quite high.

Condition: Annealed, Solution heat
treated, Aged rolled, Forged, cast.
Properties:
- Increased alloy content (Co more than
Ni), results in better resistance against
heat, increased tensile strength and
higher corrosive resistance.
ISO
Boring
Groups: Fe-based, Ni-based, Co-based
Material
S1
Iron-based alloys
S2
Nickel-based alloys
S3
Cobalt-based alloys
S4
Titanium-based alloys
S5
Tungsten-based alloys
S6
Molybdenum-based alloys
Tool holding
H
Machinability
Other information
MC

H 14
Workpiece materials
Turning
Hardened steel ISO H main characteristics
Parting and
grooving
What is hardened steel?
ardened steel is the smallest group

-H
from a machining point of view.
- Fair chip control

- Negative rake angle is required
pecific cutting force:
-S
369,750706,150 lbs/inch2
(25504870 N/mm2)
- T his group contains hardened and tempered steels with hardness >4565 HRC.
- T ypically, however, hard part turned components can be found to be within the
range of 5568 HRC.
- Cutting forces and power required are

quite high.
Milling
Threading
Drilling
Material
H1
Steels (extra hard)
H2
Chilled cast iron
H3
Stellites
Tool holding
MC
H
H
H4
Ferro-TiC
H 15
Machinability
Other information
ISO
Boring
Workpiece materials
Turning
The specific cutting force
Parting and
grooving
kc1 the material constant varies for each material

kc1
lbs/in2
(N/mm2)
T he cutting force (Fc)

is the force needed to
shear off a specific chip
cross-section in certain
conditions
870,000
(6000)
C
Threading
725,000
(5000)
Fc
580,000
(4000)
Milling
435,000
(3000)
Drilling
290,000
(2000)
145,000
(1000)
Boring
kc1 values in lbs/inch2 (N/mm2)
P 217,500 449,500
N 50,750 195,750
M 261,000 413,250
S 188,500 449,500
K 114,550 195,750
H 369,750 706,150
Tool holding
(1500 3100)
Machinability
Other information
(1800 2850)
(790 1350)
H 16
(350 1350)
(1300 3100)
(2550 4870)
T his value (Fc) is used

in the calculation of the
power consumption needed for an operation
T he specific cutting force

value (Fc) is a material
constant, expressed in
lbs (N)
Fc = kc ap fn
Workpiece materials
Turning
The ISO nomenclature in the ISO-P area
01
P10: T urning; copying; threading; milling; high cutting

speed; small to medium chip area.
10
P20: T urning; copying; medium cutting speed; facing with

small chip area; medium to difficult conditions.
20
P30: T urning; milling facing; medium to low cutting speed;

medium to large chip area; includes operations with
tough conditions.
30
40
P40: Turning; facing; milling; cutting; grooving; low cutting

speed; large chip area; large possible chip angle;
very tough conditions.
P50: W
hen very high toughness in the tool is needed in
turning, facing, grooving, cutting, low cutting speed,
large chip area, large possible chip angle, extremely
tough conditions.
B
Parting and
grooving
P01: Internal and external finishing turning; high cutting

speed; small chip area; good surface finish; narrow
tolerances; no vibrations.
C
Threading
Wear resistance
Milling
Operations and working conditions
Drilling
50
Toughness
Boring
The above diagram is related to

the ISO P area. These demands
also apply to all other ISO types
of material, i.e., M, K, N, S, H.
Tool holding
H 17
Machinability
Other information
The cutting edge
Turning
B
Parting and
grooving
The cutting edge

The design of the cutting edge and insert
geometry is of vital importance for the chip
formation process and tool life in metal
cutting.
Threading
Milling
Drilling
Boring
Tool holding
Machinability
Other information
H 18
The cutting edge
Turning
The high cutting force on a cutting edge

Guess how big the tangential force is on the cutting edge
B
Parting and
grooving
Cemented carbide has a high compressive strength resistance and can also work at high temperatures without
plastic deformation. It can also resist high cutting forces
without breaking, as long as the insert is well supported.
C
p
Material: Steel
ap = .319a inch
=8.1(8.1
mm mm)
p
CMC 02.1 180 HB
ap =13 mm
fn = .024 in
fn =0.62
(0.62
mm)
fn = .039 in
f =1.0
(1.0 nmm)
Threading
ap =a.512
inch (13 mm)
=13 mm
ap =8.1 mm
Fc = 3750
lbf kp
Ft =1700
(1700 kp)
Milling
fn =1.0
n =0.62
Ft =1700 kpFc = 3750 lbf
(1700 kp)
E
Ft =1700 kp
Drilling
Ft =1700 kp
Boring
G
Tool holding
Fc = kc x ap x fn
Fc = 304563 x .512 x .024 = 3742 = 1700 kp
Fc = 2100 x 13 x 0.62 = 16926 N (Newton) = 1700 kp
The tangential cutting force in these two

cases (approx. 3750 lbf,
16671 N, or 1700 kp) is
equivalent to the weight
of a passenger car.
H 19
Machinability
Other information
Calculation of Fc
Material: MC P2 (low alloyed steel)
180 HB
kc = 304,563 lbs/in2 (2100N/mm2)
The cutting edge
Turning
The machining starts at the cutting edge
Parting and
grooving
C
Threading
Typical chip breaking

sequences with high
speed imaging.
Milling
Cutting zone temperatures
Drilling
The maximum heat generated during cutting is on the top

part of the insert, in the chip breaker, and close to the
cutting edge. This is where the maximum pressure from
the material is, and, with the friction between chip and
carbide, causes these high temperatures.
Boring
T he rake angle, geometry and feed play

an important role in the chip formation
process.
R
emoving heat from the cutting zone
through the chip (80%) is a key factor.
G
Tool holding
T he rest of the heat is usually evenly

distributed between the workpiece and
the tool.
Machinability
Other information
H 20
The cutting edge
Turning
The design of a modern insert
Parting and
grooving
Threading
A steel turning insert for medium turning.
Milling
.010 in.
(.25 mm)
Geometry for small

cutting depths
5
C
utting edge reinforcement .010 inch (0.25
mm)
Boring
Macro geometry with

chip breaker
20
Drilling
Main cutting edge design
Rake angle 20
Primary land 5
G
Tool holding
.008 in.
(0.2 mm)
H 21
Machinability
Other information
Nose cutting edge design
The cutting edge
Turning
E
R treatment (Edge Roundness) is done
before coating, and gives the final shape
of the cutting edge (micro-geometry).
T he relation between W/H depends on

the application.
Threading
Parting and
grooving
The ER treatment gives the cutting edge the final

micro-geometry
Milling
Generally the ER
corresponds to the
thickness of a hair,
diameter: ~ .0031 inch
(80 m).
Drilling
A negative land increases the strength of the cutting edge

Milling inserts often have a negative land and reinforced
insert corners, making them stronger and more secure in
the intermittent cutting action.
F
.0039 in. (0.1 mm)
Boring
Negative
land
G
Tool holding
Chamfer
negative land increases the strength

A
of the cutting edge, but also creates
higher cutting forces.
Machinability
Other information
H 22
The cutting edge
Turning
Insert rake angle

The rake angle can be either negative or positive.
Based on that, there are negative and positive inserts,
where the clearance angles are either zero or several
degrees plus. This determines how the insert can be
tilted in the tool holder, and results in either a negative or
positive cutting action.
Parting and
grooving
C
Threading
T he insert rake angle is

the angle between the
top face of the insert and
the horizontal axis of the
workpiece.
Milling
Boring
G
Tool holding
In milling, which always has an intermittent cutting action, the edge needs to
have good bulk strength to resist breakage. A large variation in cutting edge
temperature due to interrupted cuts also
makes resistance to thermal cracks of
vital importance.
In most drilling applications there is also

coolant present, mainly for chip transportation reasons which puts the edge under
extra stress from temperature variations.
To be able to transport the chips from the
narrow chip flutes and from inside the
hole, good chip breaking into short chips
is an important factor.
In drilling, the edge must be strong

enough to last at very low cutting speeds,
and even at zero speed in the center of
the drill.
H 23
Machinability
Other information
Turning needs a durable edge that can

perform for a long time and often in
continuous cuts at high temperature. This
condition requires an edge with among
other things good chip breaking ability,
good resistance against different types of
wear and against plastic deformation.
Drilling
Positive and negative cutting action
The cutting edge
Turning
Peak performance in machining

There are major differences in insert geometry and grade
requirements between applications in turning, milling and
drilling.
Parting and
grooving
Dedicated inserts for different applications
Turning
N
eeds a durable edge that can perform
for a long time, and often in continuous
cuts at high temperature.
Threading
Good chip breaking ability
Milling
ood resistance against different types

G
of wear and against plastic deformation.
P
M
Milling
V
ariations in cutting edge temperature
due to the interrupted cuts also mean
that the resistance to thermal cracks is
of vital importance.
Drilling
N
F
Boring
Drilling
T he edge must be strong enough to last

at very low cutting speeds; in fact, at
zero speed in the center of the drill.
C
oolant is present, mainly for chip transportation reasons, which puts the edge
under extra stress from temperature
variations.
Tool holding
T o transport the chips from the narrow

chip flutes and from inside the hole,
good chip breaking is important.
H
Machinability
Other information
T he cutting action is always intermittent

and the edge needs to have good bulk
strength to resist breaking.
H 24
The cutting edge
Turning
Six main groups of workpiece materials

Different characteristics for removing chips
B
Parting and
grooving
Good chip forming usually results in high cutting forces

and excess heat, depending on the material. This can
lead to low cutting speeds with adhesive stresses as
a result. On the other hand, materials like aluminum,
unalloyed steels and low-strength cast iron produce less
cutting force.
Threading
Steel
Stainless steel
Milling
Cast iron
Drilling
Boring
Hardened steel
G
Tool holding
Heat resistant alloys
H 25
Machinability
Other information
Aluminum
The cutting edge
Turning
From universal to optimized turning inserts

General inserts
General geometry
Parting and
grooving
Optimizing with grades

Performance compromised
Threading
C
Dedicated inserts
edicated geometries
D
and grades
O
ptimized performance
according to workpiece
machinability
Application area
Milling
Application area
Dedicated inserts for the ISO P, M and K areas
Drilling
The different micro- and macro-geometries are adapted to the

various requirements in the applications.
Workpiece
material
Finishing
Roughing
.008 in.
(0.2 mm)
.013 in.
(0.32 mm)
.011 in.
(0.29 mm)
.013 in.
(0.32 mm)
Boring
.028 in.
(0.7 mm)
Medium
Tool holding
.004 in.
(0.1 mm)
Machinability
Other information
H 26
.010 in.
(0.25 mm)
The cutting edge
Medium turning
Most applications general purpose.
Wide range of D.O.C. and feed rate combinations.
Finishing
Operations at light depths of cut (D.O.C.) and low feed rates.
B
Parting and
grooving
Heavy turning
Operations for maximum stock removal and/or severe
conditions.
High D.O.C. and feed rate combinations.
fn
Feed, inch/r (mm/r)
Threading
ap Depth of
cut, inch
(mm)
Turning
Type of application - Turning
Dedicated geometries and grades
Drilling
ISO/ANSI
Milling
Todays insert/grade/geometry options are much more

dedicated towards specific application areas, giving the
full and optimized usage of the machine and tool capacity,
resulting in improved productivity and lower costs.
P STEEL
Finishing
Medium
Roughing
-WF / GC4215
-PF / GC4215
-WM / GC4205
-PM / GC4215
WR / GC4205
-PR / GC4215
Dominating application areas
Single
sided
-WF / GC4215
-WM / GC4215
-WR / GC4215
-PF / GC4215
-PM / GC4225
-PR / GC4225
Single
sided
-WR / GC4225
-PR/ GC4235
Material
Dedicated
geometries
Steel
Stainless
steel
Cast iron
Turning
F M R
F M R
F M R
Milling
L M H
L M H
L M H
Grades
GC4200
GC2000
GC3200
H 27
Tool holding
-WM / GC4225
-PM / GC4235
H
Machinability
Other information
-WF / GC4225
-PF / GC4225
Boring
Double
sided
The cutting edge
Turning
Type of application - Milling
Parting and
grooving
ap Depth of
cut, inch
(mm)
Threading
Heavy milling
Operations at maximum stock removal and/or severe
conditions.
Larger depth of cut and feed rate.
Medium milling
Most applications general purpose milling.
Medium depth of cut and feed rate.
Light milling
Operations at small depth of cut and low feed rates.
Milling
Selecting the insert geometry in milling
Drilling
Feed fz, inch/tooth (mm/tooth)
Boring
Light (-L)
Extra positive
Light machining
Tool holding
Low cutting forces

Low feed rates
Machinability
Other information
H 28
Medium (-M)
G
eneral purpose
geometry
Medium feed rates
M
edium operations to
light roughing
Heavy (-H)
Reinforced cutting edge
Heavy machining
Highest edge security
High feed rates
Turning
The selection of cutting tool material and grade is an important factor

to consider when planning a successful metal cutting operation.
B
Parting and
grooving
A basic knowledge of each cutting tool material and its performance is

therefore important to be able to make the correct selection for each
application. This should take into consideration the workpiece material
to be machined, the component type and shape, machining conditions
and the level of surface quality required for each operation.
Threading
Milling
Drilling
Boring
Tool holding
H 29
Machinability
Other information
Turning
Different types of cutting tool materials

Hardness
CD
Parting and
grooving
Diamond
2
3
CB
Cubic boron nitride
Threading
CC
Ceramics
CT
Cermets
Milling
1. Diamond
2. Cubic boron nitride
3. Ceramics
4. Cermets
5. Coated carbide
6. High Speed Steel
GC
Coated carbide
HSS
Drilling
High speed steel
Toughness
The ideal cutting tool material should:

- be hard, to resist flank wear and deformation
Boring
- be tough, to resist bulk breakage
- be chemically stable to resist oxidation and diffusion

- have good resistance to sudden thermal changes.
Tool holding
- not chemically interact with the workpiece material
Machinability
Other information
H 30
Turning
The main range of cutting tool materials

Uncoated cemented carbide (HW)
Coated cemented carbide (HC)
Cubic boron nitride (BN)
Parting and
grooving
Cermet (HT, HC)
Polycrystalline diamond (DP, HC)
C
Threading
Ceramic (CA, CN, CC)
Characteristics, features and benefits

Used in moderate to difficult applications
related to steel, HRSA, titanium, cast
iron and aluminum in turning, milling and
drilling.
Drilling
G
ood combination of abrasive wear
resistance and toughness.
Milling
Uncoated cemented carbide
Gives sharp cutting edges.
R
epresents a small portion of the total
grade program.
Boring
G
ood edge security but limited wear
resistance at higher speeds.
Tool holding
H 31
Machinability
Other information
Turning
Coated cemented carbide

General use in all kinds of components
and materials for turning, milling and drilling
applications.
Extremely good combination of wear resistance and toughness in a variety of jobs.
Consists of a large variety of grades with hard
to tough substrates, usually with gradient
sintering, and various coatings of CVD and
PVD-type.
Shows very good wear characteristics with
long tool life.
Dominates the insert program, with increasing
share.
Parting and
grooving
Threading
Cermet
Milling
Used in finishing and semi-finishing applications where close tolerance and good surface
finish is required.
Chemically stable with a hard and wear resistant substrate.
Consists of Titanium based (TiC, TiCN)
cemented carbide with cobalt as a binder.
PVD-coating adds wear resistance and tool
life. Self sharpening properties. Limited
toughness behavior.
Quite low share of total insert program.
Drilling
Ceramic
Depending on type of ceramic, the grades are
mainly used in cast iron and steel, hardened
materials and HRSA.
Ceramic grades are generally wear resistant
and with good hot-hardness. Wide application area in different types of material and
component.
Ceramics are considered brittle and need
stable conditions. With additions in the mix
and whisker reinforced ceramic, toughness is
improved.
Fairly low share of total insert usage, but
increased usage in the aerospace and hardened steel-cast iron areas.
Boring
Tool holding
Machinability
Other information
H 32
C
Threading
For finish turning of hardened steel. Roughing

of gray cast iron at high cutting speeds. Rough
turning of rolls in white/chilled cast iron.
Applications that require extreme wear resistance and toughness.
CBN consists of Boron nitride with Ceramic or
Titanium nitride binder.
Resists high cutting temperatures at high
cutting speeds.
Special application area with small volume
inserts. Trend is towards a higher volume of
hard materials to be cut.
Parting and
grooving
Turning
Cubic boron nitride
Drilling
Boring
Turning of normal aluminum at low temperature and very abrasive hypereutectic

aluminum. Used in non-metal and non-ferrous
materials.
Extremely wear resistant grades. Sensitive to
chipping.
Brazed-in corners of polycrystalline diamond
(PCD tip) to an insert or thin diamond coated
film on a substrate.
Long tool life and extremely good wear resistance. Decomposes at high temperatures.
Dissolves easily in iron.
Fairly low portion of the insert program, with
special limited applications.
Milling
Polycrystalline diamond
Tool holding
H 33
Machinability
Other information
Turning
The development of cutting tool material
Parting and
grooving
Threading
Milling
The development of cutting tool material through the

years can be seen in the reduced time taken to machine
a component 19.685 inch long, with 3.937 inch diameter
(500 mm long, with 100 mm diameter) from 1900 to
today.
At the beginning of the last century, cutting tool material was only slightly harder
than the material which needed to be cut.
Therefore tool life was poor, and cutting
speed and feed had to be kept very low.
The introduction of HSS brought major
improvements, which resulted in reduced
cutting time.
20 years later uncoated cemented carbide
brought down the required time in cut to a
staggering 6 minutes.
Today with improved geometries and new

coating technique we have reached below
1 minute in cutting time for the 19.685
inch (500 mm) steel bar.
In addition to traditional uncoated and
coated carbide, new cutting tool materials
like cermet, ceramic, cubic boron nitride
and diamond, have contributed to optimized and improved productivity.
The introduction of coated carbide again

lowered the cutting time to 1.5 minutes.
E
Carbon steel
Drilling
Min (log)
3.937
(100)
Boring
High speed steel (HSS)
19.685
(500)
Cemented carbide
G
Tool holding
Coated carbide
Insert geometries, new coatings
New cutting tool materials
Machinability
Other information
H 34
C
emented carbide is a powder metallurgical material consisting of:
Turning
What is cemented carbide and a grade?

B
- a binder metal, cobalt (Co)

-h
ard-particles of Ti,Ta,Nb

(titanium, tantalum, niobium-carbides).
Parting and
grooving
- hard-particles of WC (tungsten carbide)
Threading
C
A
grade represents the hardness or
toughness of the insert, and is determined by the mixture of ingredients
which make up the substrate.
Milling
A
thin Titanium Nitride coating layer was
added, only a few microns thick. This
improved the performance of carbide
overnight.
Coatings offer improved wear resistance
giving longer tool life and possibility to
use higher cutting data.
G
Tool holding
Today modern grades are coated with different carbide, nitride and oxide layers.
Boring
C
oating of cemented carbide was
developed in the 1960s.
Drilling
Coating of cemented carbide
H 35
Machinability
Other information
Turning
Microstructure of cemented carbide
Parting and
grooving
Cemented carbide consists of hard

particles (carbides) in a binder matrix.
The binder is more or less in all cases
cobalt (Co) but could also be Nickel (Ni).
The hard particles consist mainly of tungsten carbide (WC) with a possible addition
of gamma phase (Ti-, Ta- Nb-carbides and
nitrides).
The gamma phase has a better hot hardness and is less reactive at elevated
temperatures, so is often seen in grades
where the cutting temperature can get
high. WC has a better abrasive wear
resistance.
Threading
Elements:
Milling
Gamma-phase (TiC)
Beta-phase (Co)
Drilling
Alpha-phase (WC)
Alpha-phase
WC (tungsten carbide)
Gamma-phase
(Ti,Ta,Nb)C
(titanium, tantalum,
niobium-carbides)
Beta-phase
Co (cobalt)
Boring
Hair diameter
= .0020-.0028 inch (50-70 m)
Tool holding
Machinability
Other information
H 36
An increase in Co content and WC grain

size contributes to an increase in bulk
toughness, but also lowers the hardness.
As a result, the substrate has less resistance to plastic deformation, which means
less wear resistance/lower practical tool
life.
B
Parting and
grooving
Apart from the grain size of the WC, the

amount of binder phase (cobalt) is an
important factor determining the characteristics of the carbide. The Co content
in Sandvik Coromant grades is generally
415% of the total weight.
Turning
Fundamental characteristics
Amount of binder
Toughness
Threading
Milling
Drilling
WC grain size
Tool holding
H 37
Machinability
Other information
Wear resistant
Boring
Turning
Coating design
Many factors influence the behavior of the
insert:
- Coating process
Parting and
grooving
- Coating material
- Coating thickness
- Post treatment
C
Threading
- Surface morphology.
Milling
Example of modern steel turning grades
Drilling
Structure and build-up of the coating layers
Wear resistance
Toughness
Boring
Gradient substrate for optimized hardness and toughness
Tool holding
ISO P01 P15
ISO P05 P30
ISO P10 P35
ISO P20 P45
GC4205
GC4215
GC4225
GC4235
Machinability
Other information
H
Thicker coatings mean more wear resistance.
Harder substrates mean more deformation resistance.
H 38
Turning
Grade design
Coatings and substrates vary with the type of application
Parting and
grooving
C
K05 K15
P05 P35
M15
M25
M35
Threading
Thicker coatings mean more wear resistance.

Harder substrates mean more deformation resistance.
The coating of a modern turning grade

Milling
The grade plays a very important part of the performance
Drilling
Al2O3
Coating for chemical and
thermal wear resistance.
G
Tool holding
Functional gradient
For optimized hardness and
toughness.
Boring
TiCN
MTCVD coating for mechanical wear resistance.
Cemented carbide
Plastic deformation
resistance.
H 39
Machinability
Other information
Turning
Properties of different coating materials

CVD coating of inserts
Chemical Vapor Deposition
Parting and
grooving
TiN
TiCN provides flank wear resistance.
Al2O3
A
l2O3 provides temperature protection
(plastic deformation resistance).
Ti(C,N)
TiN provides easy wear detection.
Threading
T he most common CVD layers today are

TiN, Ti(C,N) and Al2O3.
Milling
TiN = Titanium nitride

Ti(C,N) = Titanium carbonitride
Al2O3 = Aluminum oxide
Drilling
PVD coating of inserts

Physical Vapor Deposition
P
VD coatings are generally tougher than
CVD coatings.
Boring
P
VD coatings are often used in combination with fine-grained substrates to coat
sharp cutting edges.
T otal thickness of the PVD layers is often
between .0001 .0002 inch (3 6 m).
G
Tool holding
T he coating is applied at approx. 932 F

(500 C).
Machinability
Other information
H 40
Turning
The tough environment in metal cutting

Different wear mechanisms on the inserts
Wear picture
Cause
Mechanical stress on
the insert edge
causes breakage.
Thermal
Temperature variations
cause cracks and
heat generates plastic
deformation (PD) on
the insert edge.
Chemical
A chemical reaction
between carbide and
working material
causes wear.
Abrasive
In cast iron the SiC

inclusions can wear on
the insert edge.
Milling
Mechanical
Parting and
grooving
Symbol
Threading
Type of load
Drilling
Boring
BUE = Built-Up Edge
G
Tool holding
Adhesive
With sticky material,

built-up layers/edges
are formed.
PD = Plastic Deformation
H 41
Machinability
Other information
BUE
BUE
Some of the most common wear patterns
Flank wear (abrasive)
Parting and
grooving
Turning
Wear pictures, cause and remedy
Cause
Cutting speed too high, insufficient wear resistance.
Remedy
Reduce cutting speed, select a more wear resistant
grade.
Cutting temperature too

high.
Reduce cutting speed, select a more wear resistant

grade (Al2O3 coated grade).
Cutting speed too low

Unsuitable grade.
Increase cutting speed,

choose a tougher grade,
preferably PVD coated.
Cutting speed too high or

insufficient wear resistance.
Select a more wear resistant grade or reduce cutting

speed.
Threading
Crater wear (chemical)
Milling
Drilling
Built-up edge (abrasive)
Boring
G
Tool holding
Notch wear (abrasive)
Machinability
Other information
H 42
Cause
Cutting temperature too
high, combined with a high
pressure.
Remedy
Select a harder grade,
reduce speed and feed.
B
Parting and
grooving
Plastic deformation
(thermal)
Turning
Chipping (mechanic)
Change the feed, select an
alternative insert geometry.
Milling
The chips are deflected

against the cutting edge.
Threading
Temperature variations
caused by:
Coolant should be applied

copiously, or not at all.
Boring
- intermittent machining
- varying coolant supply
Select a tougher grade

with better resistance to
thermal shock.
Drilling
Thermal cracks
Check the following:

- chip hammering
- cutting data
- sand inclusions in workpiece
- built-up edge
- vibration
- excessive wear on insert.
H 43
G
Tool holding
Overload of mechanical
tensile stresses.
H
Machinability
Other information
Edge chipping/breakage
(mechanic)
Manufacture of cemented carbide
Turning
B
Parting and
grooving
Manufacture of
cemented carbide
The manufacture of cemented carbide
inserts is a carefully designed process,
where geometry and grade are balanced to
give a product perfectly matched to the
application.
Threading
Milling
Drilling
Boring
Tool holding
Machinability
Other information
H 44
Turning
The development of cutting tool material

With the development of better carbide substrates, coatings and geometries, productivity and cost savings have
improved for the end user.
B
Parting and
grooving
Large improvements in productivity were possible in the

60s and 70s when the first coatings were developed.
After this, the developments continued - with advanced
substrate design, new geometries, edge designs, new advanced coating techniques and post treatment of coated
edges.
Threading
The effect on end-user productivity

2006
Milling
A new insert
generation
1999
New generation
coatings
1989
1980
Drilling
Functional
gradients
Thick aluminum
oxide coating
1969
Boring
G
Tool holding
Indexable
inserts
First coated
insert
H 45
Machinability
Other information
1957
Turning
Powder production
Parting and
grooving
Threading
There are two main elements of a cemented carbide

insert:
- WC = Tungsten Carbide
- Co = Cobalt
Other commonly used elements are Titanium, Tantalum
and Niobium Carbides. Designing different types of
powder and different percentages of the elements is what
makes up the different grades.
The powder is milled and sprayed-dried, sifted and poured
into containers.
Milling
Raw material
Niobium
Drilling
Milling
(Ta, Nb)C Tantalum

(5%)
Co
(7%)
Cobalt
(Ti, W)C
(8%)
Boring
Cemented carbide powder

Ready to press
Tool holding
Machinability
Other information
H 46
Titanium
WC Tungsten
(80%) carbide
Spray drying
The main raw material for the manufacture of cemented carbide is tungsten-ore
concentrate. Tungsten powder is produced
from tungstic oxide derived chemically from
the raw material. By varying the conditions
of reduction, tungsten powder of various
grain size can be manufactured. The carbide granules after spray-drying are small
and vary in size depending on grade.
C
Threading
.0039 inch
(0.10 mm)
B
Parting and
grooving
The size of the tungsten carbide grains
Turning
Tungsten powder
Amount of binder
also to a lower hardness which reduces

the wear resistance of the substrate.
Drilling
Apart from the grain size for the WC, the

amount of binder phase is an important
factor determining the characteristics
of the carbide. Increasing Co-content,
together with increasing WC-grain size,
contributes to increasing toughness but
Milling
Basic properties of cemented carbide
Toughness
Boring
Tool holding
Wear resistant
WC grain size
H 47
Machinability
Other information
Turning
Pressing powder compacts

Top and bottom
punches
B
Parting and
grooving
Press force
20 - 50 tons
Threading
Die and
core pin
Milling
Drilling
Inspection
The pressing operation consists of several pieces
of tooling:
- T op and bottom punches
- Core pin
- Cavity.
Boring
The pressing procedure:
Tool holding
owder is poured into the cavity

-P
- Top and bottom punches come together (20-50 tons)
- The insert is picked and placed via robot onto a
graphite tray.
- Random SPC is performed, to check for weight.
The insert is 50% porous at this stage.
Machinability
Other information
H 48
Turning
Sintering the pressed inserts

Sintering phase consists of the following phases:
- T he insert will shrink 18% in all directions
during the sintering phase; this
corresponds to about 50% in volume.
B
Parting and
grooving
- L oading trays of inserts into a sintering

furnace.
- The temperature is raised to ~2550 F
(~1400 C).
- This process melts the cobalt and the
cobalt acts as a binder.
C
Threading
Sintering
Milling
Insert trays
E
Shrinking
rate
Drilling
Inspection
Boring
G
Tool holding
3
1. Unsintered insert
2. Sintered insert
3. Coated insert
H 49
Machinability
Other information
Turning
Different types of grinding operations

B
Free profiling
Profiling
Parting and
grooving
Top and bottom
C
Threading
g 00
Bor
Chamfer negative land
Neg. land
Periphery
8 9
4 5
1
Milling
SI
Chamfer
S2
S3
S4
S5
S6
2 3
S7 S8
Borg 00
Drilling

The ER-treatment gives the cutting edge the final micro-geometry.
E
R-treatment (Edge Roundness) is done
before coating.
Boring
T he relation between W/H depends on

the application.
Tool holding
Generally the ER corresponds to the thickness of

a hair, diameter: ~.0031 inch (~80 m).
Machinability
Other information
H 50
Turning
CVD Chemical Vapor Deposition

Stacks of inserts are placed into a furnace, a series of
gases are introduced to the chamber, lines are purged and
another series of gases introduced. This is repeated until
the layers of coating are complete. The process is carried
out at approx. 1650 F (900 C) for 30 hours. Thickness is
approx .00008-.0005 inch (2-12 microns).
Parting and
grooving
Threading
Milling
Drilling
The ability to making thick coatings.
V
ery good adherence to the carbide
substrate.
Very good wear resistance.
Tool holding
Ability to make even coating thickness.
Boring
The advantages of CVD coatings
Possibility to make oxide coatings.
H 51
Machinability
Other information
Turning
PVD Physical Vapor Deposition
Parting and
grooving
The inserts are loaded into the coating

chamber on trays. Metal source targets are
placed on the reactor chamber walls. The
most common source is titanium (Ti). The
targets are heated to a temperature where
the solid metal ionizes.
By using a gas as carrier, the ions can

then be transported from the targets to
the inserts. As the inserts are cooler, the
ions will condensate on the insert surface
to form a coating.
The coating thickness is in the range of

.00008-.0002 inch (2-6 microns) depending on application area for the insert.
PVD provides good edge line toughness.
Threading
Milling
Drilling
Boring
Tool holding
The most common PVD layers today are

TiN, Ti(C,N), (Ti,Al)N, (Ti,Al,Cr)N and now
also aluminum oxides.
Machinability
Other information
H 52
P
VD coatings can maintain a sharp
cutting edge.
PVD can be used on brazed tips.
PVD can be used on solid carbide tools.
In a PVD coating process, the coating is

formed by metal vapor condensating on insert surfaces. PVD works the same way as
when humid air condensates on cold roads
and forms an ice layer on the road.
PVD is formed at a much lower temperature than CVD. Normal PVD process
temperatures are around 930 F (500 C).
The coating thickness is in the range of
.00008-.0002 inch (2-6 microns) depending on application area for the insert.
In a CVD coating process, the coating is

formed by a chemical reaction of different
gases. Temperature, time, gas flow, gas
atmosphere, etc., are carefully monitored
to steer the deposition of the coating layers. Depending on the type of coating, the
temperature in the reactor is about 1470
to 2000 degrees F (800 to 1100 degrees
C). The thicker the coating the longer the
process time. The thinnest CVD coating
today is below .00016 inch (4 microns)
and the thickest is above .0008 inch (20
microns).
B
Parting and
grooving
CVD (Chemical Vapor Deposition)
C
Threading
PVD (Physical Vapor Deposition)
Turning
PVD vs. CVD coating process
Milling
~1830F
~1/20 atm
Drilling
~930F
~1/100000 atm
Boring
Thicker coating
Sharper edges
More wear resistant
Tougher
Thermal resistant
H 53
Machinability
Other information
Thinner coating
Tool holding
Turning
Vision control, marking and packaging
Parting and
grooving
After inspection of dimensions, coating and grade, the

insert is marked with a grade designation and placed in a
10-piece box, labeled and packed and ready for distribution to the customer or into stock in the warehouse.
Visual inspection
Packaging
Threading
Marking
Milling
Labelling
Drilling
Distribution
Gimo
Boring
Tool holding
Machinability
Other information
H 54
Tool holding
Boring
Drilling
Milling
Threading
Parting and
grooving
Machining economy
How to improve machining economy
H 55
Machinability
Other information
Turning
Machining economy
Machining economy
Turning
Doing more machining in the same production time

B
Parting and
grooving
Productivity definition
The value of output

produced divided by the
value of input or resources.
C
Threading
= Output / Input
Milling
Drilling
Attack the productivity gap

In all industrial operations, the cost of running the
operation, e.g. for labor, raw material, equipment, etc.,
is increasing at a faster rate than the price of the goods
that are sold. In order to bridge that gap, one needs to
continuously increase efficiency, resulting in higher productivity. Bridging this gap is the only way to stay competitive and ultimately to stay in business.
Boring
135
130
120
125
Cost development
Tool holding
115
Machinability
Other information
110
105
100
95
Productivity gap
Price development
Source: Mechanical Industry in OECD.
H 56
Machining economy
Turning
Maximizing productivity
The three main machining parameters, cutting speed,
feed, and depth of cut, have an effect on tool life. The
depth of cut has the smallest effect followed by the feed
rate. Cutting speed has the largest effect by far on insert
tool life.
Parting and
grooving
Depth of cut, inch (mm)
Threading
Milling
Feed, inch/rev (mm/rev)
Optimizing the feed rate is

the best way to maximize
the productivity
Drilling
Cutting speed, ft/min (m/min)
Boring
Productivity Q is measured as the amount of material

removed in a fixed time period, inch3/min (cm3/min).
G
Tool holding
vf
Q = vc ap fn 12
Q = ap ae vf
H 57
Machinability
Other information
Machining economy
Turning
Maximizing productivity examples
Parting and
grooving
Metal removal rates for a fixed depth of cut of .118 inch (3.0 mm) using:
Low alloy steel,

MC P2
Hardness, HB 180
C
Threading
Milling
.118
(3.0)
.118
(3.0)
.118
3.0

.006
f , inch/r (mm/r)
n
(0.15)
.012
(0.3)
.020
(0.5)
Slowest cutting speed with the highest feed

= highest productivity
Using a trigon W-style insert, versus a C-style double-sided

or single-sided insert
Low alloy steel,
MC P2
Hardness, HB 180
Boring
.591
Trigon shape
Insert: double-sided for medium machining.
.118 / .157 inch
(3 / 4 mm)
No of passes / cutting
depth, ap
.039 / .118 inch
(1 / 3 mm)
22 seconds
Machining time, Tc
Rhombic shape
Insert: double sided for medium machining.
depth, ap
G
Tool holding
Machining time, Tc
1.969
Machining time, Tc
H 58
.118 / .197 inch

(3 / 5 mm)
16 seconds
Insert: Single sided for rough machining.

depth, ap
H
Machinability
Other information
25*
(412)*
Q, inch3/min
12 19
3/min)
(cm
(191)
(310)
P
Drilling

a , inch (mm)
p

1394 1132 902
v , ft/min (m/min)
c
(425)
(345)
(275)
Insert: CNMG 432-PM 4225 (CNMG 120408-PM 4225)
.079 / .295 inch

(2 / 7.5 mm)
8 seconds
Machining economy
Turning
Machine tool utilization

Incomplete use of
additional shifts
Production
60%
Tool change 10%
Parting and
grooving
Machining 20%
Set & gauge 10%
C
Threading
Breakdowns 10%
Holidays, etc.
Workpiece
change 10%
Milling
Machining economy
Drilling
Boring
G
Tool holding
Fixed costs
Costs which exist even when not in
production:
- machine and tool holders (27%)
- labor (31%)
- buildings, administration, etc. (22%).
H 59
Machinability
Other information
Variable costs
Costs incurred only during production:
- cutting tools, consumables (3%)
- workpiece materials 17%.
Machining economy
Turning
Parting and
grooving
The cost of the tooling, an easily measured value, is

always under price or discount pressure, but even when
the price is reduced by 30% it only influences the component cost by 1%.
We have a similar result of a 1% cost saving when tool
life is increased by 50%.
Increasing the cutting data by only 20% will dramatically
reduce component costs and lead to a 10% component
saving.
Threading
Cost, tool life or productivity
Milling
Decreased cost:
A 30% decrease in price
only reduces total cost per
component by 1%.
Drilling
A 50% increase in tool life only reduces

total cost per component by 1%.
Boring
Increased tool life:
Tool holding
Increased cutting data:

A 20% increase in cutting
data reduces total cost
per component by more
than 10%.
Machinability
Other information
H 60
Machining economy
Turning

Example:
Shop spends $10,000

to make 1000 parts.
Parting and
grooving
Machine cost is $10.00

per part.
20%
Increase
cutting data
Today
Lower price
Tool life
Tooling
$ .30
$ .21
$ .20
$ .45
Material
$ 1.70
$ 1.70
$ 1.70
$ 1.70
Machinery
$ 2.70
$ 2.70
$ 2.70
$ 2.16
Labor
$ 3.10
$ 3.10
$ 3.10
$ 2.48
Building
$ 2.20
$ 2.20
$ 2.20
$ 1.76
Cost per part
$ 10.00
$ 9.91
$ 9.90
$ 8.55
Milling
Variable
C
Threading
30% 50%
Fixed
Drilling
15%
Boring
1%
G
Tool holding
1%
H 61
Machinability
Other information
Savings
Machining economy
Turning
Machining ecomomy
Parting and
grooving
Threading
Cutting speed has no effect on fixed costs.

As cutting speed increases more parts are produced per hour and therefore cost per
part is reduced.
As cutting speed increases more tools are used and therefore cost per
part increases.
If we add all costs together we will get the curve of total Production cost.
1. As speed increases the Parts per hour increase until we reach a point where we are
spending a disproportionate amount of time changing tools and production rate will
start to decrease.
2. The lowest point on the Production cost curve corresponds to the economic cutting
speed.
3. The highest point on the Production cost curve corresponds to the the maximum
cutting speed.
The speed between these two points is the High Efficiency Range, which is where we
should be trying to operate.
Milling
Cutting data and cost
Cost per part
Drilling
Parts per hour

Production rate
Production cost
Boring
Tool cost
Tool holding
Fixed cost
Machine cost
Machinability
Other information
H
Economic High Efficiency Speed for maximum
speed
Range
production
H 62
Cutting speed
Machining economy
Turning
Base for cutting data recommendations

Tool life
Higher metal removal
-A
ll cutting data is based
on 15 min tool life.
If you want to change the cutting speed to obtain higher metal

removal rates the new cutting speed values can be calculated
from the following table.
5 min tool life

-1
= Factor 1.0
-U
se correction factor for
other values according to
the table.
Tool life (min)
10
15
20
25
Correction
factor
1.11
1.0
0.93
0.88 0.84
30
45
60
B
Parting and
grooving
Compensation of cutting data for difference in tool life
0.75 0.70
Threading
Example:
If the recommended cutting speed (vc) = 738 ft/min
(225 m/min.), a tool life of 10 minutes gives you
738 x 1.11 819 ft/min (225 x 1.11 250 m/min).
Milling
Compensation of cutting speed for difference in hardness, HB
-U
se correction factors for
the table.
-60 -40 -20 0 +20 +40 +60 +80 +100
P2 HB2) 180 1.44 1.25 1.11
1.0 0.91 0.84 0.77 0.72 0.67
M1 HB2) 180 1.42 1.24 1.11
1.0 0.91 0.84 0.78 0.73 0.68
K2 HB2) 220 1.21 1.13 1.06
1.0 0.95 0.90 0.86 0.82 0.79
K3 HB2) 250 1.33 1.21 1.09
1.0 0.91 0.84 0.75 0.70 0.65
N1 HB2) 75
1.05
1.0 0.95
S2 HB2) 350
1.12
1.0 0.89
H1 HRC3) 60
1.07
1.0 0.97
Drilling
Increased hardness
Boring
-E
.g ISO P HB 180 =
Factor 1.0.
Reduced hardness
ISO/
ANSI MC1) HB2)
1) MC = material classification code

2) HB = Hardness Brinell
3) HRC = Hardness Rockwell
G
Tool holding
-A
ll cutting data is based
on the reference materials and the respective
hardness.
H 63
Machinability
Other information
Hardness
Turning
Use the table or diagram to compensate the

cutting speed for different hardnesses
Diagram form for P, M and K
Parting and
grooving
Machining economy
ISO
ISO
ISO
Gray cast iron, HB220

MC K2
Stainless steel, HB180

MC M1
ISO
Nodular cast iron, HB250

MC K3
Threading
Steel, HB180
MC P2
Drilling
Specific cutting force / hardness
Boring
Factor for cutting speed
Milling
Tool holding
Machinability
Other information
H 64
K
K
Example of calculating hardness factor and cutting speed

compensation
Steel
MC P2
-R
eference hardness
HB= 180
-1
5 min tool life
= Factor 1.0
-U
se correction factor for
the table.
Reduced hardness
ISO/
ANSI MC1) HB2)
Increased hardness
-60 -40 -20 0 +20 +40 +60 +80 +100
P2 HB2) 180 1.44 1.25 1.11
1.0 0.91 0.84 0.77 0.72 0.67
M1 HB2) 180 1.42 1.24 1.11
1.0 0.91 0.84 0.78 0.73 0.68
K2 HB2) 220 1.21 1.13 1.06
1.0 0.95 0.90 0.86 0.82 0.79
K3 HB2) 250 1.33 1.21 1.09
1.0 0.91 0.84 0.75 0.70 0.65
N1 HB2) 75
1.05
1.0 0.95
S2 HB2) 350
1.12
1.0 0.89
H1 HRC3) 60
1.07
1.0 0.97
Parting and
grooving
C
Threading
ISO
Turning
Machining economy
1) MC = material classification code

2) HB = Hardness Brinell
3) HRC = Hardness Rockwell
Calculating hardness factor

- HB 266-180 = +86
- Cutting speed factor vc = 0.70.
-R
educe the cutting speed
to 70%.
HV
80
85
90
95
100
110
120
130
140
150
160
170
180
190
200
205
210
215
220
225
230
240
250
255
260
265
270
280
290
295
300
310
HB
76.0
80.7
85.5
90.2
95.0
105
114
124
133
143
152
162
171
181
190
195
199
204
209
214
219
228
238
242
247
252
257
266
276
280
285
295
HRC
20.3
22.2
23.1
24.0
24.8
25.6
27.1
28.5
29.2
29.8
31.0
N/mm2)
255
270
285
305
320
350
385
415
450
480
510
545
575
610
640
660
675
690
705
720
740
770
800
820
835
850
865
900
930
950
965
995
HRB
41.0
48.0
52.0
56.2
62.3
66.7
71.2
75.0
78.7
81.7
85.0
87.5
89.5
91.5
92.5
93.5
94.0
95.0
96.0
96.7
98.1
99.5
(101)
(102)
(105)
H 65
Drilling
-1
30,500 lbs/inch2 (900 N/mm2)
= HB 266 value according to the
table.
lbs/inch2)
36,975
39,150
41,325
44,225
46,400
50,750
55,825
60,175
65,250
69,600
73,950
79,025
83,375
88,450
92,800
95,700
97,875
100,050
102,225
104,400
107,300
111,650
116,000
118,900
121,075
123,250
125,425
130,500
134,850
137,750
139,925
144,275
Boring
- T ensile strength
130,500 lbs/inch2 (900 N/mm2)
Rockwell
G
Tool holding
- DIN 42CrNiMo4
Brinell
H
Machinability
Other information
Customer workpiece
material
Vickers
Milling
D
Tensile strength
Machining economy
Threading
How to calculate cutting data compensation

- The cutting data is based on 15 min tool life.
Increased feed fn, inch/r (mm/r)
Example 1
Starting value
Example 2
Milling
Decreased feed fn, inch/r (mm/r)
Drilling
Example 1
- Increase the feed from, e.g., fn .012 inch/r to .018 inch/r

(0.3 mm/r to 0.45 mm/r)
= +.006 inch/r (+0.15 mm/r)
-D
ecrease the cutting speed by 12% from the given cutting
speed value.
Boring
Example 2
- Decrease the feed by .007 inch/r (0.18 mm/r) from the

given feed value.
Tool holding
- Increase the cutting speed by +15% e.g from

1132 ft/min to 1312 ft/min (345 m/min to 400 m/min)
Machinability
Other information
H 66
Increased cutting speed, %
Parting and
grooving
Decreased cutting speed, %
Turning
Cutting speed and feed data compensation for turning
Machining economy
Turning
How can you improve your productivity?
Identify the material and hardness HB or

tensile strength lbs/inch2 (N/mm2).
Choose the correct geometry.
se the given cutting data values or

U
compensate the cutting data values
according to your needs.
C
orrectly applied, our tools can increase
productivity by at least 20%.
Threading
Choose the correct grade.
B
Parting and
grooving
Things to consider
Milling
Machining tips for improved tool life
M
ake use of all available corners on
inserts.
P
roper insert radius in relationship
to D.O.C.
Drilling
S
peeds and feeds within insert
parameters.
W
orn inserts can be used for
chamfering.
G
Tool holding
U
se climb milling over conventional milling wherever possible.
Boring
C
hoose the right combination of insert
radius and geometry.
H 67
Machinability
Other information
Good stability = Successful metal cutting
Machinability
Other information
Tool holding
Boring
Drilling
Milling
Threading
Parting and
grooving
Turning
A
Maintenance & tool

wear
H 68
Tool wear
H 69
Maintenance
H 71
Turning
Consequences of excessive tool wear
Parting and
grooving
Threading
Milling
Drilling
Damaged inserts
Damaged shims
Damaged tool holders
Damaged components
Boring
Damaged machine
G
Tool holding
Result:
Reduced production
Higher production costs
H 69
Machinability
Other information
Visually inspect shims & shim seats
D
amaged shims. Shims should not have
chipped corners in the cutting area.
Parting and
grooving
Turning
Inspection of tool wear
Damage
S
hims should have no visible wear from
chip breaking and/or impressions from
the insert.
Chip breakage
impression
C
Threading
Inspect pockets
P
ockets damaged or mushrooming in the
corners.
Milling
O
versized pockets due to wear. The
insert does not sit properly in the pocket
sides. Use a .0008 inch (0.02 mm)
shim to check the gap.
Drilling
mall gaps in the corners, between the

S
shim and the bottom of the pocket.
The importance of using the correct wrench

Why use the proper wrenches?
Extends life of screw and wrench.
Boring
Reduces risk of stripping screw.
G
Tool holding
What is the proper way to tighten an insert

screw?
Important to use the proper wrench.
lways use correct torque. Values are
A
marked on tool and shown in product
catalog.
Machinability
Other information
Common sense!
H 70
Torx Plus from Sandvik Coromant
B
Parting and
grooving
lbs-in (Nm)
Turning
Torx Plus wrenches
C
Threading
Torx Plus vs. Torx

Cross section
Torx Plus
Torx
Milling
Torx Plus
E
Standard Torx
screw
Drilling
Torx Plus is a registered trademark of

Camcar-Textron (USA)
parting and grooving tools an adjust On

able torque wrench is required, as the
torque is not related to screw size.
It should of course be used on all products with a clamp screw.
G
Tool holding
Torx Plus wrenches with adjustable torque
Boring
H 71
Machinability
Other information
Turning
Insert screws / clamping screws

Screw

threads, heads and Torx sockets
should be in good condition.
Use correct keys.
Parting and
grooving
Ensure correct screw-tightening torque

pply sufficient screw lubrication to
A
prevent seizure. Lubricant should be
applied to the screw thread as well as
the screw-head face.
C
Threading
Replace worn or exhausted screws.
D
Important!
Milling
Use Molykote for screw heads

and threads
Drilling
Tool maintenance
Shim and insert seat
Check shim damage.
C
lean insert seat and damaged location
and support for cutting edge.
Boring
If necessary index or replace shim.

E
nsure correct insert location against
support points.
G
Tool holding
It is important to ensure that shim corners have not been knocked off during
machining or handling.
Machinability
Other information
H 72
check supporting and contact

Always

faces of tool holders, milling cutters and
drills, making sure there is no damage
or dirt.
C
Threading
In boring operations it is especially

important to have the best possible
clamping. If the bar is not supported to
the end of the holder, overhang will be
increased and create vibration.
B
Parting and
grooving
Contact faces
Turning
Tool maintenance
l = cutting edge length (insert size)

re = nose radius
-S
elect largest possible nose radius for
insert strength.
-S
elect a smaller nose radius if there is
a tendency for vibration.
Stability
Stability is the key factor for successful
metal cutting, affecting machining costs
and productivity.
M
ake sure that any unnecessary play,
overhang, weakness, etc., has been
eliminated and that correct types and
sizes of tools are employed for the job.
Drilling
re
Boring
-S
elect largest possible point angle on
the insert for strength and economy.
H 73
Machinability
Other information
Tool holding
It
is important to select the correct
insert size, insert shape and geometry
and insert nose radius to achieve good
chip flow.
Milling
Production security
Turning
Insert handling
Inserts

should never be removed from
the original package until they are ready
to be installed.
Parting and
grooving
Threading
Summary of maintenance points
Milling
Check tool wear and shims for damage.

Make sure insert seat is clean.
Make sure of correct insert location.
Drilling
Make sure correct keys and drivers are used.

Insert screws should be correctly
Lubricate screws before tool assembly.
tightened.
Make sure contact faces are clean and undamaged on

Boring
tools, holding tools and machine spindles.
Tool holding
Machinability
Other information
Make sure boring bars are clamped well and that

holder is undamaged at the end.
A well organized, maintained and documented tool

inventory is a production cost saver.
Stability is always a critical factor in any metal cutting

operation.
H 74
Turning
B
Parting and
grooving
Formulas & definitions, calculator
Milling
H 78
Drilling
H 80
Boring
H 82
C
Threading
H 76
Milling
Turning
H 84
Boring
Tool holding
H 75
Machinability
Other information
Drilling
Calculator
Turning
Formulas and definitions for turning - INCH

B
Cutting speed, ft/min
Dm n
12
Parting and
grooving
vc =
Spindle speed, rpm
Threading
n=
vc 12
Dm
Drilling
Metal removal rate, inch3/min

Q = vc ap fn 12
Boring
Net power, HP
v ap fn kc
Pc = c
33 103
Tool holding
H
Machinability
Other information
lm
fn n
H 76
Unit
Tc =
Designation/
definition
Milling
Machining time, min
Symbol
Dm
Machined diameter
inch
fn
Feed per revolution
inch/r
ap
Cutting depth
inch
vc
Cutting speed
ft/min
Spindle speed
rpm
Pc
Net power
HP
Metal removal rate
inch3/min
hm
Average chip thickness
inch
hex
Maximum chip thickness
inch
Tc
Period of engagement
min
lm
Machined length
mm
kc
lbs/inch2
Lead angle
degree
Turning
Formulas and definitions for turning - METRIC

Cutting speed, m/min
1000
Parting and
grooving
vc =
Dm n
Spindle speed, rpm

vc 1000
Threading
n=
Dm
Milling
v ap fn kc
Pc = c
60 103
mm/r
ap
Cutting depth
mm
vc
Cutting speed
m/min
Spindle speed
rpm
Drilling
Net power, kW
mm
Feed per revolution
Pc
Net power
kW
Metal removal rate
cm3/min
hm
mm
hex
mm
Tc
Period of engagement
min
Boring
Q = vc ap fn
Machined diameter
fn
lm
Machined length
mm
N/mm2
Entering angle
degree
kc
kr
Tool holding
Metal removal rate, cm3/min
Dm
H 77
Machinability
Other information
lm
fn n
Unit
Tc =
Designation/
definition
Machining time, min
Symbol
Turning
Formulas and definitions for milling - INCH

Table feed, inch/min

vc =
Dcap n
12
Spindle speed, rpm
Milling
Feed per tooth, inch

vf
fz =
n zc
Feed per revolution, inch/rev

Drilling
fz =

Q = ap ae vf
Net power, HP
Tool holding
Boring
Pc =
ae ap vf kc
396 103
Torque, lbf ft
H
Machinability
Other information
vf
n
Mc =
H 78
Pc 16501
n
ae
Working engagement
inch
ap
Cutting depth
inch
Dcap C
utting diameter at cutting
depth ap
Unit
vc 12
Dcap
n=
Designation/
definition
Threading
Symbol
Parting and
grooving
vf = fz n zc
inch
Dm
Machined diameter
(component diameter)
inch
fz
Feed per tooth
inch
fn
Feed per revolution
inch
Spindle speed
rpm
vc
Cutting speed
ft/min
vf
Table feed
inch/min
zc
Number of effective teeth
pcs
hex
inch
hm
inch
kc
lbs/inch2
Pc
Net power
HP
Mc
Torque
lbf ft
Metal removal rate
inch3/min
Lead angle
degree
Turning
Formulas and definitions for milling - METRIC

Table feed, mm/min
B
Parting and
grooving
vf = fz n zc
Dcap n
C
Threading
1000
fz =
vf
n

Q=
ap ae vf
1000
Net power, kW
Pc =
ae ap vf kc
60 106
Torque, Nm
Mc =
Pc 30 103
Working engagement
mm
ap
Cutting depth
mm
Dcap C
utting diameter at cutting
depth ap
Milling
mm
Dm
Machined diameter
(component diameter)
mm
fz
Feed per tooth
mm
fn
Feed per revolution
mm/r
Drilling
Feed per revolution, mm/rev
ae
Spindle speed
rpm
vc
Cutting speed
m/min
vf
Table feed
mm/min
zc
pcs
hex
mm
hm
mm
kc
N/mm2
Pc
Net power
kW
Mc
Torque
Nm
Metal removal rate
cm3/min
kr
Entering angle
degree
Boring
vf
fz =
n zc
n
H 79
Tool holding
Feed per tooth, mm
D
Unit
vc 1000
Dcap
Designation/
definition
n=
Symbol
Spindle speed, r/min
H
Machinability
Other information
vc =
Turning
Formulas and definitions for drilling - INCH

Penetration rate, inch/min
vf = fn n
Parting and
grooving
Dc n
Milling
Drilling
vc 12
Dc
Feed force, N
D
Ff 0.5kc c fn sin kr
2
Boring
Q = vc Dc fn 3
Net power, HP
Tool holding
Pc =
vc Dc fn kc
132 103
Torque, lbf ft
H
Machinability
Other information
Dc
Drill diameter
inch
fn
Feed per revolution
inch/r
Spindle speed
rpm
vc
Cutting speed
ft/min
vf
Penetration rate
inch/min
Ff
Feed force
kc
lbs/inch2
Mc
Torque
lbf ft
Pc
Net power
HP
Metal removal rate
inch3/min
Lead angle
degree
Spindle speed, rpm

n=
Unit
12
Threading
vc =
Designation/
definition
Symbol
Mc =
H 80
Pc 16501
Turning
Formulas and definitions for drilling - METRIC

B
Penetration rate, mm/min
Parting and
grooving
vf = fn n
Dc n
Designation/
definition
Unit
Dc
Drill diameter
mm
fn
Feed per revolution
mm/r
Spindle speed
rpm
vc
Cutting speed
m/min
vf
Penetration rate
mm/min
Ff
Feed force
kc
N/mm2
Mc
Torque
Nm
Pc
Net power
kW
Metal removal rate
cm3/min
kr
Entering angle
degree
D
Ff 0.5kc c fn sin kr
2

v Dc fn
Q= c
4
Net power, kW
G
Tool holding
v Dc fn kc
Pc = c
240 103
Torque, Nm
Mc =
Milling
Feed force, N
Drilling
Dc
Boring
vc 1000
Pc 30 103
n
H 81
Machinability
Other information

n=
Threading
1000
Symbol
vc =
Turning
Formulas and definitions for boring - INCH

Penetration rate, inch/min
vf = fn n
Parting and
grooving
Dc n
vc =
vc 12
Milling
Dc
Feed per revolution, inch/rev
Drilling
fn = zc fz
Boring
Q = vc Dc fn 3
Net power, HP
Tool holding
Pc =
vc ap fn kc
132
103
Torque, lbf ft
H
Machinability
Other information
Dc
Drill diameter
inch
fn
Feed per revolution
inch/r
Spindle speed
rpm
vc
Cutting speed
ft/min
vf
Table speed
inch/min
Ff
Feed force
kc
lbs/inch2
Mc
Torque
lbf ft
Pc
Net power
HP
Metal removal rate
inch3/min
Lead angle
degree

(zc = 1 for step boring)
pcs
Spindle speed, rpm

n=
Unit
Threading
12
Designation/
definition
Symbol
Mc =
H 82
ap
Dc
zc
Feed force, N
Pc 16501
Ff 0.5 kc ap fn sin r
Turning
Formulas and definitions for boring - METRIC

B
Penetration rate, mm/min
Parting and
grooving
vf = fn n
Dc n
Symbol
Designation/
definition
Unit
Dc
Drill diameter
mm
fn
Feed per revolution
mm/r
Spindle speed
rpm
vc
Cutting speed
m/min
vf
Table speed
mm/min
Ff
Feed force
kc
N/mm2
Mc
Torque
Nm
Pc
Net power
kW
Metal removal rate
cm3/min
kr
Entering angle
degree

(zc = 1 for step boring)
pcs
fn = zc fz

Q=
vc Dc fn
4
Net power, kW
Pc =
vc ap fn kc
60 103
Torque, Nm
Mc =
ap
Dc
zc
Feed force, N
Pc 30 103
Milling
Feed per revolution, mm/r
Drilling
Dc
Boring
n=
Tool holding

vc 1000
Threading
1000
Ff 0.5 kc ap fn sin r
H 83
Machinability
Other information
vc =
Calculator
Turning
Parting and
grooving
Threading
The Sandvik Coromant cutting data calculator is designed to solve most calculation
problems encountered in the metal cutting
area.
The Sandvik Coromant cutting data calculator also functions as a standard

mathematical calculator. Calculations can
be done in metric or inch.
The calculator is self-explanatory and very

easy to use. Users include programmers,
operators, machinists, supervisors, foremen, designers and more.
As a user, you simply decide what parameter you want to calculate, choose the
appropriate formula from the menu in the
display and enter the input as prompted
by the calculator. This means that the user
does not need to memorize any metal cutting formulas.
Calculator metric/inch
Milling
Self-explanatory and very easy to use
Size 80x125x15 mm
Drilling
Machining Calculator App

The Machining Calculator app from Sandvik
Coromant is designed to help engineers and
machinists optimize the performance of their
turning, milling and drilling applications by
calculating optimal cut settings based on job
parameters.
Boring
The app is free and can be downloaded at the

Sandvik Coromant website.
*Available on select smartphones. See website for details.
Machinability
Other information
Tool holding
H 84

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Sandvik Coromant Academy

Metal Cutting Technology

Parting & Grooving

Choice of inserts how to apply

Turning is the combination of two movements rotation of

General turning operations

The feed movement of the tool can be along the axis of

Turning and facing as axial and radial tool movements.

Three common turning operations:

The spindle speed rpm (revolution per

The cutting speed is the surface speed,

Definition of cutting speed

vc = cutting speed, ft/min (m/min)

The definition of cutting speed as the result

Dm = machined diameter, inch (mm)

n = spindle speed, rpm

Calculation of the circumference

Circumference = 3.14 x 100

Example of cutting speed fluctuations

The cutting speed differs depending on the workpiece diameter.

Spindle speed, n = 2000 rpm

3.14 1.969 2000

fn = cutting feed (inch/r) (mm/r)

The cutting depth (ap) in inch (mm) is half

Lead (entering) angle

vc = cutting speed (ft/min) (m/min)

The cutting feed (fn) in inch/r (mm/r) is

n = spindle speed (rpm)

The cutting speed (vc) in ft/min (m/min) at

The workpiece rotates in the lathe, with

Calculating cutting data

Diameter Dm = 3.937 inch (100 mm)

Inclination and rake angles

The rake angle gamma () is a measure

Cutting depth and chip formation

The cutting depth (ap) is the length the

Chip formation varies with depth of cut,

Feed rate and the effective cutting edge length

The effective cutting edge length (la) relates to cutting

Cutting edge length

The feed rate (fn) is the

Insert shape selection, lead (entering) angle and chip

Lead angle r (Entering angle r)

Maximum chip thickness hex

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

Calculating power consumption

fn = cutting feed (inch/rev) (mm/rev)

vc = cutting speed (ft/min) (m/min)

For information about the kc value, see

The net power (Pc) in HP (kW) required for

Contact length la,

Dimension and type of

Workpiece material and

Type of turning tool:

Cutting data, tool

Remedies and solutions

1. Component and the workpiece material

Some important machine considerations:

Different ways to optimize turning

Turning with wiper inserts

New ways in profile turning

In practice, the tool holder, insert geometry,

T he depth of cut should be no less than 2/3

 ake sure that the flank wear does not

Choice of inserts how to apply

Circumference = 3.14 x 100

fn = cutting feed (inch/rev) (mm/rev)

vc = cutting speed (ft/min) (m/min)

1. Component and the workpiece material

T he depth of cut should be no less than 2/3

ake sure that the flank wear does not

Free chip flow

Free chip flow

Insert shape, size, nose radius

Cutting data effect on tool life

T hese three main basic

ISO P Steel is the largest material

ISO M Stainless steels are materials

ISO K Cast iron is, contrary to steel, a

ISO N Non-ferrous metals are softer

ISO H This group covers steels with a

M materials have a kc1 variation of:

H materials have a kc1 variation of:

S materials have a kc1 variation of:

In milling and drilling a lot of parameters influence the