C-2920-20 US 150dpi NY

Sandvik Coromant Academy
Metal Cutting Technology
Training Handbook
x D m x n

vc = 1000
Content
Turning Drilling
Theory A 4 Theory E 6
Selection procedure A 12 Selection procedure E 15
System overview A 16 System overview E 20
Choice of inserts A 22 How to apply E 26
Choice of tools Hole quality and tolerances E 37
- External A 50 Troubleshooting E 42
- Internal A 56
Code keys A 66
Boring
Troubleshooting A 70
Theory F 4
Selection procedure F 9
Parting & Grooving
System overview F 14
Theory B 4 Choice of tools F 16
Selection procedure B 7 How to apply F 21
System overview B 11 Troubleshooting F 26
Parting & grooving - how to apply B 15
- Parting off B 22
Tool holding
- General grooving B 25
- Circlip grooving B 27 History and background G 4
- Face grooving B 28 Why modular tooling G 7
- Profiling B 31 Turning centers G 15
- Turning B 33 Machining centers G 23
- Undercutting B 35 Multi-task machines G 29
Troubleshooting B 36 Chucks G 33
Threading Machinability
Theory C 4 Workpiece materials H 4
Selection procedure C 9 The cutting edge H 18
System overview C 13 Cutting tool materials H 29
How to apply C 19 Manufacturing of cemented carbide H 44
Troubleshooting C 25
Other information
Milling
Machining economy H 55
Theory D 4 Maintenance & tool wear H 68
Selection procedure D 9 Formulas and definitions H 75
System overview D 13 Cutting data calculator H 84
Choice of insert how to apply D 24
Choice of tools how to apply D 29
Troubleshooting D 36
1
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 A 50
- Internal A 56
Code keys A 66
Troubleshooting A 70
A3
A Theory
General turning operations

Turning
Turning is the combination of two movements rotation of

B the workpiece and feed movement of the tool.
The feed movement of the tool can be along the axis of
Parting and
the workpiece, which means the diameter of the part will

grooving
be turned down to a smaller size. Alternatively, the tool

can be fed towards the center (facing off), at the end of
the part.
C
Often feeds are combinations of these two directions,
resulting in tapered or curved surfaces.
Threading
Turning and facing as axial and radial tool movements.

Milling
E
Drilling
F
Boring
Three common turning operations:

G
- Longitudinal turning
Tool holding
- Facing
- Profiling.
H
Other information
Machinability
A4
Theory
A
Definitions of terms
Turning
Spindle speed
B
n (rpm) The spindle speed rpm (revolution per
minute) is the rotation of the chuck and
Parting and
workpiece.
grooving
C
Threading
Cutting speed
D
The cutting speed is the surface speed,
ft/min (m/min), at which the tool moves
vc (ft/min) along the workpiece in feet (meters) per
(m/min) minute.
Milling
E
Definition of cutting speed
Drilling
n The definition of cutting speed as the result
of the diameter, pi () and spindle speed in
revolutions per minute (rpm). The circumfer- F
ence (C) is the distance the cutting edge
moves in a revolution. Boring
C vc = cutting speed, ft/min (m/min)

Dm = machined diameter, inch (mm) G
n = spindle speed, rpm
Tool holding
Circumference, C = x Dm inch (mm)
Inch Metric
Dm n ft/min
Dm n m/min
H
vc = vc =
Other information
12 1000
Machinability
A5
A Theory
Calculation of the circumference

Turning
C
ircumference = x diameter (inch)
(mm)
B (pi) = 3.14
Parting and
Example:
grooving
Dm2 = 3
.937 inch (100 mm)
Circumference = 3.14 x 3.937
C
= 12.362 inch
Circumference = 3.14 x 100
= 314 mm
Threading
Dm1 = 1
.969 inch (50 mm)
Circumference = 3.14 x 1.969
D = 6.183 inch
Circumference = 3.14 x 50
= 157 mm
Milling
Example of cutting speed fluctuations

E The cutting speed differs depending on the workpiece diameter.
Given:
Spindle speed, n = 2000 rpm
Drilling
Diameter, Dm1 = 1.969 inch (50 mm)
F Diameter, Dm2 = 3.150 inch (80 mm)

Boring
Inch Metric
Dm n Dm n
G vc = ft/min vc = m/min
12 1000
Tool holding
3.14 1.969 2000 3.14 50 2000

vc1 = = 1030 vc1 = = 314
12 ft/min 1000 m/min
H 3.14 3.150 2000 3.14 80 2000
vc2 = = 1649 vc2 = = 502
Other information
12 ft/min 1000 m/min

Machinability
A6
Theory
A
Turning
Spindle speed
The workpiece rotates in the lathe, with
a certain spindle speed (n), at a certain B
number of revolutions per minute (rpm).
Parting and
grooving
Surface/cutting speed
The cutting speed (vc) in ft/min (m/min) at
which the periphery of the cut workpiece C
diameter passes the cutting edge.
Threading
Feed
The cutting feed (fn) in inch/r (mm/r) is
n = spindle speed (rpm) the movement of the tool in relation to the D
revolving workpiece. This is a key value
vc = cutting speed (ft/min) (m/min)
in determining the quality of the surface
fn = cutting feed (inch/r) (mm/r) being machined and for ensuring that the
chip formation is within the scope of the
Milling
ap = depth of cut (inch) (mm)
tool geometry. This value influences, not
r = entering angle only how thick the chip is, but also how the
chip forms against the insert geometry. E
r = lead angle
Depth of cut
Drilling
The cutting depth (ap) in inch (mm) is half
of the difference between the un-cut and
cut diameter of the workpiece. The cutting F
depth is always measured at right angles
Lead angle = 0 to the feed direction of the tool.
Entering angle = 90
Boring
Lead (entering) angle

The cutting edge approach to the work- G
piece is expressed through the lead angle
(r), which is the angle between the cut-
Tool holding
ting 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 H
Other information
correct turning tool for an operation.

Machinability
A7
A Theory
Calculating cutting data

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

n= = 1274 r/min n= = 1274 r/min
E 3.14 3.937 3.14 100
Inclination and rake angles

Drilling
Rake angle
F 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
Boring
strength, power consumption, finishing abil-

ity of the tool, vibration tendency and chip
G formation.
Inclination angle
Tool holding
The inclination angle lamda () is the an-

gle the insert is mounted in the tool holder.
When mounted in the tool holder, the
H insert geometry and inclination in the tool
Other information
holder will determine the resulting cutting

angle with which the cutting edge cuts.
Machinability
A8
Theory
A
Cutting depth and chip formation
Turning
ap B
ap
r
Parting and
grooving
C
The cutting depth (ap) is the length the Chip formation varies with depth of cut,
edge goes into the workpiece. lead (entering) angle, feed, material and
Threading
insert geometry.
Feed rate and the effective cutting edge length
Milling
E
Drilling
F
Feed rate Cutting edge length

Boring
The feed rate (fn) is the

distance the edge moves The effective cutting edge length (la) relates to cutting
along the cut per revolu- depth and lead (entering) angle. G
tion.
Tool holding
H
Other information
Machinability
A9
A Theory
Insert shape selection, lead (entering) angle and chip

thickness
Turning
The lead angle, r (entering angle r), of the tool and the
B 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
Parting and
(smaller entering angle).

grooving
The direction of chip flow is also changed.
C
CNMG DNMG WNMG
Lead angle r: Lead angle r: Lead angle r:

Threading
-5, 15 -17.5, -3, 27.5 -5

Entering angle r: Entering angle r: Entering angle r:
D 95, 75 107.5, 93, 62.5 95
SNMG RCMT TNMG

Milling
Lead angle r: Lead angle r: Lead angle r:

E 45, 15 Variable -3, -1, 30
Entering angle r: Entering angle r: Entering angle r:
45, 75 Variable 93, 91, 60
Drilling
VNMG
F Lead angle r: Entering angle r:

-27.5, -17.5, 17.5 117.5, 107.5, 72.5
Boring
Lead angle r (Entering angle r)
G Is defined by the holder tip seat in

combination with insert shape
selected.
Tool holding
Maximum chip thickness hex

R
educes relative to the feed rate as
H r = 45 hex fn the lead angle increases (entering
angle reduces).
Other information
hex fn x 0.71
Machinability
A 10
Theory
A
The effect of lead angle (entering angle) on chip thickness
Turning
Maximum chip thickness hex reduces relative to the feed
rate as the lead angle increases (entering angle reduces).
B
Parting and
grooving
r r r r
C
Lead angle r 5 15 30 45 0 min
Entering angle r 95 75 60 45 90 max
Threading
Chip thickness
compared to feed, .039 (1) .038 (0.96) .034 (0.87) .028 (0.71) Variable
inch (mm)
D
Contact length la,
inch (mm) at ap .079 (2) .082 (2.08) .091 (2.3) .111 (2.82) Variable
.079 inch (2 mm)
Milling
Calculating power consumption
E
The net power (Pc) in HP (kW) required for
metal cutting is mainly of interest when n = spindle speed (rpm)
roughing, where it is essential to ensure
that the machine has sufficient power for
Drilling
the operation. The efficiency factor of the fn = cutting feed (inch/rev) (mm/rev)
machine is also of great importance.
ap = depth of cut (inch) (mm) F
For information about the kc value, see
kc = s
pecific cutting force (lbs/in2)
page H 16.
(N/mm2)
Pc = net power (HP) (kW)
Boring
G
vc ap fn kc
Pc = HP
Tool holding
33 103
vc ap fn kc
Pc = kW H
60 103
Other information
Machinability
A 11
A Selection procedure
Selection procedure
Turning
B Production planning process

Parting and
grooving
Dimension and type of

operation
C
1 Component
Workpiece material and
Threading
quantity
Machine parameters
2
Milling
Machine
E
Type of turning tool:
- External/internal
- Longitudinal
3
Drilling
Choice of tool - Profiling

- Facing
F
Cutting data, tool

path, etc.
4
Boring
How to apply
G
Tool holding
5 Troubleshooting Remedies and solutions

H
Other information
Machinability
A 12
Selection procedure
A
1. Component and the workpiece material
Turning
Parameters to be considered
Component B
A nalyze the dimensions and quality demands of the
surface to be machined.
Parting and
grooving
Type of operation (longitudinal, profiling and facing).
External, internal
Roughing, medium or finishing
Tool paths
C
Number of passes
Tolerances
Threading
D
P M K Material
N S H achinability
M
Milling
Cast or pre-machined
Chip breaking
Hardness E
Alloy elements
2. Machine parameters
Drilling
Condition of the machine
F
Some important machine considerations:
- Stability, power and torque, especially for
larger diameters
- Component clamping
Boring
- Tool position
- Tool changing times/number of tools in turret G
- Spindle speed (rpm) limitations, bar feed magazine
- Sub spindle, or tail stock available?
Tool holding
- Use all possible support

- Easy to program
- Cutting fluid pressure.
H
Other information
Machinability
A 13
3. Choice of tools
Turning
Different ways to optimize turning

Turning with rhombic inserts
B
Advantages Disadvantages
Operational versatility. Can cause vibration
Parting and
Small lead angle. when turning slender

grooving
For turning and facing. components.

Good roughing strength.
C
Threading
Turning with wiper inserts

D
Increase feed and gain In back turning and profil-
productivity. ing the wiper edge is not
Use normal feed rate and effective.
Milling
gain surface quality.

Productivity booster.
E
Drilling
New ways in profile turning

F Advantages
Increase feed and gain
productivity.
Use normal feed rate and
Boring

Productivity booster
G Tolerance
Setup time
Tool holding
Rigid insert location with

T-rails.
H
Other information
Machinability
A 14
Selection procedure
A
4. How to apply
Turning
Important application considerations
The tool path has a significant impact on

B
the machining process.
It influences:
Parting and
- Chip control
grooving
- Insert wear
- Surface quality
- Tool life. C
In practice, the tool holder, insert geometry,

grade, workpiece material and tool path
Threading
influences the cycle time and productivity
considerably.
D
5. Troubleshooting
Milling
Some areas to consider
E
Insert style
U
se positive inserts for lower cutting forces in
general and for internal turning.
Drilling
Chip breaking
O
ptimize the chip breaking by changing the
Negative style Positive style depth of cut, the feed or the insert geometry. F
Nose radius
T he depth of cut should be no less than 2/3
of the nose radius (re).
Boring
Insert wear
M
ake sure that the flank wear does not G
exceed the general recommendation of .012
inch (0.3 mm).
Tool holding
ap re H
Other information
Machinability
A 15
A System overview
External turning, negative inserts

Turning
1. Longitudinal turning
B
2. Profiling
3. Facing
Parting and
grooving
1 2
Threading
D
Milling
Overview of tool holders

Drilling
F
Boring
G
N egative insert N egative insert
Tool holding
Rigid clamping system Lever clamping system

Modular/shank tools Modular/shank tools
H
Other information
Machinability
A 16
System overview
A
External turning, positive inserts
Turning
B
2. Profiling
3. Facing
Parting and
grooving
C
1
2
Threading
3
D
Milling
E
Drilling
F
Boring
P ositive insert Positive insert N egative/positive P ositive insert G

Screw clamping Screw clamping insert Screw clamping
system system All clamping sys- system
Tool holding
Modular/shank T-rail interface tems Modular/shank

tools Modular/shank Cutting heads tools
tools Modular/shank
tools H
Other information
Machinability
A 17
A System overview
Internal turning, negative/positive inserts

Turning
B
2. Profiling
2 3. Longitudinal turning
1
Parting and
Mini bars
3
grooving
C
Threading
D
Overview of internal tool holders
Milling
N egative/positive inserts N egative insert N egative insert

Drilling
Dampened boring bars Rigid clamping system Lever clamping system

Min. hole 1.575 inch Min. hole .984 inch Min. hole .787 inch
(40 mm) (25 mm) (20 mm)
F
Boring bars Modular/boring bars Modular/boring bars
Boring
G
Tool holding
egative/positive insert
N ositive insert
P D ampened boring bars
All clamping systems Screw clamping system Min. hole .512 inch
Cutting heads Cutting heads (13 mm)
Min. hole .787 inch Min. hole .236 inch Boring bars
H (6 mm)
(20 mm)
Other information
Dampened modular/ Modular/boring bars

Machinability
boring bars
A 18
System overview
A
Tools for small part machining
Turning
1. External turning
B
2. External turning
(Sliding head machines)
Parting and
1 3. Internal turning
grooving
2 (Exchangeable inserts)
4. Internal turning
C
5. Internal turning
5 (Carbide rods)
Threading
4 3
D
External tools
Milling
E
P ositive insert Quick change tools P ositive insert
Drilling
Screw clamping system Positive insert Screw clamping system
Shank tools Screw clamping system
F
Internal tools
Boring
G
Tool holding
P ositive insert P ositive insert P ositive insert

Screw clamping system Screw clamping system Carbide rods
Min. hole .236 inch Min. hole .394 inch Min. hole .012 inch H
(6 mm) (10 mm) (0.3 mm)
Other information
Machine adapted bars

Machinability
A 19
A System overview
Overview of insert clamping systems

Turning
Clamping of negative basic-shape inserts

B
Parting and
grooving
C
Rigid clamping system Lever clamping system
Threading
Clamping of positive basic-shape inserts
D
Milling
E Screw clamping system

Drilling
Screw clamping system

Boring
Clamping of positive T-rail inserts

G
Tool holding
T-rails
H
Other information
Screw clamping system

5/7
Machinability
A 20
System overview
A
Modern insert clamping for turning tools
Turning
Rigid clamping
Negative inserts B
Excellent clamping
Parting and
Easy indexing
grooving
C
Lever clamping
Threading
Negative inserts
Free chip flow D
Easy indexing
Milling
E
Screw clamping
Positive inserts
Drilling
S
ecure clamping of
the insert
F
Free chip flow
Boring
Screw clamping system, T-rail G
Positive inserts
Tool holding
Very secure clamping

High accuracy
H
Other information
Machinability
A 21
A Choice of inserts
Choice of inserts
Turning
Basic factors A 23
Parting and
grooving
Insert geometries A 32
C
Insert grades A 39
Threading
Insert shape, size, nose radius A 42
Cutting data effect on tool life A 48

D
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
A 22
Choice of inserts basic factors
A
The complex world of metal cutting
Turning
Getting metal cutting processes right means knowing
the workpiece material, then choosing the correct insert B
geometry and grade to suit the specific application.
Parting and
grooving
Workpiece material
T he interaction between
an optimized insert C
geometry and grade for a
certain workpiece mate-
rial is the key to success-
Threading
ful machining.
T hese three main basic
factors must be carefully D
considered and adapted
for the machining opera-
tion in question.
Milling
T he knowledge and
understanding of how
to work with and employ E
these factors is of vital
importance.
Drilling
Grade Geometry
The machining starts at the cutting edge

Boring
G
Tool holding
H
Typical chip breaking
Other information
sequences with high speed

Machinability
imaging.
A 23
A Choice of inserts basic factors
Six material groups

Turning
In the metal cutting industry there is an Workpiece materials are divided into 6
incredibly broad range of component major groups in accordance with the ISO-
B designs made from different materials. standard, where each group has unique
Each material has its own unique char- properties regarding machinability.
acteristics influenced by the alloying ele-
ments, heat treatment, hardness, etc. This
Parting and
grooving
strongly influences the selection of cutting

tool geometry, grade and cutting data.
Workpiece material groups

Threading
Steel ISO P Steel is the largest material

D P group in the metal cutting area, ranging
from unalloyed to high-alloyed material
including steel castings and ferritic and
martensitic stainless steels. The ma-
chinability is normally good, but differs
Milling
a lot depending on material hardness,

carbon content, etc.
E
Drilling
ISO M Stainless steels are materials

Stainless
Boring
M steel
alloyed with a minimum of 12% chro-
mium; other alloys are, e.g., nickel and
G molybdenum. Different conditions such
as ferritic, martensitic, austenitic and
austenitic-ferritic (duplex), makes this an
Tool holding
extensive material group. Common for

all these types are that they expose cut-
ting edges to a great deal of heat, notch
wear and built-up edge.
H
Other information
Machinability

A 24
A
ISO K Cast iron is, contrary to steel, a

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

N types of metals such as aluminum, cop-
Threading
per, 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 D
sharp edges.
Milling
E
Heat resistant ISO S Heat Resistant Super Alloys
S alloys include a great number of high-alloyed
iron, nickel, cobalt and titanium-based
Drilling
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 F
shorter tool life for the cutting edges.
Boring
Hardened ISO H This group covers steels with a G

H steel hardness between 45-65 HRc and also
chilled cast iron around 400-600 HB.
Tool holding
The hardness makes them all difficult to

machine. The materials generate heat
during cutting and are very abrasive to
the cutting edge.
H
Other information
Machinability
A 25
Cutting forces
Turning
Another expression of the differences tion of how much power is needed for an
in the six material groups is through the operation.
B force (FT) needed to shear off a specific
kc1 = specific cutting force for average
chip cross-section in certain conditions.
chip thickness .039 inch (1 mm).
This value, the specific cutting force value
Parting and
(kc), is indicated for various types of work-

grooving
piece materials and used in the calcula-
C
P Steel
Threading
P
materials have a kc1 variation of:
217,500-449,500 lbs/inch2
Milling
(1500-3100 N/mm2).
E M Stainless steel
Drilling
F
M materials have a kc1 variation of:
261,000-413,250 lbs/inch2
(1800-2850 N/mm2).
Boring
K Cast iron
G
Tool holding
H K
114,550-195,750 lbs/inch2
Other information
(790-1350 N/mm2).

Machinability
A 26
A
Turning
N Aluminum
Parting and
grooving
N
50,750-195,750 lbs/inch2 C
(350-1350 N/mm2).
Threading
S Heat resistant super alloys
Milling
S materials have a kc1 variation of:
- 348,000-449,500 lbs/inch2 E
(2400-3100 N/mm2) for HRSA
- 188,500-203,000 lbs/inch2
(1300-1400 N/mm2) for titanium alloys
Drilling
H Hardened material
F
Boring
H materials have a kc1 variation of: G

369,750-706,150 lbs/inch2
(2550 4870 N/mm2).
Tool holding
H
Other information
Machinability
A 27
Chip formation
Turning
There are three patterns for a chip to break

after it has been cut.
B
Self-breaking Against the tool Against the workpiece

Parting and
grooving
C
Threading
D
Milling
Self-breaking, where the Chips breaking against the Chips breaking against the
material, in combina- tool, where the chip curves workpiece, where the chip
Drilling
tion with how the chip is around until it makes snaps when making con-
curved, leads to the chips contact with the clearance tact with the surface that
F being parted as they come face of the insert or tool has just been machined.
off the insert. holder, and the resulting This type of chip breaking
strain snaps it. Although is usually not suitable in
often accepted, this applications where a good
Boring
method can in some cases surface finish is needed,

lead to chip hammering, because of possible
where the chip damages damage caused to the
G
the insert. component.
Tool holding
H
Other information

Machinability
A 28
A
Chip formation varies with different parameters
Turning
Chip formation varies with depth of cut, feed, material
and tool geometry.
B
Self-breaking Against the tool Against the workpiece
Parting and
grooving
ap
ap
r C
Threading
D
Insert rake angle
Milling
The rake angle () can be either negative or positive.
Based on this, there are negative and positive inserts, E
where the clearance angles are either zero or several de-
grees plus. This determines how the insert can be tilted
in the tool holder, giving rise to a negative or positive
cutting action.
Drilling
F
Positive cutting action Negative cutting action

Boring
G
Tool holding
H
Other information

Machinability
A 29
Insert rake angle

Turning
There is a distinction in cutting edge geom- -A

positive insert has an wedge angle of
etry between negative and positive insert less than 90.
geometry:
B The negative insert has to be inclined
- A negative insert has a wedge angle of
negatively in the tool holder so as to
90 seen in a cross-section of the basic
provide a clearance angle tangential to the
shape of the cutting edge.
Parting and
workpiece while the positive insert has

grooving
this clearance built in.
C Negative style
ouble/single sided
D Note: The clearance
Edge strength angle is the angle
between the front
Threading
Zero clearance face of the insert

External/internal machining and the vertical axis
Heavy cutting conditions of the workpiece.
D
Positive style
ingle sided
S
Milling
Low cutting forces

Side clearance
E
Internal/external machining
Slender shafts, small bores
Drilling
Insert geometries
F 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
In milling and drilling a lot of parameters influence the

G chip formation compared to turning.
Turning is a single-cut operation with a stationary tool
and a rotating workpiece.
Tool holding
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.
H
Other information
Machinability
A 30
Choice of inserts geometries
A
The design of a modern insert
Turning
Definitions of terms and geometry design
B
Nose cutting edge design Main cutting edge design
Parting and
grooving
.010 in.
(0.25 mm) 20 C
5
Macro geometry with
chip breaker C
utting edge rein-
Threading
forcement .010 inch
(0.25 mm)
Geometry for small Rake angle 20
cutting depths D
Primary land 5
.008 in. (0.2 mm)
Milling
E
The reinforcement of the cutting edge
The ER-treatment (Edge Roundness) gives the cutting
Drilling
edge the final micro-geometry.
E
R-treatment is done before coating, and F
gives the final shape of the cutting edge
(micro-geometry).
T he relationship between W/H is what
Boring
makes inserts suitable for different

applications.
G
Tool holding
H
Other information
Machinability
A 31
A Choice of inserts geometries
The working area of an insert geometry

Turning
A chip breaking diagram for an insert

B geometry is defined by acceptable chip
breaking for feed and depth of cut.
Parting and
Cutting depth,
C
utting depth (ap) and feed (fn) must be
grooving
ap inch (mm)
adapted to the chipbreaking area of the
geometry to get acceptable chip control.
C
C
hip breaking which is too hard can lead
to insert breakage.
C
hips which are too long can lead to
Threading
disturbances in the machining process

and bad surface finish.
D
Feed, fn inch/r (mm/r)

Milling
Three main application areas in turning

E
R = Roughing Roughing
M = Medium machining M
aximum stock removal and/or severe
conditions.
F = Finishing
Drilling
L arge cutting depth and feed rate combi-

Cutting depth,
nations.
F ap inch (mm)
High cutting forces.
Medium machining
Most applications general purpose.
Boring
Medium operations to light roughing.

G
W
ide range of cutting depth and feed
rate combinations.
Tool holding
Finishing
Small cutting depths and low feed rates.
Feed, fn inch/r (mm/r)

Low cutting forces.
H
Other information
Machinability
A 32
A
Chip breaking application areas
Turning
Turning of low alloy steel
Roughing R
Cutting depth, High depth of cut and feed rate combina- B
ap inch (mm)
tions. Operations requiring the highest
CNMG 432 (CNMG 120408) edge security.
Parting and
grooving
.236 (6.0)
Medium M
.157 (4.0) C
Wide range of depth of cut and feed rate
combinations.
.079 .(2.0)
Threading
Finishing F
Operations at light depths of cut and low
(0.1) (0.4) (0.8) D
.004 .016 .031 feed rates.
Feed, fn inch/r (mm/r) Operations requiring low cutting forces.
Milling
Chip breaking diagram
E
Roughing of low alloy Chip breaking area:
steel
P R
ap = .197 (.039 - .295) inch
fn = .020 (.010 - .028) inch/r
Drilling
CNMM 432-PR ap = 5.0 (1.0 - 7.5 ) mm
Cutting depth, (CNMM 120412-PR) fn = 0.5 (0.25 - 0.7) mm/r
ap inch (mm) F
The area marked
in red indicates the
area which gives
Boring
.236 (6.0) acceptable chip

breaking.
.118 (3.0) G
.059 (1.5)
Tool holding
.039 (1.0)
.020 (0.5)
H
Other information
(0.1) (0.2) (0.3) (0.4) (0.5) (0.6) (0.7) Feed, fn inch/r (mm/r)
.004 .008 .012 .016 .020 .024 .028

Machinability
A 33
Medium machining of Chip breaking area:

low alloy steel P M
Turning
ap = .118 (.020 - .217) inch

fn = .012 (.006 - .020) inch/r
B ap = 3.0 (0.5 - 5.5) mm
CNMG 432-PM fn = 0.3 (0.15 - 0.5) mm/r
Cutting depth, (CNMG 120408-PM)
ap inch (mm)
Parting and
grooving
.236 (6.0)
C
.118 (3.0)
Threading
.059 (1.5)
.039 (1.0)
D
.020 (0.5)
(0.1) (0.2) (0.3) (0.4) (0.5) Feed, fn inch/r (mm/r)

Milling
.004 .008 .012 .016 .020
E
Finishing of low alloy Chip breaking area:
steel
P F ap = .016 (.010 - .059) inch
fn = .006 (.003 - .012) inch/r
Drilling
ap = 0.4 (0.25 - 1.5) mm

Cutting depth, CNMG 434-PF fn = 0.15 (0.07 - 0.3) mm/r
F ap inch (mm) (CNMG 120404-PF)
.059 (1.5)
Boring
.049 (1.25)
G .039 (1.0)
.030 (0.75)
Tool holding
.020 (0.5)
.010 (0.25)
H
(0.1) (0.15) (0.2) (0.25) (0.3) (0.35) Feed, fn inch/r (mm/r)
Other information
.004 .006 .008 .010 .012 .014

Machinability
A 34
A
Selection of inserts
Turning
Considerations when selecting inserts
It is important to select the correct insert
size, insert shape, geometry and insert B
nose radius to achieve good chip control.
S
elect the largest possible point angle
Parting and
grooving
on the insert for strength and economy.
S
elect the largest possible nose radius
l for insert strength. C
S
elect a smaller nose radius if there is a
tendency for vibration.
re
Threading
l = cutting edge length (insert size)
re = nose radius D
Milling
Dedicated inserts for the ISO P, M and K area E
The different micro and macro-geometries are adapted to the
various requirements in the applications.
Drilling
Workpiece Finishing Medium Roughing
material
F
.003 in. .008 in. .013 in.
(0.07 mm) (0.2 mm) (0.32 mm) Boring
.012 in. .013 in. G

(0.29 mm) (0.32 mm)
Tool holding
.004 in. .010 in.

(0.1 mm) (0.25 mm)
H
Other information
Machinability
A 35
Geometry description
Turning
Every insert has a working area with optimized chip control.

A geometry description and application information are also
B available.
Geometry working Geometry Application

Parting and
area description
grooving
-PM CNMG 432-PM -PM for medium turning

(CNMG 12 04 08-PM) with broad capability for steel.
C ap = .020 .217 inch Feed: .004 .026 inch/r (0.1 0.65 mm/r)
fn = .006 .020 inch/r Depth of cut: .016 .339 inch (0.4 8.6 mm)
ap = 0.5 5.5 mm Operations: turning, facing and profiling.
Threading
fn = 0.15 0.5 mm/r Advantages: all-purpose, reliable, with problem-

ap inch (mm) free machining.
.010 in. Components: axles, shafts, hubs, gears, etc.
(0.25 mm)
.236 (6.0)
Limitations: depth of cut and feed, risk of
D .197 (5.0)
overloading the cutting edge.
.157 (4.0) .008 in.
.118 (3.0)
(0.20 mm) General recommendations: Combine with
a wear resistant grade (GC4225) for best
.079 (2.0)
productivity.
.039 (1.0)
Possible optimization: geometry WMX.
Milling
(0.1) (0.2) (0.3) (0.4) (0.5) (0.6) (0.7) (0.8) (0.9) fn inch (mm)
.004 .008 .012 .016 .020 .024 .028 .031 .035
From universal to optimized turning inserts

Universal inserts
Drilling
Universal geometry.
F Optimizing with grades.
Performance compromised.
Boring
Application area
G
Optimized inserts
Tool holding
D
edicated geometries
and grades.
H O
ptimized performance
according to workpiece
Other information
machinability.
Machinability
Application area
A 36
A
Dedicated turning inserts

For steel, stainless, cast iron, aluminum, heat resistant
Turning
super alloys and hardened steel.
Parting and
Negative basic-shape inserts Positive basic-shape inserts
grooving
ISO Finishing Medium Roughing Finishing Medium Roughing
C
Threading
D
M
Milling
K E
Drilling
N
F
S
Boring
H
Tool holding
H
Other information
Machinability
A 37
Inserts for general turning

Turning
The choice of different insert concepts
Negative, double/single-sided inserts A

negative insert has a
B
wedge angle of 90 seen in
Plain inserts a cross-section of the basic
shape of the cutting edge.
Parting and
grooving
A
vailable as double/single-
sided inserts with P-hole or
plain.
C Double Single Without With hole
sided sided hole
Threading
Positive, single-sided inserts A positive insert has a

wedge angle less than 90.
D
A
vailable with 7 or 11
clearance angle.
The
positive T-rail inserts
have a clearance angle of
Milling
Positive Positive Positive T-rail 5 or 7.

11 7 clamping
E
Chip forming at high pressure and temperatures

Drilling
The choice of cutting material and grade is critical

F for success
The ideal cutting tool material should:
-b
e hard to resist flank wear and
Boring
deformation.
- be tough to resist bulk breakage.
G
-n
ot chemically interact with the workpiece
material.
Tool holding
-b
e chemically stable to resist oxidation
and diffusion.
Temperatures given -h
ave good resistance to sudden thermal
H in Celsius
changes.
Other information
Machinability
A 38
Choice of inserts grades
A
The main range of cutting tool materials
Turning
The most common cutting tool materials are divided into
the following main groups: B
- Uncoated cemented carbide (HW) CN N
itride ceramics containing prima-
rily silicon nitride (Si3N4).
Parting and
- Coated cemented carbides (HC)
grooving
CC Ceramics as above, but coated.
- Cermets (HT, HC)
- Cubic boron nitrides (BN)
HT U
ncoated cermet containing
C
primarily titanium carbides (TiC) - Polycrystalline diamonds (DP, HC)
or titanium nitrides (TiN) or both
HC P
olycrystalline diamonds, but
HC Cermet as above, but coated coated.
Threading
- Ceramics (CA, CM, CN, CC)
CA O
xide ceramics containing primar-
D
ily aluminum oxide (Al2O3).
CM M
ixed ceramics containing
primarily aluminum oxide (Al2O3)
but containing components other
Milling
than oxides.
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
A 39
A Choice of inserts grades
How to select insert geometry and grade

Turning
Select the geometry and grade according to the application.
B Build up of a grade chart Machining conditions
Wear resistance
Parting and
Good
grooving
C
Average
Threading
Difficult
D
Milling
Good Average Difficult
E Machining conditions
Good conditions
Continuous cuts
Drilling
High speeds
Pre-machined workpiece
F Excellent component clamping
Small overhangs
Average conditions
Boring
Profiling cuts
Moderate speeds
G Forged or cast workpiece
Good component clamping
Tool holding
Difficult conditions
Interrupted cuts
Low speeds
H Heavy cast or forged skin on workpiece
Other information
Poor component clamping

Machinability
A 40
Choice of inserts grades
A
Dedicated grades for ISO P, M and K
Turning
Dedicated grades minimize tool wear development
The workpiece material influences the wear during the B
cutting action in different ways. Therefore dedicated
grades have been developed to cope with the basic wear
Parting and
mechanisms, e.g.:
grooving
- Flank wear, crater wear and plastic deformation in steel
- Built-up edge and notch wear in stainless steel
C
- Flank wear and plastic deformation in cast iron.
Threading
D
Select geometry and grade depending on the type of the
workpiece material and type of application.
Milling
E
Drilling
F
Boring
G
ISO GC 4200 ISO GC 2000 ISO GC 3200
P M K
Tool holding
H
Other information
Machinability
A 41
A Choice of inserts shape
Selection of the insert shape

Turning
The influence of large and small point angle
B The insert shape and point angle varies Each shape also has unique limitations.
considerably from the smallest, at 35, to For example:
the round insert. - high edge accessibility during machining
Parting and
leads to a weaker cutting edge.

grooving
Each shape has unique properties:

- some provide the highest roughing
strength
C
-o
thers give the best profiling
accessibility.
Threading
Round 90 80 80 60 55 35
R S C W T D V
D
Milling
Cutting edge
Accessibility
strength
Drilling
Vibration Power
F tendency consumption
Boring
Large point angle Small point angle
G Stronger cutting edge Weaker cutting edge

Higher feed rates Increased accessibility
Tool holding
Increased cutting forces Decreased cutting forces

Increased vibration Decreased vibration
H
Other information
Machinability
A 42
Choice of inserts shape
A
Factors affecting choice of insert shape
Turning
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
B
insert strength and reliability.
= Most suitable
Parting and
grooving
= Suitable
C
Insert shape
Threading
Roughing strength

Light roughing/semi-
finishing D
Finishing
Milling
Longitudinal turning
E
Profiling
Facing
Drilling
Operational versatility
F
Limited machine power Boring
Vibration tendencies
Hard material G

Tool holding
Intermittent machining
Small lead angle

H
Other information
Large lead angle

Machinability
A 43
A Choice of inserts shape
Number of cutting edges

Turning
Insert shape
B
ISO (first letter) R S C W T D V

Parting and
grooving
Number of edges,
4/8 2/4 3/6 3/6 2/4 2/4
negative inserts
C
Number of edges,
4 2 3 3 2 2
positive inserts
Threading
D Selection of the nose radius

Effect of small and large nose radius
Milling
re
E re
re
Drilling
Large nose radius

Boring
Small nose radius

Ideal for small cutting Heavy feed rates
G depth Rule of thumb
Large depths of cut
Reduces vibration The depth of cut
Strong edge security
Tool holding
Weak cutting edge should be no less

Increased radial than 2/3 of the nose
pressures radius r.
H
Other information
Machinability
A 44
Choice of inserts nose radius
A
A small nose radius should be first choice
Turning
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 B
surface texture and more even pressure on the cutting
edge.
Parting and
grooving
C
DOC
DOC
Threading
DOC
D
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
Milling
is smaller than the DOC.
Effect of nose radius and DOC
Drilling
The radial force exerted on the workpiece However with a round insert, radial pres-
grows linearly until the nose radius of the sure will never stabilize because the
insert is less than the depth of cut where theoretical nose radius is half the insert
F
it stabilizes at the maximum value. diameter (iC).
Boring
G
Tool holding
H
Other information
Machinability
A 45
A Choice of inserts nose radius
High feed turning with wiper inserts

Turning
Wiper General information

Why use a wiper
B Wiper insert Increase feed and gain
productivity.
Rmax U
se normal feed rate and
Parting and
rWiper
grooving

When to use wipers
Use wipers as a first
C
choice where its pos-
sible.
Limitations
Threading
Conventional insert General limitation is

vibration.
D Rmax V
isually, surfaces can
rISO
look different even
though the measured
surface is great.
Milling
E
Wiper Technical solution
O
ne wiper cutting edge is based on
Drilling
3-9 radii.
C
ontact surface between insert and
F component is longer with wipers.
L onger contact surface makes a better
surface finish.
L onger contact surface increases cutting
Boring
forces which makes a wiper insert more

sensitive to vibration when machining
G unstable components.
Tool holding
H
Other information
A conventional nose radius compared

Machinability
with a wiper nose radius.
A 46
Choice of inserts nose radius
A
Wiper Surface finish
Turning
Traditional
insert
B
Rule of thumb
Parting and
grooving
T wo times feed with a wiper will
generate as good surface as con-
Wiper insert ventional geometries with normal
Twice the feed. C
feed, same Ra T he same feed with a wiper will
generate twice as good surface
Threading
compared with conventional
geometries.
D
Wiper insert
Same feed,
half Ra
Rt = Maximum value peak-to-valley height
Milling
Ra = A
rithmetic average height of the
profile E
Drilling
Achieved surface traditional ISO inserts and wipers
Ra F
(m)
236 (6.00)
197 (5.00) Insert geometry

Boring
157 (4.00) Standard -PM

G
118 (3.00) Wiper -WM
Tool holding
79 (2.00)
Wiper -WMX
39 (1.00)
0 (0.00) H
(0.20) (0.35) (0.50) (0.65) Feed, fn inch/r (mm/r)
Other information
.008 .014 .020 .026

Machinability
A 47
A Choice of inserts speed and tool life
Cutting data parameters affect tool life

Turning
B
Use the potential of:
Parting and
- ap to reduce number of cuts

grooving
- fn for shorter cutting time

- vc for best tool life
C
Threading
Cutting speed
Tool life
D
vc large effect on tool life.
Adjust vc for best economy.
Milling
E Cutting speed vc
Drilling
Feed
Tool life
fn less effect on tool life than vc.

F
Boring
Feed fn
Cutting depth
Tool life
Tool holding
ap little effect on tool life.
H
Other information
Machinability
Cutting depth ap
A 48
Choice of inserts speeds and tool life
A
Effects of cutting speed
Turning
The single largest factor determining tool life
Too high Too low B

Rapid flank wear Built-up edge
Parting and
Poor finish Uneconomical
grooving
Rapid cratering
Plastic deformation
C
Threading
Effects of feed rate
D
The single largest factor determining productivity
Too high Too low
Milling
Loss of chip control Stringers
Poor surface finish Uneconomical
E
C
ratering, plastic defor-
mation
High power consumption
Drilling
Chip welding
Chip hammering F
Boring
Effects of depth of cut

Too deep Too small G
High power consumption Loss of chip control
Tool holding
Insert breakage Vibrations

Increased cutting forces Excessive heat
Uneconomical
H
Other information
Machinability
A 49
A Choice of tools external turning
External turning
Turning
Tool selection and how to apply

B
General guidelines
Parting and
S
ecure insert and tool holder clamping is
grooving
an essential factor for stability in turning.

T ool holder types are defined by the lead
C (entering) angle, the shape and size of
the insert used.
T he selection of tool holder system is
Threading
mainly based on the type of operation.

A
nother important selection is the use of
negative versus positive inserts.
D
W
henever possible choose modular
tools.
Milling
Definitions of key figures

Drilling
F
Boring
22 Max in copy angle

G Lead angle r 3
(Entering angle r = 93)
Feed directions
Tool holding
H Insert shape
Other information
Insert point angle 60

Machinability
A 50
Choice of tools external turning
A
Four main application areas
Turning
Longitudinal turning/facing
B
The most common turning operation.
Rhombic shape C-style (80) insert is frequently used.
Parting and
Holders with lead angles of 5 and 3 (entering angles of
grooving
95 and 93) are commonly used.
Alternatives to the C-style insert are D-style (55), W-style (80)
and T-style (60). C
Threading
Profiling
Versatility and accessibility is the determining factor.
The effective lead angle (r ) (entering angle (kr)) should be D

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.
T he most frequently used insert shapes are D-style (55),
Milling
V-style (35) and T-style (60) inserts.
E
Facing
The tool is fed in towards the center.
Drilling
P
ay attention to the cutting speed which will change progres-
sively when feeding towards the centre.
L ead angles of 15 and 5/1 (entering angles of 75 and
95/91) are commonly used.
F
C-style (80), S-style (90), and T-style (60) inserts are fre-
quently used.
Boring
Plunging
G
A method to produce or widen shallow grooves.
R
ound inserts are very suitable for plunge turning as they can
Tool holding
be used for both radial and axial feeds.

Neutral 90 holders for round inserts are commonly used.
H
Other information
Machinability
A 51
Small lead angle

Turning
Features / Benefits
Cutting forces directed towards chuck.
B
Can turn against a shoulder.
Higher cutting forces at entrance and exit of cut.
Parting and
grooving
5 Tendency to notch in HRSA and hard materials.
C
Threading
Large lead angle

D
Features / Benefits
Milling
Produces a thinner chip

- Increased productivity.
E Reduced notch wear.
Cannot turn against a shoulder.
45
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
A 52
A
The lead angle
Turning
Important consideration in profile turning
B
In-copying Longitudinal turning Out-copying
Parting and
r
grooving
r
r
C
Threading
T he effective lead angle (r) should also be considered
for satisfactory machining when the operation involves
profiling. D
T he maximum in-copying angle beta () is recommend-
ed for each tool type and is specified in the catalogs.
Milling
E
Axial and radial cutting forces
Small lead angle Large lead angle
Drilling
F
Ff = axial
Ff = axial
Fp = radial
Boring
Fp = radial
G
Forces directed toward the chuck. Less Forces are directed both axially and
tendency for vibration. radially.
Tool holding
Higher cutting forces especially at Reduced load on the cutting edge.

entrance and exit of cut.
F orces are directed both axially and
radially.
H
- Vibration tendencies.
Other information
Machinability
A 53
Define the suitable clamping system

Turning
Tooling system
Longitudinal
B
Plunging
Profiling
turning
Facing
++
Parting and
=R ecommended tool
grooving
holder system
+ = Alternative system
Rigid clamp
design ++ ++ ++
Threading
Negative inserts
D Lever
design + + + +
Milling
Wedge
E clamp + + +
design
Drilling
Screw
clamp + ++ + ++
Positive inserts
design
F
Screw
clamp + ++
Boring
design T-rail
G
Rigid clamp
++ ++ ++
Ceramic and CBN
design
Tool holding
inserts
H Top clamp
design + + + ++
Other information
Machinability
A 54
A
Insert recommendation depending on operation
Turning
Insert shape
Longitudinal
B
Plunging
Profiling
turning
Facing
Parting and
++ =
grooving
Recommended insert shape
+= Alternative shape
C
C Rhombic 80 ++ +
Threading
D Rhombic 55 + ++ +
R Round + + + ++ D
S Square + ++
+ + + +
Milling
T Triangular
W Trigon 80 + + E
V Rhombic 35 +
Drilling
K Rhombic 55 + + +
F
Modern insert clamping for turning tools

Boring
Screw clamping, G
Rigid clamping P lever style Screw clamping
T-rail
Tool holding
H
Other information
Machinability
A 55
A Choice of tools - internal turning
Internal turning
Turning
Tool selection and how to apply

B
General guidelines
Parting and
In internal turning (boring operations)

grooving
the choice of tool is very much restricted

by the components hole diameter and
length.
C
-C
hoose the largest possible bar diame-
ter and the smallest possible overhang.
Threading
-C
hip evacuation is a critical factor for
successful boring.
- T he clamping method has a decisive ef-
D
fect on the performance and result.
Milling
E
Drilling
F
Selection factors
Tool and insert geometry Chip evacuation Tool requirements
Boring
Lead (entering) angle Chip size Reduced length

Insert shape, negative/ Chip control Increased diameters
G positive
Techniques Optimized shape
Insert geometry
Different tool materials
Tool holding
Nose radius
Clamping
H
Other information
Machinability
A 56
Choice of tools internal turning
A
Effect of cutting forces on internal turning
Turning
Radial and tangential cutting forces deflect the boring bar
B
Tangential cutting force, Ft
F orces the tool down, away from the
Parting and
center line.
grooving
Gives a reduced clearance angle.
C
Radial cutting force, Fr
Alters cutting depth and chip thickness.
Threading
G
ives out of tolerance dimension and
risk of vibration.
Fr
D
Feed force, Fa
Fa
Directed along the feed of the tool.
Milling
Ft F
E
Selecting lead (entering) angles

Lead angle and cutting forces
Drilling
S
elect a lead angle close to 0 (entering
angle close to 90). F
Boring
If possible, do not choose a lead angle

more than 15 (entering angle less than G
75), since this leads to a dramatic
increase of the radial cutting force Fr.
Tool holding
- L ess force in radial direction = less

deflection.
H
Other information
Machinability
A 57
A Choice of tools internal turning
Four main application areas

Turning
Longitudinal turning/facing
B The most commonly used internal turning operation.
Rhombic shape C-style (80) insert is frequently used.
Parting and
Boring bars with lead angles of 5 and 3 are

grooving
commonly used.
D
-style (55), W-style (80) and T-style (60) insert shapes
are also frequently used.
C
Profiling
Threading
Versatility and accessibility is the determining factor.
D The effective lead angle (r) should be considered.

Bars with lead angle of 3, allowing an in-copying angle be-
tween 2227, are commonly used.
D
-style (55), V-style (35) and T-style (60) inserts are
Milling
frequently used.
E
Longitudinal turning
Boring operations are performed to open up existing holes.
Drilling
A lead angle of close to 0 is recommended.

Use smallest possible overhang.
F C
-style (80), S-style (90) and T-style (60) inserts are fre-
quently used.
Boring
Back boring
G
Back boring is a boring operation with reverse feed.
It is used for turning shoulders less than 90.
Tool holding
B
oring bars with 3 lead angles and D-style (55) inserts are
commonly used.
H
Other information
Machinability
A 58
Choice of tools internal turning
A
Insert recommendation depending on operation
Turning
Insert shape Longitudinal Profiling Facing
turning B
++ = Recommended insert shape
Parting and
+=
grooving
Alternative shape
C Rhombic 80 + ++
C
D Rhombic 55 + ++ +
Threading
R Round + +
S Square + D
T Triangular ++ + +
+ +
Milling
W Trigon 80
V Rhombic 35 + E
Selecting the insert basic shape
Drilling
Positive inserts generate lower cutting force and tool deflection
Inserts with clearance angle 7 F
- First choice for small and medium holes
from .236 inch (6 mm) diameter.
Inserts with clearance angle 11
Boring
- First choice when small cutting forces

and long overhangs are required.
F or best economy G
- Use negative inserts in stable condi-
tions and with short overhang.
Tool holding
11, positive, 7, positive, Negative,

single sided single sided double sided
inserts inserts inserts H
Other information
Machinability
A 59
A Choice of tools internal turning
Insert point angle

Turning
Small point angle:

- Increases accessibility Use the smallest
B angle giving accept-
- Decreases vibration able strength and
- Decreases cutting forces. economy
Parting and
grooving
Round 90 80 80 60 55 35
C R S C W T D V
Threading
D
Cutting edge
Accessibility
strength
Vibration tendency Power consumption

Milling
Chip area and nose radius

Cutting forces and cutting tool deflection
Drilling
F
Rule of thumb!
Choose a nose
radius which is some-
Boring
what less than the

cutting depth.
B
oth small and large The relationship between
G
chip areas can cause r (nose radius) and ap
vibration: (depth of cut) affects
vibration tendencies.
Tool holding
- Large due too high

cutting forces L ess force in radial direc-
- Small due too high tion = less deflection.
friction between the tool
H
and the workpiece.
Other information
Machinability
A 60
Choice of tools how to apply
A
Clamping the boring bar
Turning
Critical stability factors for optimized performance
B
dmm M
aximum contact between tool and tool
holder (design, dimensional tolerance).
Parting and
C
lamping length 3 to 4 times bar diam-
grooving
eter (to balance cutting forces).
Holder strength and stability.
C
3-4 x dmm
Threading
D
Milling
Tool requirements for clamping E
Maximum contact between tool and tool holder
Drilling
Best choice
Coromant Capto coupling F
Acceptable
Boring
G
Not recommended
Tool holding
Not recommended H
Other information
Machinability
A 61
A Choice of tools - how to apply
EasyFix sleeves
Turning
For correct clamping of cylindrical bars
B
Guarantees correct center height
Parting and
grooving
Benefits:
Cutting edge in right position
C
Best cutting action gives better surface finish
Reduced setup time
Threading
Even insert wear.
D Silicon sealer
Milling
E Groove
Drilling
F
Boring
Spring plunger
G A spring plunger mounted in the sleeve clicks into a

groove in the bar and guarantees correct center height.
The slot in the cylindrical sleeve is filled with a silicon
Tool holding
sealer which allows the existing coolant supply system to

be used.
H
Other information
Machinability
A 62
Choice of tools - how to apply
A
Factors that affect vibration tendencies
Turning
Vibration tendencies grow towards the right
B
Parting and
grooving
Lead (entering)
angle C
Threading
Nose radius
Micro and
D
macro geometry
Edge design
Milling
E
Lead (entering) angle Edge design

Choose a lead angle as close to 0
Drilling
Insert wear changes the clearance
(entering angle as close to 90) as pos-
between the insert and the hole wall.
sible, never more than 15 (less than
This can affect the cutting action and
75 for entering angle). F
lead to vibration.
Nose radius
Inserts with thin coatings, or uncoated
Choose a nose radius which is some-
inserts, are to be preferred as they
what smaller than the cutting depth.
normally give lower cutting forces.
Boring
Micro and macro geometry

Use a positive basic-shape insert, as
these give lower cutting forces com- G
pared to negative inserts.
Tool holding
H
Other information
Machinability
A 63
A Choice of tools - how to apply
Chip evacuation
Turning
Chip evacuation is a critical factor for successful boring
B C
entrifugal force presses the chips to
the inside wall of the bore.
Parting and
T he chips can damage the inside of the

grooving
bore.
- Internal coolant can help with chip

C evacuation.
-B
oring upside down helps to keep chips
away from the cutting edge.
Threading
Chip evacuation and chip control

Hard breaking of chips, short chips
Milling
Power demanding and can increase the

vibration.
E
C
an cause excessive crater wear and
result in poor tool life and chip jamming.
Drilling
F Long chips
Can cause chip evacuation problems.
Causes little vibration tendency, but can
in automated production cause prob-
Boring
lems due to chip evacuation difficulties.
G
Tool holding
Short and spiral chips

To be preferred. Easy to transport and
do not cause a lot of stress on the cut-
ting edge during chip breaking.
H
Other information
Machinability
A 64
Choice of tools - how to apply
A
Recommended tool overhang
Turning
Maximum overhang for different types of bars
B
Steel bar
up to 4 x dmm
Parting and
grooving
Carbide bar
up to 6 x dmm
Short, dampened bar C

up to 7 x dmm
Long, dampened bar
Threading
up to 10 x dmm
Carbide reinforced, damp-
ened bar
up to 14 x dmm D
Clamping
length:
Overhang: ... x dmm 14 10 7 6 4
4 x dmm
Milling
Eliminate vibrations E
Internal machining with dampened boring bars
Drilling
Rubber damper Increase productivity in deep bores
Coolant tube Minimize vibration

F
Oil M
achining performance can be main-
tained or improved
D
ampened boring bars are available
Boring
in diameters from .394 inch (10 mm)

High density mass - F or max overhang 14 x dmm (carbide
reinforced) G
Cutting head
Tool holding
Steel bar
H
Other information
Dampened bar
Machinability
A 65
A Code keys
Code key for inserts and toolholders - INCH

Turning
Extract from ISO 18321991

B
INSERT Tolerances Insert thickness
Nose radius
Parting and
grooving
C
C N M G 4 3 2 - PF
1 2 3 4 5 6 7 8
Threading
1. Insert shape
5. Insert size
D
2. Insert clearance angle

Milling
TOOL HOLDERS
E
External
D C L N R 16 4 D
Drilling

B 1 C 2 D E 5 F
F
C3 -
A
Internal
Boring
G
S 16 T S C L C R 4
H E F B 1 C 2 D 5
Tool holding
Bar diameter
S = Solid steel bar Holder lead angle

A = Steel bar with coolant supply
H E = Carbide shank bar
Coromant Capto
Other information
F = Dampened, carbide shank bar

coupling size
Machinability
A 66
Code keys
A
1. Insert shape 2. Insert clearance angle
Turning
80 55 35 80
C D R S T V W
B C P N B
4. Insert type 5. Insert size
Parting and
grooving
A G Inscribed circle is indicated in 1/8"
S T W
M T
C
7. Nose radius
0 r = .008 First choice nose radius recommendations:
Threading
1 r = 1/64
T-MAX P CoroTurn 107
2 r = 1/32
3 r = 3/64 Finishing 2 1
4 r = 1/16 Medium 2 2
6 r = 3/32 Roughing 3 2
D
8. Geometry manufacturers option
Milling
The manufacturer may add a further two symbols to the code describing the
insert geometry e. g.
E
-PF = ISO P Finishing
-MR = ISOMRoughing
B. Clamping system
Drilling
C D M,W P S F
Top clamping Rigid clamping (RC) Top and hole clamping Hole clamping Screw clamping
Boring
D. Hand of tool E. Shank or bar size G. Tool length
Shanks: height External, l1 in inch Internal, l1 in inch G

R and width
A = 4.000
Right-hand style
B = 4.500
Tool holding
C = 5.000
L D = 6.000
Left-hand style M = 6.000
Bars: M = 4.000
R = 8.000
S = 10.000 H
N
Other information
T = 12.000
Neutral U = 14.000
Machinability
A 67
A Code keys
Code key for inserts and toolholders - METRIC

Turning
Extract from ISO 18321991

B
INSERT Tolerances Insert thickness
Nose radius
Parting and
grooving
C
C N M G 09 03 08 - PF
1 2 3 4 5 6 7 8
Threading
1. Insert shape
5. Insert size = cutting edge length
D
2. Insert clearance angle

Milling
TOOL HOLDERS
E
External
D C L N R 16 16 H 09
Drilling

B 1 C 2 D E F G 5
F
C3 -
A
Internal
Boring
G
A 25 T S C L C R 09
H J G B 1 C 2 D 5
Tool holding
Bar diameter
S = Solid steel bar Holder style

A = Steel bar with coolant supply
H E = Carbide shank bar
Coromant Capto
Other information
F = Dampened, carbide shank bar

coupling size
Machinability
A 68
Code keys
A
1. Insert shape 2. Insert clearance angle
Turning
80 55 35 80
C D R S T V W
B C P N B
4. Insert type 5. Insert size = Cutting edge length
Parting and
grooving
A G
M T l mm: 0625 0715 0632 0925 0627 1116 0608
C
7. Nose radius
02 r = 0.2 First choice nose radius recommendations:
Threading
04 r = 0.4
T-MAX P CoroTurn 107
08 r = 0.8
12 r = 1.2 Finishing 08 04
16 r = 1.6 Medium 08 08
24 r = 2.4 Roughing 12 08
D
8. Geometry manufacturers option
Milling
The manufacturer may add a further two symbols to the code describing the
insert geometry e. g.
E
-PF = ISO P Finishing
-MR = ISOMRoughing
B. Clamping system
Drilling
D M P S F
Rigid clamping (RC) Top and hole clamping Hole clamping Screw clamping
Boring
D. Hand of tool E. Shank height G. Tool length
Tool length G
R = l1 in mm
Right-hand style
Tool holding
L F. Shank width H = 100 S = 250

Left-hand style K = 125 T = 300
M = 150 U = 350
P = 170 V = 400 H
N
Other information
Q = 180 W = 450
Neutral R = 200 Y = 500
Machinability
A 69
A Troubleshooting
Troubleshooting
Turning
Chip control
B Problem Cause Solution
Long unbroken snarls winding F eed too low for the chosen Increase the feed.
around the tool or workpieces. geometry.
Parting and
S
elect an insert geometry
with better chip breaking
grooving
capabilities.
U
se a tool with high pres-
C sure coolant.
Threading
D
epth of cut too shallow for Increase the depth of cut or
the chosen geometry. select a geometry with bet-
ter chip breaking capability.
Nose radius too large. S

elect a smaller nose
radius.
Milling
Unsuitable lead angle S

elect a holder with as small
E a lead angle as possible
(r =0 [r =90]).
Drilling
Very short chips, often sticking Feed too high for the chosen C
hoose a geometry
together, caused by too hard geometry designed for higher feeds,
F chip breaking. Hard chip break- preferably a single-sided
ing often causes reduced tool insert.
life or even insert breakages
due to too high chip load on Reduce the feed.
the cutting edge.
Boring
Unsuitable lead angle. Select a holder with as small

G a lead angle as possible
(r =4515 [r=4575]).
Tool holding
Nose radius too small. Select a larger nose radius.

H
Other information
Machinability
A 70
Troubleshooting
A
Surface finish
Turning
Problem Cause Solution
The surface looks and feels The chips are breaking Select a geometry which
hairy and does not meet the against the component guides the chips away. B
tolerance requirements and marking the finished
surface. Change lead angle.
Reduce the depth of cut.
Parting and
grooving
S
elect a positive tool system
with a neutral angle of
inclination.
C
Hairy surface caused by Select a grade with better
Threading
excessive notch wear on the resistance to oxidation wear,
cutting edge. e.g., a cermet grade.
Reduce the cutting speed.
D
Too high feed in combination Select a wiper insert or a
Milling
with too small nose radius larger nose radius.
generates a rough surface.
Reduce the feed.
E
Burr formation
Drilling
Burr formation at the end of The cutting edge is not U
se inserts with sharp
the cut when the cutting edge sharp enough. edges:
is leaving the workpiece. - PVD coated inserts F
The feed is too low for the - ground inserts at small
edge roundness. feed rates, < .004 inch/r
(< 0.1 mm/r).
Boring
Notch wear at depth of cut, U

se a holder with a large G
or chipping. lead angle.
Tool holding
E
nd the cut with a chamfer
or a radius when leaving the H
workpiece.
Other information
Machinability
A 71
A Troubleshooting
Vibration
Turning

High radial cutting forces due - Unsuitable lead angle. S
elect as small lead
B to: angle as possible (r = 0)
Parting and
grooving
Nose radius too large. S

elect a smaller nose
radius.
Vibrations or chatter marks
C which are caused by the
tooling or the tool mounting.
Typical for internal machining -U
nsuitable edge rounding, or S
elect a grade with a thin
with boring bars. negative chamfer. coating, or an uncoated
grade.
Threading
-E
xcessive flank wear on cut- S
elect a more wear resistant
D ting edge. grade or reduce speed.
Milling
High tangential cutting forces - Insert geometry creating high S

elect a positive insert
E due to: cutting forces. geometry.
Drilling
-C
hip-breaking is too hard R
educe the feed or select a
giving high cutting forces. geometry for higher feeds.
-V
arying or too low cutting Increase the depth of cut
forces due to small depth slightly to make the insert
of cut. cut.
Boring
G
- Tool incorrectly positioned. Check the center height.
Tool holding
H
Other information

Machinability
A 72
A
Turning
- Instability in the tool due to Reduce the overhang
long overhang. B
U
se the largest bar
diameter.
Use a Silent Tool or a car-
Parting and
bide bar.
grooving
C
Threading
-U
nstable clamping offers E
xtend the clamping length D
insufficient rigidity. of the boring bar.
U
se EasyFix for cylindrical
bars.
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
A 73
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
A Theory
Parting & grooving theory

Turning
Parting off
B
Chip evacuation is essential
Parting and
Chip evacuation is a critical factor in parting operations.

grooving
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
C smoothly. Consequences of poor chip evacuation are chip
obstruction, which leads to poor surface quality, and chip
jamming, leading to tool breakdown.
Threading
D C
hip evacuation is a critical factor in
parting operations.
C
hip breaking is difficult in the confined
slots created as tools cut deep into the
Milling
workpiece.
T ypical chips are clock-spring shaped,
E narrower than the groove.
T he insert geometry shrinks the chip
width.
Drilling
F
Parting off definition of terms
n
Boring
n = spindle speed (rpm)

G vc = cutting speed (ft/min) (m/min)
fnx = radial cutting feed (inch/r) (mm/r)
Tool holding
ar = depth of groove (inch) (mm)

(outer dia. to center or bottom of
groove)
H
Other information
Machinability
B4
Theory
A
Cutting speed value
Turning
Feed rate reduction is often advantageous for performance
when machining towards the center to minimize the pressure
on the cutting edge.
B
Parting and
grooving
C
utting speed declines to zero at the
C
center.
Threading
D
100 0% of vc
Milling
Feed reduction towards center E
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.
Drilling
F
R
educe feed by 75% when approaching
Boring
the center, around .079 inch (2 mm)

before the part comes off.
Feed reduction reduces pip size. G
F eed reduction reduces vibration and

Tool holding
increases tool life.
H
.079
Other information
(2mm)
Machinability
B5
A Theory
Grooving definition of terms

Turning
The tool movement in directions X and Z is called feed

rate (fn), or fnx/fnz, inch/r (mm/r). When feeding towards
B 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.
Parting and
grooving
C
n vc = cutting speed (ft/min) (m/min)
Threading
fnz = axial cutting feed (inch/r) (mm/r)

D (outer dia. to center or bottom of
groove)
ap = depth of cut in turning
Milling
E
Face grooving definition of terms
The feed has a great influence on chip formation, chip
Drilling
breaking, and thickness, and also influences how chips

form in the insert geometry. In sideways turning or profil-
F ing (fnz), the depth of the cut (ap) will also influence chip
formation.
Boring

G vc = cutting speed (ft/min) (m/min)
n fnz = axial cutting feed (inch/r) (mm/r)

Tool holding

H
Other information
Machinability
B6
Selection procedure
A
Tool selection procedure
Turning
Production planning process B
<.0004 (.01 mm)
Parting and
grooving
Dimension and quality
of the groove or face
C
1 Component
Workpiece material,
Threading
chip evacuation
Machine parameters
2
Milling
Machine
E
Type of tool:
- Spring-clamp
- Screw-clamp
3
Drilling
Choice of tool
- Insert type
Cutting data, method,

cutting fluid, etc
4
Boring
How to apply
G
Tool holding
5 Troubleshooting Remedies and

solutions
H
Other information
Machinability
B7

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

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

(HRSA). Reduces notch wear.
H
Other information
Machinability
B9
4. How to apply
Turning
C
enter height is important, .004 inch
B
(0.1 mm).
R
educe feed by up to 75% around .079
Parting and
inch (2 mm) before center.

grooving
.079
Max .004 inch U
se shortest possible overhang, ar inch
(0.1 mm) (mm).
C
L argest height dimension on blade for
bending stiffness.
Use coolant to improve chip flow.
Threading
ar
Milling
5. Troubleshooting
E Some areas to consider
Insert wear and tool life

Check the wear pattern and if necessary
Drilling
adjust cutting data accordingly.
F To improve chip formation & tool wear

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

Neutral inserts (insert without front
angle).
Tool holding
To save material, use smallest possible

insert width.
Largest possible tool holder.
Shortest possible overhang, ar.
H
Other information
Machinability
B 10
System overview
A
System overview
Turning
External parting and grooving
B
1. Parting-off solid bars and tubes 4. Shallow to deep grooving
2. Turning and recessing 5. Face grooving
Parting and
3. Undercutting 6. Profiling
grooving
4 C
Threading
6
D
1
4
Milling
3 4
2
E
Drilling
Internal grooving F
1. Grooving and pre-parting

2. Face grooving
Boring
3. Profiling
G
3
Tool holding
1 2
H
1
Other information
Machinability
B 11
A System overview
Different systems
Turning
Insert type
B
Q-Cut Q-Cut U-Lock
Application CoroCut2 CoroCut1 CoroCut3 151.2 151.3 154.0
Parting and
Parting
grooving
(Cut off)
Medium Deep Shallow Deep
C
Grooving
Internal,
Threading
small dia.
Face grooving
D
Turning
Milling
Profiling
E
Undercutting
Drilling
Circlip groov-
F ing
Boring
Deep parting 4.409 inch (112 mm)

G First choice
Medium parting 1.575 inch (40 mm)

Tool holding
Second Shallow parting .472 inch (12 mm)

choice
H
Other information
Machinability
B 12
System overview
A
Internal parting and grooving
Turning
Different systems
B
Internal grooving min hole diameter
Parting and
grooving
.472 .984
.165 .394 (25) C
(12)
(4.2) (10)
Threading
D
.165 .394 .472 .984 Min. hole

(4.2) (10) (12) (25) diameter,
Milling
inch (mm)
Face grooving min/max first cut diameter
Drilling
F
.244 .472 .906 1.339
(6.2) (12) (23) (34) Boring
G
Tool holding
.244 .709 .472 1.181 .906 2.756 1.339 First cut

(6.2 18) (12 30) (23 70) (34 ) diameter,
inch (mm)
H
Other information
Machinability
B 13
A System overview
Inserts
Turning
Overview
B
Application
Parting and
grooving
Parting
C Machining (Cut off)
Grooving Turning Profiling Profiling
condition
Threading
Finishing CF GF TF
D
Medium CM GM TM RM AM
Milling
Roughing CR
E
Optimizer RO
Drilling
Sharp CS RS
F
ER treated
GE RE
Boring
G
Tool holding
H
Other information
Machinability
B 14
Parting and grooving how to apply
A
Turning
B
Parting & grooving
and how to apply
Parting and
grooving
Parting & grooving and how to apply B 16
C
Parting off and how to apply B 22
Threading
General grooving and how to apply B 25
Circlip grooving and how to apply B 27 D
Face grooving and how to apply B 28
Milling
Profiling and how to apply B 31
E
Turning and how to apply B 33
Undercutting and how to apply B 35
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
B 15
A Parting and grooving how to apply
Tool overhang & workpiece deflection

Turning
The tool overhang should always be minimized for

improved stability. In parting and grooving operations
B 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.
Parting and
grooving
Best stability
Threading
O
verhang (ar) should be as small as
possible.
D
Largest seat size should be used.
ar = 8 x la max
Milling
E
Internal machining
Shank type:
Drilling
Steel bars 3 x dmm

F Dampened steel bars 5 x dmm
Carbide bars 5 x dmm
C
arbide reinforced dampened bars, up
Boring
to 7 x dmm.
G
Tool holding
Inserts:
Use smallest possible width
Use light cutting geometries.
H
Other information
Machinability
B 16
A
Tool holder selection parameters
Turning
System considerations
B
Deep parting 4.409 inch (112 mm)
Parting and
grooving
Medium parting 1.575 inch (40 mm)
Shallow parting .472 inch (12 mm)

C
Threading
D
Deep parting Medium parting Shallow parting

F irst choice are spring- First choice for medium U
se the 3-edge insert
Milling
clamp blades with single- parting are screw-clamp for economic parting in
edge inserts. holders with 2-edge mass production.
inserts. E
General tool holder considerations
Drilling
Tool block with spring-clamp tool blade for
tool overhang adjustment. F
Shortest possible overhang, ar inch (mm)

Boring
Maximum tool holder shank

Largest height dimension
G
Maximum blade width
ar
Tool holding
H
Other information
Machinability
B 17
Spring-clamp design blades

Turning
Features/Benefits
Quicker insert change
B
Cut off larger diameter
Adjustability
Parting and
grooving
Deep grooving
Double ended
C Radial feed only
Threading
Screw-clamp design holders

D
Features/Benefits
Smaller diameters
Shallow grooving
Milling
Radial & axial feed

E Increased rigidity
Single ended
Drilling
Screw-clamp design holders

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

Very tight insert indexing tolerance.
H The productivity choice, 3 cutting edges.
Other information
Machinability
B 18
A
Parting-off bars
Turning
Overhang should not exceed 8 x la (width
of insert).
Max ar = 8 x la B
(width of insert) Use as narrow an insert as possible:
- To save material
Parting and
- Minimize cutting force
grooving
- Minimize environmental pollution.
Threading
D
Material savings
Milling
E
Drilling
F
Positioning of the tool
Use maximum deviation of .004 inch
Max .004 inch (0.1 mm)
(0.1 mm) from center line.
Boring
Too high cutting edge

G
Clearance will decrease.
Cutting edge will rub (break).
Tool holding
Too low cutting edge

Tool will leave material in center (PIP).
H
Other information
Machinability

B 19

Turning
90 mounting of tool holder

P erpendicular surface
B Reduce vibrations
Parting and
grooving
C
Hand of insert
Three types of insert with different entering
Threading
angles:
Hand of insert
- Right hand (R)
- Neutral (N)
D - Left hand (L)
Milling
Right hand (R)
E
Insert geometry
Neutral entering angle
Drilling
Increases strength
Higher feed/productivity
F r Better surface finish
laa Straighter cut
r r = 0 Pip stays on part falling off.
Boring
G Small/large corner radius
r Small corner radius

Tool holding
Smaller PIP
Better chip control
Lower feed rate
H Large corner radius
Increased feed rate
Other information
Longer tool life

Machinability
B 20
A
Recommendations for boring bar solutions
Turning
EasyFix sleeves
B
Use EasyFix clamping sleeves for
Parting and
accurate machining with less
grooving
vibration and precise height.
Threading
D
Recommended overhang
Milling
dmm
E
Carbide reinforced
dampened bars
Drilling
l <7 x dmm
dmm F
Dampened steel bars

Carbide bars
Boring
l 5 x dmm G
dmm
Tool holding
Solid steel bars
H
Other information
l 3 x dmm
Machinability
B 21
A Parting off how to apply
Parting off
Pip reduction by using different front angles
Turning
C
hoose left or right hand front angle to
B control the pip or burr.
When
the front angle is:
Parting and
- increased, the pip/burr is decreased

grooving
- decreased, the chip control and tool life

are improved.
C
C
entrifugal force will always push away
R the parted off component
- Tool will leave material in center (PIP).
Threading
D
Milling
Note!
A front-angled insert will give reduced
E chip control due to the direction of the
chip flow. (A neutral insert directs the chip
Example of front angles on
1-, 2- and 3-edge inserts: straight out of the groove).
5, 10, 8, 12, 15, 20
Drilling
F Tool selection - Review
General recommen- Consider:

dations:
Boring
G -N eutral inserts - utting depth

C
- Smallest possible - Insert width
insert width - Front angle
Tool holding
- Largest possible - Corner radius.

tool holder.
H
Other information
Machinability
B 22
Parting off how to apply
A
Parting-off tubes
Turning
Parting-off tubes
Use insert with the smallest possible B
width (la) to save material, minimize cutting
force and environmental impact.
Parting and
grooving
C
Parting-off thin walled tubes
Threading
Make sure that the lowest possible cutting
forces are generated. Use inserts with the
smallest possible width and sharpest cut- D
ting edges.
Milling
Practical hints E
Max .004 inch
(0.1 mm) C
enter height is impor-
tant, .004 inch (0.1
Drilling
mm).
If subspindle is used,
pull away the component F
approximately .040 inch
.040 inch (1 mm) before center.
(1
0.1 mm)
R
educe feed by up to
Boring
75%, approximately
.079 inch (2 mm) before
center also for tube G
parting.
0.25 x fn
Tool holding
H
Other information
.079
Machinability
fn (2mm)
B 23
A Parting off how to apply
Use cutting fluid

Turning
Cutting fluid has an important function since the space

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

Direct at the cutting edge.
Use coolant adapter.
Threading
Has positive effect on chip formation.

Prevents chip jamming.
D
Milling
E
Drilling
F
Boring
G Example of external coolant supply in

addition to internal coolant channels.
Tool holding
H
Other information
Machinability
B 24
Grooving how to apply
A
General grooving
Turning
S
ingle cut grooving is the most
economic and productive method to B
produce grooves.
If the depth of the groove is bigger than
Parting and
grooving
the width, multiple grooving is the best
method for rough grooving.
A
screw-clamp tool holder should be
C
selected for grooving operations.
Threading
D
Milling
E
Single cut grooving
E
conomic and productive method to
Drilling
produce grooves.
F inishing geometry has width tolerance
F
of .0008 inch (0.02 mm) and works
well in low feeds.
W
iper inserts give extremely high quality
surface on the side of the groove.
Boring
G
Tool holding
H
Other information
Machinability
B 25
A Grooving how to apply
Multiple grooving
Turning
T he best method for rough grooving

when depth is bigger than width.
B
U
se the insert width to produce full
grooves and then remove the rings.
Parting and
grooving
C
Threading
D
Practical hints
When producing high quality grooves, there is often a
need for chamfered corners.
Milling
E
One way is to use the corners on the in-
A sert, for example, of a finishing grooving
insert, to chamfer; see illustration A.
Drilling
F
Boring
B A better way to make grooves with

G chamfer in mass production is to order a
Tailor Made insert with the exact cham-
fer form; see illustration B.
Tool holding
H
Other information
Machinability
B 26
Circlip grooving how to apply
A
Circlip grooving
Turning
Circlips on shafts and axle components
are very common.
B
C
irclip grooving can be performed with
three-edge inserts or two-edge grooving
Parting and
inserts.
grooving
F or internal grooving there is also a wide
choice of inserts and boring bars.
C
Threading
Systems to choose from
D
3-edge inserts 2-edge inserts
F or best economy, use 3-edge inserts
in widths .039 - .125 inch (1.00 - 3.18
mm).
Milling
O
r 2-edge inserts in widths
.059 - .236 inch (1.50 - 6.00 mm).
E
internal inserts Carbide rod inserts
Internal inserts are available for min.
hole diameter .394 inch (10 mm) and
with circlip widths .043 - .163 inch (1.10
Drilling
- 4.15 mm).
M
in hole diameter for carbide rod inserts F
is .165 inch (4.2 mm) and circlip widths
are .031 - .079 inch (0.78 - 2.00 mm). Boring
Milling is an alternative for non-rotating

internal Internal/external components
G
T he circlip widths for diameters
.382 - 1.366 inch (9.7 34.7 mm) cut-
Tool holding
ters are .028 - .203 inch (0.70 - 5.15

mm).
T he circlip widths for diameters
1.535 - 2.480 inch (39 80 mm) cutters
Cutter diameter are .043 - .203 inch (1.10 - 5.15 mm).
H
Cutter diameter
Other information
.382 - 1.366 inch 1.535 - 2.480 inch

(9.7 34.7 mm) (39 80 mm)
Machinability
B 27
A Face grooving how to apply
Face grooving
Turning
Making grooves axially on the faces on a

component requires tools dedicated to the
B application.
T he correct curve on the tool is depend-
Parting and
ent on the radius of the workpiece.

grooving
T he inner and outer diameters of the

groove need to be taken into account in
C order to select the tool.
Threading
D
Milling
Tools for face grooving

E
Drilling
F
Boring
C
urved tool for face C
urved tool for face E
xchangable cutting
G grooving, shank 0 style. grooving, shank 90 blades make it possible
style. to make a special tool
from standard tools.
Tool holding
H
Other information
Machinability
B 28
Face grooving how to apply
A
Choice of R and L tools depending on rotation
Turning
T ool is fed axially towards
the end surface of the
part. B
T ool must be adapted to
the bending radius of the
Parting and
groove.
grooving
M
achine largest diameter
and work inwards for
best chip control. C
Left hand (L) tool
Threading
D
Right hand (R) tool
Milling
Choice of A and B curve, right or left hand tool E
Choose the correct tool A or B curve, right or left hand
style depending on machine setup and workpiece rotation.
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
B 29
A Face grooving how to apply
First cut consederation

Turning
1 If the insert support rubs workpiece

inside dia:
B - maybe the dia. range is wrong
- tool is not parallel to axis
- check center height
Parting and
- lower the tool below center line.

grooving
1
2
C
2 If the insert support rubs workpiece
outside dia:
- maybe the dia. range is wrong
Threading
- tool is not parallel to axis

- check center height
- lift the tool above center line.
D
Roughing and finishing

Milling
Roughing Finishing
E
2
1
Drilling
First cut (1) always starts Machine the first cut (1) within the given
on the largest diameter diameter range.
and works inwards. The
Boring
Cut two (2) finishes the diameter. Always start outside

first cut offers chip control
and turn inwards.
but less chip breaking.
G
Finally, cut three (3) finishes the inner diameter to the
Cuts two (2) and
correct dimensions.
three (3) should be
Tool holding
0.50.8 x width of the in-

sert. Chip breaking will now
be acceptable and the feed
can be increased slightly.
H
Other information
Machinability
B 30
Profiling how to apply
A
Profiling
Turning
When machining components with complex
shapes, profiling inserts offer great oppor-
tunities for rationalization. B
M
odern parting and grooving tool sys-
Parting and
tems can also perform turning.
grooving
A
screw-clamp tool holder should be
selected for turning and profiling
operations in view of achieving maximum C
stablility.
A
neutral tool holder is suitable for both
opening up or completing a recess.
Threading
T he round shape inserts have dedicated
geometries for these operations.
D
Milling
E
Drilling
F
Boring
Ramping
G
Tool holding
U
se round inserts for outstanding chip control and good
surface finish.
In unstable setups, use ramping to avoid vibrations.
H
Other information
Machinability
B 31
A Turning how to apply
Profile turning
Turning
Insert radius < component radius
B L arge area of insert creates high cutting pressure so

Recommended feed should be reduced.
If possible, use an insert radius that is smaller than the
Parting and
component radius.
grooving
If you must have the same insert radius as the com-
ponent radius, use micro-stops to make the chip short
C and avoid vibrations.
Threading
D Insert radius component radius is not

recommended
Milling
fn1 = parallel cuts max. chip thickness .006 - .016 inch (0.150.40 mm).
Drilling
fn2 = radius plunging 50% max. chip thickness.
F
Boring
G
Tool holding
H
Other information
Machinability
B 32
Turning how to apply
A
Turning
Turning
The most common applications for wide
grooves or turning between shoulders
are multiple grooving, plunge turning or B
ramping. All three methods are roughing
operations and have to be followed by
Parting and
a separate finishing operation. A rule of
grooving
thumb is that if the width of the groove is
smaller than the depth multiple grooving
should be used and vice versa for plunge C
turning. However, for slender components,
the ramping method may be used.
Threading
D
U
se holders with smallest possible over-
hang, screw clamping and insert with rail
Milling
shape if possible.
U
se a stable, modular tooling system if
possible. E
Reinforced blade will increase stability.
Drilling
Roughing F
Boring
G
Tool holding
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.
4. Retract radially .020 inch (0.5 mm).
H
Other information
Machinability
B 33
A Turning how to apply
Finishing
Turning
As the insert contours around the radius, most of the move-

ment is in the Z direction. This produces an extremely thin
B chip along the front cutting edge which can result in rubbing
and hence vibration.
Parting and
grooving
C
Threading
T he axial and radial cutting depth should

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

surface finish.
Drilling
Y
ou get the best wiper effect when you
Ra max find the right combination between
feed (fn) and blade deflection.
F
a value below 20RA (0.5 m) will be
R
generated with high bearing.
Boring
G
Tool holding
H
Other information
Machinability
B 34
Undercutting how to apply
A
Undercutting
Turning
When a clearance is needed.
T hese applications require dedicated inserts with round B
cutting edges that are sharp and accurate.
T he tolerance of these inserts is high: .0008 inch
Parting and
(0.02 mm).
grooving
C
Threading
D
Tools for undercutting
Angled Angled 20 Angled 45
7 ,45 and 70
Milling
E
Drilling
F
H
older for external under- H
older for internal under- H
older for external under-
cutting. Insert with two cutting. Insert with two cutting. Insert with one
cutting edges. cutting edges. cutting edge.
Boring
G
Tool holding
H
Other information
Machinability
B 35
A Troubleshooting
Troubleshooting
Turning
Tool wear
B
Problem
Parting and
grooving
Plastic de- Built-up

Flank wear Crater wear Chipping Fracture
C formation edge
Solution
Threading
More positive
geometry ++
D
Tougher grade ++
Milling
More wear
E resistant grade ++ + +
Increase cutting
+
Drilling
speed
F
Decrease cut-
ting speed + + ++
Boring
Reduce feed
G rate ++ + +
Tool holding
Choose stronger
geometry + ++
H
Other information
+ + = Best possible remedy + = Possible remedy

Machinability
B 36
Troubleshooting
A
Problem Solution
Turning
Bad surface
U se a short and stable C heck speed/feed guide-
tool. lines. B
Take away the chips Use wiper geometry.
use geometry with good Check tool setup.
Parting and
chip control.
grooving
C
Bad surface on aluminum
Threading
Select the sharpest S
elect a special soluble
geometry. oil for the material.
Use geometry with good
chip control. D
Milling
Bad chip breaking
hange geometry.
C
Select a higher feed. E
Use dwelling (pecking).
Increase coolant.
Drilling
Vibration
F
U se a stable setup. C heck tool condition.
Check speed/feed guide- Check tool setup.
lines.
Use shorter overhang.
Boring
Change geometry.
G
Poor tool life
Tool holding
C heck center height. C

heck condition of blade.
Check angle between If blade is old, the insert
tool and component. could be unstable in the
tip seat. H
Other information
Machinability
B 37
F2
Threading
Thread turning is the process of an indexable insert tool
making a number of passes along the section of a work-
piece 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
A Theory
Threading theory
Turning
The threading methods

B
The prime functions of a thread are:
- to form a mechanical coupling
Parting and
grooving
- to transmit motion by converting rotational movement

into linear and vice-versa
C - to obtain a mechanical advantage; using a small force to

create a larger one.
Threading
Different ways of making threads

D
Molding Grinding Rolling

Milling
E
Drilling
F
Metal cutting threading methods
Thread turning Milling Tapping
Boring
G
Tool holding
H
Other information
Machinability
C4
Theory
A
Turning
n = spindle speed (rpm) B
ap = total depth of thread (inch) (mm)
Parting and
nap = number of passes
grooving
C
Threading
P = p
itch, mm or threads
per inch (t.p.i.) D
= angle of the thread
d1 = minor diameter external
Milling
D1 = minor diameter internal
d2 = pitch diameter external
E
D2 = pitch diameter internal
d = major diameter external
D = major diameter internal
Drilling
= helix angle of the thread
F
Boring
G
Tool holding
H
Other information
Machinability

C5
A Theory
Turning
1. Root
The bottom surface joining the two
adjacent flanks of the thread crest.
B
2. Flank
The side of a thread surface connect-
Parting and
ing the crest and the root.

grooving
3. Crest
The top surface joining the two sides,
C or flanks.

Threading
Helix angle
D The helix angle ()is dependent on and
related to the diameter and pitch (P) of
the thread.
B
y changing the shim, the flank clear-
Milling
ance of the insert is adjusted.

T he angle of inclination is lambda ().
E The most common angle of inclination is
1 which is the standard shim in the tool
holder.
Drilling
F
Boring
Cutting forces in and out of the thread

The highest axial cutting force in the
G 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.
H
Other information
Machinability
C6
Theory
A
Inclining the insert for clearance
Turning
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 B
can be made by referring to a chart in the catalog.
As standard, all tool holders are delivered with the shim
Parting and
set at 1.
grooving
C
Threading
D
Standard shim = 1
P
tan =
d2
Milling
E
Pitch, mm Threads/inch
Drilling
F
Boring
G
Tool holding
H
Other information
Workpiece mm
Machinability
diameter inch
C7
A Theory
Selecting shims for inclination

The diameter and pitch influence the inclination angles.
Turning
Example of how to use the diagram.

B
1. The workpiece diameter is 40 mm 2. T he workpiece diameter is 4 inches
(1.575 inch) with a thread with a pitch (102 mm) with a thread with a pitch of
of 6 mm (.236 inch). From the diagram 5 threads. From the diagram we can
Parting and
grooving
we can see that the required shim see that the required shim must have
must have an angle of inclination of 3 an angle of inclination of 1.
(standard shim can be used).
C
Pitch, mm Threads/inch
Threading
D
3
1
Milling
1
Drilling
F
Workpiece mm
diameter inch
Marking of threading inserts and shims

Boring
How to read and understand markings.

G Angle of shim
inclination
Tool holding
Thread profile
Pitch
H
Internal (O)
Other information
External, no marking
Carbide grade
Machinability
C8
Tool selection
A
Turning
Parting and
grooving
Dimension and
quality of the
thread
C
1 Component
Workpiece mate-
Threading
rial, thread profile
and quantity
Machine parameters
2
Milling
Machine
E
Type of tool:
- Full profile
- V-profile
3
Drilling
Choice of tool
- Multi-point
Cutting data,
in-feed etc.
4
Boring
How to apply
G
Tool holding
Remedies and
5 Troubleshooting
solutions
H
Other information
Machinability
C9
A Tool selection

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

grooving
Right- or left-hand thread

Type of profile (metric, UN, etc.)
C
Pitch size
Number of thread starts
Threading
Tolerance (profile, position)
P M K
D
N S H
Milling
Material
Machinability
E
Chip breaking
Hardness
Alloy elements
Drilling
F 2. Machine parameters

pindle interface
S
Boring
Machine stability
The spindle speed
G Coolant supply
Clamping of the workpiece
Horizontal or vertical spindle
Tool holding
Power and torque

Tool magazine
H
Other information
Machinability
C 10
Tool selection
A
3. Choice of tools
Turning
Different ways to make threads
Full profile inserts B
The thread is cut by the insert with good Advantages
control over the geometrical properties as the
Better control over the
Parting and
distance between the root and the crest is
thread form.
grooving
controlled.
Less deburring.
The insert can only cut one pitch.
As the insert is generating both the root and C
the crest, the tool pressure increases, putting Disadvantages
high requirements on setup and overhang. Each insert can only cut
one pitch.
Threading
D
V-profile inserts
The insert can accommodate a range of Advantages
pitches thus reducing stock. The root and
Flexibility, one insert
flanks are being formed by the insert.
can be used for several
Milling
The crest is controlled in a prior turning opera-
tion, resulting in high tolerances. pitches.
In setups prone to vibrations, a non-topping
insert can often prove to be a solution due to Disadvantages E
the reduction of cutting pressure. Can result in burr forma-
tion that needs to be
taken away.
Drilling
F
Multi-point inserts Advantages

A full profile (topping) insert with several teeth Reduced number of
Boring
reduces the number of required in-feeds and infeeds.

generates high productivity, e.g. a multi-point Very high productivity.
insert with two teeth reduces the number of
in-feeds to half. G
Disadvantages
The tool pressure increases exponentially,
Requires stable setups.
Tool holding
requiring stable setups and shortened over-

hangs. Sufficient room behind the last thread Needs sufficient room
is also needed. behind the last thread.
H
Other information
Machinability
C 11
A Tool selection
4. How to apply
Turning

The infeed method can have a significant
B
impact on the thread machining process.
It influences:
Parting and
- chip control
grooving
- insert wear
- thread quality
C - tool life
In practice, the machine tool, insert

Threading
geometry, workpiece material and thread

pitch influence the choice of infeed
method.
D
Milling
E 5. Troubleshooting
Drilling
Check the wear pattern and if necessary

adjust the cutting data accordingly.
F
Infeed type
Optimize infeed method, number and
size of pass.
Boring
Insert inclination
G Ensure there is sufficient and even
clearance (insert inclination shims).

Tool holding
Insert geometry
Make sure the right insert geometry is
used (all-purpose, F or C geometries).
H
Other information
Machinability
C 12
System overview
A
System overview
Turning
External threading 1. Small part threading
B
2. Conventional threading
3. Oil pipe threading
Parting and
grooving
C
Threading
3
0.5 8 mm
10 5 t.p.i 2
32 3 t.p.i 1 D
0.2 2 mm
Milling
E
Internal threading 10 5 t.p.i
Min hole: 2.374
0.5 8 mm inch (60.3 mm)
Drilling
32 3 t.p.i
Min hole: .472 inch 4
0.5 2.5 mm
32 10 t.p.i
(12 mm) F
Min hole: .394 inch 3
0.5 3 mm
(10 mm)
56 16 t.p.i
2
Boring
Min hole: .157 inch

(4 mm)
1 G
Tool holding
1. Carbide rods
2. Threading mini-bars
3. Conventional threading H
Other information
4. Oil pipe threading

Machinability
C 13
A System overview
External threading assortment

Turning
Choose from an extensive program

B
Inserts
Parting and
grooving
C
Threading
Pitch
D 0.2 2.0 5.0 8.0 mm
32 10 3 t.p.i
Milling
Three standard geometries
E F our insert sizes:

1/4, 3/8, 1/2 and
5/8 inch (11, 16, 22
and 27 mm) 1/4 3/8 1/2 5/8
Drilling
(11) (16) (22) (27)
Tool holders
Boring
1. Coromant Capto cutting units
G 2. Shank tools
3. Boring bars
Tool holding
4. Exchangable cutting heads

5. Cartridges
H
Other information
Machinability
C 14
System overview
A
Internal threading assortment
Turning
Choose from an extensive program and several systems
B
Conventional bars Bars for oil pipe
Carbide rods Old system threading
Parting and
grooving
Conventional bars
Mini-bars New system
C
2.362 inch
Threading
.472 inch .984 inch (60 mm)
.157 inch .394 inch (25 mm)
(4 mm) (12 mm)
(10 mm)
Milling
.157 .394 .472 .984 2.362
(4) (10) (12) (25) (60)
E
Min. hole diameter, inch (mm)
Drilling
For high precision, internal threading of small components
F
Carbide rods Inserts for mini-bars Boring
G
Tool holding
H
Other information
Machinability
C 15
A System overview
Thread forms
Turning
Application Insert/thread form Thread type Code
B
ISO metric MM
General use
American UN UN
Parting and
grooving
Whitworth, NPT
WH, NT
Pipe thread British Standard (BSPT), NPTF
PT, NF
American National Pipe Threads
C
Food and fire Round DIN405 RN
Threading
MJ MJ
Aerospace
UNJ NJ
D API Rounded RD
Oil and gas API V form 60 V38, 40,
50
Milling
Oil and gas Buttress, VAM BU
E Trapezoidal TR
Motion
ACME AC
General use
Stub ACME SA
Drilling
General usage Oil & Gas

Good balance between load bearing Extreme load bearing and leak proof re-
capacity and volume of material. quirements, with limitations of thin wall
F
thickness of pipe.
Pipe Threads
Ability to bear loads. Motion
Symmetrical form.
A
ble to form leak-proof connections
Boring
(threads are often conical). Large contact surface.

Sturdy form.
Food & Fire
G
Same as for pipe threads but round, for
easy cleaning for food.
Tool holding
Easily repeated connecting/disconnect-

ing for fire.
Aerospace
High precision and minimized risk for
H
stress concentration and breakage.
Other information
Machinability
C 16
System overview
A
Insert types
Turning
Three different types of threading inserts
B
Full profile inserts
For high productivity in threading.
Parting and
grooving
C
V-profile inserts - 60 and 55
F or threading with minimum tool
Threading
inventory.
D
Multi-point inserts
F or highly productive, economic threading
Milling
in mass production.
Three different geometries
Drilling
All-purpose geometry F-geometry C-geometry
First choice in most Sharp geometry. Chip breaking geometry.
F
operations.
Boring
G
Tool holding
Good chip forming in a Gives clean cuts in sticky Optimized geometry for low
wide range of materials. and work hardening carbon, low alloy and easily
materials. machined stainless steel. H
Other information
Machinability
C 17
A System overview
A new, modern threading solution

Turning
Ultra-rigid threading tool

B
U
ltra-rigid threading with fixed position
Parting and
inserts.
grooving
T he insert locates in the correct position

with guidance of the rail.
C 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
Threading
faces).
D
Milling
A variety of tool holder solutions

E
Quick change Coromant
coupling Boring bar Capto coupling Drop head
Drilling
F
Boring
G
Tool holding
H
Other information
CoromantCapto Shank tool Exchangable

Machinability
coupling cutting head
C 18
How to apply
A
How to apply
Turning
Three different types of infeed
The infeed method can have a significant In practice, the machine tool, insert B
impact on the thread machining process. geometry, workpiece material and thread
It influences: pitch influence the choice of infeed
Parting and
- chip control method.
grooving
- insert wear
- thread quality
- tool life. C
Threading
Modified flank infeed
M
ost newer CNC machines can be programmed for
modified flank.
D
U
sed with C-geometry as the chip breaker will not
function with radial infeed.
Axially directed cutting forces reduce the risk of vibra-
Milling
tions.
Controlled chip direction.
E
Radial infeed
Drilling
Used by all manual machines and most canned CNC
programs.
F irst choice for work hardening materials and suitable F
for fine pitches.
Boring
Incremental infeed G
N
ormally used with very large profiles and pitches, long
Tool holding
work threading cycles where tool life needs to match

the length of the thread.
Requires special programming.
H
Other information
Machinability
C 19
A How to apply
Modified flank infeed

Turning
M ost CNC machines have a programmed cycle using

this infeed.
B 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
Parting and
insert.
grooving
Less heat is transferred to the insert.

First choice for most threading operations.
C
Feed direction
Threading
Chip flow Chip flow
D
Milling
Feed direction
Feed direction
E
B etter chip control.

Better surfaces.
C-geometry
Drilling
For C-geometry insert, modified flank

insert infeed is the only suitable infeed.
F
Radial infeed
M ost commonly used method - and only method pos-
Boring
sible on older non-CNC lathes.

Makes a stiff V chip.
G Even insert wear.
Insert tip exposed to high temperatures, which restricts
Tool holding
depth of infeed.
Suitable for fine pitches.
Vibration possible and poor chip control in coarse
pitches.
H First choice for work hardening materials.
Other information
Machinability
C 20
How to apply
A
Incremental infeed
Turning
Recommended for large profiles.
E
ven insert wear and longest tool life in B
very coarse threads.
C
hips are directed both ways, making
Parting and
control difficult.
grooving
C
Programming methods
Threading
Ways of improving the machining result
Decreasing depth per pass (Constant chip area)
D
Allows for constant chip T he deepest pass is the
area. first pass.
This is the most common Follows recommenda-
Milling
method in CNC programs. tion on infeed tables in
catalog.
More balanced chip E
area.
Last pass actually
around .0028 inch (0.07
Drilling
mm).
Constant depth per pass Boring
Each pass is of an equal M uch more demanding

depth, regardless of the on the insert.
number of passes. Offers best chip control. G
Should not be used for
pitches larger than 1.5
Tool holding
mm or 16 t.p.i.
H
Other information
Machinability
C 21
A How to apply
Threading with full profile inserts

Turning
Use extra stock/material for topping the thread

For topping inserts, .001 .003 inch (0.03 - 0.07 mm) material should be
B left from prior turning operations to allow for proper forming of the crest.
Parting and
+.004
0
T he blank does not need to be turned to the
grooving
exact diameter prior to the threading.

A
dd extra stock/material on the workpiece
C ~.005 diameter, .002 .006 inch (0.06 - 0.14 mm)
for topping the finish diameter of the thread.
Threading
Infeed values recommendations

Number of infeeds and total depth of thread.
D
ISO inch, external
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
C 22
How to apply
A
Turning
Max .004 inch ( 0.1 mm) Use maximum deviation of .004 inch
(0.1 mm) from centerline.
Too high cutting edge B
Clearance will decrease.
Parting and
Cutting edge will rub (break).
grooving
Too low cutting edge
C
The thread profile can be incorrect.
Threading
Method of threading
Right and left hand threads and inserts D
External Internal
Right hand threads Left hand threads Right hand threads Left hand threads
Milling
E
Right hand Left hand

Right hand Left hand tool/insert tool/insert
Drilling
tool/insert tool/insert
F

Boring
G
Left hand Right hand
Tool holding
Left hand Right hand

tool/insert tool/insert Left hand Right hand
tool/insert tool/insert H
Other information
A negative shim must be used.

Machinability
C 23
A Troubleshooting
Thread turning application hints

Turning
Some vital factors to consider to achieve success
B C
heck the workpiece diameter for cor- O
ptimize infeed method, number and
rect working allowance before thread- size of passes.
turning (add .006 inch (0.14 mm) as
Parting and
E
nsure the correct cutting speed for the
crest allowance).
grooving
demands of the application.

P
osition the tool accurately in the
In case of pitch error on component
machine.
C thread, check to see if machine pitch is
C
heck the setting of the cutting edge in correct.
relation to pitch diameter.
It is recommended that the tool should
Threading
M
ake sure the correct insert geometry start a minimum distance of 3 times
is used (all-purpose, F or C). the thread pitch before engaging the
workpiece.
Ensure there is sufficent and even
D clearance (insert-inclination shims)
to achieve correct flank clearance by
selecting the appropriate shim.
If threads are rejected, check entire
Milling
setup, including machine tool.
E C
heck the available CNC program for
thread turning.
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability

C 24
Troubleshooting
A
Troubleshooting
Turning
Plastic deformation
B
1. Excessive temperature in 1. R
educe the cutting speed,
cutting zone. increase the number of
Parting and
infeeds.
2. Inadequate supply of
grooving
A B coolant. Reduce the largest infeed
3. Wrong grade. depth, check the diameter
Starts as plastic deformation before threading.
(A). C
2. Improve coolant supply.
which leads to edge chipping
(B). 3. C
hoose a grade with better
resistance to plastic defor-
Threading
mation.
Built-up edge (BUE) D

-O
ften occurs in stainless - Increase cutting speed.
material.
-C
hoose an insert with good
-O
ften occurs in low carbon toughness, preferably PVD
Milling
steel. coated.
A B
- Unsuitable grade.
BUE (A) and edge spalling (B) E
often occur in combination. -C
utting edge temperature
Accumulated BUE is then too low.
ripped away together with
small amounts of insert
Drilling
material, which leads to
spalling.
F
Insert breakage
1. Wrong turned diameter prior 1. Turn to correct diameter
to threading. before threading operation,
Boring
.001 .003 inch (0.03

2. Infeed series too tough. 0.07 mm) radially larger
3. Wrong grade. than max. diameter for G
thread.
4. Poor chip control.
2. Increase number of infeeds.
Tool holding
5. Center height incorrect. Reduce size of the largest

infeeds.
3. Choose a tougher grade.
4. C
hange to C-geometry and
use modified flank infeed.
H
Other information
5. Correct center height.

Machinability

C 25
A Troubleshooting

Turning
Rapid flank wear

1. Highly abrasive material. 1. W
rong grade. Choose a
B more wear resistant grade.
2. Cutting speed too high.
2. Reduce cutting speed.
3. Infeed depths too shallow.
Parting and
3. Reduce number of infeeds.

4. Insert is above center line.
grooving
4. Correct center height.
Abnormal flank wear

Threading
1. Incorrect method for flank 1. C

hange method of flank
infeed. infeed for F-geometry and
standard geometry; 3 - 5
2. Insert inclination angle from flank, for C-geometry;
D does not agree with the 1 from flank.
lead angle of the thread.
Poor surface on one flank of 2. C
hange shim to obtain
thread. correct angle of inclination.
Milling
E
Vibration
1. Incorrect clamping of the 1. Use soft jaws.
Drilling
workpiece.
2. O
ptimize center hole and
2. Incorrect setup of the tool. check pressure of face
F driver.
3. Incorrect cutting data.
4. Incorrect center height. Minimize overhang of tool.
Check that the clamping

sleeve for bars is not worn.
Boring
Use 570-3 anti-vibration

G bars.
3. Increase cutting speed; if
this does not help, lower
Tool holding
the speed dramatically.
Try F-geometry.
4. Adjust center height.
H
Other information
Machinability

C 26
Troubleshooting
A
Turning
Poor surface finish
1. Cutting speed too low. 1. Increase cutting speed.
B
2. The insert is above the 2. Adjust center height.
center height.
3. U
se C-geometry and modi-
Parting and
3. Uncontrolled chips. fied flank infeed.
grooving
Poor chip control C
1. Incorrect method of infeed. 1. Modified flank infeed 3 - 5.
2. Incorrect thread geometry. 2. U
se C-geometry with modi-
Threading
fied flank infeed 1.
Shallow profile D
1. Wrong center height. 1. Adjust center height.
2. Insert breakage. 2. Change cutting edge.
Excessive wear.
Milling
Incorrect thread profile
E
1. Unsuitable thread profile 1. C
orrect tool, shim and
(angle of thread and nose insert combination.
radius) external inserts
used for internal operation 2. Adjust center height.
Drilling
or vice versa. 3. Adjust to 90.
2. Wrong center height. 4. Correct the machine.
3. Holder not 90 to center F
line.
4. Pitch error in machine.
Boring
Excessive edge pressure G

1. Work hardening material 1. R
educe the number of
Tool holding
in combination with infeed infeeds.

depths which are too shal-
low. Change to F-geometry.
2. Excessive pressure on cut- 2. Change to a tougher grade.
ting edge. H
3. Use modified flank infeed.
Other information
3. Profile with too small thread

profile angle.
Machinability
C 27
D2
Milling
Milling is performed with a rotating, multi-edge cut-

ting 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 in-
creasing demands to produce other forms and surfaces.
Theory D4
Selection procedure D9
System overview D 13
Choice of inserts how to apply D 24
Choice of tools how to apply D 29
Troubleshooting D 36
D3
A Theory
Milling theory
Turning
B Spindle speed, cutting speed and cutter diameter
Parting and
grooving
n = S
pindle speed, rpm
(revolutions per minute)
C vc = Cutting speed (ft/min) (m/min)

ve = E
ffective cutting speed (ft/min)
(m/min)
Threading
Dc = Cutter diameter (inch) (mm)

De = Dcap = C
utting diameter (inch)
D (mm) [at cutting depth]
Milling
E
Drilling
F Spindle speed (n) in rpm is the number of revolutions the

milling tool on the spindle makes per minute.
Cutting speed (vc) in ft/min (m/min) indicates the surface
speed at which the cutting edge machines the workpiece.
Boring
Specified cutter diameter (Dc), having an effective cutting

diameter (De), which is the basis for the cutting speed vc
G
or ve.
Tool holding
H
Other information

Machinability
D4
Theory
A
Turning
Feed, number of teeth and spindle speed
B
fz = F eed per tooth (inch/tooth) (mm/
tooth)
Parting and
vf = Table feed (inch/min) (mm/min)
grooving
zn = Number of cutter teeth (pcs)
zc = E
ffective number of teeth (pcs) C
[in engagement]
fn = F eed per revolution (inch/rev)
Threading
(mm/rev) [fz x zc]
n = Spindle speed (rpm)
D
Milling
vf = fz zc n 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
F
thickness value.
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
Boring
time-unit related to feed per tooth and number of teeth in

the cutter.
G
The number of available cutter teeth in the tool (zn) varies
considerably and is used to determine the table feed
Tool holding
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 deter- H
mine the finishing capability of a cutter.
Other information

Machinability
D5
A Theory
Turning
Depth of cut
B ae = R
adial depth of cut (inch) (mm)
[working engagement]
ap = Axial depth of cut (inch) (mm)
Parting and
grooving
C Axial depth of cut, ap inch (mm), is what Radial cutting width, ae inch (mm), is the
the tool removes in metal on the face of width of the component engaged in cut by the
the workpiece. This is the distance the diameter of the cutter. It is the distance across
tool is set below the unmachined surface. the surface being machined or, if the tool diam-
Threading
eter is smaller, that is covered by the tool.
D
Net power, torque and specific cutting force
ap = Axial depth of cut (inch) (mm)

ae = Radial depth of cut (inch) (mm)
Milling
[working engagement]
vf = Table feed (inch/min) (mm/min)
E
kc = Specific cutting force (lbs/inch2)
(N/mm2)
Pc = Net power (Hp) (kW)
Drilling
Mc = Torque (lbf ft) (Nm)
F The net power (Pc) is the power the Inch

machine must be able to provide to ap ae vf kc
the cutting edges in order to drive the Pc = Hp
396 103
cutting action. The efficiency of the ma-
chine must be taken into consideration Metric
Boring
when selecting cutting data. ap ae vf kc

Pc = kW
G The torque (Mc) is the torque value 60 106
produced by the tool during cutting ac-
tion, which the machine must be able Inch
Tool holding
to provide. Pc 16501
Mc = lbf ft
The specific cutting force value (kc) is n
a material constant, expressed in
lbs/inch2 (N/mm2). The values can be Metric
H
found in our main ordering catalog and Pc 30 103
Other information
technical guide. Mc = Nm
n
Machinability
D6
Theory
A
Climb or conventional milling
Turning
Climb milling preferred method
Using climb milling (also In climb milling, the in-
referred to as down mill- sert starts its cut with a
B
ing), the burnishing effect large chip thickness.
is avoided, resulting in less
Parting and
heat and minimal work-
grooving
hardening tendency.
Conventional milling
Threading
The feed direction of the In conventional milling
workpiece is opposite to (also referred to as up
that of the cutter rotation milling) the chip thick-
at the area of cut. ness starts at zero and D
increases to the end of
the cut.
Milling
Always use climb milling
for best cutting conditions. E
Cutter diameter and position
Drilling
The selection of milling cutter diameter is The position of the cutter in relation to the
usually made on the basis of the work- workpiece engagement, and the contact F
piece width with the availability of the ma- which the cutter teeth have, are vital fac-
chine power also being taken into account. tors for a successful operation. Boring
C
utter diameter should be 20 50% larger than the
width of cut. G
2
/3 rule (i.e., 5.906 inch (150 mm) cutter)
- 2/3 in cut, 3.937 inch (100 mm)
Tool holding
- 1/3 out of cut, 1.969 inch (50 mm).

B
y moving the milling cutter off the center, a more
constant and favorable direction of cutting forces will be
obtained. H
Other information
Machinability
D7
A Theory
Chip formation through cutter position

Turning
The cutting edge in a radial direction engages with the

workpiece in three different phases:
B
1. Entrance into cut
2. Arc of engagement in cut
Parting and
3. Exit from cut

grooving
C
Dc = Cutter diameter
ae = working engagement
The centerline of the cutter is well inside the workpiece

Threading
width, ae >75% of Dc.

M
ost favorable cutting conditions and optimized use of
D the cutter diameter.
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.
Milling
E T he centerline of the cutter is well outside the workpiece

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

the tool.
F
The centerline of the cutter is in line with the workpiece

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

= Alternative cutter position.
Other information
= Not recommended cutter position.

Machinability
D8
Selection procedure
A
Selection procedure
Turning
Parting and
grooving
Type of operation and
method
C
1 Component
Workpiece material and
Threading
quantity
Milling
Machine Machine parameters
3 Select type of cutter
Drilling
Choice of tool
4
Boring
How to apply Cutting data, method etc.
G
Tool holding
5 Troubleshooting Remedies and solutions

H
Other information
Machinability
D9

Turning
B Geometric shape
Flat surface
Parting and
Deep cavities
grooving
Thin walls/bases
Slots
C
Threading
Material Tolerances
P M K
D N S H Machinability Dimensional accuracy
Chip forming Surface finish
Hardness Part distortion
Milling
Alloy elements Surface integrity
Drilling

F
Material Tool holding
Available power Long overhang
Age/condition stability Poor holding
Boring
Horizontal/vertical Axial/radial runout

G Spindle type and size
N
umber of axes/configu-
Tool holding
ration
Workpiece clamping
H
Other information
Machinability
D 10
Selection procedure
A
3. Choice of tools
Turning
Different ways to optimize milling
Cutters with round inserts
B
Robust milling cutters. R
ound inserts require
Parting and
more stable machines.
grooving
V
ery flexible for face mill-
ing and profiling.
H
igh performance multi- C
purpose cutters.
Threading
45 face mill
D
G
eneral choice for face Max cutting depth
milling. .236-.394 inch
Milling
(6-10 mm).
B
alanced radial and axial
cutting forces.
E
Smooth entry into cut.
Drilling
90 square shoulder face mill
Advantages Disadvantages F
Great versatility. F eed per tooth is rela-

tively low while fz = hex.
Large depth of cut.
Boring
L ow axial cutting forces

(thin workpieces).
G
Light-cutting inserts with
true four edges.
Tool holding
H
Other information
Machinability
D 11
4. How to apply
Turning

Number of cutting Stability
B edges/pitch
C
hoose largest possible
S electing the right spindle size or outer
Parting and
number of edges or pitch diameter.

grooving
is very important.
It affects both productiv- Chip formation through cut-
ity and stability. ter positioning
C
Insert geometry A lways use climb milling.
Move the cutter off the
S
elect between a geom-
Threading
center.
etry for Light, Medium or
Use a cutter with a diam-
Heavy machining.
eter 2050% larger than
D the cut.
Milling
5. Troubleshooting
Drilling
F Insert wear and tool life Unsatisfactory surface

finish
C
heck the wear pattern
and if necessary adjust C heck spindle runout.
the cutting data accord- Use wiper inserts.
ingly.
Boring
Decrease feed per tooth.

G Vibration
eak fixture.
W
Tool holding
Long tool overhang.

Weak workpiece.
Size of spindle taper.
H
Other information
Machinability
D 12
System overview
A
System overview
Turning
Face milling
B
Cutters for general use
Face and square shoulder
milling cutter for light face
Parting and
milling operations
grooving
Face milling cutter with round inserts
for tough conditions
C
General purpose face milling
cutter with 45 lead (entering)
angle
Threading
D
Milling
E
Dedicated cutters
Drilling
High feed face milling Face milling cutters for cast iron machining
K F
Boring
G
Heavy duty face milling
Face milling cutters for aluminum
Tool holding
machining
H
Other information
Machinability

D 13
Shoulder milling
Turning

Face and shoulder milling for light
B shoulder milling operations
Face and shoulder milling
cutter for heavy machining
Parting and
grooving
C
Threading
Side and face milling cutter

used for shoulder milling operation
D
End mills and long edge cutters

Milling
End mill with exchangeable, solid carbide head
E Indexable insert end

mill
Drilling
F
Long edge milling cutter
Solid carbide end mill
Boring
Dedicated cutters
G
Edging with square shoulder milling cutters
Deep shoulder milling
Tool holding
H
Other information

Machinability
D 14
System overview
A
Profiling
Turning
Cutters for general use roughing
Round insert cutter B
Parting and
grooving
Round insert end mill
Threading
D
Cutters for general use finishing
End mill with exchange-
able, solid carbide head
Milling
Solid carbide
ball nose end mill E
Drilling
F
Boring
Other methods
Turn milling Blade milling G
Tool holding
H
Other information
Machinability

D 15
A System overview
Slot milling
Turning

radial slot milling
B Side and face mill for slot
milling
Parting and
Slitting cutter for grooving

grooving
and parting off
C
End mill for internal shallow
grooving and slotting
Threading
Cutter for external, shallow grooving and slotting
D
axial slot milling
Indexable insert end mill
Milling
End mill with exchangeable,

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

Tool holding
H
Other information
Machinability
D 17
A System overview
Milling methods
Turning
Milling machines may be manually operated, mechanically

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

C
Vertical milling machines
In conventional 3-axis machines, milling
most frequently entails the generation of
Threading
flat faces, shoulders and slots.

Surfaces and forms, other than those
D described below, are increasing steadily as
the number of five-axis machining centers
and multi-task machines grows.
Milling
E
Drilling
Face milling High-feed milling Shoulder milling Slot milling

F
Boring
G
Cutting off Chamfering Plunge milling
Tool holding
H
Other information
Machinability
D 18
System overview
A
Advanced milling methods
Turning
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, B
and machining centers have turning capability via turnmill
or mill-turn machines. CAM developments mean that
Parting and
5-axis machines are increasing.
grooving
The results of these trends C
and the development of meth-
ods put new demands and
Threading
opportunities on the tooling,
such as:
Increased flexibility
Fewer machines/setups to
D
complete a component
Reduced stability
Longer tool lengths
Milling
Lower depth of cut.
Drilling
Profile milling Turn milling Trochoidal milling Circular milling
F
Boring
G
Linear ramping Circular ramping Thread milling
Tool holding
H
Other information
Machinability
D 19
A System overview
Positioning of cutters for face milling

Turning
Type of milling
B cutter
Parting and
grooving
C
Considerations Round inserts 10 45 90
Machine/spindle
Threading
ISO 40, 50 ISO 40, 50 ISO 40, 50 ISO 30, 40, 50

size
D Stability
High High Medium Low
requirement
Roughing Very good Good Very good Acceptable

Milling
E Finishing Acceptable Acceptable Very good Good
Cutting depth ap Medium Small Medium High

Drilling
Versatility Very good Good Good Very good

F
Productivity Very good Very good Very good Good

Boring
G
Tool holding
H
Other information
Machinability
D 20
System overview
A
Positioning of cutters for shoulder milling
Turning
Type of milling
cutter B
Parting and
grooving
C
90 90 90 90
Considerations
Threading
Machine/spindle
ISO 40, 50 ISO 30, 40, 50 ISO 40, 50 ISO 30, 40, 50
size
Stability D
High High Medium Low
requirement
Roughing Very good Good Acceptable Good
Milling
Finishing Acceptable Acceptable Very good Good E
Cutting depth ap Large Medium Small Large
Drilling
Material All All Aluminum Aluminum
F
Versatility Very good Very good Acceptable Good Boring
G
Tool holding
H
Other information
Machinability
D 21
A System overview
Positioning of cutters for profile milling

Turning
Type of milling
B cutter
Parting and
grooving
C
Considerations Round inserts Ball nose Ball nose Ball nose
Machine/spindle
Threading
ISO 40, 50 ISO 40, 50 ISO 30, 40 ISO 30, 40

size
Stability
D High Medium Medium Low
requirement
Roughing Very good Good Acceptable Acceptable

Milling
E Finishing Acceptable Acceptable Very good Very good
Cutting depth ap Medium Medium Small Small

Drilling
Versatility Very good Very good Very good Very good

F
Productivity Very good Good Good Good

Boring
G
Tool holding
H
Other information
Machinability
D 22
System overview
A
Positioning of cutters for slots and grooves
Turning
Type of milling cutter
B
Parting and
grooving
C
Considerations Side and face Grooving Long edge
Machine/spindle size ISO 50 ISO 40, 50 ISO 40, 50
Threading
Slot open Open Open Open
Slot closed D
Cutting width Small Small Very good
Cutting depth ap inch (mm) 4.508 (114.5) .256 (6.5) Good
Milling
Versatility Limited Good Good
E
Type of milling cutter
Drilling
F
Considerations Indexable insert Exchangable- Solid carbide end

Boring
end mill head end mill mill
Machine/spindle size ISO 30, 40, 50 ISO 30, 40, 50 ISO 30, 40, 50
G
Slot open Open Open Open
Tool holding
Slot closed Closed Closed Closed
Cutting width Good Small Small
Cutting depth ap Very good Small Large H

Other information
Versatility Very good Very good Very good

Machinability
D 23
A Choice of inserts how to apply
Choice of inserts and how to apply

Turning
B
Parting and
grooving
Modern milling inserts for

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

Milling

E
Corner design Main cutting edge

design
Drilling
.005 .005
C
utting edge reinforce- C
utting edge reinforcement
ment .005 inch (0.13 .005 inch (0.13 mm).
Boring
mm).
Rake angle 30.
Rake angle 30.
G Primary land 17.
Primary land 11.
Tool holding
Corner reinforcement Main cutting edge

design
H
Other information
Chip former
Machinability
D 24
Choice of inserts how to apply
A
Making the tool choice in milling
Turning
First choice
Low Operation stability High
B
Cutter pitch
L M H
Parting and
grooving
Coarse pitch (-L) Close pitch (-M) Extra close pitch (-H) C
Threading
D
Light (-L) Medium (-M) Heavy (-H)
Machining conditions/
Wear resistant Toughness
Grades
Milling
E
Good conditions Average conditions Difficult conditions
Drilling
Type of application
ap Depth of cut, F
inch (mm) Heavy milling
H Operation for maximum stock removal and/or severe
conditions.
Larger depth of cut and feed rate.
Boring
Operations requiring highest edge security.
Medium milling G
M Most applications general purpose milling.
Tool holding
Medium depth of cut and feed rate.
Light milling
L Operations at small depth of cut and low feed rates.
Operations requiring low cutting forces. H
Other information
fn
Machinability
Feed, inch/tooth (mm/tooth)
D 25
A Choice of inserts how to apply
Selecting the insert geometry

Turning
B
Parting and
grooving

C
Extra positive. G
eneral purpose Reinforced cutting edge.
geometry.
Light machining. Heavy machining.
Medium feed rates.
Threading
Low cutting forces. Highest edge security.

M
edium operations to
Low feed rates. High feed rates.
light roughing.
D
Milling
Achieving good surface finish in milling

E
Surface
roughness U
se wiper inserts for
higher productivity and
improved surface finish.
Drilling
Standard One wiper

insert insert L imit the feed to 60% of
F the parallel land.
M
ount the wiper inserts
correctly.
fn
S
et the wiper inserts
Boring
fn1 = .031 x bs1 fn1 = .024 x bs2 Feed, inch/tooth

(fn1 = 0.8 x bs1) (fn1 = 0.6 x bs2) (mm/tooth)
below other inserts.
G
bs1 bs2
Tool holding
.002 inch

(0.05 mm)
H bs, inch .079 .323

(mm) (2.0)
Other information
(8.2)
Machinability
D 26
A
How to select insert grade
Turning
Select the geometry and grade according to the application.
Build-up of a grade chart Machining conditions B
Parting and
Good
grooving
Average
C
Difficult
Threading
Good Average Difficult D
Milling
Define machining conditions
E
Drilling
F

Boring
C
utting depth 25% of C
utting depth 50% of C
utting depth 50% of
max ap or less. max ap or more. max ap or more. G
Overhang under two O
verhang two to three O
verhang over three
times cutter diameter. times cutter diameter. times cutter diameter.
Tool holding
Continuous cuts. Interrupted cuts. Interrupted cuts.

Wet or dry machining. Wet or dry machining. Wet or dry machining.
H
Other information
Machinability

D 27
A Choice of inserts and to apply
Dedicated grades for ISO P, M and K

Turning
Dedicated grades minimize tool wear development

B 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
Parting and
mechanisms, e.g.:
grooving
- Flank wear, crater wear and plastic deformation in steel

- Built-up edge and notch wear in stainless steel
C
- Flank wear and plastic deformation in cast iron.
Threading
D
Select geometry and grade depending on the type of
workpiece material and type of application.
Milling
E
Drilling
F
Boring
G
ISO GC 4200 ISO GC 2000 ISO GC 3200
P M
Tool holding
H
Other information
Machinability
D 28
A
Choice of cutter and how to apply
Turning
B
Parting and
grooving
C
High performace face milling
Threading
cutters for small to medium
cutting depths.
D
Making the tool choice in milling
Milling
First choice
Low Operation stability High E
Cutter pitch
L M H
Drilling
F
Coarse pitch (-L) Close pitch (-M) Extra close pitch (-H)
Boring

Tool holding
Machining conditions/
Wear resistant Toughness
Grades
H
Other information

Machinability
D 29
A Choice of tools how to apply
Selecting cutter pitches

Turning
First choice
B Low Operation stability High

Cutter pitch
Parting and
grooving
L M H
Threading
Coarse pitch (-L) Close pitch (-M) Extra close pitch (-H)
R
educed number of General purpose H
igh number of inserts
D inserts. for maximum productivity.
S
uitable for mixed
Limited stability. production. Stable conditions.
Long overhang. S
mall to medium Short chipping materials.
machines
Milling
S
mall machines/limited Heat resistant materials.
horsepower. Usually first choice.
E D
eep, full slotting
operations.
Differential pitch.
Drilling
F Limited stability Stable

First choice
conditions
Boring
G
Long overhang
K S
Tool holding
Cast iron Heat

(CMC 08) resistant
alloys
Limited (CMC 20)
H horsepower
Other information
Machinability
D 30
A
Cutting forces and entering angle
Turning
90 entering angle 45 entering angle Round insert cutters
B
Parting and
grooving
C
Threading
D
Milling
E
Thin-walled components G
eneral purpose first S
trongest cutting edge
choice. with multiple indexes.
W
eak-fixtured compo-
nents. R
educed vibration on General purpose cutter.
Drilling
long overhang.
W
here 90 form is Increased chip thinning
required. C
hip thinning effect al- effect for heat resistant
lows increased produc- alloys. F
tivity.
Boring
G
Tool holding
H
Other information
Machinability
D 31
Axial and radial cutting forces

Turning
Effect of entering angle (90)
B Thin-walled components.
Axially weak fixtured components.
Parting and
Square shoulder
grooving
hex = fz (In case ae > 50% x Dc)
C
Threading

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

ing angle).
E
Drilling

F
On round inserts, the chip load and entering angle vary with the
depth of cut.
S
trongest cutting edge with multiple
Boring
indexes.
General purpose cutter.
G
Increased chip thinning effect for heat
resistant alloys.
Tool holding
hex = depends on ap.
H
Other information
Machinability
D 32
A
Formulas for cutters with round inserts
Turning
Max. cutting diameter at a
specific depth (inch). B
Dcap = Dc + iC2 (iC 2 ap)2
Parting and
grooving
Facemilling round insert
(ap<iC/2) (inch). C
hex iC
fz =
2 ap iC ap 2
Threading
Slide milling (ae<Dcap/2) and round insert
(ap<iC/2) (inch). D
hex iC Dcap
fz =
4 ap iC ap 2 Dcap ae ae 2
Milling
E
Feed compensation for different entering angles
Drilling
90 = (fz or hex) 1.0
Boring
45 = (fz or hex) 1.41

G
Tool holding
Round = depends on ap
H
Other information
Machinability
D 33
Calculating cutting data

Turning
Example in face milling
Given: Need:
B
.157 Cutting speed, vc = Spindle speed, n (rpm)
(4 mm) 738 ft/min (225 m/min)
Parting and
Table feed, vf
(inch/min) (mm/min)
grooving
Feed per tooth, fz =

.0082 inch (0.21 mm) Metal removal rate, Q
Number of cutter teeth, zn = 5 (inch3/min) (cm3/min)
C 3.346 Cutter diameter, Dc = Power consumption (Hp) (kW)
(85 mm) 4.921 inch (125 mm)
Cutting depth, ap =
.157 inch (4 mm)
Threading
Working engagement, ae =
3.346 inch (85 mm)
Spindle speed Given: vc = 738 ft/min (225 m/min)

Milling
Inch Metric
vc 12 vc 1000
n= (rpm) n= (rpm)
E Dc Dc
738 12 225 1000

n= = 575 rpm n= = 575 rpm
3.14 4.921 3.14 125
Drilling
F
Table feed Given: n = 575 rpm
Inch Metric
vf = n fz zn (inch/min) vf = n fz zn (mm/min)
Boring
vf = 575 .0082 5 = 23.6 inch/min vf = 575 0.21 5 = 600 mm/min

G
Metal removal rate Given vf = 23.6 inch/min (600 mm/min)
Tool holding
Inch Metric
ap ae vf
Q = ap ae vf (inch3/min) Q= (cm3/min)
1000
H
4 85 600
Other information
Q = .157 3.346 23.6 = 12.4 inch3/min Q= = 204 cm3/min

Machinability
1000
D 34
A
Net power consumption
Turning
Given: Material CMC 02.1
Inch Metric
B
ae ap vf kc ae ap vf kc1
Pc = (Hp) Pc = (kW)
396 103 60 106
Parting and
grooving
C Cutting
Milling with large engagement Metric
Threading
Specific Hardness
cutting force Brinell CT530
kc 1
Max chip thickness
CMC 0.1 0.15 0.2
ISO No. Material N/mm2 HB mc Cutting speed vc, m
Steel
P
Unalloyed
01.1
01.2
C = 0.10 0.25%
C = 0.25 0.55%
1500
1600
125
150
0.25
0.25 D
43039050
38535015
01.3 C = 0.55 0.80% 1700 170 0.25 36533000
01.4 1800 210 0.25 31529060
01.5 2000 300 0.25 23521095
Low alloyed (alloying elements d 5%)
02.1 Non-hardened 1700 175 0.25 30027545
02.2 Hardened and tempered 1900 300 0.25 19518060
High alloyed (alloying elements > 5%)
Milling
03.11 Annealed 1950 200 0.25 23020585
03.13 Hardened tool steel 2150 200 0.25 19017055
03.21 2900 300 0.25 16515035
03.22 3100 380 0.25 1059585
Castings
06.1
06.2
Unalloyed
Low alloyed (alloying elements d 5%)
1400
1600
150
200
0.25
0.25 E
30528050
24522000
06.3 High alloyed (alloying elements > 5%) 1950 200 0.25 18016045
Specific Hardness
cutting force Brinell CT530
kc 1
Max chip thickness
CMC 0.1 0.15 0.2
ISO No. Material N/mm2 HB mc Cutting speed vc, m
3.346 .157 23.6 246500 Stainless steel 85 4 600 1700
Drilling
M
Pc = = 7.7 Hp
Ferritic/martensitic
05.11 Non-hardened Pc = 1800
= 5.8 kW
200 0.21 285 255 230
396 103 05.12 PH-hardened 60 106 2850 330 0.21 205 185 165
05.13 Hardened 2350 330 0.21 215 190 170
Austenitic
05.21
05.22
Non-hardened
PH-hardened
1950
2850
200
330
0.21
0.21 F
265 240 215
200 175 160
The calculation above is approximate05.51and valid for an Austenitic-ferritic (Duplex)
Non-weldable t 0.05%C 2000 230 0.21 260 235 210
maximum chip thickness (hex) of .0039
05.52 inch (0.1 mm). Weldable < 0.05%C
Stainless steel Cast
2450 260 0.21 230 205 185
For a more accurate value of power consumption

15.11
(Pc) the Ferritic/martensitic
Non-hardened 1700 200 0.25 255 230 205
kc value should be calculated accordingly.

15.12 PH-hardened 2450 330 0.25 180 160 145
Boring
15.13 Hardened 2150 330 0.25 195 175 155

15.21 Austenitic 1800 200 0.25 255 225 205
15.22 PH-hardened 2450 330 0.25 180 160 145
Inch 15.51
Austenitic-ferritic (Duplex)
Non-weldable t 0.05%C 1800 230 0.25 245 220 195
( )
15.52 Weldable < 0.05%C 2250 260 0.25 215 190 170
o Specific Hardness G
kc = kc1 hm-mc 1 (lbs/inch2) hm = Average chip thickness cutting force
kc 1
Brinell CB50
Max chip thickness
Material
100 CMC 0.1 0.15 0.2
ISO No.
o = Insert rake angle N/mm HB
2 mc Cutting speed v , m c
Tool holding
Malleable cast iron

K
07.1
07.2
m c =
Ferritic (short chipping)
Pearlitic (long chipping)
C
hip thickness compensation
790
900
130
230
factor
0.28
0.28
-
-
Grey cast iron
Metric 08.1 Low tensile k c = Specific cutting force 890
strength 180 0.28 850 720 620
08.2 High tensile strength 1100 245 0.28 910 780 670
k iron = S pecific cutting force for average chip
( )
Nodular cast
c1
o 09.1 Ferritic 900 160 0.28 -
kc = kc1 hm-mc 1 (N/mm

09.2
2) Pearlitic
45-60q entering
1)
thickness .039 inch1350
angle. Positive cutting geometry and coolant should be used.
(1 mm)250 0.28 495 420 360
H
100
Other information
Condit
Cutter,
Machinability
100 mm 125 mm over the

engage
D 35
MILLING Cutting data

A Troubleshooting
Application hints for milling

Turning
Power capacity
Check power capability and machine
B rigidity, making sure that the machine
can handle the cutter diameter required.
Parting and
Overhang
grooving
Machine with the shortest possible tool

overhang on the spindle.
C
Select correct cutter pitch
Use the correct cutter pitch for the
operation to ensure that there are not
Threading
too many inserts engaged in cut, as this

may cause vibration.
D
Cutting engagement
Ensure there is sufficient insert engage-
ment with narrow workpieces or when
Milling
milling over voids.

E
Up to .020 inch (0.50 mm)

Drilling
Use correct feed

F 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 pos-
G
sible.
Tool holding
H
Other information

Machinability
D 36
Troubleshooting
A
Turning
Choice of insert geometry
Use positive geometry indexable inserts
whenever possible for smooth cutting
B
action and lowest power consumption.
Parting and
Dampened milling tools
grooving
For longer overhang of more than 4 times
the tool diameter, vibration tendencies
can become more apparent, and damp- C
ened cutters can improve the productivity
radically.
Threading
Entering angle
Select the most suitable entering angle.
Cutter diameter
Select the right diameter in relation to
the workpiece width.
Milling
Cutter position E
Position the milling cutter correctly.
Drilling
Coolant
Only use coolant if considered neces- F
sary. Milling is generally performed better
without.
Boring
Maintenance
G
Follow tool maintenance recommenda-
tions and monitor tool wear.
Tool holding
H
Other information
Machinability
D 37
2
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
Hole quality and tolerances E 37
Troubleshooting E 42
E3
A Theory
The drilling process

Turning
B T he drill is always engulfed in the work-

piece, leaving no view of the operation.
Chips must be controlled.
Parting and
grooving
C
hip evacuation is essential; it affects
hole quality, tool life and reliability.
C
Threading
Four common drilling methods

Milling
E
Drilling Trepanning
Drilling is classified into
four common methods:
Drilling
- Drilling
F - Trepanning
- Chamfer drilling
- Step drilling
Boring
Chamfer drilling Step drilling

G
Tool holding
H
Other information
Machinability
E4
Theory
A
The most common holes
Turning
B
Parting and
grooving
C
Threading
D
1 2 3 4 5 6
The most common holes are:
Milling
1 Holes with clearance for bolts
2 Holes with a screw thread
E
3 Countersink holes
4 Holes that have a good fit
Drilling
5 Holes that form channels
6 Holes to remove weight for balancing. F
Boring
G
Tool holding
H
Other information
Machinability
E5
A Theory
Maximum hole depth

Turning
Hole depth (l4) determines the choice of

B tool.
Chip evacuation
Maximum hole depth is a function of hole
diameter Dc and hole depth (l4).
Parting and
grooving
Example: max hole depth l4 = 3 x Dc.
C
Threading
D
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
E6
Theory
A
Drilling theory
Turning
Cutting speeds for indexable drills
C
utting speed (vc) for indexable drills B
declines from 100% at the periphery to
zero at the center.
Parting and
T he central insert operates from cutting
grooving
speed zero to approx. 50% of vc max.
The peripheral insert works from 50% of
vc max up to 100% of vc max. C
0.5 x vc max vc = 0
Threading
vc max
Milling
E
Cutting speeds for solid and brazed carbide drills

T wo effective cutting edges, from the
Drilling
center to the periphery.
Two edges/rev: z = 2. F
Boring
vc = 0 G
vc max
Tool holding
H
Other information
Machinability
E7
A Theory
Solid carbide drill (SCD) vs. high speed drills (HSS)

Turning
Point angle and chisel edge

B
Solid carbide drill
C
hisel edge is practically
Parting and
eliminated with the solid

grooving
carbide drill.
T he axial cutting force
C is reduced considerably,
because the chisel edge
140 point angle
is eliminated on solid
Threading
Chisel edge carbide drills.

HSS drill
T his results in better
centering features and
D cuts chips close to the
center of the drill point.
This eliminates the need
for a center drill.
Milling
118 point angle

E
2 2
1 Main cutting edge 1
4 1
Drilling
2 Chisel edge
3 Primary clearance
F 6
6
4 Secondary clearance 8
5 Flute 3 9
7
6 Margin 5
Boring
5
7 First split
C hisel edge is practically
G eliminated.
8 Negative chamfer
The main cutting edge
9 Clearance surface
reaches the center point.
Tool holding
Gives longer life and

productivity.
Lower thrust and torque.
H Better tolerances.
Other information
Machinability
E8
Theory
A
Turning
Cutting speed
B
fn = feed per revolution (inch/r) (mm/r)
Parting and
vf = penetration rate (inch/min) (mm/
grooving
min)
Dc = drill diameter (inch) (mm)
C
Inch
Dc n
ft/min
Threading
vc =
12
Metric
D
Dc n
vc = m/min
1000
Productivity in drilling is strongly
Milling
related to the penetration rate, vf. vf = fn n inch/min (mm/min)
Cutting speeds for indexable drills

Cutting speed (vc) for indexable drills de- vc = 0
vc max
Drilling
clines from 100 % at the periphery to zero 2
at the center. vc max
F
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.
Boring
G
Cutting speeds for solid and brazed carbide drills vc = 0
Two edges, from the center to the periphery.
Tool holding
vc = max
Two edges/rev: z = 2.
H
Other information
Machinability

E9
A Theory

Effects of cutting speed vc (ft/min) (m/min)
Turning
Affects the power Pc (Hp) (kW) and torque Mc (lbf-ft) (Nm).

B The largest factor determining tool life.
H
igher speed generates higher temperature and in-
creased flank wear, especially on the peripheral corner.
Parting and
grooving
H
igher speed is beneficial for chip formation in long chip-
ping, soft materials, i.e., low carbon steel.
C
Threading
D
Cutting speed (vc) affects:
- tool life
- power consumption.
Milling
Too high cutting speed causes:

- rapid flank wear
E
- plastic deformation
- poor hole quality
- bad hole tolerance.
Drilling
Too low cutting speed causes:

- built-up edge
F
- bad chip evacuation
- longer time in cut.
Boring
G
Tool holding
H
Other information
Machinability
E 10
Theory
A
Feed rate
Turning
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). B
Controls chip formation.
Parting and
Contributes to hole quality.
grooving
Primarily influences surface finish.
Contributes to mechanical and thermal stress.
C
Threading
fn = fz 2 inch/r (mm/r)
D
Feed rate (fn) affects:

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

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

- higher risk of drill breakage
- reduced hole quality.
Boring
Low feed rate:

- longer, thinner chips
- quality improvement
G
- accelerated tool wear
Tool holding
- longer time in cut.
H
Other information
Machinability
E 11
A Theory
Approximate calculation of power consumption

Turning
CoroDrill 880 CoroDrill Delta-C

B
vc = c utting speed (ft/min) (m/min)
Parting and
fn = feed per revolution (inch/rev)

grooving
(mm/rev)
vf = penetration rate (inch/min)
C (mm/min)
Dc = drill diameter (inch) (mm)
fz = feed per edge (inch) (mm)
Threading
kc1 = specific cutting force (lbf ft/

inch2) (N/mm2)
Pc = power consumption (Hp) (kW)
D Ff = feed force (N)
Mc = torque (lbf ft) (Nm)
Milling
Inch Metric
E fn vc Dc kc1 fn vc Dc kc1
Pc = Hp Pc = kW
132 103 240 103
Drilling
F
Boring
G
Tool holding
For information about the kc value, see page H16.
H
Other information
Machinability
E 12
Theory
A
Accurate calculation of power consumption
Turning
CoroDrill 880 CoroDrill Delta-C
B
Parting and
grooving
C
0 = 30
Threading
Inch Metric
D
fn vc Dc kc fn vc Dc kc
Pc = Hp Pc = kW
132 103 240 103
Milling
0
kc = kc1 (fz sin r)-mc ( 1
100 ) E
Drilling
F
Boring
G
Tool holding
For information about the kc value, see page H16.
H
Other information
Machinability
E 13
A Theory
Calculation of torque and feed force

Turning
B n = Spindle speed (rpm)

fn = F eed per revolution (inch/rev)
(mm/rev)
Parting and
grooving
Dc = Drill diameter (inch) (mm)

Power
consumption kc1 = S
pecific cutting
C (Hp) (kW) force (lbf ft/inch2) (N/mm2)
Ff = Feed force (N)
Mc = Torque (lbf ft) (Nm)
Threading
D Torque (lbf ft)

(Nm)
Milling
Dc
Feed force (N) Ff 0.5 kc fn sin r (N)
E 2
Inch Metric
Drilling
Pc 16501 Pc 30 103
Mc = (lbf ft) Mc = (Nm)
F n n
Boring
G
Tool holding
H
Other information
Machinability
E 14
Tool selection
A
Turning
Parting and
grooving
Hole dimension
and quality
C
1 Component
Workpiece material, shape
Threading
and quantity
Milling
Machine Machine parameters
3 Type of tool
Drilling
Choice of tool
Cutting data, coolant,

4
Boring
How to apply
etc.
G
Tool holding
Remedies and
5 Troubleshooting
solutions
H
Other information
Machinability
E 15
A Tool selection

Turning
Component:
B - Is the component rotation symmetric
around the hole, i.e., can the hole be
machined with a stationary drill?
Parting and
grooving
-C
lamping, clamping forces and cutting
forces. Is the component sensitive to
vibrations?
C
- Is a tool extension needed to reach the
surface where the hole will be drilled, i.e.,
long tool overhangs?
Threading
D
Material:
- achinability
m
Milling
- chip breaking
- hardness
E - alloy elements.
Drilling
F 2. Important machine considerations
Condition of the machine:

- achine stability
m
Boring
- spindle speed
G - coolant supply
- coolant pressure
- clamping of the workpiece
Tool holding
- horizontal or vertical spindle

- power and torque
- tool magazine.
H
Other information
Machinability
E 16
Tool selection
A
3. Choice of drilling tools
Turning
Different ways to make a hole
The basic parameters are: The hole type, and the required precision B
affect tool choice.
diameter
depth Drilling can be affected by irregular or
Parting and
quality (tolerance, surface finish, angled entry/exit surfaces and by cross
grooving
straightness). holes.
Threading
Drilling and boring Step drilling Milling, helical
interpolation
Milling
E
Advantages Advantages Advantages
Drilling
Simple standard tools. Simple Tailor Made tools. Simple standard tools.
Relatively flexible. F astest way to make a Very flexible.
hole. F
Low cutting forces.
Disadvantages
Disadvantages
T wo tools, adapters and Disadvantages
Boring
basic holders. Requires more power and

stability. Longer cycle times.
R
equires two tool
positions. Less flexibility. G
Tool holding
H
Other information
Machinability
E 17
A Tool selection
4. How to apply
Turning

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

Drilling
C
hip formation and evacuation is the
dominant factor in drilling and affects
hole quality.
F
Cutting Thicker and

Boring
speed stiffer chips
G
Tool holding
More open due to

less friction
H
Other information
Feed
Machinability
E 18
Tool selection
A
5. Troubleshooting
Turning
B
-C
heck the wear pattern and if necessary adjust cutting
Parting and
data accordingly.
grooving
Chip evacuation
C
- Check chip breaking and cutting fluid supply.
Threading
Hole quality and tolerances
.984 in.
(25mm) -C
heck clamping of drill/workpiece, feed rate, machine
conditions and chip evacuation.
D
Cutting data
-C
orrect cutting speed and feed rate is essential for high
Milling
productivity and tool life.
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
E 19
A System overview
Drilling tools
Turning
Drilling tools covering diameters from .0118 inch up to

4.331 inch (0.30 mm 110 mm) and even larger as
B
engineered products.
Parting and
Conventional drilling
grooving
C
Irregular surface and
cross-hole drilling
Threading
D
Milling
Solid carbide drill Deep hole drill

Drilling
Brazed carbide drill Short hole drill

F
L/Dc
Large diameter drill

Boring
15xDc
G
10xDc Trepanning drill
Tool holding
5xDc
H Drill
diameter, Dc
Other information
.394 .787 1.181 1.575 1.969 2.362 2.756 3.150 4.331 inch
Machinability
(10) (20) (30) (40) (50) (60) (70) (80) (110) (mm)
E 20
System overview
A
Choice of drilling tools
Turning
Step and chamfer drilling
B
Step or step and chamfer
Chamfer drilling drilling
Parting and
grooving
C
Threading
D
Milling
Other methods
E
Solid drilling Plunge drilling
Drilling
Radial adjusted
drilling Helical interpolation Trepanning
Boring
G
Tool holding
H
Other information
Machinability
E 21
A System overview
Diameter and hole depth

Turning
Positioning of short hole drills

B Indexable insert drills Application areas
Always to be considered M edium and large

as the first choice due to
Parting and
diameter holes.
grooving
lower cost per hole. They Medium tolerance

are also very versatile demands.
tools. Blind holes requiring a
C
flat bottom.
Plunge drilling or boring
operations.
Threading
Solid carbide drills

D
First choice for smaller S mall diameter.
diameters and when closer Close or precision
hole tolerance is required. tolerance holes.
Milling
Short to relatively deep

holes.
E
Brazed carbide drills

Drilling
An alternative choice to a Complement to solid car-

solid carbide drill for larger bide for larger diameters or
diameters and when stabil- when process stability is
F ity is bad (due to the less poor the steel part of the
sensitive steel body). drill provides toughness.
Boring
G
Tool holding
H
Other information
Machinability
E 22
System overview
A
Indexable insert drills
Turning
The basic drill
B
T he most economical way to
Parting and
produce a hole.
grooving
For all workpiece materials.
S
tandard, Tailor Made and special drills
available. C
A
versatile tool that can do more than
just drilling.
Threading
D
Milling
E
Mounting options
Different mounting options are available, which enables
the user to mount the drill to almost all machine configu-
Drilling
rations. Today, machine tool manufacturers are offering
mounting options integrated to the spindle.
F
Cylindrical shank Coromant Capto coupling Cylindrical with flat

Boring
G
Tool holding
P-shank Whistle Notch Other modular systems
H
Other information
Machinability
E 23
A System overview
Solid carbide drills

Turning
The basic choice Material-optimized drills

B
Parting and
grooving
C P M K K N S
N S H
Threading
Application-optimized drills Special tools
D Chamfer drill Precision

drill for
hard steel
Milling
P M K P
E N S H H
Drilling
F
Short hole drills ISO material groups
ISO material group
P M K N S H
Boring
G Solid carbide
drills
Tool holding
Brazed carbide
drills
H
Indexable
Other information
insert drills
Machinability
E 24
Selection procedure
A
Large hole diameters
Turning
Large diameter drill
Indexable insert drills are available in diameters B
up to 3.150 inch (80 mm).
Parting and
grooving
C
Threading
Trepanning drill
Trepanning is used for larger hole diameters and where
D
machine power is limited, because it is not as power con-
suming as solid drilling. Trepanning drills are available up
to diameter 4.331 inch (110 mm) as standard.
Milling
E
Drilling
Milling, helical interpolation
F
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
G
Tool holding
H
Other information
Machinability
E 25
A How to apply
How to apply
Turning

B
Setup routine
Use the shortest possible drill.
Parting and
grooving
Check programming length.

S
tart drilling with a mid-range recommended feed rate
C to a depth of .125 inch (3.2 mm).
Check chip formation and measure hole size.
Inspect the drill to make sure no drill-to-hole rubbing is
Threading
taking place.
Increase or decrease feed rate according to chip
D formation, vibration, hole-surface quality, etc.
Milling
Chip control
Drilling
Improved chip evacuation is initially achieved by improv-

ing chip formation.
F Long chips may cause chip jamming in the drill flutes.
A
lso the surface finish may be affected and the insert
or tool may be at risk.
Excellent
Rectification involves selecting the correct insert
Boring
geometry and adjusting cutting data.

G CoroDrill 880 has three insert geometries to suit
Acceptable different materials and cutting conditions.
Tool holding
Not accept-
H able
Other information
Machinability
E 26
How to apply
A
Rotating drill
Turning
Alignment
If over- or under-sized holes are produced
B
or if the center insert tends to chip, it is
often because the drill is off center.
Parting and
T urning the drill 180 in its holder may
grooving
solve this problem.
B
ut it is important to ensure that the
center axis of the drill and the axis of C
rotation are parallel in order to achieve
accurate holes.
Threading
T he machine spindle and the holder
must be in good condition.
Milling
Radial adjustment E
Adjustable holder
etting is achieved by turning the scale
S
Drilling
ring surrounding the holder, marked in
increments of .002 inch (0.05 mm),
indicating a diametrical movement of the F
tool.
R
adial adjustment -.008 /+.028 inch
(-0.2 /+0.7 mm). Note that the adjust-
Boring
ment range for the drill should not be

exceeded. (Maximum adjustment can
be seen on the ordering pages in the G
catalog).
It may be necessary to reduce the
Tool holding
feed/rev (fn) due to longer tool overhang

and less balanced cutting forces created
by the offsetting.
S
leeves are used to adapt various ISO H
Other information
shank sizes for one holder.

Machinability
E 27
A How to apply
Adjustable sleeve for drills with ISO 9766 shanks

Turning
B
Parting and
grooving
C
Rotating drill eccentric sleeve
Threading
Drill diameter can be adjusted for closer

hole tolerance. The adjustment range is
approx. .012 (0.3 mm), but adjustment
D in the negative direction should be made
only if the drill produces an oversized hole
(not in order to achieve undersized holes).
O
ne dot increases/decreases the diam-
Milling
eter by .004 inch (0.10 mm).

Increase the diameter by turning the
E sleeve clockwise.
D
ecrease the diameter by turning the
sleeve counterclockwise.
Drilling
U
se both screws to clamp the drill in the
fixture and make sure the bolts in the
holder are long enough.
F
Boring
G
Tool holding
H
Other information
Machinability
E 28
How to apply
A
Non-rotating drill
Turning
Alignment
.001 inch T he total runout between the center line B

of the machine and the workpiece must
not exceed .001 inch (0.03 mm).
Parting and
grooving
T he drill should be mounted so that the
top face of the peripheral insert is paral-
lel to the machines transverse move-
ment (usually X-axis). C
Threading
D
Milling
Dial indicator and test bar E
Misalignment also has the effect of
radial offsetting, which produces either
an over- or under-sized hole.
Drilling
T esting can be carried out with a dial
indicator together with a test bar.
F
Drill with four flats

Boring
Another way is by making a drill with four

flats equally positioned around the drill
shank. G
1 M
ake holes with the drill mounted in
each of the four flat positions. Hole
Tool holding
measurement will indicate the state of

2 machine alignment.
H
4
Other information
3
Machinability
E 29
A How to apply
Deflection of turret
Turning
Problem solving
D
eflection of the turret on a CNC lathe
B
can be caused by the feed force.
Parting and
grooving
F irst, check if you can minimize torque

by mounting the tool differently.
C Feed force Position B is preferable to position A.
Threading
D
B
Milling
A
E
A
T o avoid wear on the drill body and

Drilling
retraction marks in the hole, mount the

drill with the peripheral insert as shown
F in the picture.
F inally, a reduction of the feed/revolution
(fn) can be made to minimize the feed
force.
Peripheral insert
Boring
G
Tool holding
Feed force
H
Other information
Machinability
E 30
How to apply
A
Radial offset
Turning
H
oles can be drilled larger than the nominal size of the
drill as well as enlarged and finished with a subsequent B
boring pass.
N
on-rotating indexable insert drills can also be used to
Parting and
generate tapered holes.
grooving
A
lso chamfering and reliefs can be machined
with the drill.
C
A
hole which is to be threaded can be prepared in one
pass along with chamfering.
Threading
D
Milling
Entering non-flat surfaces
When entering non-flat surfaces there is E
A B a risk of drill deflection. To avoid this, the
feed can be reduced when entering.
A. Convex surface
Drilling
Normally no feed reduction needed.
F
B. Concave surface
to 1/3 of original feed rate.
C D
Boring
C. Inclined surface
W
ith entering angle of 289, reduce G
feed to 1/3 of original feed rate.
Tool holding
D. Curved surface
Reduce feed 1/3 of original feed rate.
H
Other information

Machinability
E 31
A How to apply
Irregular surfaces and pre-drilled holes

Turning
When entering or exiting an irregular sur-

face there is a risk of the inserts chipping.
B
T he feed rate should therefore be
reduced.
Parting and
A
pre-drilled hole should be small rather
grooving
than large - not more than 25% of the

drill diameter - to avoid drill deflection.
C H
owever, reduced feed does allow broad
machining of pre-drilled holes.
Threading
Coolant supply
Milling
Internal coolant supply

E
A
lways to be preferred especially in long-
chipping materials and when drilling
deeper holes (4-5 x Dc).
Drilling
External coolant supply

C
an be used when chip formation
F is good and when the hole depth is
shallow.
Compressed air, minimal lubrication or dry
drilling
Boring
C
an be successful in favorable condi-
tions, but is generally not recommended.
G
Tool holding
H
Other information
Machinability

E 32
How to apply
A
Coolant Important for successful performance
Turning
Coolant supply is essential in drilling and influences:
- chip evacuation B
- hole quality
- tool life.
Parting and
grooving
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.
C
The volume capacity can be checked using a stopwatch
and a suitably-sized bucket.
Threading
D
The cutting fluid
Milling
Soluble oil (emulsion)
5 to 12% oil (10-25% for stainless steels). E
EP (extreme pressure) additives.
Neat oil
Drilling
always with EP additives.
to be preferred for stainless steels.
both solid carbide and indexable insert drills work well F
with neat oil.
Mist cutting fluid or minimal lubrication

can be used with good performance especially at high
Boring
cutting speeds.
G
Dry drilling, without any coolant
can be performed in short-chipping materials.
Tool holding
hole depths up to 3 times the diameter.

preferably in horizontal applications.
tool life will be influenced negatively.
H
Other information
Machinability
E 33
A How to apply
Brazed and solid carbide drills

Turning
Tool runout
B Rotating drill Minimum tool runout is one of the main
criteria for successful use of solid carbide
.0008 inch (0.02 mm) drills.
Parting and
grooving
The runout should not exceed .0008 inch

(0.02 mm) in order to achieve:
C - close hole tolerance
- good surface finish
Stationary drill - long and consistent tool life.
Threading
.0008 inch (0.02 mm)

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

H hydro-mechanical, hydraulic or
shrink fit chuck.
Other information
Machinability
E 34
How to apply
A
Coolant
Turning
Internal or external
B
Is always to be preferred to avoid chip jamming.
S
hould always be used at hole depths above 3 times
Parting and
the diameter.
grooving
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
Can be acceptable in short-chipping materials.
T o improve chip evacuation at least one coolant nozzle
(two if drill is stationary) should be directed close to the D
tool axis.
C
an sometimes help to avoid built-up edge formation
due to a higher edge temperature.
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
E 35
A How to apply
Safety precautions
Turning
Safety against G
uarding against through-hole discs is
B dangerous discs important to avoid damage or injury,
especially when using non-rotating drills.
Parting and
grooving
C
Threading
D
Rotating stop A
rotation stop may be necessary for
is an important
rotating drills.
measure
Milling
If the coolant contains chip particles, the

slit seatings may seize and as a result
E the housing will rotate.
If the rotating connector has not been
used for a long time, check that the
holder rotates in the housing before the
Drilling
machine spindle is started.
F
Boring
G
Tool holding
H
Other information
Machinability
E 36
Hole quality and tolerance
A
Turning
Steps to ensure good hole quality in drilling
B
The
machine tool should be in good
condition.
Parting and
grooving
T ool holding influences hole quality and
tool life.
U
se the shortest possible drill for maxi- C
mum stability.
C
hip breaking and chip evacuation must
Threading
always be satisfactory.
C
oolant supply and coolant pressure is
important.
D
Milling
E
Hole and hole tolerance
Drilling
Hole dimensions are characterized by
Dmax three parameters:
Dmin - nominal
value (the theoretical exact
F
value)
- tolerance
width (a number), e.g., IT 7 ac-
cording to ISO
Boring
- position
of the tolerance (designated by
capital letters according to ISO). G
Tool holding
Dmax minus Dmin is the tolerance width,

also called, e.g., IT 7.
H
Other information
Machinability
E 37
A Hole quality and tolerance
Hole tolerance according to ISO

Turning
Diameter range, inch/mm

B
.118 .236 .394 .709 1.181 1.969 3.150
.236 .394 .709 1.181 1.969 3.150 4.724 Examples
Parting and
Tolerance 36 610 1018 1830 3050 5080 80120

grooving
IT6 .0003 .0004 .0004 .0005 .0006 .0007 .0009

0.008 0.009 0.011 0.013 0.016 0.019 0.022 Bearings

C 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
1)
0.018 0.022 0.027 0.033 0.039 0.046 0.054 Holes for
threading
Threading
IT9 .0012 .0014 .0017 .0020 .0002 .0029 .0034

0.030 0.036 0.043 0.052 0.062 0.074 0.087
Normal tap
IT10 .0019 .0022 .0028 .0033 .0039 .0047 .0055 holes
D 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
Milling
0.120 0.150 0.180 0.210 0.250 0.300 0.350

IT13 .0071 .0087 .0106 .0130 .0154 .0181 .0213
E 0.180 0.220 0.270 0.330 0.390 0.460 0.540
1) Holes for threading with fluteless taps (rolled threads)

Drilling
The lower the IT-number, the closer the tolerance.

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

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

+0.00 (IT 10 acc. to ISO)
Tool holding
Position: 0 to plus
(H acc. to ISO)
H
Other information
Machinability
E 38
A
Turning
Hole tolerances according to ISO
B
The hole tolerance is often
connected to the tolerance
of an axle, that should fit
Parting and
the hole.
grooving
Axle Hole
.787 inch .787 inch
(20 mm) h7 (20 mm) H7
C
Threading
Hole and axle tolerance according to ISO D
Axle tolerance position is denominated by lower case let-

ters corresponding to the hole tolerance. The figure below
gives a complete picture.
Milling
E
Most common
Drilling
Hole larger Axle larger than F
than axle hole
Boring
Running fit Slide fit Drive fit Interface

Tool holding
Play Grip = negative play

(bearings) (fix joints)
H
Other information
Machinability
E 39
A Hole quality and tolerance
Hole and tool tolerance

Turning
Obtainable hole tolerance with different tools
B Solid carbide drills Brazed carbide drill Indexable insert drill

Parting and
grooving
R844 R840
R842
C R850
Tolerance
IT6
Threading
IT7
IT8
D IT9 With pre-setting
IT10
IT11
Milling
IT12
E IT13
Solid carbide and brazed drills

Drilling
Drill diameter Dc tolerance

Drill tolerance
F
T he drill is ground to a cer-
tain diameter tolerance,
designated by lower case
letters according to ISO.
Boring
Dc tolerance for a solid carbide drill and a brazed carbide drill

G The hole tolerance
F or modern solid carbide
or brazed carbide drills
Tool holding
like CoroDrill Delta-C and

Coromant Delta, the hole
tolerance is very close to
H the drill tolerance.
Other information
Machinability
E 40
A
Turning
Drill tolerance Hole tolerance
T he diameter tolerance of an indexable Indexable insert drills give an optimal
insert drill is a combination of the tip cutting force balance and a plus toler- B
seat tolerance in the drill body and the ance (oversized) hole, because most
insert tolerance. holes are with H-tolerance.
Parting and
grooving
C
Threading
Drill depth 2-3 x Dc
Drill diameter, inch (mm) .472 1.732 1.732 2.086 2.087 2.500 D
(12.00 43.99) (44.00 52.99) (53.00 63.50)
Hole tolerance, inch (mm) 0/+.0098 0/+.0110 0/+.0118
(0/+0.25) (0/+0.28) (0/+0.30)
Milling
Tolerance Dc, inch (mm) 0/+.0079 0/+.0098 0/+.0110
(0/+0.20) (0/+0.25) (0/+0.28)
Drill depth 4-5 x Dc E

Drill diameter, inch (mm) .472 1.732 1.732 2.086 2.087 2.500
(12.00 43.99) (44.00 52.99) (53.00 63.50)
Hole tolerance, inch (mm) 0/+.0157 0/+.0169 0/+.0177
Drilling
(0/+0.40) (0/+0.43) (0/+0.45)
Tolerance Dc, inch (mm) +.0016/+.0094 +.0016/+.0114 +.0016/+.0126
(+0.04/+0.24) (+0.04/+0.29) (+0.04/+0.32) F
How to improve the hole tolerance

Boring
One way of eliminating the manufacturing

tolerance of the drill body and inserts is to G
.9876 in (25.084 mm)
preset the drill.
.9843 in (25 mm)
This can be done in a lathe or with an ad-
Tool holding
justable holder/sleeve, see page E27.

.9843 inch
(25 mm) H10 A tolerance width (IT) inside .004 inch
(0.10 mm) can then be obtained.
H
Other information
Machinability
E 41
A Troubleshooting
Troubleshooting
Turning
Indexable insert drill

B Problem Solution
Oversized holes Rotating drill Non-rotating drill
1. Increase coolant flow, clean 1. Check alignment on lathe.
Parting and
filter, clear coolant holes 2. Rotate drill 180.

grooving
in drill. 3. Try a tougher geometry on

2. Try a tougher geometry on peripheral side (keep center
peripheral side (keep center insert).
C insert).
Undersized holes Rotating drill Non-rotating drill

Threading
1. Increase coolant flow, clean 1. Stationary:

filter, clear coolant holes Check alignment on lathe.
in drill. 2. Stationary:
D 2. Try a tougher geometry on Rotate drill 180.
center side and a light cut- 3. Try a tougher geometry
ting geometry on peripheral on peripheral side (keep
side. center).
Milling
Pin in hole Rotating drill Non-rotating drill

1. Increase coolant flow, clean 1. Check alignment on lathe.
E filter, clear coolant holes 2. Increase coolant flow, clean
in drill. filter, clear coolant holes
2. Try a different geometry on in drill.
peripheral side and adjust 3. Shorten drill overhang.
feed rate within recom- 4. Try a different geometry on
Drilling
mended cutting data. peripheral side and adjust

3. Shorten drill overhang. feed rate within recom-
mended cutting data.
F
Vibrations 1. Shorten drill overhang, Improve the workpiece stability.

2. Reduce cutting speed.
3. Try a different geometry on peripheral side and adjust feed
Boring
rate within recommended cutting data.
G
Tool holding
Insufficient machine torque 1. Reduce feed.

2. Choose a light cutting geometry to lower the cutting force.
H
Other information
Mc lbf-ft (Nm)
Machinability

E 42
Troubleshooting
A
Problem Solution
Turning
Insufficient machine power 1. Reduce speed.
2. Reduce feed.
3. Choose a light cutting geometry to lower the cutting force. B
Parting and
grooving
Pc HP (kW)
Hole not symmetrical 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 C
rate within recommended cutting data.
3.Shorten drill overhang.
Threading
Poor tool life 1. Reduce feed. D
2. Choose a light-cutting geometry to lower the cutting force.
Milling
E
Broken insert screws 1. Use torque wrench to fasten the screw together, apply
Molykote.
Drilling
F
Bad surface finish 1. Important to have good chip control.

2. Reduce feed (if it is important to keep vf, increase speed as
well).
Boring

4. Shorten drill overhang, improve the workpiece stability.
Chip jamming in the Caused by long chips

Tool holding
drill flutes 1. Check geometry and cutting data recommendations.

3. Reduce feed within recommended cutting data.
4. Increase cutting speed within recommended cutting data.
H
Other information
Machinability
E 43
A Troubleshooting
Tool wear Indexable insert drill

Turning
Flank wear
B
a) C utting speed too high. a) R educe cutting speed.
b) Insufficiently wear resistant b) Choose a more wear resistant
grade. grade.
Parting and
grooving
C
Crater wear
Peripheral insert Peripheral insert
Threading
Diffusion wear caused by tem- Select GC4024 or GC4014 with

perature too high on rake face. Al2O3 coating against oxidation.
Reduce speed.
Central insert:
D Abrasive wear caused by built-up Central insert:
edge and smearing. Choose GC1044, if H13A is used.
Reduce feed.
General:
Choose a more positive geometry.
Milling
E
Plastic deformation (peripheral insert)
a) C utting temperature (cutting ab) S elect a more wear resistant
speed) too high, combined with grade with better resistance
high pressure (feed, hardness of to plastic deformation, i.e.,
Drilling
workpiece). GC4014 or GC4024.

b) As a final result of excessive ab) Reduce cutting speed.
F flank wear and/or crater wear. a) Reduce feed.
Chipping
Boring
a) Insufficent toughness of grade. a) S elect a tougher grade, i.e.,

b) Insert geometry too weak. GC4044.
G c) Built-up edge (BUE). b) Select a stronger geometry,
d) Irregular surface. i.e., -GT.
e) Bad stability. c) Increase cutting speed or select
Tool holding
f) Sand inclusions (cast iron). a more positive geometry.

d) Reduce feed at entrance. Choose
geometry -GT.
e) Improve stability.
f) Choose a stronger geometry, i.e.,
H -GR or -GT. Reduce feed.
Other information
Machinability

E 44
Troubleshooting
A
Turning
Built-up edge (BUE)

a) L ow cutting speed (temperature a) Increase cutting speed or change
B
too low at the cutting edge). to a coated grade.
b) Cutting geometry too negative. b) Select a more positive geometry.
Parting and
c) Very sticky material, such as c-d) Increase oil mixture and
grooving
certain stainless steels and pure volume/pressure in cutting
aluminum. fluid.
d) Percent of oil mixture in cutting
fluid too low.
C
Threading
D
Chip evacuation - general recommendations

Checkpoints and remedies
Milling
1. M
ake sure the right cutting data and
drill geometry are used. E
2. Inspect chip form (compare with picture
on page E 26).
3. C
heck if the cutting fluid flow and pres-
Drilling
sure can be increased.
4. Inspect the cutting edges. Chipping on F
the edge can cause long chips because
the chip is divided.
5. C
heck if the machinability has changed
Boring
due to a new batch of workpiece

material. Cutting data may need to be
adjusted. G
6. A
djust feed and speed. See diagram on
page E 18.
Tool holding
H
Other information
Machinability
E 45
A Troubleshooting
Peck drilling solid carbide / brazed drills

Turning
Peck drilling can be used if no other solution can be

found.
B There are two different ways to perform a peck drilling
cycle:
Parting and
1 2 3 4 5 6 7 8 - Method 1 for best productivity

grooving
Do not retract the drill more than

approx. .012 inch (0.3 mm) from the
hole bottom. Alternatively, make a
C periodical stop, while the drill is still
rotating, before continuing to drill.
Threading
1 2 3 4 5 6 7 8 - Method 2 for best chip evacuation
D After each drilling cycle, retract the

drill out from the hole to ensure that
no chips are stuck onto the drill.
Milling
E
Tool wear solid carbide / brazed drills
Cause Solution
Drilling
Built-up edge
1. C utting speed too low and edge 1. Increase cutting speed or use
F temperature too high. external cutting fluid.
2. Negative land too large. 2. Sharper cutting edge.
3. No coating. 3. Coating on the edge.
4. Percentage of oil in the cutting 4. Increase the percentage of oil in
fluid too low. the cutting fluid.
Boring
G
Chipping on the edge corner
1. Unstable fixturing. 1. heck fixture.
C
Tool holding
2. TIR too large. 2. Check radial runout.

3. Intermittent cutting. 3. Decrease the feed.
4. Insufficient cutting fluid (thermal 4. Check cutting fluid supply.
cracking). 5. Check the tool holder.
5. Unstable tool holding.
H
Other information
Machinability

E 46
Troubleshooting
A
Turning
Cause Solution
Large wear on the cutting edge
1. Cutting speed too high. 1. ecrease the cutting speed.
D B
2. Feed too low. 2. Increase the feed.
3. Grade too soft. 3. Change to harder grade.
4. Lack of cutting fluid. 4. Check for proper cutting fluid
Parting and
supply.
grooving
Chipping on the cutting edge C
1. Unstable conditions. 1. C heck the setup.
2. Maximum allowed wear 2. Replace drill sooner.
exceeded. 3. Change to softer grade.
Threading
3. Grade too hard.
D
Wear on the circular lands
1. TIR too large. 1. C heck the radial runout.
2. Cutting fluid too weak. 2. Use neat oil or stronger
3.Cutting speed too high. emulsion.
Milling
4. Abrasive material. 3. Decrease cutting speed.
4. Change to harder grade.
E
Wear on the chisel edge
1. Cutting speed too low. 1. Increase cutting speed.
2. Feed too high. 2. Decrease feed.
Drilling
3. Chisel edge too small. 3. Check dimensions.
Wear due to plastic deformation

1. C utting speed and/or feed too 1. D ecrease the cutting speed
high. and/or feed.
Boring
2. Not enough cutting fluid supply. 2. Increase cutting fluid pressure.

3. Unsuitable drill/grade. 3. Use a harder grade.
G
Tool holding
Thermal cracks (notches)

1. Inconsistent cutting fluid 1. Check cutting fluid supply
2. Fill cutting fluid tank
H
Other information
Machinability
E 47
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
A Theory
Boring theory
Turning
The boring process

B
T ypically, boring operations are per-
formed in machining centers and
Parting and
horizontal boring machines.

grooving
T he rotating tool is fed axially through

the hole.
C M
ost holes are through-holes, often in
prismatic components such as housings
and casings.
Threading
D Three different basic boring methods

Boring with a Boring with a Milling, helical
stationary tool rotating tool interpolation
Milling
E
Drilling
F T o be used only for sym- F or unsymmetrical com- V

ery flexible solution
metrical components in a ponents machined in a where one milling cutter
turning lathe. machining center. can be used for different
diameters.
P
rofiling can be carried F lexible tool solutions
Boring
out with standard boring with adjustable diam- S

aves space in the tool
bars. eters. magazine.
G V
ery flexible tool solu- V
ery productive in rough- G
ood solution when chip
tions with interchange- ing operations. breaking is a problem.
able cutting heads.
Tool holding
H
igh quality hole toler- H
igh quality demands of
ance and surface (for the machine (for finish-
finishing). ing).
H
Other information
Machinability
F4
Theory
A
Turning
Definitions of cutting data terms
n = spindle speed (rpm) B

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) C
fz = feed per tooth (inch/rev) (mm/rev)
zc = effective number of teeth that ma-
Threading
chine the final surface
Cutting speed D
Inch
The boring tool rotates at a certain number Dc n
of revolutions (n) per minute generating a vc = (ft/min)
certain diameter (Dc). This gives a specific 12
Milling
cutting speed (vc) measured in ft/min
(m/min) at the cutting edge. Metric
E
Dc n
vc = (m/min)
1000
Drilling
Feed
The axial tool movement is called feed rate vf = fn n (inch/min) (mm/min) F
(fn) and is measured in inch/revolution
(mm/rev). The feed rate is obtained by mul-
tiplying the feed per tooth, inch/rev (mm/
rev), by the number of effective teeth (zc).
Boring
fn = zc fz (inch/r) (mm/r)
The feed rate is the key value in determining
the quality of the surface being machined
G
and for ensuring that the chip formation is
within the scope of the insert geometry.
Tool holding
Penetration rate Cutting depth

The penetration rate (vf) is the speed of The cutting depth (ap) is the difference
the axial movement and is strongly related between the uncut and the cut hole radius. H
to productivity.
Other information
Machinability
F5
A Theory
Calculating power consumption and torque

Turning
B
Parting and
grooving
fn = feed per revolution (inch/r)

Pc Hp (Nm) (mm/r)
Dc = boring diameter (inch) (mm)
C
kc = specific cutting force (lbs/inch2)
(N/mm2)
Pc = power consumption (Hp) (kW)
Mc lbf ft (Nm)
Threading
Mc = torque (lbf ft) (Nm)
D
Milling
Torque Inch
E The torque (Mc) is the torque value pro- Pc 16501
duced by the boring tool during cutting Mc = (lbf ft)
action, which the machine must be able to n
provide.
Drilling
Metric
Net power Pc 30 103

F Mc = (Nm)
The net power (Pc) is the power the
n
machine must be able to provide to the
cutting edges in order to drive the cutting
action. The mechanical and electrical
Boring
efficiency of the machine must be taken
G
into consideration when selecting cutting
data.
Pc =
ap fn kc vc
60 103 ( )
1
ap
Dc
(Hp)
(kW)
Tool holding
Specific cutting force

Cutting force/area for a given chip thick-
ness in tangential direction.
H The kc value indicates the machinability
of a certain material and is expressed
Other information
in lbs/inch2 (N/mm2).
Machinability
F6
Theory
A
Tools for roughing and finishing
Turning
Rough boring tool with multiple edges
B
R
ough boring operations are performed to open up the
existing hole to prepare for fine boring.
Parting and
grooving
C
Threading
Single-edge fine boring tool
F ine boring operations are performed to make the hole

within final hole tolerance, position and surface finish D
limits.
T he diameter of a fine boring tool can be adjusted
within microns.
Milling
.9843 in
(25 mm) H7
E
.9843 in (25 mm)
.9851 in (25.021 mm)
Drilling
Hole tolerance of boring and reaming tools F
Rough boring Single-edge fine Multi-edge

tool with mul- boring tool reamer for high
Boring
tiple edges feed finishing
IT6
Tool holding
IT7
IT8 H
Other information
IT9
Machinability
F7
A Theory
Hole making methods

Turning
Single-edge boring
B 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
Multi-edge boring
Threading
Involves two or three cutting edges and is employed for

roughing operations where metal removal rate is the first
priority.
D
Milling
E Step boring
Performed in roughing by a boring tool having the inserts

set at different axial heights and diameters. Employed
Drilling
where large stock removal is required or to get improved

chip control. Good choice for off-center holes.
F
Boring
G Reaming
A light finishing operation performed with a multi-edge
reamer at high feeds.
Tool holding
H
Other information
Machinability
F8
Tool selection
Turning
Parting and
grooving
Hole dimension
and quality .9843 in
(25 mm) H7
C
1 Component
Workpiece .9843 in (25 mm)
Threading
material, shape .9851 in (25.021 mm)
and quantity
Machine
2 Machine
Milling
parameters
Drilling
Choice of tool Type of tool
Cutting data,
4
Boring
How to apply
coolant, etc.
G
Tool holding
Remedies and
5 Troubleshooting
solutions
H
Other information
Machinability
9
A Tool selection

Turning
Parameters to be considered Component

B Identify the type of operation and note
characteristics regarding the hole to
be machined, limitations, material and
Parting and
machine.
grooving
C
lamping, clamping forces and cutting
forces. Is the component sensitive to
C vibrations?
S
elect the tool that covers the boring
diameter range and depth for the
Threading
operation, surface finish and tolerance.
D
Material
achinability
M
Milling
Chip breaking
Hardness
E Alloy elements
Drilling
F 2. Machine parameters

pindle interface
S
Boring
Machine stability
G The spindle speed
Coolant supply
Clamping of the workpiece
Tool holding
Horizontal or vertical spindle

Power and torque
Tool magazine
H
Other information
Machinability
F 10
Tool selection
A
3. Choice of tools
Turning
Roughing Finishing
B
Parting and
grooving
C
Multi-edge Step boring Single-edge Single-edge Reaming
boring boring boring
Threading
Multi-edge boring Step-boring Single-edge boring
High metal removal rate. F or rough boring with For general fine boring.
large stock removal. D
Productive boring. Tolerance capability IT6.
Improved chip control.
Single-edge boring
Reaming
Milling
V
ery good surface finish
L ess machine-power at high penetration rates. E
demanding.
S
uitable for mass
production.
Drilling
F
Boring
Special boring operations

G
Engineered tools
Many operations in one tool.
Tool holding
T he operations can be completed during one

feed motion.
H
Other information
Machinability
F 11
A Tool selection
4. How to apply
Turning

Tool holding
B
A
lways use the strongest coupling and
aim for the shortest tool overhang.
Parting and
F or best stability and hole quality use

grooving
Coromant Capto, dampened tools and

tapered shanks.
C
Tool considerations
C
onsider lead (entering) angle, insert
Threading
geometry and grade.
D Chip evacuation and cutting fluid

C
hip formation and evacuation are im-
portant factors in boring and affect hole
quality and hole tolerance.
Milling
Cutting data
E Cutting speed,
vc ft/min (m/min) C
orrect cutting speed and feed rate is
essential for high productivity, tool life
and hole quality.
Drilling
F
Boring
Feed, inch/r
(mm/r)
G
Tool holding
H
Other information
Machinability
F 12
Tool selection
A
5. Troubleshooting
Turning
B
C
orrect geometry, grade and cutting data
is essential in boring operations.
Parting and

grooving
Chip evacuation
C
heck the chip breaking and cutting fluid
C
supply.
Threading
C
heck clamping of boring tool/work-
piece, feed rate, machine conditions and
.9843 in chip evacuation. D
(25 mm) H7
Cutting data
.9843 in (25 mm) C
orrect cutting speed, feed rate and
Milling
.9851 in (25.021 mm) cutting depth is essential for high pro-
ductivity, tool life and to avoid vibrations.
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
F 13
A System overview
System overview
Turning
Rough boring tools

Rough boring operations are performed to open up an
B existing hole to prepare for finishing.
Heavy duty tool with two

Parting and
inserts Tool with two inserts Tool with one insert

grooving
C
Tool with three inserts
Threading
Tool with dampened adapter

Milling
E Fine boring tools

Fine boring operations are performed to finalize hole within
tolerance and surface finish limits.
Drilling
Single-edge tool with

dampened adapter
F Single-edge tool with
modular adapter
Single-edge tools
Multi-edge reamer
Boring
G
Fine boring head for
fine boring bars
Tool holding
H
Other information
Machinability
F 14
System overview
A
Turning
Rough boring tool with three inserts
Diameter range 1.378 - 12.047 inch (35 - 306 mm)
B
Parting and
Rough boring tool with two inserts
grooving
Diameter range .984 - 10.630 inch (25 - 270 mm)
Heavy duty rough boring tool with two inserts

Diameter range 5.906 - 21.654 inch (150 - 550 mm)
Threading
D
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
Milling
Multi-edge reamer
Diameter range .394 - 1.250 inch (10 - 31.75 mm) E
Fine boring head
Drilling
Diameter range .118 - 1.654 inch (3 - 42 mm)
Single-edge boring tool with integrated adapter

Diameter range .906 - 6.953 (23 - 176.6 mm)
Boring
G
Single-edge boring tool with modular adapter
Tool holding
Diameter range 5.906 - 38.646 inch (150 - 981.6 mm)
Diameter
H
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
Machinability
F 15
A Choice of tool
Choice of tools
Turning
Roughing
Multi-edge boring
B
H igh metal removal rate.
Productive boring.
Parting and
grooving
Single-edge boring
C Less machine-power demanding.
Step-boring
Threading
F or rough boring with large stock

removal.
D
Finishing
Milling
Single-edge boring
E F or general fine boring.
Tolerance capability IT6.
Reaming
Drilling
V ery good surface finish at high penetra-

tion rates.
F
Suitable for mass production.
Boring
Special boring operations

G
Engineered tools
Tool holding
M any operations in one tool.

The operations can be completed during
one feed motion.
H
Other information
Machinability
F 16
Choice of tool
A
Rough boring tools
Turning
Rough boring tool with three inserts
First choice recommendation for medium and high power
machines is a rough boring tool with three cutting edges B
for optimized productivity.
Parting and
grooving
Rough boring tool with two inserts C
A rough boring tool with two cutting edges is first choice
for low to medium power machines, unstable operations
Threading
or large diameters.
Dampened rough boring tool for long overhangs
Milling
Choose dampened rough boring tools for overhangs
longer than 4 times the coupling diameter.
E
Drilling
Boring tool setup F
All rough boring tools can be set up in three different
ways. Boring
Single-edge boring Multi-edge boring Step boring
G
Tool holding
H
All rough boring tools can be ordered and assembled, adapted to
Other information
the chosen type of rough boring method.

Machinability
F 17
A Choice of tool
Slides for rough boring tools

Turning
Slides with negative inserts

F or stable conditions, choose negative
B shape inserts for better insert economy.
U
se negative inserts in tough applica-
tions that require strong inserts and
Parting and
improved process security.

grooving
C
Slides with positive inserts
In rough boring, it is an advantage to use
Threading
positive basic-shape inserts as they give

lower cutting forces compared to nega-
tive inserts.
D
A small nose angle and small nose
radius also contribute to keeping the
cutting forces down.
Milling
E
Lead (entering) angle and insert shape
The lead (entering) angle of boring tools affects the direc-
tion 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
Drilling
radial cutting force.
F Positive inserts Negative inserts
15/6 - For interrupted cuts, sand

(75/84) inclusions, stack boring etc.
Through holes only.
Boring
6 15 6
(84) (75) (84)
G 0 - F irst choice for general
(90) operations, step boring and for
shoulder operations.
Tool holding
0 0
(90) (90)
5 - F or high feeds or improved
H (95) surface finish with Wiper
inserts in stable conditions.
Other information
Machinability
-5 -5
(95) (95)
F 18
Choice of tool
A
Fine boring tools
Turning
Single-edge fine boring tool
A single-edge fine boring tool is the first choice for fine B

boring operations.
Parting and
grooving
C
Fine boring head with fine boring bars
Threading
For small diameters a fine boring head with fine boring
bars is required.
Milling
Silent Tools for long overhangs
E
Silent Tools (dampened) are the first choice for overhangs
longer than 4 times the coupling diameter.
Drilling
F
Multi-edge reamer
Boring
Multi-edge reamers are suitable for high feeds in mass

production.
G
Tool holding
H
Other information
Machinability
F 19
A Choice of tool
Cartridges for fine boring tools

Turning
General recommendations
In fine boring, positive basic-shape in-

B
serts are used, as they give lower cutting
forces compared to negative inserts.
Parting and
P
ositive basic-shape inserts with 7
grooving
Positive inserts clearance angle are the first choice

7 clearance angle
L ight-cutting insert geometries, thin
C coatings and a small nose radius
(maximum .016 inch (0.4 mm)) also con-
tribute to keep the cutting forces down.
Positive inserts
Threading
11 clearance angle
Adapters
Milling
Choose the shortest possible adapter length.

E Choose the largest possible diameter/size of adapter.
F or long overhangs (larger than 4 x coupling diameter)
use dampened adapters.
Drilling
If possible, use a tapered adapter to increase the static

stiffness and to reduce the deflection.
F F or long overhangs, ensure rigid clamping with flange
contact to spindle if possible.
Boring
G
Tool holding
H
Other information
Machinability
F 20
How to apply
A
How to apply
Turning
Fine boring tools
Adjustable fine boring mechanism B
Single-edge fine boring tools have adjust-
Parting and
ment possibilities to accurately pre-set the
grooving
cutting edge within microns.
Threading
Tool deflection
B
oring tools for finishing, with one cut- D
ting edge, will experience some degree
of radial deflection during machining due
to the cutting forces.
Milling
T he depth of cut and length of overhang
influence the radial deflection of the
boring tool. E
T he deflection might cause undersized
holes or vibrations.
A
measuring cut is normally needed,
Drilling
followed by a final adjustment of the tool.
Boring
G
Tool holding
H
Other information
Machinability
F 21
A How to apply
Boring tools general

Turning
Cutting fluid supply

B Chip evacuation, cooling and lubrication between the
tool and the workpiece material are primary functions
of cutting fluid.
Parting and
grooving
A
pply cutting fluid for optimized chip
evacuation, cooling and lubrication.
C Affects hole quality and tool life.

Internal cutting fluid is recommended in
order to direct the fluid to the cutting
zone.
Threading
Chip control and chip evacuation

Chip formation and chip evacuation are critical issues in
Milling
boring operations, especially in blind holes.
E Ideally, chips should be in the form of defined commas

or spirals.
Cutting depth,
Drilling
ap inch (mm) Factors that have an influence on chip

breaking are:
F - the insert micro and macro geometry
- nose radius
- lead (entering) angle
- cutting depth
Boring
- feed
- cutting speed
G - material.
Feed, inch/r (mm/r)

Tool holding
H
Other information
Machinability
F 22
How to apply
A
Cutting data recommendations
Turning
The cutting data for the insert geometry and grade
chosen can generally be followed with the following
exceptions: B
- Rough boring
Max start value vc = 656 ft/min (200 m/min).
Parting and
grooving
- 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 C
(90 120 m/min).
- Fine boring:
Threading
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. D
Cutting speed is mainly limited by:

- vibration tendencies
Milling
- chip evacuation
- long overhangs.
E
Power and torque consumption
Drilling
M
Mcc lbf-ft (Nm) When rough boring, make sure the machine can provide
sufficient power and torque.
F
Important parameters are:
- feed
- number of inserts
Boring
- diameter
- depth of cut.
G
Tool holding
H
Other information
Machinability
F 23
A How to apply
Tool maintenance and use of torque wrench

Turning
A
lways use a torque wrench and apply the recommend-
ed torque on screws for insert and tool assembly.
B Check inserts and insert seats regularly.
Replace worn or exhausted screws and washers.
Parting and
Clean all assembly items before assembly.

grooving
L ubricate all assembly items with oil at least

once a year.
C
L ubricate the fine adjustment mechanism for fine boring
regularly.
Threading
D
Milling
E 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

F less than .0020 inch (0.05 mm).
A small runout is very important for reaming operations.
Maximum recommended runout is 5 microns.
Boring
M
ake sure the reamer is concentric with the pre-ma-
chined hole.
G Choose the shortest possible tool holder and shank.
E
mulsion as cutting fluid generates better tool life
Tool holding
than oil.
Use recommended cutting data.
H
Other information
Machinability
F 24
A
Troubleshooting
Troubleshooting
Turning
Factors that affect vibration tendencies
Vibration tendencies grow towards the right. B
Parting and
grooving
C
Threading
D
inch (mm)
.008 (0.2) .016 (0.4) .031-.047 (0.8-1.2)
Milling
E
Drilling
Decrease cutting speed. C
heck that all units in the tool assembly
F
are assembled correctly with the correct
Apply step boring.
torque.
Choose a 2-edge rough boring tool.
Reduce feed or increase feed.
C
hoose a light-cutting geometry and
Boring
Use the largest tool diameter possible.

grade.
Use the shortest tool overhang possible.
Use a smaller nose radius. G
Check workpiece clamping.
Tool holding
C
heck machine spindle, wear, clamping,
etc.
Increase depth of cut (finishing).
Decrease depth of cut (roughing). H
Other information
Use dampened tools if long overhang.

Machinability
F 25
A Troubleshooting
Insert wear
Turning
Insert wear patterns and remedies in boring are generally

very similar to turning.
B
Chip breaking
Parting and
grooving
Cause Solution
Too short, hard Increase cutting speed

C
Decrease feed
C
hange geometry to a more
open chip breaker
Threading
D
Too long Increase feed
Decrease cutting speed
C
hange geometry to a more
closed chip breaker
Milling
E
Surface
Tool vibration
Drilling
Too high feed Decrease feed

Too high speed Decrease speed
F Too large cutting depth Apply step boring
Too high cutting forces Decrease depth of cut

Boring
Use positive inserts

Use smaller nose radius
G
Tool holding
Feed marks
Too high feed C
hoose knife edge wiper
insert
H Use larger nose radius

Other information
Decrease feed

Machinability
F 26
Troubleshooting
A
Cause Solution
Turning
Insert wear
B
Wrong cutting data C
hange cutting edge and
investigate reason for wear
pattern cutting data, insert
Parting and
geometry and insert grade.
grooving
C
Chips scratching surface
Bad chip breaking Change cutting data
Threading
Change insert geometry
Surface finish
Milling
Bad surface finish Increase speed
Use coolant
E
Use a cermet grade
Drilling
Machine power limitation
Limited machine power Decrease cutting data
F
Apply step boring
Boring
G
Tool holding
H
Other information
Machinability
F 27
Tool holding
The clamping of a cutting tool can influence the produc-
tivity 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 prod-
ucts.
History and background G4
Why modular tooling G7
Turning centers G 15
Machining centers G 23
Multi-task machines G 29
Chucks G 33
G3
A History and background
Tool holding systems

Turning
T he tool holding interface with the

machine plays a very important part in
B the cutting process.
S
tability, time for tool changing, accuracy,
flexibility, modularity, handling and stor-
Parting and
ing is of vital importance for successful

grooving
machining.
C
ompared to conventional shank tools,
C a quick change system can increase the
effective cutting time by 25% in turning
centers.
Threading
D
Milling
E
Tool holding systems today
T ooling has evolved through the neces-
Drilling
sity to produce new types of machine

manufacturing standards.
F These tools have generally followed the
spindle interface design of MTMs, with-
out any standardization controls.
There are over 35 types of spindle
Boring
interface on machines today, with as

many tooling options to support, hence
G exchangeability and assortment avail-
ability decreases dramatically.
Tool holding
H
Other information
Machinability
G4
History and background
A
History of machine tapers
Turning
T his style of taper was introduced 40
years ago.
T he taper was the basis of most B
machine tool spindles, due to the long
taper, giving secure contact and stability.
Parting and
grooving
It is still popular today, in various sizes,
using taper 7/24, but it is not a modular
tooling solution.
C
Threading
D
Quick change systems
Milling
T here is an ever increasing supply of
quick change and modular tooling sys- E
tems on the market today.
nfortunately, these systems are not
U
interchangeable with each other, and are
Drilling
very limited in their flexibility between
machining centers and CNC lathes.
F
M
ost of these systems are not suitable
for multi-task machining operations. Boring
G
Tool holding
H
Other information
Machinability
G5
A History and background
Coromant Capto
Turning
A multi-purpose, quick-change modular tooling system

B
Parting and
grooving
C
Threading
Capto is Latin and means to grab.
The history of the Coromant Capto system

Milling
Machining center / Rotating tools
Solid holders Varilock Coromant Capto/

Drilling
Basic holders
F
1980 1990
Turning center / Turning tools

Boring
G Standard
ISO 26623
Tool holding
Shank holders Block Tool Coromant Capto/

System Clamping units
H
Other information
Machinability
G6
Why modular tooling
A
A dramatic development of the machines
Turning
Machining centers
B
Parting and
grooving
C
Threading
D
Turning centers
Multi-task machines
Milling
Trends E
Machines and machining methods
M
ulti-task machines requiring one holder system for
both spindle and turrets.
Drilling
S
everal turrets on multi-task machines and turning
centers.
F
More multi-function tools for multi-task machines.
Driven tools in turning centers.
P
owerful interfaces in the machine control system for
Boring
higher degrees of automation.

3
-D models of tools and holders to virtually check the G
machine process.
Integration of various manufacturing technologies into
Tool holding
fewer machine types.

High pressure coolant.
H
Other information
Machinability
G7
A Why modular tooling
When to use quick change tooling

Turning
M
achine requires frequent setup
B changes.
M
easuring cuts are necessary to get
correct size.
Parting and
grooving
M
achining is performed with high cutting
data and relatively short tool life.
C O
ne operator services more than one
machine.
Threading
D
Milling
Reduce downtime in your turning centers

E
Only 36% of the machine time is used for metal cutting
-S
ervice and mainte-
Drilling
nance
F - Insert change and tool

change
-M
easuring of the tool
and workpiece
Boring
25% - Change of workpiece

G
Conventional shank Coromant Capto - Effective cutting time

Tool holding
tools quick- change system
Quick change tooling offers a productivity increase of 25%

H
Other information
Machinability
G8
Why modular tooling
A
A true modular tooling system
Turning
One system! One solution! For the entire workshop
Coromant Capto is a flexible tooling system, suitable
B
for all types of machining. This makes it possible to
standardize on one system in your entire workshop.
Parting and
grooving
C
Turning centers Vertical lathes
Threading
D
Milling
E
Drilling
F
Machining centers Multi-task machines
Boring
G
Tool holding
H
Other information
Machinability
G9
Minimize tool holder inventory

Turning
By combining basic holders, adapters and (when needed)

extensions or reductions, many different assemblies for
B different machines can be built.
The below examples represent a customer that has four
different spindles resulting in:
Parting and
- taper 40, taper 50, HSK 63 and HSK 100,

grooving
- two extensions
- 30 different adapters for milling, drilling, tapping, etc.
C - 10 different boring tools.
Threading
Modular Solid
ISO 40 ISO 50 HSK 100 HSK 63

D
Milling
E
Drilling
Number of items with modular tools: Number of items with solid tools:
4 + 2 + 30 + 10 = 46 items 4 x 3 x (30 + 10) = 480 items
Boring
G
Tool holding
Modular tools give access to a very

H large number of tooling solutions,
with very few items!
Other information
Machinability
G 10
Why modular tooling
A
The Coromant Capto coupling
Turning
The unique Coromant
Taper polygon Gripper groove Capto coupling has some
very specific features: B
- T he ground flange contact
face in relation to the
Parting and
ground taper polygon
grooving
gives maximum stability
due to two-face contact
and interference fit. C
- T here are four gripper
grooves for the automatic
tool changer.
Threading
- T here is one slot for
angular positioning of the
Slot for angular cutting tool. D
positioning
Flange contact
Milling
E
Coolant channel in There are two options for

coupling coolant supply:
Drilling
-C
oolant supply through
Coolant through center center
-C
oolant channel in the
F
coupling.
Boring
G
Tool holding
H
Other information
Machinability
G 11
Coupling features and benefits

Turning
The main feature of the coupling is the positive 3-way locking
B 1. The radial centering is taken care of by Due to the above features - radial and
the conical part of the polygon. axial contact and self centering ability - the
coupling has extremely good repeatability,
2. T he low taper angle makes it possible
Parting and
within .00008 inch (2 microns).

to transmit the full force into the flange
grooving
contact. The strength of the polygon

coupling makes it possible to clamp
C 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
D 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
1 1
E

1.4

3
Drilling
F 2
3 2
3-way locking
Boring
G
Tool holding
H
Other information
C3 C10
Machinability
G 12
Why modular tooling
A
Six different coupling sizes
Turning
C3 = D 1.260 inch (32 mm)
C4 = D 1.575 inch (40 mm)
B
C5 = D 1.969 inch (50 mm)
C6 = D 2.480 inch (63 mm)
Parting and
grooving
C8 = D 3.150 inch (80 mm)
C10 = D 3.937 inch (100 mm)
C
Three different methods of clamping
Threading
One coupling offers 3 methods of clamping.
D
Segment clamping Center bolt clamping Front clamping
Milling
E
Clamping method for quick- For modular clamping solu- Machine interface for quick
Drilling
change and automatic tool tions, e.g., when using exten- change in machines.
changing. sions and basic holders.
F
Excellent repetitive accuracy and guaranteed

center height
Boring
T he repeatable accuracy is .00008 inch

G
(2 microns [m]) of the center height,
A length and the radial measurement
B (A),(B),(C).
Tool holding
F ew or no measuring cuts needed if

pre-measuring is used (first component
right).
C H
Other information
Machinability
G 13
Transmission of torque
Turning
The polygon shape transmits torque with-

out any loose parts such as pins or keys.
B No pins, keys, etc.
No play in the coupling.
Parting and
Symmetrical loads.
grooving
Two face contact/high clamping force.
C
Threading
D
Milling
Less vibration with stable coupling

E 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
F
Boring
The boring bar is very often clamped with

Tool holding
2-3 screws. This causes problems with

vibration, bad surface finish, inserts worn
out quickly and production disturbances,
H with downtime spent on adjusting cutting
data and measuring the component.
Other information
Machinability
G 14
Turning centers
A
Quick change tooling for turning centers
Turning
Machining centers
B
Parting and
grooving
C
Threading
D
Turning centers
Multi-task machines
Milling
What is a turning center?
E
T he principle of lathes and turning cent- W
hen a cutting tool is applied to
ers is to cut a rotating component with a the workpiece, it can be shaped to
stationary cutting tool. produce a component which has
Drilling
rotational symmetry.
T he cutting tool moves parallel and
perpendicular to the workpiece axis to
provide the desired finished shape. F
Boring
The turning center has a choice of configurations G

Horizontal and vertical design.
Tool holding
Sub-spindle for two-sided machining.

Driven tools.
Y-axis for eccentric boring and milling.
H
Other information
Machinability
G 15
A Turning centers
Configuration of a turning center

Turning
Spindle rotation and definitions of axis
B
S
everal multi-axis machine tool pro-
grams can provide turning results from
Parting and
roughing and grooving to threading and

grooving
finishing.
C
Threading
Quick change tooling for turning centers

Milling
A quick-change system offers:

E
- faster and efficient tool changing
- inserts which can be changed outside the
machine
Drilling
- pre-setting possibilities.
F
The most economical system for:
-s
mall batch production, quicker setup
times
Boring
- operations with frequent insert changes.
G Less than 180 for clamp and unclamp

Tool holding
H
Other information
Machinability
G 16
Turning centers
A
Typical clamping units for turning centers
Turning
VDI angled Square shank Automatic unit
Camshaft activated Camshaft activated Hydraulically operated
B
Parting and
grooving
C
Threading
VDI straight Round shank Special applications
Camshaft activated Segment clamping Segment clamping
D
Milling
E
Drilling
Methods of installing quick change F
Directly integrated into the turret
Coromant Capto directly integrated in

Boring
turrets is the best solution to get maxi-

mum performance out of the Coromant
Capto coupling.
G
Tool holding
H
Other information
Machinability
G 17
A Turning centers
Conversion of a turret by using standard clamping units

Turning
Turning lathes can easily be converted to

Coromant Capto quick-change tools using
B standard clamping units. No modification
to the turret, and no special adapters
required.
Parting and
grooving
C
Threading
D
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
G 18
Turning centers
A
Machine adapted clamping units
Turning
Coromant Disc Interface (CDI)
B
F lexible and symmetrical interface, 180
mountable.
Parting and
Same interface for static and driven tool
grooving
holders. Static and driven tool holders can be
used in all positions.
Higher cutting performance.
C
Longer cutting tool life.
Better workpiece quality.
Threading
M
ore available tool length for radial drilling
operations.
Increased production.
Rationalized tooling. D
Reduction in tooling costs.
Milling
Static clamping unit, E
Driven drill/milling unit,
straight straight
Drilling
F
Static clamping unit, Driven drill/milling unit,

Boring
right angle right angle
G
Tool holding
H
Other information
Machinability
G 19
A Turning centers
A quick change system

Turning
Insert change by using sister tools

Less downtime.
B
F ew or no measuring cuts. Improved
profitability.
Parting and
N
o risk of losing insert screws in the
grooving
chip conveyer.
Ergonomic.
C 1. 2.
E
asy to clean the tip seat outside the
machine.
Threading
D 0.5 min 1.5 min

Milling
E
Drilling
Changing to a sister tool with a quick

change system is faster than changing
Boring
the insert inside the machine.
G
Tool holding
H
Other information
Machinability
G 20
Turning centers
A
Different ways how to install quick change
Turning
Tooling alternatives in conventional turrets
A Hydraulically operated clamping units
B
A
Manual push-button tool changing
Parting and
F ully automatic tool changing
grooving
possibilities.
C
B B Shank type clamping units
S
quare and round shank tools as
Threading
C well as cutting units for external and
internal operations.
C Clamping units for VDI turrets

A
ngled and straight clamping units for
Milling
external and internal operations.
E
Drilling
F
Boring
G
Tool holding
H
Other information
Example of installations.
Machinability
G 21
A Turning centers
Coromant Capto driven tool holders

Turning
Driven tool holders provide the key to dramatic improve-

B ments in machining economy by allowing milling, turning
and drilling operations to be carried out in a single setup.
Parting and
grooving
C V
arious licensed manufacturers of these
units are available.
S
pindle dimensions
Threading
- Machine type and model

- Maximum turret swing diameter
- Maximum tool length.
D
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Example of installations.
Machinability
G 22
Machining centers
A
Modular tooling for machining centers
Turning
B
Machining centers
Parting and
grooving
C
Threading
D
Turning centers
Milling
Multi-task machines
E
What is a machining center?
Drilling
A
machining center is a multi-function 5
-axis machining centers add two more
machine that typically combines boring, axes in addition to the three normal
drilling and milling tasks. axes (X/Y/Z). F
Machining centers could be in horizontal

design as well as vertical design.
Boring
G
Tool holding
H
Other information
Machinability
G 23
A Machining centers

Turning
Configuration of a vertical machining center

B
Parting and
grooving
C
Threading
Configuration of a horizontal machining center

D
Milling
E
Drilling
What is a basic holder?

A basic holder is an adapter
F which connects the modular tools
to the machine interface.
Basic holders with front clamp
solution offer quick change in ma-
Boring
chines that do not have automatic

tool changing.
G
Tool holding
Front clamping Center bolt clamping
H
Other information
Machinability
G 24
Machining centers
A
Commonly used tool holding range
Turning
Milling machines, machining centers, multi-task machines
Basic holders
B
Parting and
grooving
Cat V-Flange Cat V-Flange DIN 2080 ISO 7388/1 DIN 96871 MAS BT MAS BT HSK
BIG-PLUS/ Form B Form B C
40 ISO 40 ISO 30 ISO 30 50-A/C
90 rotated
45 ISO 50 ISO 40 ISO 40 ISO 40 ISO 40 63-A/C
50 40 ISO 50 ISO 50 ISO 50 ISO 50 100-A/C
60 50 ISO 60 125-A/C
MAS BT 80-F
Threading
Cat V-Flange ISO 7388/1 BIG-PLUS
DIN 69871 BIG-PLUS ISO 40
Form B ISO 40 ISO 50
40 ISO 50
50 D
Chucks and adapters
Milling
E
Drilling
Modular tooling for machining centers F
Boring
A modular tooling system integrated into

machining centers gives many advantages:
- one single system in the machine G
-m
aximum power of the machine can be
Tool holding
utilized thanks to the rigidity of the coupling

-e
asier handling as modular tools are rela-
tively small in size and weight.
H
Other information
Machinability
G 25
A Machining centers
Spindle integration in machining centers

Turning
Integration of the female coupling in the spindles

B
An integrated clamping mechanism could
be used in most of the machines on the
Parting and
market today and gives many advantages:

grooving
- standardization in the workshop

- better torque transmission and stability
C
- shorter tools due to integration tools
- more space in the machine
Threading
- no need for basic holders.
D
Milling
E
Directly integrated in the spindle or via basic holder
Drilling
F
Boring
G
Integrated in the spindle Basic holder solution
Tool holding
H
Other information
Machinability
G 26
Machining centers
A
Right combination for best possible rigidity
Turning
Extension adapters
Extended tools for machining centers are frequently B
required to be able to reach the surface to be machined.
With Coromant Capto modular system it is possible to
Parting and
build an assembly, so the right length can be achieved.
grooving
It is important that the minimum length C
is used, particularly when long overhangs
are required.
Threading
W
ith modular tools it is always possible
to use optimal cutting data for best
productivity!
M
odular tools are built together D
in minutes!
Get closer tolerances.
Milling
E
Minimize tool holder inventory in machining centers
Modular tools give access to a very large number of
tooling solutions, with very few items!
Drilling
Modular Solid
F
Boring
G
Tool holding
H
Number of items with modular tools: Number of items solid tools:
Other information
4 + 2 + 30 + 10 = 46 items. 4 x 3 x (30 + 10) = 480 items.

Machinability
G 27
A Multi-task machines
Modular tooling for multi-task machines

Turning
B Machining centers
Parting and
grooving
C
Threading
Turning centers
Multi-task machines
Milling
What is a multi-task machine?

Drilling
M
ulti-task machines come in a variety of In a multi-task machine, the workpiece
configurations: can be completed in a single machine
F - horizontal or vertical design setup, e.g., turning, milling, contour-
ing and milling of angled surfaces, and
- two spindles (main and sub) and a
grinding.
B-axis spindle enable milling and turn-
ing operations on both front and back M
ulti-task machines are a combination
Boring
face of the workpiece of a turning center and a machining

center.
- each spindle acts as a workpiece
G holder allowing multi-axis machining
on either front or back face of the
workpiece.
Tool holding
H
Other information
Machinability
G 28
Multi-task machines
A
Definitions of the spindle directions
Turning
The program language for defining the spindle direction
B
M03 = C
lockwise spindle
direction
Parting and
grooving
M04 = C
ounterclockwise
spindle direction C
Threading
D
Milling
E
Configuration of a multi-task machine
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
G 29
Definitions of the spindle directions

Turning
The milling spindle in a multi-task machine Therefore multi-task machine tools needed
B tool should be able to carry both rotating a tooling system with unsurpassed rigidity
and non-rotating tools. Coromant Capto is and repetitive accuracy both radially and
the only tooling system that can fulfill this axially, like Coromant Capto.
Parting and
demand without compromise.

grooving
Multi-task machine tools are often used in

done-in-one applications in which opera-
C tions run from roughing to finishing in one
machine tool setup.
Threading
D
Milling
E
The Coromant Capto tooling
system is directly integrated in
the spindle.
Drilling
F
Boring
G
Turret with Coromant Capto
tooling system
Tool holding
Multi-task machine tool with Coromant Capto integrated tool

spindle and lower turning turret with Coromant Capto clamping
units.
H
Other information
Machinability
G 30
Multi-task machines
A
New multifunctional tools for multi-task machines
Turning
For taking advantage of versatile multi-task machine tools
and to optimize their efficiency, there is sometimes a B
demand for running them with dedicated tooling. These
tools are only available with Coromant Capto and have been
Parting and
invented for multi-task machine tools, offering:
grooving
- accessibility, stability and higher productivity
- reduced tool changing time
C
- saved tool pocket in tool magazine
- cost reduction - one tool replaces many tools.
Threading
D
Milling
E
Drilling
Multifunctional tools
one milling and four turn-
Twin tools
ing tools in one F
two turning tools in one
Boring
G
Tool holding
Mini-turrets
four turning tools in one H
Other information
Machinability
G 31
Build your own mini-turret

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

exchangeable cutting heads for turning,
threading, parting and grooving opera-
Parting and
tions for building an optimized tool for the

grooving
component.
R educe tool changing time

C
Save tool pockets in tool magazine
For both external and internal use
Axial
Threading
D
Milling
Use of shank tools in a multi-task machine

E Tool adapters for shank tools
Turning tool adapters for
- shanks
- bars
Drilling
- blades
- mini-turrets
F
to make it possible to use shank tools
also in a multi-task machine with an inte-
grated modular tool system in the spindle.
Boring
G
Tool adapter with blade for Tool adapter for boring bar
parting off
Tool holding
H
Other information
Machinability
G 32
Chucks
A
Chucks
Turning
Chucks are mechanical, hydro-mechanical and hydraulic
chucks respectively, for holding end mills and drills.
B
Parting and
grooving
Choice of chucks and adapters
Hydraulic Hydro- Shrink fit Collet Endmill Drill C
chuck mechanical adapter chuck (Weldon) adapter
chuck adapter
Threading
D
Rank 1 2 3 4 5 6
Milling
Clamping E
area
Clamping
Drilling
force
< .787 in.
( <20 mm) +++ +++ +++ + +++ +++
F
< .787 in.

( <20 mm)
+++ +++ ++ + +++ +++
Boring
G
Runout +++ +++ +++ + + +
Tool holding
Balanced Balanced Balanced Balanced Balanced

Balance by rotation- by rotation- by design by design by design No
al testing al testing (C4-C5) (C3-C5) (C3-C5) H
Other information
Machinability
G 33
A Chucks
Hydraulic chucks
Turning
igh clamping forces.

H
Large assortment of collets.
B High accuracy, runout max .00024 inch (6 m) at 3xD.
Large assortment of tools.
For drilling, reaming and milling.
Parting and
Fast tool changing time.

grooving
Can damage hydraulic membrane if not used properly.

Any shank type can be used, but recommended to use
C solid round-shank cutting tools.
High speed capability
Threading
D
Milling
E
Clamping
part
Drilling
F Pressure
screw
Piston
Collet
Boring
G
Tool holding
H
Other information
Machinability
G 34
Chucks
A
Hydro-mechanical chucks
Turning
igh clamping force.
H
Any shank type can be used. B
High accuracy, runout max .00024 inch (6 m) at 3xD.
Medium tool changing time.
Parting and
Minimum investment compared to shrink fit.
grooving
Better reliability than power chucks or shrink fit.
h6 shank
Any shank type can be used, but recommended to use
solid round-shank cutting tools. C
Threading
Shrink fit adapters
S mall collapsibility.
D
High clamping forces for small diameters - low clamping
force for large diameters.
No collets.
Tools can be made slender - narrow.
Milling
High accuracy, low runout.
Expensive heating systems.
E
h6 shank Long tool changing time.
Heavy investment in tools and machinery.
Low tool lifetime.
Can only clamp solid round-shank cutting tools.
Drilling
F
Collet chuck adapter ER type

Large collapsing range.
Boring
h
6 or h7 tolerance shanks can be used due to large
collapsibility. G
Low to medium clamping force.
Tool holding
General purpose clamping system.

h6/h7
shank Industry standard.
H
Other information
Machinability
G 35
A Chucks
Drill adapter for drills, screw type

Turning
Screw type adapter for drills.

Good general purpose tool.
B
Limited clamping area, typically less than 10%.
R
unout typically is around .0016 inch (40 m) at the
Parting and
surface of the chuck.

grooving
Can cause vibration problems.
C
Threading
Endmill (Weldon) holders

Screw type holders.
D Good general-purpose tool.
Limited clamping area, typically less than 10%.
R
unout typically is around .0016 inch (40 m) at the
surface of the chuck.
Milling
Can cause vibration problems.

E
Low-cost solution for holding tools.
Drilling
F Try to minimize the gauge length

It is important to maintain as short a
gauge length as possible to increase
Boring
stability and reduce deflection.

Overhang
G L ength reduction as little as 20% can
(20%) have a significant reduction in deflection
(-50%).
Tool holding
Tool protru-
sion
H (50%)
Other information
Machinability
G 36
Chucks
A
Influence of runout on tool life
Turning
R
unout should be < .001 inch
(< 0.025 mm).
F or every .0004 inch (0.01 mm) runout B
- up to 50% decrease in tool life.
Parting and
M
ore critical as tool diameter gets
grooving
smaller.
Tool holding requirements
Threading
Application - Roughing and semi-finishing
Main criteria = clamping force.
High torque capability. D
F or best performance use cylindrical
shanks.
Milling
Versatility of collets.
E
Application - Finishing
Main criteria = runout.
Drilling
Max runout .00024 inch (6 m) Influence on tool life and component
- finish and accuracy.
F
Boring
Unbalance in tool holders G

Unbalance in tool holders causes:
Tool holding
- poor surface finish

- poor part tolerances
- reduction in tool life
H
- premature machine-spindle wear.
Other information
Machinability
G 37
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
Cutting tool materials H 29
Manufacturing of cemented carbide H 44
Other information
Machining economy H 55
Maintenance and tool wear H 68
Formulas and definitions H 75
H3
A Workpiece materials
Workpiece materials
Turning
Six main groups

B 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
Parting and
the tool.
grooving
ISO ISO ISO

C Steel Stainless steel Cast iron
P M K
Threading
D ISO ISO ISO

Aluminum Heat Resistant Super Alloys Hardened material
N S H
Milling
E
The largest variety of different types of The aircraft industry and manufactur-
P components is probably in the P-area
N ers of aluminum automotive wheels
as it covers several different sectors in dominate the N-area.
Drilling
the industry.
In the M-area, a big part of the applica- Difficult to machine S-area materials
M tion is in gas and oil, tubes, flanges, S are found in the aerospace, gas turbine
process industry and the pharmaceuti- and power generator industries.
Boring
cal business.
The K-area is dominated by automotive Hardened materials in the H-area are

K H
Tool holding
components, the machine builders and seen in a variety of industries such as

the iron works production. automotive and their subcontractors, as
well as in machine builders and the die
and mold business.
H
Other information
Machinability
H4
Workpiece materials
A
Characteristics for chip formation and removal
Turning
Factors that must be identified in order to - T he cutting tool material (grade), e.g.
determine a materials machinability: coated cemented carbide, ceramic, CBN,
PCD, etc. B
-C lassification, metallurgical/mechanical,
of the workpiece material. The selections will have a great influence
- The cutting edge micro- and macro geom- on the machinability of the material at
Parting and
etry to be used. hand.
grooving
ISO ISO ISO
Steel Stainless steel Cast iron C
P M K
Threading
ISO ISO ISO D
Aluminum
N S Heat resistant and super alloys H Hardened material
Milling
E
P ISO-P materials are generally long chipping

and have a continuous, relatively even
K Chip formation for ISO-K materials varies
from near-powderlike chips to a long chip.
flow of chip formation. Variations usually The power needed to machine this material
Drilling
depend on carbon content. group is generally low.
Low carbon content = tough sticky Note that there is a big difference between
material. gray cast iron (often near-powder) and
ductile iron, which many times has a chip F
High carbon content = brittle material.
Cutting force and power needed varies breaking more similar to steel.
very little.
Low power needed per inch3 (mm3), but due

N
Boring
to the high metal removal rate, it is still a

good idea to calculate the maximum power
ISO-M forms a lamellar, irregular chip for- required.
M mation where the cutting forces are higher
G
compared to normal steel. There are many
The range is wide, but in general high cut-
different types of stainless steels. S
Tool holding
Chip breaking varies depending on the ting forces are present.

alloying properties and the heat treatment,
from easy to almost impossible-to-break
chips. Often a continuous, red-glowing chip. This
H high temperature helps to lower the kc1
value and is important to help out with the
H
Other information
application.
Machinability
H5
The complex world of metal cutting

Turning
Many parameters influence the cutting process

B
Parting and
grooving
C
Workpiece material Application Condition
Turning Cutting conditions

Threading
P Steel
D M Stainless steel
Milling
K Cast iron
Milling
E N Aluminum
Milling
Clamping conditions
S Heat resistant alloys

Drilling
F H Hardened steel
H Roughing/
R Heavy
M Medium
M
Boring
L Finishing/
F Light
G
The ISO material groups There are three major types of All components are different
Tool holding
are divided into 6 different application, all requiring differ- in look, need various setups,
types where each type has ent tools, inserts and grades. and require special attention
unique properties regarding These also depend on the and demands from the tool.
machinability. load on the cutting edge, from
finishing to roughing.
H
Other information

Machinability
H6
Workpiece materials
A
Turning
B
Parting and
grooving
C
Component Hardness Cutting environment
Threading
D
Milling
Hardness Brinell Coolant
E
Drilling
F
Dry machining Boring
Depending on the size, type Usually there is a relation be- Carbide performs best when
of material, setup and ma- tween material hardness and machining at high, constant
chining method, a different tool life, as well as machining temperatures. Dry conditions
choice of tooling is required data and type of geometry and should therefore be the first G
(turning, milling, drilling, etc). grade. The higher the hard- choice. Some grades are, how-
ness, the shorter the tool life, ever, developed for wet condi-
Tool holding
with more rapid wear on the tions; for example, grades for
cutting edge. cast iron machining.
H
Other information
Machinability
H7
The interaction between workpiece material, geometry

and grade
Turning
Workpiece material T he interaction between an optimized

B
geometry and grade for a certain work-
piece material is the key for a success-
ful machining process.
Parting and
grooving
T hese three basic factors must be con-

sidered carefully and adapted for each
machining operation.
C
T he knowledge and understanding of
how to work with and adjust these fac-
tors is of vital importance.
Threading
Insert grade Insert geometry

D
Workpiece materials, main groups

Milling
E Materials are classified using MC codes
Heat resistant super

Steel Cast iron
alloys and titanium
Drilling
F
P M K N S H
Boring
Stainless steel Aluminum Hardened material

G
Tool holding
Within each material group there are subgroups

depending on the hardness of the material, kc1 value,
and metallurgical and mechanical properties.
H
Other information
* MC = A new material classification that replaces the CMC

Machinability
(Coromant Material Classification) codes.
H8
Workpiece materials
A
MC code structure
Turning
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. B
Example 1:
Parting and
The code P1.2.Z.AN is interpreted this way:
grooving
P = ISO code for steel
1 = material group: unalloyed steel C
2 = material subgroup: carbon content ?0.25% 0.55% C
Z = manufacturing process: forged/rolled/cold drawn
Threading
AN = heat treatment: annealed, supplied with hardness values
Example 2:
Milling
The code N1.3.C.AG is interpreted this way:
N = ISO code for non-ferrous metals
E
1 = material group: aluminum
2 = material subgroup: aluminum with Si content 1-13%
Z = manufacturing process: casting
Drilling
AN = heat treatment: aging
F
By describing not only the material composition, but also the manufacturing process
Boring
and heat treatment, which influences the mechanical properties, a more exact de-
scription is available, which can be used to generate improved cutting data recom-
mendations. G
Tool holding
H
Other information
Machinability
H9
Steel ISO P main characteristics

Turning
B
Parting and
grooving
C
Machining characteristics: What is steel?
- Long-chipping material -S
teel is the largest group in the metal
Threading
cutting area.
- Relatively easy, smooth chip control
-S
teels can be non-hardened or hardened
- Low carbon steel is sticky and needs
D and tempered with hardness up to
sharp cutting edges
400 HB.
- Specific cutting force kc:
-S
teel is an alloy with the element iron
217,500449,500 lbs/inch2
( Fe) as the major component. It is pro-
(15003100 N/mm2)
Milling
duced through a melting process.

- Cutting force, and the power needed to
-U
nalloyed steels have a carbon content
E machine ISO P materials, stays within a
lower than 0,8 %, and only Fe, with no
limited range.
other alloying elements.
-A
lloyed steels have a carbon content
which is lower than 1,7 % and alloying
Drilling
elements like Ni, Cr, Mo, V, W.
F
Boring
ISO MC Material
G P1 Unalloyed steel
Low-alloyed steel
Tool holding
P2 (5% alloying elements)

P
High-alloyed steel
P3 (>5% alloying elements)
H See Technical Guide Chapter H
Other information
for detailed MC code listing P4 Sintered steels

Machinability
H 10
Workpiece materials
A
Stainless steel ISO M main characteristics
Turning
B
Parting and
grooving
C
Machining characteristics: What is stainless steel?
- Long-chipping material -S
tainless steels are materials alloyed
Threading
with min 1112% chromium.
-C hip control is fair in ferritic, to difficult in
austenitic and duplex - T he carbon content is often low (down to
max 0.01%). D
- Specific cutting force:
261,000413,250 lbs/inch2 - Alloys are mainly Ni (Nickel), Mo
(18002850 N/mm2) (Molybdenum), and Ti (Titanium).
-M
achining creates high cutting forces, - T he formed Cr2O3 layer on the steel
Milling
built-up edge, heat and deformation surface makes it non-corrosive.
hardening.
E
Drilling
F
Boring
ISO MC Material
P5 Ferritic/Martensitic stainless G
steel
Tool holding
M1 Austenitic stainless steels
M
M2 Super-austenitic, Ni20%
See Technical Guide Chapter H H

Other information
for detailed MC code listing M3 Duplex (austenitic/ferritic)

Machinability
H 11
Cast iron ISO K main characteristics

Turning
B
Parting and
grooving
C
Machining characteristics: What is cast iron?
- Short chipping material - T here are 3 main forms of cast iron:
Threading
gray (GCI), nodular (NCI) and compacted

- Good chip control in all conditions
graphite (CGI).
-S
pecific cutting force:
D -C
ast iron is an Fe-C composition with
114,550195,750 lbs/inch2
relatively high content of Si (13%).
(7901350 N/mm2)
-C
arbon content is over 2% which is the
- Machining at higher speeds creates
max solubility of C in the Austenitic
abrasive wear
Milling
phase.
- Moderate cutting forces.
-C
r (Chromium), Mo (Molybdenum), and
E V (Vanadium) form carbides which in-
crease strength and hardness, but lower
machinability.
Drilling
ISO MC Material
F
K1 Malleable cast iron
Boring
K2 Gray cast iron
G
K K3 Nodular SG iron
Tool holding
K4 CGI

Other information
for detailed MC code listing K5 ADI

Machinability
H 12
Workpiece materials
A
Non-ferrous materials ISO N main characteristics
Turning
B
Parting and
grooving
C
Machining characteristics: What is Non-ferrous material?
- Long-chipping material - T his group contains non-ferrous, soft
Threading
metals with hardness under 130 HB.
- Relatively easy chip control if alloyed
-A
luminum (Al) alloys with up to 22%
-A
luminum (Al) is sticky and needs sharp
silicon (Si) make up the largest part. D
cutting edges
- Copper, bronze, brass
50,750101,500 lbs/inch2 - Plastic
(350700 N/mm2)
Milling
- Composites (Kevlar)
- Cutting force, and the power needed to
machine ISO N materials, stays within a E
limited range.
Drilling
F
ISO MC Material Boring
N1 Aluminum-based alloys
G
N2 Magnesium-based alloys
Tool holding
N
N3 Copper-based alloys

Other information
for detailed MC code listing N4 Zinc-based alloys

Machinability
H 13
Heat resistant super alloys and titanium

ISO S main characteristics
Turning
B
Parting and
grooving
C
Machining characteristics: What are Heat Resistant Super Alloys?
- Long-chipping material -- Heat
Resistant Super Alloys (HRSA)
Threading
include a great number of high alloyed

- Difficult chip control (segmented chips)
iron, nickel, cobalt or titanium based
-N
egative rake angle is required with materials.
D ceramics, a positive rake angle with
Groups: Fe-based, Ni-based, Co-based
carbide

Condition: Annealed, Solution heat
treated, Aged rolled, Forged, cast.
For HRSA:
Milling
348,000449,500 lbs/inch2 Properties:

(24003100 N/mm2) - Increased alloy content (Co more than
E Ni), results in better resistance against
For titanium: heat, increased tensile strength and
188,500203,000 lbs/inch2 higher corrosive resistance.
(13001400 N/mm2)
Drilling
- Cutting forces, and power required are

quite high.
ISO MC Material
F
S1 Iron-based alloys
Boring
S2 Nickel-based alloys
G S3 Cobalt-based alloys
S
Tool holding
S4 Titanium-based alloys
S5 Tungsten-based alloys
Other information
for detailed MC code listing

S6 Molybdenum-based alloys
Machinability
H 14
Workpiece materials
A
Hardened steel ISO H main characteristics
Turning
B
Parting and
grooving
C
Machining characteristics: What is hardened steel?
- Long-chipping material -H
ardened steel is the smallest group
Threading
from a machining point of view.
- Fair chip control
- T his group contains hardened and tem-
- Negative rake angle is required
pered steels with hardness >4565 HRC. D
-S
pecific cutting force:
- T ypically, however, hard part turned com-
369,750706,150 lbs/inch2
ponents can be found to be within the
(25504870 N/mm2)
range of 5568 HRC.
Milling
- Cutting forces and power required are
quite high.
E
Drilling
F
Boring
ISO MC Material
H1 Steels (extra hard) G

Tool holding
H2 Chilled cast iron
H
H3 Stellites

Other information
for detailed MC code listing H4 Ferro-TiC

Machinability
H 15
The specific cutting force

Turning
kc1 the material constant varies for each material
B
kc1
lbs/in2
(N/mm2)
Parting and
T he cutting force (Fc)

grooving
870,000 is the force needed to

(6000) shear off a specific chip
cross-section in certain
C conditions
725,000
(5000)
Fc T his value (Fc) is used
Threading
in the calculation of the

580,000 power consumption need-
(4000)
D H ed for an operation
435,000 T he specific cutting force

(3000)
value (Fc) is a material
Milling
M constant, expressed in
P S lbs (N)
290,000
E (2000)
145,000 K N Fc = kc ap fn
Drilling
(1000)
F
Boring
kc1 values in lbs/inch2 (N/mm2)

G
P 217,500 449,500 N 50,750 195,750
(1500 3100) (350 1350)
Tool holding
M 261,000 413,250 S 188,500 449,500

(1800 2850) (1300 3100)
K 114,550 195,750 H 369,750 706,150

H (790 1350) (2550 4870)
Other information
Machinability
H 16
Workpiece materials
A
The ISO nomenclature in the ISO-P area
Turning
Operations and working conditions
P01: Internal and external finishing turning; high cutting B

Wear resistance speed; small chip area; good surface finish; narrow
tolerances; no vibrations.
P
Parting and
01 P10: T urning; copying; threading; milling; high cutting
grooving
speed; small to medium chip area.
P20: T urning; copying; medium cutting speed; facing with
10 small chip area; medium to difficult conditions. C
P30: T urning; milling facing; medium to low cutting speed;
medium to large chip area; includes operations with
Threading
20 tough conditions.
P40: Turning; facing; milling; cutting; grooving; low cutting
speed; large chip area; large possible chip angle; D
30 very tough conditions.
P50: W
hen very high toughness in the tool is needed in
turning, facing, grooving, cutting, low cutting speed,
Milling
large chip area, large possible chip angle, extremely
40 tough conditions.
E
50
Drilling
Toughness
F
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.
Boring
G
Tool holding
H
Other information
Machinability
H 17
A
Turning The cutting edge
B
The cutting edge
Parting and
grooving
The design of the cutting edge and insert

C geometry is of vital importance for the chip
formation process and tool life in metal
cutting.
Threading
D
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
H 18
The cutting edge
A
The high cutting force on a cutting edge
Turning
Guess how big the tangential force is on the cutting edge
B
Cemented carbide has a high compressive strength re-
sistance and can also work at high temperatures without
plastic deformation. It can also resist high cutting forces
Parting and
without breaking, as long as the insert is well supported.
grooving
C
ap =a.512 inch (13 mm)
=13 mm Material: Steel
p ap = .319a inch
=8.1(8.1
mm mm)
p
ap =13 mm CMC 02.1 180 HB
Threading
ap =8.1 mm
fn = .024 in fn = .039 in
fn =0.62 f =1.0
(0.62 mm) (1.0 nmm)
fn =1.0 D
n =0.62
Milling
Fc = 3750 lbf kp
Ft =1700 Ft =1700 kpFc = 3750 lbf
(1700 kp) (1700 kp)
E
Ft =1700 kp Ft =1700 kp
Drilling
F
Boring
The tangential cut- G

Calculation of Fc ting force in these two
Material: MC P2 (low alloyed steel) cases (approx. 3750 lbf,
Tool holding
180 HB 16671 N, or 1700 kp) is

kc = 304,563 lbs/in2 (2100N/mm2) equivalent to the weight
of a passenger car.
Fc = kc x ap x fn
Fc = 304563 x .512 x .024 = 3742 = 1700 kp H
Other information
Fc = 2100 x 13 x 0.62 = 16926 N (Newton) = 1700 kp

Machinability
H 19
A The cutting edge
The machining starts at the cutting edge

Turning
B
Parting and
grooving
Typical chip breaking

sequences with high
Threading
speed imaging.
D
Cutting zone temperatures
The maximum heat generated during cutting is on the top
Milling
part of the insert, in the chip breaker, and close to the

cutting edge. This is where the maximum pressure from
E the material is, and, with the friction between chip and
carbide, causes these high temperatures.
Drilling
F
T he rake angle, geometry and feed play
an important role in the chip formation
process.
Boring
R
emoving heat from the cutting zone
through the chip (80%) is a key factor.
G
T he rest of the heat is usually evenly
distributed between the workpiece and
Tool holding
the tool.
H
Other information
Machinability
H 20
The cutting edge
A
The design of a modern insert
Turning
B
Parting and
grooving
C
Threading
A steel turning insert for medium turning.
Milling
E
Nose cutting edge design Main cutting edge design
Drilling
.010 in.
(.25 mm)
20
5 F
Macro geometry with
chip breaker C
utting edge reinforce-
ment .010 inch (0.25
mm)
Boring
Geometry for small Rake angle 20

cutting depths
Primary land 5
G
.008 in.
(0.2 mm)
Tool holding
H
Other information
Machinability
H 21
A The cutting edge

Turning
The ER treatment gives the cutting edge the final

B micro-geometry
E
R treatment (Edge Roundness) is done
Parting and
before coating, and gives the final shape

grooving
of the cutting edge (micro-geometry).

T he relation between W/H depends on
C the application.
Threading
Generally the ER
corresponds to the
thickness of a hair,
diameter: ~ .0031 inch
D (80 m).
Milling
E 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.
Drilling
F
Negative
land .0039 in. (0.1 mm)
Boring
G
Chamfer
Tool holding
A
negative land increases the strength
of the cutting edge, but also creates
H higher cutting forces.
Other information
Machinability
H 22
The cutting edge
A
Insert rake angle
Turning
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 B
degrees plus. This determines how the insert can be
tilted in the tool holder, and results in either a negative or
Parting and
positive cutting action.
grooving
C
T he insert rake angle is
the angle between the
top face of the insert and
Threading
the horizontal axis of the
workpiece.
Milling
E
Positive and negative cutting action
Turning needs a durable edge that can In most drilling applications there is also
Drilling
perform for a long time and often in coolant present, mainly for chip transpor-
continuous cuts at high temperature. This tation reasons which puts the edge under
condition requires an edge with among extra stress from temperature variations. F
other things good chip breaking ability, To be able to transport the chips from the
good resistance against different types of narrow chip flutes and from inside the
wear and against plastic deformation. hole, good chip breaking into short chips
is an important factor.
Boring
In milling, which always has an intermit-

tent cutting action, the edge needs to
have good bulk strength to resist break- G
age. A large variation in cutting edge
temperature due to interrupted cuts also
Tool holding
makes resistance to thermal cracks of

vital importance.
In drilling, the edge must be strong
enough to last at very low cutting speeds, H
and even at zero speed in the center of
Other information
the drill.
Machinability
H 23
A The cutting edge
Peak performance in machining

Turning
Dedicated inserts for different applications

There are major differences in insert geometry and grade
B requirements between applications in turning, milling and
drilling.
Parting and
grooving
Turning N
eeds a durable edge that can perform
for a long time, and often in continuous
C cuts at high temperature.
Good chip breaking ability
G
ood resistance against different types
Threading
P of wear and against plastic deformation.
D
M Milling
T he cutting action is always intermittent
and the edge needs to have good bulk
Milling
K strength to resist breaking.

V
ariations in cutting edge temperature
E due to the interrupted cuts also mean
N that the resistance to thermal cracks is
of vital importance.
Drilling
S
F
Drilling
H T he edge must be strong enough to last
at very low cutting speeds; in fact, at
Boring
zero speed in the center of the drill.

C
oolant is present, mainly for chip trans-
G portation 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
Other information
Machinability
H 24
The cutting edge
A
Six main groups of workpiece materials
Turning
Different characteristics for removing chips
Good chip forming usually results in high cutting forces B
and excess heat, depending on the material. This can
lead to low cutting speeds with adhesive stresses as
Parting and
a result. On the other hand, materials like aluminum,
grooving
unalloyed steels and low-strength cast iron produce less
cutting force.
C
Threading
D
Milling
Steel Stainless steel Cast iron
E
Drilling
F
Aluminum Heat resistant alloys Hardened steel

Boring
G
Tool holding
H
Other information
Machinability
H 25
A The cutting edge
From universal to optimized turning inserts

Turning
General inserts
B General geometry
Optimizing with grades
Parting and
Performance compromised
grooving
C Application area
Dedicated inserts
Threading
D
edicated geometries
and grades
D O
ptimized performance
according to workpiece
machinability
Application area
Milling
E Dedicated inserts for the ISO P, M and K areas

The different micro- and macro-geometries are adapted to the
various requirements in the applications.
Drilling
Workpiece Finishing Medium Roughing

material
F
.028 in. .008 in. .013 in.
(0.7 mm) (0.2 mm) (0.32 mm)
Boring
G .011 in. .013 in.

(0.29 mm) (0.32 mm)
Tool holding
.004 in. .010 in.

(0.1 mm) (0.25 mm)
H
Other information
Machinability
H 26
The cutting edge
A
Type of application - Turning
Turning
ap Depth of
cut, inch Heavy turning
(mm)
R Operations for maximum stock removal and/or severe
conditions.
B
High D.O.C. and feed rate combinations.
Parting and
grooving
Medium turning
M Most applications general purpose.
Wide range of D.O.C. and feed rate combinations. C
Finishing
Threading
F Operations at light depths of cut (D.O.C.) and low feed rates.
Operations requiring low cutting forces.
fn
Feed, inch/r (mm/r) D
Dedicated geometries and grades

Todays insert/grade/geometry options are much more
Milling
dedicated towards specific application areas, giving the
full and optimized usage of the machine and tool capacity,
resulting in improved productivity and lower costs. E
Drilling
ISO/ANSI P STEEL
Finishing Medium Roughing
-WF / GC4215 -WM / GC4205 WR / GC4205
-PF / GC4215 -PM / GC4215 -PR / GC4215
F
-WF / GC4215
Single
sided Dominating application areas
-WM / GC4215 -WR / GC4215
Double
sided
P M K
Single
sided
-PF / GC4215 -PM / GC4225 -PR / GC4225
-WF / GC4225 -WM / GC4225 -WR / GC4225
Boring
-PF / GC4225 -PM / GC4235 -PR/ GC4235
Stainless
Material Steel Cast iron
steel
G
Turning F M R F M R F M R
Dedicated
Tool holding
geometries
Milling L M H L M H L M H
Grades GC4200 GC2000 GC3200 H

Other information
Machinability
H 27
A The cutting edge
Type of application - Milling

Turning
ap Depth of
cut, inch Heavy milling
(mm)
B H Operations at maximum stock removal and/or severe
conditions.
Larger depth of cut and feed rate.
Parting and
grooving
Medium milling
M Most applications general purpose milling.
C Medium depth of cut and feed rate.
Light milling
Threading
L Operations at small depth of cut and low feed rates.

Operations requiring low cutting forces.
D Feed fz, inch/tooth (mm/tooth)

Milling
Selecting the insert geometry in milling

E
Drilling

Boring
Extra positive G
eneral purpose Reinforced cutting edge
geometry
Light machining Heavy machining
G
Medium feed rates
Low cutting forces Highest edge security
M
edium operations to
Low feed rates High feed rates
Tool holding
light roughing
H
Other information
Machinability
H 28
Cutting tool materials
A
Turning
The selection of cutting tool material and grade is an important factor
to consider when planning a successful metal cutting operation.
A basic knowledge of each cutting tool material and its performance is B
therefore important to be able to make the correct selection for each
application. This should take into consideration the workpiece material
Parting and
to be machined, the component type and shape, machining conditions
grooving
and the level of surface quality required for each operation.
Threading
D
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
H 29
A Cutting tool materials
Different types of cutting tool materials

Turning
Hardness
B
1
CD
Diamond
Parting and

2
grooving
CB
3
Cubic boron nitride
C 4
5
CC
Threading
Ceramics
D
6
CT
Cermets
1. Diamond
2. Cubic boron nitride GC
Milling
3. Ceramics
4. Cermets Coated carbide

5. Coated carbide
6. High Speed Steel
E HSS
High speed steel
Toughness
Drilling
The ideal cutting tool material should:

F
- be hard, to resist flank wear and deformation
- be tough, to resist bulk breakage
- not chemically interact with the workpiece material
Boring
- be chemically stable to resist oxidation and diffusion

G
- have good resistance to sudden thermal changes.
Tool holding
H
Other information
Machinability
H 30
A
The main range of cutting tool materials
Turning
Uncoated cemented carbide (HW)
Coated cemented carbide (HC) B
Cermet (HT, HC)
Parting and
Ceramic (CA, CN, CC)
grooving
Cubic boron nitride (BN)
Polycrystalline diamond (DP, HC) C
Threading
D
Uncoated cemented carbide
Characteristics, features and benefits
Milling
Used in moderate to difficult applications
related to steel, HRSA, titanium, cast E
iron and aluminum in turning, milling and
drilling.
G
ood combination of abrasive wear
Drilling
resistance and toughness.
Gives sharp cutting edges.
F
G
ood edge security but limited wear
resistance at higher speeds.
R
epresents a small portion of the total
Boring
grade program.
G
Tool holding
H
Other information

Machinability
H 31
Coated cemented carbide

Turning

General use in all kinds of components
B and materials for turning, milling and drilling
applications.
Extremely good combination of wear resist-
ance and toughness in a variety of jobs.
Parting and
Consists of a large variety of grades with hard

grooving
to tough substrates, usually with gradient

sintering, and various coatings of CVD and
PVD-type.
Shows very good wear characteristics with
C long tool life.
Dominates the insert program, with increasing
share.
Threading
Cermet
D Used in finishing and semi-finishing applica-
tions where close tolerance and good surface
finish is required.
Chemically stable with a hard and wear resist-
ant substrate.
Milling
Consists of Titanium based (TiC, TiCN)

cemented carbide with cobalt as a binder.
PVD-coating adds wear resistance and tool
E life. Self sharpening properties. Limited
toughness behavior.
Quite low share of total insert program.
Drilling
F
Ceramic
Depending on type of ceramic, the grades are
mainly used in cast iron and steel, hardened
materials and HRSA.
Boring
Ceramic grades are generally wear resistant

and with good hot-hardness. Wide applica-
G tion area in different types of material and
component.
Ceramics are considered brittle and need
stable conditions. With additions in the mix
Tool holding
and whisker reinforced ceramic, toughness is

improved.
Fairly low share of total insert usage, but
increased usage in the aerospace and hard-
H ened steel-cast iron areas.
Other information
Machinability

H 32
A
Cubic boron nitride
Turning
For finish turning of hardened steel. Roughing
of gray cast iron at high cutting speeds. Rough B
turning of rolls in white/chilled cast iron.
Applications that require extreme wear resist-
ance and toughness.
Parting and
CBN consists of Boron nitride with Ceramic or
grooving
Titanium nitride binder.
Resists high cutting temperatures at high
cutting speeds.
Special application area with small volume C
inserts. Trend is towards a higher volume of
hard materials to be cut.
Threading
D
Polycrystalline diamond
Turning of normal aluminum at low tempe-
rature and very abrasive hypereutectic
Milling
aluminum. Used in non-metal and non-ferrous
materials.
Extremely wear resistant grades. Sensitive to E
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 resist-
Drilling
ance. Decomposes at high temperatures.
Dissolves easily in iron.
Fairly low portion of the insert program, with
special limited applications.
F
Boring
G
Tool holding
H
Other information
Machinability
H 33
The development of cutting tool material

Turning
The development of cutting tool material through the

years can be seen in the reduced time taken to machine
B a component 19.685 inch long, with 3.937 inch diameter
(500 mm long, with 100 mm diameter) from 1900 to
today.
Parting and
grooving
At the beginning of the last century, cut- Today with improved geometries and new
ting tool material was only slightly harder coating technique we have reached below
than the material which needed to be cut. 1 minute in cutting time for the 19.685
C Therefore tool life was poor, and cutting inch (500 mm) steel bar.
speed and feed had to be kept very low.
In addition to traditional uncoated and
The introduction of HSS brought major coated carbide, new cutting tool materials
Threading
improvements, which resulted in reduced like cermet, ceramic, cubic boron nitride
cutting time. and diamond, have contributed to opti-
mized and improved productivity.
D 20 years later uncoated cemented carbide
brought down the required time in cut to a
staggering 6 minutes.
The introduction of coated carbide again
Milling
lowered the cutting time to 1.5 minutes.
Min (log) Carbon steel

Drilling
3.937
(100)
F High speed steel (HSS) 19.685

(500)
Boring
Cemented carbide
Coated carbide
Tool holding
Insert geometries, new coatings

New cutting tool materials
H
Other information
Machinability
H 34
A
What is cemented carbide and a grade?
Turning
C
emented carbide is a powder metallur-
gical material consisting of:
B
- hard-particles of WC (tungsten carbide)
Parting and
- a binder metal, cobalt (Co)
grooving
-h
ard-particles of Ti,Ta,Nb
(titanium, tantalum, niobium-carbides).
C
A
grade represents the hardness or
toughness of the insert, and is deter-
mined by the mixture of ingredients
Threading
which make up the substrate.
Milling
E
Coating of cemented carbide
C
oating of cemented carbide was
Drilling
developed in the 1960s.
A
thin Titanium Nitride coating layer was
added, only a few microns thick. This F
improved the performance of carbide
overnight.
Coatings offer improved wear resistance
Boring
giving longer tool life and possibility to

use higher cutting data.
G
Today modern grades are coated with dif-
ferent carbide, nitride and oxide layers.
Tool holding
H
Other information
Machinability
H 35
Microstructure of cemented carbide

Turning
Cemented carbide consists of hard The gamma phase has a better hot hard-
particles (carbides) in a binder matrix. ness and is less reactive at elevated
B The binder is more or less in all cases temperatures, so is often seen in grades
cobalt (Co) but could also be Nickel (Ni). where the cutting temperature can get
The hard particles consist mainly of tung- high. WC has a better abrasive wear
sten carbide (WC) with a possible addition resistance.
Parting and
grooving
of gamma phase (Ti-, Ta- Nb-carbides and

nitrides).
C
Threading
Elements:
D Alpha-phase
Gamma-phase (TiC) WC (tungsten carbide)
Gamma-phase
Milling
Beta-phase (Co) (Ti,Ta,Nb)C

(titanium, tantalum,
E niobium-carbides)
Alpha-phase (WC)
Beta-phase
Drilling
Co (cobalt)
F
Hair diameter
= .0020-.0028 inch (50-70 m)
Boring
G
Tool holding
H
Other information
Machinability
H 36
A
Fundamental characteristics
Turning
Apart from the grain size of the WC, the An increase in Co content and WC grain
amount of binder phase (cobalt) is an size contributes to an increase in bulk
important factor determining the charac- toughness, but also lowers the hardness. B
teristics of the carbide. The Co content As a result, the substrate has less resist-
in Sandvik Coromant grades is generally ance to plastic deformation, which means
415% of the total weight. less wear resistance/lower practical tool
Parting and
grooving
life.
Threading
Amount of binder
Toughness
Milling
E
Drilling
F
Boring
Wear resistant WC grain size
G
Tool holding
H
Other information
Machinability
H 37
Coating design
Turning
Many factors influence the behavior of the

insert:
B
- Coating process
- Coating material
Parting and
- Coating thickness
grooving
- Post treatment
C - Surface morphology.
Threading
D
Milling
E
Example of modern steel turning grades
Structure and build-up of the coating layers
Drilling
Wear resistance P Toughness

F
Boring
Gradient substrate for optimized hardness and toughness

G
Tool holding
ISO P01 P15 ISO P05 P30 ISO P10 P35 ISO P20 P45
GC4205 GC4215 GC4225 GC4235
H
Thicker coatings mean more wear resistance.
Other information
Machinability
Harder substrates mean more deformation resistance.
H 38
A
Grade design
Turning
Coatings and substrates vary with the type of application
Parting and
grooving
C
K05 K15 P05 P35 M15 M25 M35
Thicker coatings mean more wear resistance.
Threading
Harder substrates mean more deformation resistance.
The coating of a modern turning grade

The grade plays a very important part of the performance
Milling
E
Al2O3
Coating for chemical and
thermal wear resistance.
Drilling
TiCN F
MTCVD coating for mechan-
ical wear resistance. Boring
Functional gradient
For optimized hardness and G
toughness.
Tool holding
Cemented carbide
Plastic deformation
resistance.
H
Other information
Machinability
H 39
Properties of different coating materials

Turning
CVD coating of inserts

B Chemical Vapor Deposition
T he most common CVD layers today are

Parting and
TiN, Ti(C,N) and Al2O3.

grooving
TiN
TiCN provides flank wear resistance.
Al2O3 A
l2O3 provides temperature protection
C
(plastic deformation resistance).
Ti(C,N) TiN provides easy wear detection.
Threading
D
TiN = Titanium nitride
Ti(C,N) = Titanium carbonitride
Al2O3 = Aluminum oxide
Milling
PVD coating of inserts

Drilling
Physical Vapor Deposition

F P
VD coatings are generally tougher than
CVD coatings.
P
VD coatings are often used in combina-
tion with fine-grained substrates to coat
Boring
sharp cutting edges.
G T otal thickness of the PVD layers is often

between .0001 .0002 inch (3 6 m).
T he coating is applied at approx. 932 F
Tool holding
(500 C).
H
Other information
Machinability
H 40
A
The tough environment in metal cutting
Turning
Different wear mechanisms on the inserts B
Type of load Symbol Wear picture Cause
Parting and
grooving
Mechanical stress on
Mechanical the insert edge C
causes breakage.
Threading
Temperature variations
cause cracks and
Thermal heat generates plastic D
deformation (PD) on
the insert edge.
Milling
A chemical reaction
between carbide and E
Chemical working material
causes wear.
Drilling
In cast iron the SiC F
Abrasive inclusions can wear on
the insert edge.
Boring
BUE
BUE
With sticky material, G
Adhesive built-up layers/edges
are formed.
Tool holding
BUE = Built-Up Edge

H
PD = Plastic Deformation
Other information
Machinability
H 41
Wear pictures, cause and remedy

Turning
Some of the most common wear patterns
B Flank wear (abrasive) Cause Remedy

Cutting speed too high, in- Reduce cutting speed, se-
sufficient wear resistance. lect a more wear resistant
Parting and
grade.
grooving
C
Threading
Crater wear (chemical)

Cutting temperature too Reduce cutting speed, se-
D high. lect a more wear resistant
grade (Al2O3 coated grade).
Milling
Built-up edge (abrasive)

Drilling
Cutting speed too low Increase cutting speed,

Unsuitable grade. choose a tougher grade,
F preferably PVD coated.
Boring
G
Notch wear (abrasive)
Tool holding
Cutting speed too high or Select a more wear resist-

insufficient wear resistant grade or reduce cutting
ance. speed.
H
Other information
Machinability
H 42
A
Turning
Plastic deformation
(thermal) Cause Remedy B
Cutting temperature too Select a harder grade,
high, combined with a high reduce speed and feed.
Parting and
pressure.
grooving
C
Threading
Chipping (mechanic)
The chips are deflected Change the feed, select an
against the cutting edge. alternative insert geometry.
D
Milling
E
Thermal cracks
Temperature variations Select a tougher grade
caused by: with better resistance to
Drilling
thermal shock.
- intermittent machining
- varying coolant supply Coolant should be applied
copiously, or not at all. F
Boring
Edge chipping/breakage
(mechanic)
G
Overload of mechanical Check the following:
tensile stresses. - chip hammering
Tool holding
- cutting data
- sand inclusions in work-
piece
- built-up edge
- vibration H
Other information
- excessive wear on insert.

Machinability
H 43
A
Turning Manufacture of cemented carbide
B
Manufacture of
cemented carbide
Parting and
grooving
The manufacture of cemented carbide

C inserts is a carefully designed process,
where geometry and grade are balanced to
give a product perfectly matched to the
Threading
application.
D
Milling
E
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
H 44
Manufacture of cemented carbide
The development of cutting tool material
Turning
With the development of better carbide substrates, coat-
ings and geometries, productivity and cost savings have B
improved for the end user.
Large improvements in productivity were possible in the
Parting and
60s and 70s when the first coatings were developed.
grooving
After this, the developments continued - with advanced
substrate design, new geometries, edge designs, new ad-
vanced coating techniques and post treatment of coated C
edges.
Threading
D
The effect on end-user productivity
2006
A new insert
Milling
generation
1999
New generation E
coatings
1989
Functional
Drilling
gradients
1980
Thick aluminum
oxide coating F
1969
First coated
1957 insert
Indexable
inserts
Boring
G
Tool holding
H
Other information
Machinability
H 45
A Manufacture of cemented carbide
Powder production
Turning
There are two main elements of a cemented carbide

B insert:
- WC = Tungsten Carbide
- Co = Cobalt
Parting and
grooving
Other commonly used elements are Titanium, Tantalum

and Niobium Carbides. Designing different types of
powder and different percentages of the elements is what
C makes up the different grades.
The powder is milled and sprayed-dried, sifted and poured
into containers.
Threading
Raw material Milling

Milling
Niobium
E
(Ta, Nb)C Tantalum
(5%)
(Ti, W)C
Drilling
Co (8%) Titanium
(7%)
WC Tungsten
F Cobalt (80%) carbide
Cemented carbide powder

Spray drying
Boring
Ready to press
G
Tool holding
H
Other information
Machinability
H 46
A
Tungsten powder
Turning
The size of the tungsten carbide grains
The main raw material for the manufac-
ture of cemented carbide is tungsten-ore B
concentrate. Tungsten powder is produced
from tungstic oxide derived chemically from
Parting and
the raw material. By varying the conditions
grooving
of reduction, tungsten powder of various
grain size can be manufactured. The car-
bide granules after spray-drying are small C
and vary in size depending on grade.
.0039 inch
(0.10 mm)
Threading
D
Basic properties of cemented carbide

Apart from the grain size for the WC, the also to a lower hardness which reduces
Milling
amount of binder phase is an important the wear resistance of the substrate.
factor determining the characteristics
of the carbide. Increasing Co-content,
E
together with increasing WC-grain size,
contributes to increasing toughness but
Drilling
Amount of binder Toughness
Boring
G
Tool holding
H
Other information
Machinability
Wear resistant WC grain size
H 47
Pressing powder compacts

Turning
Top and bottom

B punches
Press force
20 - 50 tons
Parting and
grooving
C
Threading
D
Die and
core pin
Milling
Inspection
E
The pressing operation consists of several pieces
of tooling:
- T op and bottom punches
Drilling
- Core pin
- Cavity.
F
The pressing procedure:
-P owder is poured into the cavity
Boring
- Top and bottom punches come together (20-50 tons)

- The insert is picked and placed via robot onto a
G graphite tray.
- Random SPC is performed, to check for weight.
Tool holding
The insert is 50% porous at this stage.
H
Other information
Machinability
H 48
A
Sintering the pressed inserts
Turning
Sintering phase consists of the following phases:
- L oading trays of inserts into a sintering - T he insert will shrink 18% in all directions
furnace. during the sintering phase; this
B
- The temperature is raised to ~2550 F corresponds to about 50% in volume.
(~1400 C).
Parting and
grooving
- This process melts the cobalt and the
cobalt acts as a binder.
Sintering
Threading
Insert trays D
Milling
E
Shrinking
Inspection rate
Drilling
F
Boring
2 3 G
Tool holding
1. Unsintered insert
2. Sintered insert
3. Coated insert
H
1
Other information
Machinability
H 49
Different types of grinding operations

Turning
B Top and bottom Free profiling Profiling

Parting and
grooving
C
g 00
Bor
Threading
Chamfer negative land Periphery
D Neg. land
7 8 9
4 5 6
1 2 3
S3 S4 S5 S6 S7 S8
SI S2
Milling
Chamfer Borg 00
E
Drilling

F
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

G the application.
Tool holding
Generally the ER corresponds to the thickness of

a hair, diameter: ~.0031 inch (~80 m).
H
Other information
Machinability
H 50
A
CVD Chemical Vapor Deposition
Turning
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
B
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
C
Threading
D
Milling
E
Drilling
F
The advantages of CVD coatings

The ability to making thick coatings.
Boring
Ability to make even coating thickness.

V
ery good adherence to the carbide G
substrate.
Tool holding
Very good wear resistance.

Possibility to make oxide coatings.
H
Other information
Machinability
H 51
PVD Physical Vapor Deposition

Turning
The inserts are loaded into the coating By using a gas as carrier, the ions can
chamber on trays. Metal source targets are then be transported from the targets to
B placed on the reactor chamber walls. The the inserts. As the inserts are cooler, the
most common source is titanium (Ti). The ions will condensate on the insert surface
targets are heated to a temperature where to form a coating.
Parting and
the solid metal ionizes.

grooving
C
Threading
D
Milling
E
Drilling
F
Boring
G The coating thickness is in the range of PVD provides good edge line toughness.
.00008-.0002 inch (2-6 microns) depend-
P
VD coatings can maintain a sharp
ing on application area for the insert.
cutting edge.
Tool holding
The most common PVD layers today are

PVD can be used on brazed tips.
TiN, Ti(C,N), (Ti,Al)N, (Ti,Al,Cr)N and now
also aluminum oxides. PVD can be used on solid carbide tools.
H
Other information
Machinability
H 52
A
PVD vs. CVD coating process
Turning
PVD (Physical Vapor Deposition) CVD (Chemical Vapor Deposition)
In a PVD coating process, the coating is In a CVD coating process, the coating is
formed by metal vapor condensating on in- formed by a chemical reaction of different B
sert surfaces. PVD works the same way as gases. Temperature, time, gas flow, gas
when humid air condensates on cold roads atmosphere, etc., are carefully monitored
Parting and
and forms an ice layer on the road. to steer the deposition of the coating lay-
grooving
PVD is formed at a much lower tem- ers. Depending on the type of coating, the
perature than CVD. Normal PVD process temperature in the reactor is about 1470
temperatures are around 930 F (500 C). to 2000 degrees F (800 to 1100 degrees C
The coating thickness is in the range of C). The thicker the coating the longer the
.00008-.0002 inch (2-6 microns) depend- process time. The thinnest CVD coating
ing on application area for the insert. today is below .00016 inch (4 microns)
Threading
and the thickest is above .0008 inch (20
microns).
Milling
~930F ~1830F
~1/100000 atm ~1/20 atm E
Drilling
F
Boring
G
Tool holding
Thinner coating Thicker coating

Sharper edges More wear resistant
H
Tougher Thermal resistant
Other information
Machinability
H 53
Vision control, marking and packaging

Turning
After inspection of dimensions, coating and grade, the

B insert is marked with a grade designation and placed in a
10-piece box, labeled and packed and ready for distribu-
tion to the customer or into stock in the warehouse.
Parting and
grooving
C Visual inspection
Marking Packaging
Threading
D
Milling
E
Labelling
Distribution
Drilling
Gimo
F
Boring
G
Tool holding
H
Other information
Machinability
H 54
Machining economy
How to improve machining economy
H 55
Machining economy
F
C
E
A
H
Machinability Tool holding Boring Drilling Milling
D
Threading Parting and

B
Turning
G
Other information grooving
A Machining economy
Doing more machining in the same production time

Turning
B
Productivity definition
Parting and
grooving
The value of output

produced divided by the
value of input or resources.
C
= Output / Input
Threading
D
Milling
Attack the productivity gap

E 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 pro-
Drilling
ductivity. Bridging this gap is the only way to stay competi-

tive and ultimately to stay in business.
F
135
Boring
130
125 Cost development
G 120
115
110
Tool holding
105 Productivity gap

100
Price development
95
H
Other information
Machinability
Source: Mechanical Industry in OECD.
H 56
Machining economy
A
Maximizing productivity
Turning
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 B
rate. Cutting speed has the largest effect by far on insert
tool life.
Parting and
grooving
Depth of cut, inch (mm)
C
Threading
Feed, inch/rev (mm/rev) D
Milling
E
Cutting speed, ft/min (m/min)
Optimizing the feed rate is

the best way to maximize
Drilling
the productivity
Productivity Q is measured as the amount of material

removed in a fixed time period, inch3/min (cm3/min).
Boring
vf
G
Tool holding
H
Other information
Q = vc ap fn 12 Q = ap ae vf
Machinability
H 57
A Machining economy
Maximizing productivity examples

Turning
Metal removal rates for a fixed depth of cut of .118 inch (3.0 mm) using:
B Low alloy steel, Insert: CNMG 432-PM 4225 (CNMG 120408-PM 4225)
P MC P2
.118 .118 .118
Hardness, HB 180 a , inch (mm)
Parting and
p (3.0) (3.0) 3.0

grooving
.006 .012 .020

f , inch/r (mm/r)
n (0.15) (0.3) (0.5)
C
1394 1132 902
v , ft/min (m/min)
c (425) (345) (275)
Threading
Q, inch3/min 12 19 25*
(191)
(cm 3/min) (310) (412)*
D
* Slowest cutting speed with the highest feed
= highest productivity
Milling
Using a trigon W-style insert, versus a C-style double-sided

E or single-sided insert
Low alloy steel, Trigon shape

P MC P2 Insert: double-sided for medium machining.
Hardness, HB 180 .118 / .157 inch
Drilling
No of passes / cutting (3 / 4 mm)

depth, ap .039 / .118 inch
F (1 / 3 mm)
Machining time, Tc 22 seconds
.591 Rhombic shape

Boring
Insert: double sided for medium machining.

No of passes / cutting .118 / .197 inch
G depth, ap (3 / 5 mm)
Tool holding
1.969
Insert: Single sided for rough machining.
No of passes / cutting .079 / .295 inch
depth, ap (2 / 7.5 mm)
H
Other information

Machinability
H 58
Machining economy
A
Machine tool utilization
Turning
Incomplete use of B
additional shifts Machining 20%
Parting and
grooving
Production Tool change 10%
60%
Set & gauge 10% C
Breakdowns 10%
Threading
Holidays, etc.
Workpiece
change 10%
D
Machining economy
Milling
E
Drilling
F
Boring
G
Variable costs Fixed costs
Costs incurred only during production: Costs which exist even when not in
Tool holding
- cutting tools, consumables (3%) production:

- workpiece materials 17%. - machine and tool holders (27%)
- labor (31%)
- buildings, administration, etc. (22%).
H
Other information
Machinability
H 59
A Machining economy

Turning
Cost, tool life or productivity
The cost of the tooling, an easily measured value, is

B
always under price or discount pressure, but even when
the price is reduced by 30% it only influences the compo-
nent cost by 1%.
Parting and
grooving
We have a similar result of a 1% cost saving when tool

life is increased by 50%.
C Increasing the cutting data by only 20% will dramatically
reduce component costs and lead to a 10% component
saving.
Threading
D
Decreased cost:
A 30% decrease in price
Milling
only reduces total cost per

component by 1%.
E
Drilling
Increased tool life:

A 50% increase in tool life only reduces
F total cost per component by 1%.
Boring
Increased cutting data:

G
A 20% increase in cutting
data reduces total cost
Tool holding
per component by more

than 10%.
H
Other information
Machinability
H 60
Machining economy
A
Turning
Example:
Shop spends $10,000 B
to make 1000 parts.
Machine cost is $10.00
Parting and
per part.
grooving
C
30% 50% 20%
Threading
Increase
Variable Today Lower price Tool life cutting data
Tooling $ .30 $ .21 $ .20 $ .45 D
Material $ 1.70 $ 1.70 $ 1.70 $ 1.70
Milling
Fixed
Machinery $ 2.70 $ 2.70 $ 2.70 $ 2.16 E
Labor $ 3.10 $ 3.10 $ 3.10 $ 2.48
Building $ 2.20 $ 2.20 $ 2.20 $ 1.76
Drilling
Cost per part $ 10.00 $ 9.91 $ 9.90 $ 8.55
Savings 1% 1% 15% Boring
G
Tool holding
H
Other information
Machinability
H 61
A Machining economy
Machining ecomomy
Turning
Cutting data and cost

Cutting speed has no effect on fixed costs.
B 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
Parting and
part increases.
grooving
If we add all costs together we will get the curve of total Production cost.
C 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.
Threading
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
D cutting speed.
The speed between these two points is the High Efficiency Range, which is where we
should be trying to operate.
Milling
Parts per hour

Cost per part
Drilling
Production rate
Production cost
F
Tool cost
Boring
G
Tool holding
Fixed cost
Machine cost
H
Cutting speed
Other information
Economic High Efficiency Speed for maximum

speed Range production
Machinability
H 62
Machining economy
A
Base for cutting data recommendations
Turning
Compensation of cutting data for difference in tool life
Tool life Higher metal removal
B
-A
ll cutting data is based If you want to change the cutting speed to obtain higher metal
removal rates the new cutting speed values can be calculated
on 15 min tool life. from the following table.
Parting and
-1
5 min tool life
grooving
= Factor 1.0
-U
se correction factor for Tool life (min) 10 15 20 25 30 45 60
other values according to Correction
C
factor 1.11 1.0 0.93 0.88 0.84 0.75 0.70
the table.
Example:
Threading
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).
D
Milling
Compensation of cutting speed for difference in hardness, HB E
Hardness Reduced hardness Increased hardness

-A
ll cutting data is based ISO/
Drilling
ANSI MC1) HB2) -60 -40 -20 0 +20 +40 +60 +80 +100
on the reference materi-
als and the respective P P2 HB2) 180 1.44 1.25 1.11 1.0 0.91 0.84 0.77 0.72 0.67
hardness. M M1 HB2) 180 1.42 1.24 1.11 1.0 0.91 0.84 0.78 0.73 0.68
F
K2 HB2) 220 1.21 1.13 1.06 1.0 0.95 0.90 0.86 0.82 0.79
-E
.g ISO P HB 180 = K
K3 HB2) 250 1.33 1.21 1.09 1.0 0.91 0.84 0.75 0.70 0.65
Factor 1.0.
N N1 HB2) 75 1.05 1.0 0.95
-U
se correction factors for S2 HB2) 350 1.12 1.0 0.89
Boring
S
other values according to H H1 HRC3) 60 1.07 1.0 0.97
the table. 1) MC = material classification code
2) HB = Hardness Brinell G
3) HRC = Hardness Rockwell
Tool holding
H
Other information
Machinability
H 63
A Machining economy
Use the table or diagram to compensate the

cutting speed for different hardnesses
Turning
B Diagram form for P, M and K

Parting and
ISO Steel, HB180 ISO Gray cast iron, HB220

P K
grooving
MC P2 MC K2
ISO Stainless steel, HB180 ISO Nodular cast iron, HB250
C M MC M1 K MC K3
Threading
D
Factor for cutting speed
Milling
E
Drilling
F Specific cutting force / hardness

Boring
G
Tool holding
H
Other information
Machinability
H 64
Machining economy
A
Example of calculating hardness factor and cutting speed

compensation
Turning
ISO
Steel Reduced hardness Increased hardness
B
P MC P2 ISO/
ANSI MC1) HB2) -60 -40 -20 0 +20 +40 +60 +80 +100
-R
eference hardness P P2 HB2) 180 1.44 1.25 1.11 1.0 0.91 0.84 0.77 0.72 0.67
Parting and
HB= 180
grooving
M M1 HB2) 180 1.42 1.24 1.11 1.0 0.91 0.84 0.78 0.73 0.68
-1
5 min tool life K
K2 HB2) 220 1.21 1.13 1.06 1.0 0.95 0.90 0.86 0.82 0.79
= Factor 1.0 K3 HB2) 250 1.33 1.21 1.09 1.0 0.91 0.84 0.75 0.70 0.65
N N1 HB2) 75 1.05 1.0 0.95 C
-U
se correction factor for
S S2 HB2) 350 1.12 1.0 0.89
other values according to
the table. H H1 HRC3) 60 1.07 1.0 0.97
Threading
1) MC = material classification code
2) HB = Hardness Brinell
3) HRC = Hardness Rockwell
D
Tensile strength Vickers Brinell Rockwell
Customer workpiece lbs/inch2) N/mm2) HV HB HRC HRB
material 36,975 255 80 76.0
39,150 270 85 80.7 41.0
Milling
- DIN 42CrNiMo4 41,325 285 90 85.5 48.0
44,225 305 95 90.2 52.0
- T ensile strength
46,400 320 100 95.0 56.2
130,500 lbs/inch2 (900 N/mm2) E
50,750 350 110 105 62.3
55,825 385 120 114 66.7
-1
30,500 lbs/inch2 (900 N/mm2) 60,175 415 130 124 71.2
= HB 266 value according to the 65,250 450 140 133 75.0
table. 69,600 480 150 143 78.7
Drilling
73,950 510 160 152 81.7
79,025 545 170 162 85.0
83,375 575 180 171 87.5
88,450 610 190 181 89.5
F
92,800 640 200 190 91.5
Calculating hardness factor 95,700 660 205 195 92.5
97,875 675 210 199 93.5
- HB 266-180 = +86 100,050 690 215 204 94.0
Boring
102,225 705 220 209 95.0

- Cutting speed factor vc = 0.70. 104,400 720 225 214 96.0
107,300 740 230 219 96.7
-R
educe the cutting speed 111,650 770 240 228 20.3 98.1
G
to 70%. 116,000 800 250 238 22.2 99.5
118,900 820 255 242 23.1
Tool holding
121,075 835 260 247 24.0 (101)

123,250 850 265 252 24.8
125,425 865 270 257 25.6 (102)
130,500 900 280 266 27.1
134,850 930 290 276 28.5 (105)
137,750 950 295 280 29.2 H
Other information
139,925 965 300 285 29.8

144,275 995 310 295 31.0
Machinability
H 65
A Machining economy
Cutting speed and feed data compensation for turning

Turning
How to calculate cutting data compensation

B - The cutting data is based on 15 min tool life.
Parting and
Increased feed fn, inch/r (mm/r)

grooving
Decreased cutting speed, %
Example 1 Starting value

C
Increased cutting speed, %

Threading
D
Example 2
Decreased feed fn, inch/r (mm/r)

Milling
E
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)
Drilling
= +.006 inch/r (+0.15 mm/r)

-D
ecrease the cutting speed by 12% from the given cutting
F speed value.
Example 2
- Increase the cutting speed by +15% e.g from
Boring
1132 ft/min to 1312 ft/min (345 m/min to 400 m/min)

- Decrease the feed by .007 inch/r (0.18 mm/r) from the
G
given feed value.
Tool holding
H
Other information
Machinability
H 66
Machining economy
A
How can you improve your productivity?
Turning
Things to consider
B
Identify the material and hardness HB or
tensile strength lbs/inch2 (N/mm2).
Parting and
Choose the correct geometry.
grooving
Choose the correct grade.
U
se the given cutting data values or C
compensate the cutting data values
according to your needs.
Threading
C
orrectly applied, our tools can increase
productivity by at least 20%.
Milling
Machining tips for improved tool life
E
S
peeds and feeds within insert
parameters.
M
ake use of all available corners on
Drilling
inserts.
P
roper insert radius in relationship
to D.O.C. F
C
hoose the right combination of insert
radius and geometry.
Boring
U
se climb milling over conventional mill-
ing wherever possible.
W
orn inserts can be used for G
chamfering.
Tool holding
H
Good stability = Successful metal cutting
Other information
Machinability
H 67
F
C
E
A
H
Machinability Tool holding Boring Drilling Milling
D
Threading Parting and
B
Turning
G
Other information grooving
H 68
Maintenance & tool wear
wear
Tool wear
Maintenance
Maintenance & tool
H 71
H 69
A
Consequences of excessive tool wear
Turning
B
Parting and
grooving
C
Threading
D
Milling
E
Drilling
Damaged inserts
Damaged shims
F
Damaged tool holders
Damaged components
Damaged machine
Boring
Result:
Tool holding
Reduced production
Higher production costs
H
Other information
Machinability
H 69
A Maintenance & tool wear
Inspection of tool wear

Turning
Visually inspect shims & shim seats
B D
amaged shims. Shims should not have
chipped corners in the cutting area.
S
hims should have no visible wear from
Parting and
Damage chip breaking and/or impressions from

grooving
the insert.
Chip breakage
C impression
Inspect pockets
Threading
P
ockets damaged or mushrooming in the
corners.
O
versized pockets due to wear. The
insert does not sit properly in the pocket
sides. Use a .0008 inch (0.02 mm)
Milling
shim to check the gap.

E S
mall gaps in the corners, between the
shim and the bottom of the pocket.
Drilling
The importance of using the correct wrench

F
Why use the proper wrenches?
Extends life of screw and wrench.
Reduces risk of stripping screw.
Boring
G
What is the proper way to tighten an insert
Tool holding
screw?
Important to use the proper wrench.
A
lways use correct torque. Values are
H marked on tool and shown in product
catalog.
Other information
Common sense!
Machinability
H 70
A
Torx Plus wrenches
Turning
Torx Plus from Sandvik Coromant
lbs-in (Nm) B
Parting and
grooving
C
Torx Plus vs. Torx
Threading
Cross section
Torx Plus Torx

Torx Plus D
Milling
E
Torx Plus is a registered trademark of

Standard Torx
Camcar-Textron (USA)
screw
Drilling
F
Torx Plus wrenches with adjustable torque

Boring
On
parting and grooving tools an adjust-
able torque wrench is required, as the G
torque is not related to screw size.
Tool holding
It should of course be used on all prod-

ucts with a clamp screw.
H
Other information
Machinability
H 71
Insert screws / clamping screws

Turning
Screw
threads, heads and Torx sockets
should be in good condition.
B
Use correct keys.
Ensure correct screw-tightening torque
Parting and
grooving
A
pply sufficient screw lubrication to
prevent seizure. Lubricant should be
applied to the screw thread as well as
C the screw-head face.
Replace worn or exhausted screws.
Threading
Important!
Use Molykote for screw heads
Milling
and threads
Tool maintenance
Drilling
Shim and insert seat
F Check shim damage.

C
lean insert seat and damaged location
and support for cutting edge.
If necessary index or replace shim.
Boring
E
nsure correct insert location against
support points.
G
It is important to ensure that shim cor-
ners have not been knocked off during
Tool holding
machining or handling.
H
Other information
Machinability
H 72
A
Tool maintenance
Turning
Contact faces
Always
check supporting and contact
faces of tool holders, milling cutters and B
drills, making sure there is no damage
or dirt.
Parting and
In boring operations it is especially
grooving
important to have the best possible
clamping. If the bar is not supported to
the end of the holder, overhang will be C
increased and create vibration.
Threading
D
Production security
It
is important to select the correct
insert size, insert shape and geometry
Milling
and insert nose radius to achieve good
chip flow.
l -S
elect largest possible point angle on E
the insert for strength and economy.
re -S
elect largest possible nose radius for
insert strength.
Drilling
l = cutting edge length (insert size) -S
elect a smaller nose radius if there is
re = nose radius a tendency for vibration. F
Stability
Boring
Stability is the key factor for successful

metal cutting, affecting machining costs G
and productivity.
M
ake sure that any unnecessary play,
Tool holding
overhang, weakness, etc., has been

eliminated and that correct types and
sizes of tools are employed for the job.
H
Other information
Machinability
H 73
Insert handling
Turning
Inserts
should never be removed from
the original package until they are ready
B to be installed.
Parting and
grooving
C
Threading
D
Summary of maintenance points
Check tool wear and shims for damage.
Milling
Make sure insert seat is clean.
E Make sure of correct insert location.
Make sure correct keys and drivers are used.

Drilling
Insert screws should be correctly

tightened.
F Lubricate screws before tool assembly.
Make sure contact faces are clean and undamaged on

tools, holding tools and machine spindles.
Boring
Make sure boring bars are clamped well and that

G holder is undamaged at the end.
A well organized, maintained and documented tool

Tool holding
inventory is a production cost saver.
Stability is always a critical factor in any metal cutting

H operation.
Other information
Machinability
H 74
Formulas and definitions
A
Turning
B
Formulas & defini-
tions, calculator
Parting and
grooving
Turning H 76
C
Milling H 78
Threading
Drilling H 80
Boring H 82 D
Milling
E
Calculator
Drilling
Cutting data calculator H 84
F
Boring
G
Tool holding
H
Other information
Machinability
H 75
A Formulas and definitions
Formulas and definitions for turning - INCH

Turning
Cutting speed, ft/min

B
Dm n
vc =
12
Parting and
grooving
C
Spindle speed, rpm
vc 12
Threading
n=
Dm
D
Designation/
Machining time, min

definition
Symbol
Unit
Milling
lm
Tc =
fn n
E Dm Machined diameter inch
fn Feed per revolution inch/r
ap Cutting depth inch
vc Cutting speed ft/min
Drilling
Metal removal rate, inch3/min

n Spindle speed rpm
F Q = vc ap fn 12 Pc Net power HP
Q Metal removal rate inch3/min
hm Average chip thickness inch
hex Maximum chip thickness inch
Boring
Tc Period of engagement min

Net power, HP
G lm Machined length mm
v ap fn kc Specific cutting force lbs/inch2
Pc = c kc
33 103 r
Tool holding
Lead angle degree
H
Other information
Machinability
H 76
A
Formulas and definitions for turning - METRIC
Turning
Cutting speed, m/min
B
Dm n
vc =
1000
Parting and
grooving
C
Spindle speed, rpm
vc 1000
Threading
n=
Dm
Designation/ D
Machining time, min

definition
Symbol
Unit
Milling
lm
Tc =
fn n
Dm Machined diameter mm E
fn Feed per revolution mm/r
ap Cutting depth mm
vc Cutting speed m/min
Drilling
Metal removal rate, cm3/min
n Spindle speed rpm
Q = vc ap fn Pc Net power kW F
Q Metal removal rate cm3/min
hm Average chip thickness mm
hex Maximum chip thickness mm
Boring
Tc Period of engagement min

Net power, kW
lm Machined length mm G
v ap fn kc Specific cutting force N/mm2
Pc = c kc
60 103 kr
Tool holding
Entering angle degree
H
Other information
Machinability
H 77
Formulas and definitions for milling - INCH

Turning
Table feed, inch/min

B
vf = fz n zc
Parting and
grooving
Cutting speed, ft/min
C Dcap n
vc =
12
Threading
Spindle speed, rpm
Designation/
vc 12
n=
definition
D Dcap
Symbol
Unit
Feed per tooth, inch
ae Working engagement inch
Milling
vf
fz = ap Cutting depth inch
n zc
Dcap C
utting diameter at cutting
E depth ap inch
Feed per revolution, inch/rev Dm Machined diameter
(component diameter) inch
vf
fz =
Drilling
fz Feed per tooth inch

n
fn Feed per revolution inch
F n Spindle speed rpm
Metal removal rate, inch3/min vc Cutting speed ft/min
vf Table feed inch/min
Q = ap ae vf
zc Number of effective teeth pcs
Boring
hex Maximum chip thickness inch

G Net power, HP hm Average chip thickness inch
ae ap vf kc kc Specific cutting force lbs/inch2

Pc =
Tool holding
Pc Net power HP
396 103
Mc Torque lbf ft
Torque, lbf ft Q Metal removal rate inch3/min
H Pc 16501 r Lead angle degree
Mc =
Other information
n
Machinability
H 78
A
Formulas and definitions for milling - METRIC
Turning
Table feed, mm/min
B
vf = fz n zc
Parting and
grooving
Cutting speed, m/min
Dcap n C
vc =
1000
Threading
Spindle speed, r/min
Designation/
vc 1000
n=
definition
Dcap D
Symbol
Unit
Feed per tooth, mm
ae Working engagement mm
Milling
vf
fz = ap Cutting depth mm
n zc
Dcap C
utting diameter at cutting
depth ap mm
E
Feed per revolution, mm/rev Dm Machined diameter
(component diameter) mm
vf
fz =
Drilling
fz Feed per tooth mm
n
n Spindle speed rpm F
Metal removal rate, cm3/min vc Cutting speed m/min
ap ae vf vf Table feed mm/min
Q=
1000 zc Number of effective teeth pcs
Boring
hex Maximum chip thickness mm

Net power, kW hm Average chip thickness mm G
ae ap vf kc kc Specific cutting force N/mm2
Pc =
Tool holding
Pc Net power kW
60 106
Mc Torque Nm
Torque, Nm Q Metal removal rate cm3/min
Pc 30 103 kr Entering angle degree H

Mc =
Other information
n
Machinability
H 79
Formulas and definitions for drilling - INCH

Turning
B Penetration rate, inch/min
vf = fn n
Parting and
grooving
C Cutting speed, ft/min

Dc n
vc =
12
Threading
Designation/
D Spindle speed, rpm
definition
Symbol
vc 12
Unit
n=
Dc
Milling
Dc Drill diameter inch

fn Feed per revolution inch/r
Feed force, N
E n Spindle speed rpm
D
Ff 0.5kc c fn sin kr vc Cutting speed ft/min
2
vf Penetration rate inch/min
Drilling
Ff Feed force N
Metal removal rate, inch3/min kc Specific cutting force lbs/inch2

F Mc Torque lbf ft
Q = vc Dc fn 3 Pc Net power HP
r
Boring
Lead angle degree

Net power, HP
G
vc Dc fn kc
Pc =
132 103
Tool holding
Torque, lbf ft
H
Pc 16501
Mc =
Other information
n
Machinability
H 80
A
Formulas and definitions for drilling - METRIC
Turning
Penetration rate, mm/min B
vf = fn n
Parting and
grooving
Cutting speed, m/min C
Dc n
vc =
1000
Threading
Designation/
Spindle speed, r/min D
definition
Symbol
vc 1000
Unit
n=
Dc
Milling
Dc Drill diameter mm
Feed force, N
n Spindle speed rpm E
D
Ff 0.5kc c fn sin kr vc Cutting speed m/min
2
vf Penetration rate mm/min
Drilling
Ff Feed force N
Metal removal rate, cm3/min kc Specific cutting force N/mm2

Mc Torque Nm F
v Dc fn
Q= c Pc Net power kW
4
kr
Boring

Net power, kW
G
v Dc fn kc
Pc = c
240 103
Tool holding
Torque, Nm
H
Pc 30 103
Mc =
Other information
n
Machinability
H 81
Formulas and definitions for boring - INCH

Turning
B Penetration rate, inch/min
vf = fn n
Parting and
grooving
C Cutting speed, ft/min

Dc n
vc =
12
Threading
Designation/
Spindle speed, rpm
D
definition
vc 12
Symbol
n=
Unit
Dc
Milling
Dc Drill diameter inch
Feed per revolution, inch/rev fn Feed per revolution inch/r

E n Spindle speed rpm
fn = zc fz vc Cutting speed ft/min

vf Table speed inch/min
Drilling
Ff Feed force N
Metal removal rate, inch3/min kc Specific cutting force lbs/inch2

F Mc Torque lbf ft
Q = vc Dc fn 3 Pc Net power HP
r
Boring
Lead angle degree

Net power, HP zc Number of effective teeth pcs
( (
G (zc = 1 for step boring)
vc ap fn kc ap
Pc = 1
132 103 Dc
Tool holding
Torque, lbf ft Feed force, N

H Pc 16501
Mc = Ff 0.5 kc ap fn sin r
Other information
n
Machinability
H 82
A
Formulas and definitions for boring - METRIC
Turning
Penetration rate, mm/min B
vf = fn n
Parting and
grooving
Cutting speed, m/min C
Dc n
vc =
1000
Threading
Designation/
Spindle speed, r/min
D
vc 1000 definition
Symbol
n=
Unit
Dc
Milling
Dc Drill diameter mm
Feed per revolution, mm/r fn Feed per revolution mm/r

n Spindle speed rpm E
fn = zc fz vc Cutting speed m/min
vf Table speed mm/min
Drilling
Ff Feed force N
Metal removal rate, cm3/min kc Specific cutting force N/mm2

Mc Torque Nm F
vc Dc fn
Q= Pc Net power kW
4
kr
Boring

Net power, kW zc Number of effective teeth pcs
( (
(zc = 1 for step boring) G
vc ap fn kc ap
Pc = 1
60 103 Dc
Tool holding
Torque, Nm Feed force, N

Pc 30 103 H
Mc = Ff 0.5 kc ap fn sin r
Other information
n
Machinability
H 83
A Calculator
Cutting data calculator

Turning
Self-explanatory and very easy to use
B
The Sandvik Coromant cutting data calcu- The Sandvik Coromant cutting data calcu-
lator is designed to solve most calculation lator also functions as a standard
problems encountered in the metal cutting mathematical calculator. Calculations can
Parting and
area. be done in metric or inch.

grooving
The calculator is self-explanatory and very

easy to use. Users include programmers,
C
operators, machinists, supervisors, fore-
men, designers and more.
As a user, you simply decide what param-
Threading
eter you want to calculate, choose the

appropriate formula from the menu in the
display and enter the input as prompted
D by the calculator. This means that the user
does not need to memorize any metal cut-
ting formulas.
Calculator metric/inch
Milling
Size 80x125x15 mm
E
Drilling
F
Machining Calculator App
The Machining Calculator app from Sandvik

Coromant is designed to help engineers and
Boring
machinists optimize the performance of their

turning, milling and drilling applications by
G calculating optimal cut settings based on job
parameters.
Tool holding
The app is free and can be downloaded at the

Sandvik Coromant website.
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Sandvik Coromant Academy

Metal Cutting Technology

Turning generates cylindrical and rounded forms with a

Choice of inserts how to apply A 22

General turning operations

Turning is the combination of two movements rotation of

the workpiece, which means the diameter of the part will

be turned down to a smaller size. Alternatively, the tool

Turning and facing as axial and radial tool movements.

Three common turning operations:

Definition of cutting speed

C vc = cutting speed, ft/min (m/min)

Circumference, C = x Dm inch (mm)

Calculation of the circumference

Example of cutting speed fluctuations

Diameter, Dm1 = 1.969 inch (50 mm)

F Diameter, Dm2 = 3.150 inch (80 mm)

3.14 1.969 2000 3.14 50 2000

12 ft/min 1000 m/min

Lead (entering) angle

ting edge and the workpiece plane. It can

correct turning tool for an operation.

Calculating cutting data

1312 12 400 1000

Inclination and rake angles

strength, power consumption, finishing abil-

The inclination angle lamda () is the an-

holder will determine the resulting cutting

Cutting depth and chip formation

Feed rate and the effective cutting edge length

Feed rate Cutting edge length

The feed rate (fn) is the

Insert shape selection, lead (entering) angle and chip

(smaller entering angle).

The direction of chip flow is also changed.

Lead angle r: Lead angle r: Lead angle r:

-5, 15 -17.5, -3, 27.5 -5

SNMG RCMT TNMG

Lead angle r: Lead angle r: Lead angle r:

F Lead angle r: Entering angle r:

Lead angle r (Entering angle r)

G Is defined by the holder tip seat in

Maximum chip thickness hex

The effect of lead angle (entering angle) on chip thickness

B Production planning process

Dimension and type of

Choice of tool - Profiling

Cutting data, tool

5 Troubleshooting Remedies and solutions

1. Component and the workpiece material

- Use all possible support

Different ways to optimize turning

Small lead angle. when turning slender

For turning and facing. components.

Turning with wiper inserts

gain surface quality.

New ways in profile turning

gain surface quality.

Rigid insert location with

The tool path has a significant impact on

In practice, the tool holder, insert geometry,

External turning, negative inserts

Overview of tool holders

Choice of inserts how to apply A 22

G Is defined by the holder tip seat in

Choice of tool - Profiling

1. Component and the workpiece material

- Use all possible support

For turning and facing. components.

Rigid clamping system Lever clamping system

P ositive insert Positive insert N egative/positive P ositive insert G

Modular/shank T-rail interface tems Modular/shank

N egative/positive inserts N egative insert N egative insert

Dampened boring bars Rigid clamping system Lever clamping system

Dampened modular/ Modular/boring bars

P ositive insert Quick change tools P ositive insert

P ositive insert P ositive insert P ositive insert

Machine adapted bars

Very secure clamping

Insert shape, size, nose radius A 42

Cutting data effect on tool life A 48

Steel ISO P Steel is the largest material

ISO M Stainless steels are materials

ISO K Cast iron is, contrary to steel, a

Aluminum ISO N Non-ferrous metals are softer

Hardened ISO H This group covers steels with a G

H materials have a kc1 variation of: G

Zero clearance face of the insert

Low cutting forces

In milling and drilling a lot of parameters influence the

The insert rake angle, geometry and feed play an

L arge cutting depth and feed rate combi-

Medium operations to light roughing.