min

Some informations on machining of tool steel
Staffan Gunnarsson Uddeholm Tooling AB, R&D
Machinability laboratory
ASSIGNMENTS:
Investigate the machinability in our own and competitors
tool steels
When possible, improve the machinability in our tool steels
Tests of different cutting tools
Draw up cutting data recommendations
Support our customers
T urning
π ⋅D⋅n
( m / min )
1000
1000 ⋅ v c
( rev / min )
π ⋅D
Material removal rate , Q = v c ⋅ a p ⋅ f ( cm 3 / min )
Cutting speed , v c =
Spindle speed , n =
Surface roughness , Ra ≈
f 2 ⋅ 50
rε
( µ m)
Le ge nd
Nine team members
Turning
Turning
Cutting speed, vc (m/min)
Feed, f (mm/rev)
Depth of cut, ap (mm)
Suitable grades
Q = Ma terial rem o val rate (cm /m in)
D
f
R a = Surfa ce ro ughn es s (µm )
r e = No s e radius (m m )
Cemented carbide
n
Roughing
Finishing
110-160
160-210
0,2-0,4
0,05-0,2
2-4
0,5-2
K20, P20 coated HM
K15, P15 coated HM
1. Cutting fluid is recommended.
2. For turning with interrupted cut or face turning of large workpieces use a
thougher cemented carbide grade.
Slot milling
3-5
Uncoated HSS
Coated HSS
Drilling
6-8)
1-5
1-2)
Cutting s peed, vc (m /min)
Feed, f (mm/rev)
3-4)
carbide 5-7)
Brazed cem ented
5-7)
0,10-0,20
10-12
0,20-0,30
0,07-0,18
0,18-0,25
Correction
factor
for side
0,25-0,35
0,35-0,40
0,40-0,45
Feed, f (mm/rev)
Cutting s peed, vc (m /min)
0,30-0,35
0,015-0,03
0,015-0,03
Cutting speed, vc (m/min)
Feed, fz (mm/tooth)
Suitable grades
30 - 40
0,05-0,10
Cutter diameter (mm)
5 - 10
10 - 20
20 - 30
5-8
0,02-0,03
0,03-0,04
0,04-0,05
0,05-0,08
Face milling
14-18
0,03-0,04
0,04-0,05
0,05-0,06
14-18
Cutting0,04-0,05
speed, vc (m/min)
0,03-0,04
Feed, fz (mm/tooth)
40-50
Cemented carbide
0,06-0,09
Roughing
Finishing
110-130
130-160
0,2-0,4
0,1-0,2
Face milling
0,35-0,40
30 - 40
3. Milling should generally be done without coolant.
If a high surface finish is required coolant may be used.
milling
60-80
0,08-0,10 5 0,10-0,20
0,20-0,30
30-40
0,30-0,35
0,15-0,25
0,35-0,40
Feed, f (mm/rev)
0,25-0,35
10
20
( cm 3 / m in )
Feed, fz (mm/tooth)
Radial depth
of cut:
Suitable
grades
ae = 2 mm
Remarks:
Cutter diameter / Radial depth of cut, D/ae
50
n
DIEVAR
= Spindle s pee d (rev/m in)
3
Q = Ma terial rem o val rate (cm /m in)
vc = Cu tting s p eed (m /m in)
vf = Fe ed s pe ed (m m /m in)
z
= Nu m ber of te eth
π
Spindle speed , n =
D
= Drill diam eter (m m )
3. If the machine tool power is inadequate for the data given reduce the depth of cut,
40
ae
< 0 ,3
D
ae = 0.5 x D
1xD
Feedae =per
rev ,
90-120
80-110
0,15-0,2
0,1-0,15
K20, P20 coated HMLe ge nd
f = Fe ed per rev (m m /re v)
1. Climb
D/ae = 40/2
= 20 milling should generally be used.
= two
Spindle
s pee
d (rev/m in)
2. to
Choose
the cutter
diam
eter (D)
and the radial depth of cut (a e) so that at n
least
cutting
edges
Feed acc.
table slot
milling
= 0.18
mm/tooth
are engaged
Correction factor
acc. tosimultaneously.
chart: Cf = 2.8
30
valid for
⋅ D ⋅n
( m / min )
1000
1000 ⋅ v c
( rev / min )
π ⋅D
Feed speed , v f = f ⋅ n ( m m / m in )
vf
f =
( m m / rev )
n
Cutting speed , v c =
Square shoulder milling
ae = 0.1 x D
100-150
0,25-0,3
CUTTING DATA RECOMMENDATIONS
( m m)
M aterial removal rate , Q =
Drilling
Example:
Cutter diameter:
Cutting speed, vc (m/min)
D = 40 mm
ae
D
ap ⋅ ae ⋅ v f
1000
Average chip thickness, h m = fz ⋅
a e = Ra dia l depth of cut (m m )
Tool: Square shoulder milling with cemented carbide
CC insert
4
1. The cutting fluid should be ample and directed at the tool.
2. When drilling with short "NC drills" the feed may be increas ed by up to 20%.
3
For extra long drills the feed m ust be decreas ed.
3. TiCN-coating is recomm ended when drilling with coated HSS.
4. Use insert grades in the range of ISO P20-P30.
Under unstable conditions a tougher carbide grade should be used for the centre
position.
2
5. Use a high cutting fluid press ure and flow rate for a good chip rem oval.
6. If machining with solid or brazed cemented carbide drills, a rigid set-up and stable working conditions are required.
7. The use of drills with internal cooling channels is recom mended.
1
8. Use a cutting fluid concentration of 15-20 %.
0
π ⋅ D ⋅n
( m / min )
1000
1000 ⋅ v c
Spindle speed , n =
( rev / min )
π ⋅D
Table speed , v f = f z ⋅ n ⋅ z = f ⋅ n ( m m / m in )
Cutting speed , v c =
Le ge nd
120-150 with the radial depth of cut. See in the chart below
4. Cermets
be of use
when C
finishing
Divide the cutter diameter
whichcan
correction
factor,
f, this under stable conditions.
0,10-0,15
corresponds0,05-0,10
to, and multiply
the chosen feed in the table for slot milling with this factor.
Remarks:
vc = Cu tting s p eed (m /m in)
12-15
0,05-0,3
0,5-3
a p = Axia l d epth o f cu t (m m )
2-5
-2
Depth 0,006-0,01
of cut, ap (mm) 0,01-0,02
0,02-0,04
K20,
P20 coated HM
K15, P15 coated HM D = Cu tter diam e ter (m m )
HM
Suitable gradesK15, P20 coated
f = Fe ed per rev (m m /re v)
For side milling the same cutting speed as for slot milling can
Remarks:
fz = Fe ed per too th (m m /too th)
be used, but the feeds must be adjusted in order to obtain a
1. Use a milling cutter with a positive-negative or positive-positive geometry.
suitable average chip thickness.
h m = Averag e chip thickn es s (m m )
2. Climb milling should generally be used.
16-18
Cutting s peed, vc (m /min)
(cem. carbide ins erts ) Feed, f (mm/rev)
Solid cem ented
Cutting s peed, vc (m /min)
carbide
Indexable insert
(cemented carbide
Drill diameter
inserts)(mm)
Side
milling20 - 30
5 - 10
10 - 20
Cutting s peed, vc (m /min)
Feed, f (mm/rev)
Indexable insert
0,008-0,02
Correction factor, C f
Coated HSS
Cutting speed, vc (m/min)
Feed, fz (mm/tooth)
Cutting speed, vc (m/min)
Feed, fz (mm/tooth)
Cutting speed, vc (m/min)
Feed, fz (mm/tooth)
Solid cemented
5-8)
carbide
Drilling
Uncoated HSS 1-2)
1-4)
1-4)
= Wo rkp iece diam eter (m m )
= Fe ed HSS
per rev (m m /re v)
= Spindle s pee d (rev/m in)
Milling
Remarks:
End milling
3
a p = Axia l d epth o f cu t (m m )
vc = Cu tting s p eed (m /m in)
vf = Fe ed s pe ed (m m /m in)
Ô
Ô MAIN
MAIN MENU
MENU
butmilling:
do not reduce the feed.
Feed for side
fz = 2.8 x 0.18 =0.50 mm/tooth
Remarks: (slot and side milling)
Tapping with HSS
Cutting s peed, vc = 8-10 m/min
Remarks:
1. Threading compound or cutting oil gives a longer tool life than emulsion.
2. Fluteles s tap (non-cutting) is recomm ended.
1.
2.
3.
4.
5.
Climb milling is generally recommended.
Use a cutter with chipbreaker when side milling with radial depths of cut, ae > 0.3 xD.
When side milling with small radial depths of cut (ae) the cutting speed can be increased by up to 15%.
Use liberal amounts of cutting fluid.
It is recommended to use a TiCN coated cutter when milling with solid cemented carbide tools.
The axial depth of cut should not exceed the cutter diameter when slot milling.
6. Climb milling is generally recommended.
7. When side milling with small radial depths of cut (ae) the cutting speed can be increased by up to 30%.
8. The radial run-out, at the cutting edges, must be small and not exceed 0.03 mm.
Machining data are always dependent on the actual operation, the machine tool and
the cutting data used. The machining data given is this datasheet are general guidelines
that may have to be adjusted to the actual conditions of a specific machining operation.
Factors that chiefly influence the
machinability
Chemical composition
Structure
Steel-making process
Hardness
Non-metallic inclusions
Residual stresses
Machinability versus carbon content in a low
alloyed tool steel when turning with cemented
carbide
Cutting speed, m/min
400
FORMAX
300
UHB 11
200
UHB 20
100
0
0,0
0,2
0,4
0,6
0,8
Carbon content %
1,0
1,2
The higher alloyed a steel is,
the more difficult it is to machine with a
cutting tool
Machinability versus sulphur content
HSS-Machining
Cutting speed v30 m/min
70
60
Free cutting steel
50
RAMAX 2
S
40
HOLDAX
30
20
High performance steel
10
0
0
0,05
0,1
0,15
0,2
0,25
Sulphur content %
Microstructure-Machinability
10 µm
SVERKER 21 (D2) 1.5 C 12Cr 0.8Mo 0.8V
10 µm
CORRAX (0.03C 12Cr 9Ni 1.4Mo 1.6Al)
10 µm
STAVAX ESR (420 mod.) 0.3C 13Cr 0.3V
10 µm
AISI 304 (0.03C 18Cr 8Ni)
Material hardness versus productivity for an
engineering steel
Steel grade:
Initital size:
IMPAX SUPREME
Ø 80 mm
Number of shafts
per unit time
78
10
500
8
6
4
2
0
200 HB
300 HB
400 HB
50 HRC
Machinability as a function of hardness and
carbide content in the work material
Machinability
v30 m/min
340
320
300
ORVAR
280
260
Material
Material with
with
low
low carbide
carbide
content
content
STAVAX ESR
DIEVAR
240
220
200
Material
Material with
with high
high
carbide
content
carbide content
180
IMPAX
160
RAMAX 2
140
SVERKER 21
120
100
Material
with
Material
with high
high
80
carbide
carbide content
content
60
(Spray
formed)
(Spray
formed)
40
20
SVERKER 3
IMPAX HI HARD
VANADIS 4E
VANADIS 23
VANCRON 40
ELMAX
SVERKER SF
VANADIS 6
VANADIS 60
VANADIS 10
ROLTEC
WEARTEC
0
100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440
Hardness HB
Steel-making process-Machinability
Ingot cast tool steel
PM produced tool steel
Spray formed tool steel
You can never detect machinability of a
tool steel just by looking at one factor
Determination of the machinability
of a material
Four crucial
machining factors
Surface finish
Chip formation
350
Fx
Fy
Fz
300
250
200
150
100
50
Tool wear
0
-50 0
0,02
0,04
0,06
0,08
0,1
-100
-150
Time (s)
Cutting forces
0,12
Standard machinability tests
Type of operation
Machinability
test
Cutting tools
Cutting data
Turning with carbide
V30 HM
Coromant
Uncoated
SPGN 120304-P30
Feed 0,1 mm/varv
Depth of cut 1,0 mm
Turning with HSS
V30 HSS
Alesa
HSSE uncoated SEGA 120404-P30
Feed 0,1 mm/rev
Depth of cut 1,0 mm
Face miling with carbide
V5
Seco S25M
SEAN 1203 AFTN
Feed 0,2 mm/tooth
Depth of cut 2,0 mm
Drilling with HSS
V1000
Wedevåg Double-X Ø5 mm
V2000
Wedevåg Double-X Ø10 mm
Feed 0,15 mm/rev
Drilling depth 12,5 mm
Feed 0,3 mm/rev
Drilling depth 20 mm
End miling with HSS
V4000
Wedevåg HSS end mill Ø14 mm,
3 fluted
Feed 0,03 mm/tooth
Depth of cut, ap 7,0 mm
Square shoulder milling
with HSS
V40
Dormer C200 HSS end mill Ø12 mm,
4 fluted, uncoated
Feed 0,14 mm/tooth
Depth of cut, ap 18 mm
Depth of cut, ae 1,2 mm
Cavity milling with round
carbide inserts
V5000
Coromant R200 Ø40 mm, 3 inserts
L=145 mm
RCKT 1204 MO-PM 4030
Feed 0,25 mm/tooth
Depth of cut, ap 2 mm
Depth of cut, ae 12 mm
Cavity milling with solid
carbide ball nose cutters
Rough milling
Finishing milling
Mitsubishi VC-2SSB Ø10 mm, 2 fluted
Feed 0,06 (0,15) mm/tooth
Depth of cut, ap 1,0 (0,15) mm
Depth of cut, ae 2,5 (0,15) mm
1)
Stainless steel
Machinability, turning with carbide
13
WEARTEC SF
16
ROLTEC SF
Spray formed tool steels
PM tool steels
Conventional tool steels
23
VANADIS 10
34
VANADIS 6
52
ELMAX
SVERKER SF
74
SVERKER 3
75
VANADIS 23
82
VANCRON 40
82
100
VANADIS 4 EXTRA
103
SVERKER 21
125
UHB 20
SLEIPNER
128
RIGOR
129
RAMAX-S
129
138
CORRAX
140
IMPAX SUPREME
167
CARMO
HOLDAX
180
STAVAX SUPREME
180
192
GRANE
FERMO
195
CALMAX
196
200
UNIMAX
202
ARNE
205
CHIPPER
ALVAR 14
207
STAVAX ESR
208
HOTVAR
208
250
QRO 90 SUP
253
DIEVAR
260
ORVAR SUP
270
THG 2000
289
UHB 11
332
FORMAX
0
50
100
150
200
Cutting speed vc m/min ( v30 - value
)
250
300
350
Machinability, cavity milling with carbide
Cutting data:
Vc = Varying
fz = 0,25 mm/tooth
ap = 2 mm
ae = 12 mm
Milling tool: Coromant R200-028A32-12M, Ø 40 mm, l = 145 mm
Carbide grade: Coromant RCKT 1204 MO-PM 4030
33
Dievar 38 HRC
76
Vanadis 4 Extra 229 HB
91
Ramax 2 350 HB
105
Impax Hi-Hard 378 HB
Caldie 211 HB
145
Hotvar 205 HB
147
PM steels
Prehardened
Soft annealed
154
Stavax Supreme 262 HB
160
Sleipner 235 HB
176
Stavax ESR 207 HB
Holdax 298 HB
207
Unimax 187 HB
208
213
Dievar 159 HB
218
Carmo 250 HB
339
Calmax 200 HB
350
Orvar Supreme 188 HB
378
Grane 205 HB
0
50
100
150
200
250
V5000-value (m/min)
300
350
400
Machinability comparison in hardened condition
Calmax
52 HRC
1600
Tool: Mitsubishi VC-2SSB Ø10 mm
Number of teeth: 2
Depth of cut: ap = 1,00 mm
Radial depth of cut: ae = 2,5 mm
Tooth feed: 0,06 mm/tooth
1400
Calmax
58 HRC
Hotvar
56 HRC
Sleipner
62 HRC
Machined volume [cm3]
1200
Sverker 21
60 HRC
Vanadis 6
61 HRC
446 min
1000
Weartec SF
64 HRC
Dievar
51 HRC
800
385 min
Unimax
56 HRC
Orvar Supreme
48 HRC
479 min
600
180 min
Grane
49 HRC
Stavax ESR
52 HRC
400
Stavax Supreme
52 HRC
200
Vanadis 10
62 HRC
110 min
Caldie
58 HRC
3 min
Vancron 40 61 HRC
0
0
50
100
150
200
Cutting speed [m/min]
250
300
350
Example of cost to mill a cavity with a diameter
10mm ball end cutter
Steel grade
Cost for rough and finishing
milling
Machining time for
rough and finishing
milling
Orvar Supreme 48-51 HRC
656 + 326 SEK
=982 SEK
34 + 18 min
=52 min
Calmax 52-54 HRC
1 260 + 325 SEK
=1 585 SEK
52 + 18 min
=1 h 10 min
Hotvar 56 HRC
1504 + 353 SEK
=1 857 SEK
69 + 18 min
=1 h 27 min
Dievar 51 HRC
2 272 + 326 SEK
=2 598 SEK
115 + 18 min
=2 h 13 min
Vanadis 6 59-60 HRC
10 800 + 671 SEK
=11 471 SEK
432 + 25 min
=7 h 37 min
Vanadis 10 62 HRC
16 976 + 1 193 SEK
=18 169 SEK
381 + 19 min
=6 h 40 min
Cavity
100x100x25 mm
~ 160 cm3
~ 140 cm2
How to find the right cutting tool?
Example: Face milling
with carbide inserts
Example: Face milling with carbide inserts
The large number of possible combinations makes the tool selection
very difficult
Classification
Tool steels that give typically abrasive wear
– Steels that contains carbides, all spray formed steels and PM
steels, Sverker 21 etc.
Tool steels that give typically adhesive wear
– Dievar, Stavax Supreme, Corrax, Unimax, Caldie
Tool steels that give a normal wear behaviour
– Orvar Supreme, Impax Supreme, Nimax, Arne etc.
Tool steels that give typically abrasive wear
To improve cutting tool life:
Wear resistant coating (i.e. CVD-Al2O3)
High feed rates
Big depth of cut
Tool steels that give typically adhesive wear
To improve cutting tool life:
Sharp cutting edges and thin coatings (i.e. PVD)
Tough cutting tool material/carbide grade
Low cutting speed (especially when machining in hardened
condition)
Coolant normally gives better tool life
Tool steels that give a normal wear behaviour
Not so sensitive for the choice of cutting tool
Standard cutting tool material/carbide grade
High cutting speed
Always dry milling
Face milling in Weartec
Face milling in WEARTEC
0,4
with different
carbide inserts
0,4
CERATIP AFTN PR730
Cutting data:
Vc = 125 m/min
fz = 0,2mm/tooth
ap = 2 mm
ae = 60 mm
Insert type = SEKN 1203
CERATIP AFTN TN100M
1,1
SUMITOMO AFTN ACZ350
SUMITOMO AFTN ACZ310
1,2
CERATIP AFTN PR510
1,2
2,2
SECO AFTN-M14 T250M
Cutting speed, vc = 125 m/min
Cutting speed, vc = 92 m/min
2,4
SECO AFTN-M14 T25M
SANDVIK AZ-4030
3,2
SANDVIK AZ-4040
3,2
3,21
KENNAMETAL AFTN CH2
3,7
ISCAR 42 AFN IC4050
6,2
4,4
ISCAR 42 AFN IC450
5,4
MITSUBISHI AGSN JH F5010
6
SANDVIK AZ-3040
11
6,4
SECO AFTN-M14 T150M
8,5
10
SANDVIK AZ-3020
15
11
11
KENNAMETAL 42AFEN LN-KC994M
0
2
4
6
8
Milling time, min
10
12
14
16
Example from Germany
Face milling of granulating knifes
Material: Weartec, soft annealed
Cutting condition used as recommended by
cutting tool producer:
Vc: 200 m/min
Fz:0.1
Ap:0,5 mm
Ae:60 mm (Cutter Ø 80 mm)
Carbide grade: P40 PVD coated carbide
Tool life: 15 sek.
After following our recommendations:
Tool life: 20 min.
The customer was not following our recommendations !
Face milling in Dievar
Face milling in DIEVAR with
Coromant 12T3M-PM, 530
1,5
different carbide
inserts
Coromant 12T3E-PL, 530
Cutting speed, vc = 156 m/min
Tooth feed, fz = 0.21 mm/tooth
Radial depth of cut, ae = 67 mm
Axial depth of cut, ap = 2,0 mm
2
Pramet SEER 1203 AF-SN, 836
10,5
Iscar SEKR 1203 AFN-42, 328
15
Seco OFER 0705N-ME10,F30M
16
Iscar SEKR 1203 AFN-76, 635
17
Seco SEKR 1203 AFTN-ME10,T25M
17
Iscar SEKT 12T3 AFTN, 328
19
Seco SEKR 1203 AFTN-ME13, F40M
20
Seco SEAN 1203 AFTN-M14, T20M
22
Ceratip SEKR 1203 AFEN-S, PR 660
23
Seco OFEN 070405TN-D18, T20M
23
Seco OFER 070405TN-ME10, F40M
30
Seco SEKR 1203 AFTN-ME10, F40M
30
Coromant R245-12T3E-MM, 2040
34
Coromant R245-12T3E-ML, 2030
41
Seco T250M OFER 070405TN-ME10
51
Coromant R245-12T3E-ML, 2040
53
53
Iscar SEKR 42AFN-76, IC 950
0
10
20
30
Milling time (min)
40
50
60
Coromant Milling Grade Recommendation
in Uddeholm Tool Steels
Suitable grades for roughing operations, abrasive wear
Coromant Milling Grade Recommendation
in Uddeholm Tool Steels
Suitable grades for roughing operations, adhesive wear
Different carbide grades for different tool steels
Weartec SF
K grade of carbide
Stavax Supreme
M grade of carbide
Weartec SF
M grade of carbide
Stavax Supreme
K grade of carbide
NIMAX DV54973
Test of different high feed cutters in Nimax (380HB)
Sandvik R210-025T12-09M z=2
R120-0904 12M-PM 4240
Sandvik R210-025T12-09M z=2
R120-0904 12M-PM 4020
Sandvik R210-025T12-09M z=2
R120-0904 12M-PM 1030
Pokolm 325 248 Ø25 RP1,5 z=3
SDMX 09T307SN P40
Sandvik R210-025T12-09M z=2
R210-090414E-PM 4230
Pokolm B.-NR ZZ25273 Ø25R1 z=3
WDHX 100310 HSC05
Pokolm B.-NR ZZ25273 Ø25R1 z=3
WDHX 100310 P40
Seco YT-HR-2525R z=3
218.19-100T-MD06 F25M
Iscar FFEW D25-080-W25-06-C z=2
FF WOMT 060212T-M IC908
Kennametal 25Y03R090A25 SWP05 z=3
WPMW05X315 ZZSRHN KC 522M
Sandvik R210-025T12-09M z=2
R210-090414E-PM 1030
Pokolm 325 248 Ø25 RP1,5 z=3
SDMX 09T307SN P25
Kennametal 25Y03R090A25 SWP05 z=3
WPMW05X315 ZZSRHN KC 525M
Innotool KU. 025,002 z=3
UHLD08T310R-M IN 2006
Pokolm 325 248 Ø25 RP1,5 z=3
SDHX 09T307SN K10
2
2
3
4
6
20
22
Cutting data:
vc 150 m/min
fz 1,0 mm/tooth
ap 1,0 mm
ae 11 mm
Criteria: flank wear 0,3 mm
28
31
46
51
69
69
85
>130
0
20
40
60
80
Milling tim e (m in)
100
120
140
Test of milling cutters in Dievar 45 HRC
Hitachi EPBT 2100 TH belagd
4,7
Mitsubishi VC-2SSB (omslipad)
End milling with ballnose cutters Ø10 mm
Work material: Dievar 45 HRC
Cutting data:
Vc = 200 m/min
fz = 0,06 mm/tooth
ap = 1,0 mm
ae = 2,5 mm
Wear criteria = flank wear 0,2 mm
6,7
Seco MM10-10010-B90-MD04 F30M
10
SMICUT RH1010 B10 L78 FC
12,5
EZI Diaroc 23421X
13,2
Jabro JH110 K100 Mega
14,1
SGS SER 59MB CEM Ti-Namite A
17,2
Rubig Speedmax UHM-K10UF
17,8 18,9
20,1
Iscar Multimaster MM EB100A07-2T06 908
Garryson Rapide SPE 007
29,7
Acculube
Coolant
Compressed air
20,7
Hitachi CEPB 2100 Century Coating
23,4
Jabro JH41 Mega
29,9
Seco MM10-10010-B90P-M04 F30M
33,6
Mitsubishi VC-2SSB
35,9
Mitsubishi ECOMASTER E2MBR0500
36
Mitsubishi VC 2SSB (omslipad 2)
41
Fraisa CZ 5286 STG56 U-DURO
42,2
Karnach JO6476 UFX-22
43,3
Coromant R216.42-10030-AK196 1610
45,2
Coromant R216.42-10030-AK11H 1610
64,6
Fraisa D5100450 HX-S
66
0
10
20
30
40
50
Milling time [min]
60
70
80
Test of milling cutters in Vanadis 10 62 HRC
Rubig Speedmax UHM-K10VF
12,1
SGS SER 59MB CEM Ti-Namite A
12,1
Nachi 2GSR
13,3
Nachi XSHR
13,5
Jabro JH41 THRS SMG
15
Nachi 2GEOR
End milling with ballnose cutters Ø10 mm
Work material: Vanadis 10 62 HRC
Cutting data:
Vc = 60 m/min
fz = 0,11 mm/tooth
ap = 0,3 mm
ae = 0,3 mm
Spindle inclination 7°
Wear criteria = flank wear 0,2 mm
16
SMICUT RH1010 B10 L78 FC
17
Hitachi Fineball
19
Mitsubishi VC-2MB
19
Hitachi CEPB 2100 Century coating
With acculube
With coolant
fz = 0,127
21
Mitsubishi VC2SSB reground
23,7
Coromant R216.42-10030-AK11H 1610
25,6
Coromant Plura 1610
27
Seco MM10-10010-B90P-M04 F30M (insert)
27
Jabro JH41 Mega
27,5
Karnach JO6476 UFX-22
28,1
Seco MM10-10010-B90PF-M02 F15M (insert)
29
28,8
30,3
31,8
33,3
Coromant R216.42-10030-AK11H NBA
Jabro JH110K Mega
13,5
Mitsubishi VC 2SSB TBA 43
42,5
Mitsubishi VC-2SSB
57,6
Fraisa CZ 5286 STG56 U-DURO
63,6
Hitachi EPBT 2100 TH coating
78
0
10
20
30
40
50
Milling time [min]
60
70
80
Test with coin mills
Machine type:
Cutting tool:
Modig MD 7200, HSK 63A, 18 000 rpm
carbide insert ballnose cutters
2-fluted Ø20 mm
Chuck type:
MST A63-CTH25
Axial depth of cut, ap: 2,5 mm
Radial depth of cut, ae 0,5 mm
Feed rate, fz:
0,175 mm/tooth
Tool overhang:
120 mm
Test of milling cutters in Dievar 47 HRC
116,6
WALTER P3204-D20 WXH15
Cutting data:
Tool overhang 120 mm 6XD
Tooth feed = 0.175 mm
Axial depth of cut = 2.5 mm
Radial depth of cut = 0.5 mm
30,1
49
WALTER P3201-D20 WXH15
497
SECO 219.19-200-MD08
F17M
109,6
200 m/min
12,3
100 m/min
SECO 219.19-200P-M06
F17M
33
143
22,3
ISCAR HBR D200-QF IC 908
Also tested with a carbide shaft
Tool life=51 min
132
102
HITACHI PCA 15M ZPFW200
236
COROMANT R216F-2050E-L
P20A
50
900
COROMANT R216F-2050E-L
P10A
1
0
Did not work
100
200
300
400
500
Tool life [min]
600
700
800
900
1000
Selecting the right tool geometry
Sharp geometry
Dull geometry
Selecting the right machining strategy
In some tool steel the machining strategy i.e. the tool passes are
very important.
Typical steels where you have to “think twice” before you make
a recommendation are: Dievar, Stavax Supreme, Unimax and Corrax
Rough milling Orvar Supreme 45 HRC
Type of tool: solid carbide end mill, 6-flute Ø10 mm
ap:
7,5 mm,
ae:
adaptive 0.3-0,5 mm
Tool path:
adaptive trochoidial milling
vc:
400 m/min, 12 700 rpm
fz:
0.08 mm 6000 mm/min
Mach. time:
2 h 10 min
Tool life:
> 5 hours*
*Made 2 cavities with same cutter
First with 250 m/min, 2 h 50 min
Rough milling Dievar 45 HRC
Type of tool: solid carbide end mill, 6-flute Ø10 mm R1.5
Prototyp H80 82348
ap:
adaptive <9 mm (7,5 mm)
ae:
adaptive 0.3-0,5 mm
Tool path:
adaptive trochoidial milling
vc:
200 m/min, 6366 rpm
fz:
0.08 mm 3820 mm/min
Mach. time:
2,5 hours
Tool life:
25 min
Orvar Supreme 5 hours tool life
Roughing out a rectangular open pocket
Dievar 52 HRC
0
10
24
90
Carbide insert cutter Ø25
Sandvik Coromant 390
Insert grade 1030-PL
3 inserts
Roughing out a rectangular open pocket
Dievar 52 HRC
Traditional
vc=80 m/min, fz=0.12 mm/tooth
ap=0.5 mm, ae=full
Tool life=10 min and Qtot=72 cm3
Machining time=50 min, time for
indexing the inserts not included!
Why not?
vc=40 m/min, fz=0.04 mm/tooth
ap=8 mm, ae=full
Tool life=60 min and Qtot=216 cm3
Machining time=21 min
Roughing out a rectangular open pocket
Dievar 52 HRC
Machining strategies for crank shaft dies
Machining of a crank shaft die, Dievar 44-46
HRC
The machining is done on a part of a crank shaft die
740
73 mm
300 mm
Machining strategy No. 1
Drilling and rough end milling with 90º cutters
Drilling
Ø29 mm short hole drill
Coromant 880
Insert = 880-0503H-C-LM 1044
880-0503W08H-P-LM 4024
n = 2415 rpm (220 m/min)
f = 362 mm/min (0,15 mm/turn)
Drilling time = 1 min
Depth = 39 mm
End milling
Ø25 straight end mill, z=3
Sandvik Coromant 390
Insert = R390-11T308M-PM
1030
n = 460 rpm (36 m/min)
vf = 41 mm/min (0,03
mm/tooth)
ap = 8 mm
ae = 24 mm
Depth = 36,5 mm
Stock to leave = 0,3 mm
Milling time = 80 min
Drilling
Ø16 drill short hole drill
Sandvik 880
Inserts 880-030305H-C-GM 1044
880-0303W05H-P-GM 4044
n = 455 rpm (23 m/min)
f = 68 mm/min (0,15 mm/turn)
Depth = 39-69 mm
Drilling time = 1 min
End milling
Ø16 straight end mill, z=2
Sandvik Coromant 390
Insert = R390-11T308M-PM 1030
n = 2400 rpm (120 m/min)
vf = 710 mm/min (0,15 mm/tooth)
ap = 8 mm
ae = 8 mm
Depth = 0-63 mm
Stock to leave = 0,3 mm
Milling time = 5 min
Rest milling
Ø16 straight end mill, z=2
Sandvik Coromant 390
Insert = R390-11T308M-PM 1030
n = 2400 rpm (120 m/min)
vf = 710 mm/min (0,15 mm/tooth)
ap = 2 mm
ae = 8 mm
Depth = 0-63 mm
Stock to leave = 0,3 mm
Milling time = 21 min
Rest milling
Ø20 ball end mill, z=2
Sandvik R216F-2050E-L
Insert = P20A
n = 2400 rpm (150 m/min)
vf = 470 mm/min (0,1 mm/tooth)
ap = 1 mm
ae = 2 mm
Depth = 0-50 mm
Stock to leave = 0,3 mm
Milling time = 1 h 12 min
Semi finishing milling
Ø10 ball end mill, z=2
Fraisa HX-S
n = 3100 rpm (97 m/min)
vf = 890 mm/min (0,15 mm/tooth)
ap = 1 mm
ae = 2 mm
Depth = 0-73 mm
Stock to leave = 0,3 mm
Milling time = 52 min
Total machining time
Operation
Drilling Ø29
Milling Ø25
Drilling Ø16
Milling Ø16
Rest milling Ø16
Rest milling Ø20 ballnose
Rough/semi finishing milling Ø10 ball
Total machining time
Time
1 min
80 min
1 min
5 min
21 min
1 h 12 min
52 min
Depth
0-39 mm
0-36,5 mm
39-69 mm
0-63 mm
0-63 mm
0-50 mm
0-73 mm
3 h 41 min
Estimated machining time for a complete die part ~11 hours 30 min
Machining strategy No. 2
Rough end milling with ballnose cutters
End milling
Ø20 ballnose end mill, z=2
Sandvik R216F-2050E-L
Insert = P20A
n = 4000 rpm (86-250 m/min)
vf = 2000 mm/min (0,25
mm/tooth)
ap = 0,6 mm
ae = 3,6 mm
Depth = 50 mm
Stock to leave = 0,3 mm
Milling time = 90 min
Rest milling
Ø16 ballnose end mill, z=2
Seco Minimaster
Insert = 16016-B90-MD07
F30M
n = 5000 rpm (95-250
m/min)
vf = 2000 mm/min (0,2
mm/tooth)
ap = 0,6 mm
ae = 2,0 mm
Depth = 50 mm
Stock to leave = 0,3 mm
Milling time = 17 min
Rest milling
Ø10 ballnose end mill, z=2
Sandvik Coromant 1610
n = 8141 rpm (100-255 m/min)
vf = 3956 mm/min (0,25
mm/tooth)
ap = 0,4 mm
ae = 2,5 mm
Depth = 50 mm
Stock to leave = 0,3 mm
Milling time = 44 min
Rough milling
Ø12 ball end mill, z=2
Iscar Multimaster
Insert = MMEB120A09-2T08
908
n = 3700 rpm (80-140
m/min)
vf = 1480 mm/min (0,2
mm/tooth)
ap = 0,4 mm
ae = 2,0 mm
Depth = 50-70 mm
Stock to leave = 0,3 mm
Milling time = 51 min
Finishing milling
Ø10 ball end mill, z=2
Fraisa HX-S
n = 9000 rpm (96-280m/min)
vf = 2300 mm/min (0,13 mm/tooth)
ap = 0,3 mm
ae = 0,3 mm
Depth = 73 mm
Stock to leave = 0 mm
Milling time = ?? min
Total machining time
Operation
Rough milling Ø20
*Rest milling Ø16
Rest milling Ø10
Semi finishing milling Ø10
Rough milling Ø12
Time
90 min
17 min
44 min
52 min
51 min
Depth
0-50 mm
0-50 mm
0-50 mm
0-50 mm
50-70 mm
Total machining time 4 h 14 min
*3 h 57 min
* May not be necessary
Machining time for a complete die part ~11 hours 51 min
High-Feed Cutter test
UDDEHOLM DIEVAR 42-45 HRC
Questions from the customer
The customer is using a “High feed cutter” when machining
the material in soft condition. Is it also possible to use the
same tool to finish machining in hardened state?
From a tool producer, he has been recommended to use a
Dijet cutter, but will this give the wanted tool life of two
hours? (He is used to get a tool life of two hours when
making the same mould in Orvar Supreme)
DIEVAR 42-45 HRC, High-Feed Cutters diam. 25 mm
Flat surface
DIJET
High-Feed Diemaster
JC8015
wall not tested
INNOTOOL
IN2005
wall not tested
COROMANT
R210
1030
Vertical wall
All tests use same feed: 3000 mm/min
ap= 0,35 mm ae=0,35 mm
Cutting tool diam: 25 mm
2500 rpm
wall not tested
POKOLM
QuadWorx
P10
wall not tested
POKOLM
QuadWorx
P10
1860 rpm
Milling over 10 mm holes on flat surface
0
1
2
3
4
Milled time (h)
Inserts still OK
5
6
7
8
Cutting tool (Pokolm QuadWorx)
Conclusion High-Feed milling in hardened DIEVAR
Test indicates that the Dijet JC8015 insert doesn’t work good in
DIEVAR 42-45 HRC
All tests have the same Material Removal Rate (MRR) as used when
milling ORVAR SUPREME
We have tested 4 different cutting tools, both 2 and 3 inserts
Pokolm QuadWorx cutter and insert K10 works very good
– more then 5 hours tool life on flat surface with 10 mm diam. holes
– more then 1 hour tool life when milling a vertical wall
– This is the only insert that is ground on all surfaces: giving high precision
plus a well defined and sharp cutting edge
Too low rpm will create chipping caused by vibrations
Increasing tool life in UDDEHOLM DIEVAR
Hardened condition
Reduce temperature at cutting tool edge by:
Lowering rpm (cutting speed)
Using coolant is also a good alternative (mist or flood)
Try to keep feed at same level as before (check suppliers
recommendations regarding feed/tooth)
– Using a cutter with 1 more insert can be a good choice e.g.. from
2 to 3 inserts
Counter boring ejector pin holes in
Dievar 44-46 HRC
Counterboring Tool Steel 44-46 HRC
AMEC T-A drill as used in test.
Insert have a chamfer and not a
radius as specified from customer.
Special order is possible for radius
and will take 5 weeks.
Test setup
Simulating unstable condition
due to diameter mismatch,
hole (17,5 mm) – drill (17.0
mm)
Drill was also positioned off
centre from hole by 0,2 mm.
7 holes were tested at a drill
dept of 2mm/hole, without any
wear of cutting tool.
190 mm is max depth for this
setup.
Result
Flat bottom drill from AMEC gave good results (High Speed
Steel)
Milling alternative will therefore not be tested
6 holes was tested (2 mm each) without any wear on tool
Cutting data
– Cutting speed 10 m/min
– Feed 0,08 mm/revolution
Coolant
– Emulsion
– 6 bar pressure
Corner radius on drill insert can be ordered and will add about
5 weeks to order.
High Speed Steel insert seems to do this job good and will be
best alternative if unstable machine or setup is used
A machining centre was used in test
Milling of recycling knife made of
Roltec hardened to 62 HRC
Possible to mill, or is it better to wire EDM ??
Production cost for a cavity
Steel grade
Cost for rough and finishing
milling
Machining time for
rough and finishing
milling
Orvar Supreme 48-51 HRC
656 + 326 SEK
=105 Euro
34 + 18 min
=52 min
Calmax 52-54 HRC
1 260 + 325 SEK
=170 Euro
52 + 18 min
=1 h 10 min
Hotvar 56 HRC
1504 + 353 SEK
=200 Euro
69 + 18 min
=1 h 27 min
Dievar 51 HRC
2 272 + 326 SEK
=280 Euro
115 + 18 min
=2 h 13 min
Vanadis 6 59-60 HRC
10 800 + 671 SEK
=1233 Euro
432 + 25 min
=7 h 37 min
Vanadis 10 62 HRC
16 976 + 1 193 SEK
=1953 Euro
381 + 19 min
=6 h 40 min
Cavity
100x100x25 mm
~ 160 cm3
~ 140 cm2
Cutting conditions
Machine tool:
Cutting tool:
Collet chuck type:
Axial depth of cut, ap:
Radial depth of cut, ae:
Cutting speed, vc:
Table feed, vf:
Q:
Modig MD 7200, HSK 63A, 18 000 rpm
Hitachi EPHT 6120, solid carbide end mill,
6-fluted Ø12 mm
MST A63-CTH25
13 mm
0.4 mm
40 m/min, (1060 rpm)
445 mm/min
2,3 cm3/min
Cutting conditions
Stock removed:
Machining time:
Tool life:
8 mm, ~ 200 cm3 (39 x 647 x 8 mm)
~ 90 min
> 90 min
R 7.5
8
99
359
Cutting strategy
Work piece tighten to a steel plate by
screws
Side milling in 3 steps
The work piece was turned upside
down before milling the last level
First level
Second level
Third level
Finished part
1,5 hour machining time
One end mill
Total
Time to wire erode
Cost
150 €
150 €
300 €
10 h
400 €
Varför denna skillnad?
6
Vanadis 10 62 HRC
Vc
=20 m/min
Vf
=127 mm/min
ap/ae =1,0/2,5
z
=2
Roltec
Vc
vf
ap/ae
z
0,3 cm3/min
160 cm3
Verktygslivslängd=20 cm3
2,3 cm3/min
200 cm3
Verktygslivslängd=260 cm3
~9 mm använd skärlängd
(2x4,5 mm)
~102 mm använd skärlängd
(6x17 mm)
SF 62 HRC
=40 m/min
=445 mm/min
=13/0,4
=6
13
Resharpening of a trim die for a car hood
Tests including:
Three different milling operations
Tool life comparison
Stress measurements
Width of cut
12 mm
Three milling strategies
End milling
Face milling
Side milling
Ballnose end milling
Ballnose cutters Ø 10 mm, 2 fluted
vc = 60 m/min
ap/ae = 0.3 mm
fz = 0.11 mm/tooth
Spindle inclination = 7°
7°
Tool life for different cutters
Face milling
Round insert cutter Pokolm Ø 80 mm, 6 inserts
Insert type = Ø 16 mm
vc = 40 m/min
ap = 0.3 mm
ae = 12 mm
fz = 0.2 mm/tooth
Spindle inclination = 0.5° forward
Tool life when end milling
0,35
Face milling in Vanadis 10, 61 HRC with Ø 80 mm cutter with round inserts
Insert size = Ø 16 mm
Number of inserts = 6
Cutting speed, vc = 40 m/min
Chip load, fz = 0,2 mm/tooth
Axial depth of cut, ap = 0,3 mm
Radial depth of cut, ae = 10 mm
0,3
0,25
Flank wear [mm]
22 000 mm2 (10 min)
0,2
0,15
0,1
0,05
0
0
5 000
10 000
15 000
20 000
2
Machined area [mm ]
25 000
30 000
Side milling
Straight milling cutters, Ø 10 mm, 6 fluted
vc = 40 m/min
ap = 12 mm
ae = 0.3 mm
fz = 0.06 mm/tooth
Tool life when side milling
0,35
0,3
2
456 000 mm (55 min)
0,25
2
335 000 mm (35 min)
2
Flank wear [mm]
204 900 mm (25 min)
0,2
2
480 000 mm (58 min)
End milling in Vanadis 10, 61 HRC
with Ø 10 mm side milling cutter
Cutting speed, vc = 60 m/min
Chip load, fz = 0,06 mm/tooth
Table feed, vf = 688 mm/min
Axial depth of cut, ap = 12 mm
Radial depth of cut, ae = 0,3 mm
0,15
0,1
Hitachi EPHT 6100 TH-coating
0,05
Hitachi CEPR 6100
Sandvik Coromant
Sandvik Coromant (vc=76 m/min, fz=0,055 mm/tooth)
0
0
100 000
200 000
300 000
Machined area [mm2]
400 000
500 000
600 000
Summary of the results
End milling
Tool life = 78 min, machined area = 21 670 mm2
Face milling
Tool life = 10 min, machined area = 22 000 mm2
Side milling
Tool life = 79 min, machined area = 651 000 mm2
Side milling seems to be the most effective
Stress measurements and surface
finish on the machined surface
Tool
Ra
(µm)
Rz
(µm)
Rmax
(µm)
Surface stresses
(MPa)
Ground
reference sample
1,66
10,0
13,4
-257
EPBT 2100
new
0,37
1,9
2,2
-537
EPBT 2100
worn (0.2 mm)
1,97
9,3
11,2
-934
Face milling cutter
new inserts
1,05
3,7
6,1
-447
Face milling cutter
worn inserts (0.2 mm)
0,77
2,7
4,0
-677
Side milling cutter
new tool
-206
Side milling cutter
worn tool
-384
EDM surface
+682
Surface finish measured with cutoff length = 0,8 mm
Stress distribution below surface
1300
Ballnose cutter, new tool
Ballnose cutter, worn tool
Face milling cutter, new inserts
Face milling cutter, worn inserts
800
Side milling cutter, new tool
Stress amplitude (MPa)
Side milling cutter, worn tool
EDM surface
300
0
10
20
30
40
50
60
70
80
90
-200
-700
0° milling direction
90° measuring direction
-1200
Distance from surface (µm)
100
Fatigue test of milling cutter
Fatigue life of milling cutters that have been machined
in soft alternative in hardened state
1750000
1500000
1250000
Number of
cycles
1000000
750000
500000
250000
0
800
900
1000
1100
1200
1300
1400
Load,N
THG2000 44.5 HRC
THG2000 44.5 HRC machined in hard condition
1500
1600
Thanks for your attention
The machining team
Always at your service