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TOOL APPLICATION
HANDBOOK
,...
KENNAMfTAL
TOOL
APPLICATION HANDBOOK
No.9
The Ken namelal Tool Applicalion Handbook
is d esigned primarily 10 help ma chine operalOrs,
1001 layoul and 1001 main len a n c e men in Ihe se
leclion, applicalion, and main le n a n c e of Ke n na
mela l lOoling 10 oblain maximum econ omic bene
fils. Tool e n gineers and d esigners should also fi n d
il valuable a s Ihe informalion herein i s based on
d a m from ma ny years of developmenl work in ou r
research laboralOries as well as experience gain
ed from aClual shop operalions.
2
TOOL SELECTION
Too l No menclature
Before begi nning any detailed discussion of tools,
tool selection, and tool performance, it is well to
have certain basic questions of nomenclature settled.
The body of the tool which is held in the machine
and which supports the cutting edge is known as
the shank.
The cutting material, which may be clamped or
brazed to the shank, is the "insert" or "tip."
Perti nent dimensions are illustrated in the dia
gram below.
3
KENDEX KENLOC
"THROW-AWAY" "THROW-AWAY"
INSERT INSERT
TOOL TOOL
STANDARD KENDEX
BRAZED SCREW-ON
TOOL INSERT
TOOL
4
Re place able Inse rt Too ls
"Throw-Away" insert tools are the most econom
ical for practically all types of metal-cutting oper
ations for two reasons: (1) The inserts provide a
number of low-cost, indexable cutting edges. ( 2)
After all edges are used, it is more economical to
replace the insert than it is to regrind a brazed tool.
• Kendex top clamp tools are available in a wide
range of styles and size with negative and positive
rake angles for turning, facing, chamfering, thread
ing, grooving, profiling, and boring operations.
The top clamp design permits use of utility or
precision inserts with or without chip breaker
plates, as well as inserts with pin lock center
holes.
• Small Kendex "screw-on" insert tools provide
indexable i nserts for jobs where design or size of
holder does not permit the use of clamped insert
tools. On large tools the heavy duty "screw-on"
insert may be indexed "once around" and then
replaced; or it may be reground a limited number
of times - depending on the size of insert and
operation.
• Kenloc tools for general purpose machining utilize
economical inserts with preformed chip control
grooves and central holes for insert locking. All
inserts are negative rake type, usable on top and
bottom faces to provide up to eight indexable
cutting edges. Tools are available with triangular,
square, round, or diamond-shaped inserts.
Brazed Too ls
• Standard brazed tools-which are low in initial
cost-aI'e suitable for most general purpose ma
chining operatio ns where maximum tool perform
ance is of secondary importance. They can be easily
modified for special purpose, short run applica
tions.
5
K enna meta l Standard Too l St y les
Kennametal tools conform to industry standards
and are mad e in styles and sizes for all general types
of machining operations:
6
.o� )D
Style 0 for finish turn Style E for V-threading
ing, profiling, or cham or grooving.
fering.
10
Style Ffor facing, straddle facing, or turning with
shank parallel to work axis.
�I
Style G for turning close to chuck or shoulder, or
facing to a corner.
7
Kendex "Throw -Awa y " Insert Too ls
Kendex "throw-away" insert tools bring the eco
nomical advantages of indexable, mechanically-held
cutting edges to tools with shanks as small as 3/8-
inch square. They use flat multiple-edge inserts in
triangular, square, round and diamond shapes. In
serts are clamped in heat-treated holders at negative,
positive or neutral rake angles.
Kendex negative rake tools permit inserts to be
turned over, thus doubling the number of cutting
edges available. Inserts used with positive rake tools
are indexable but cutting edges are provided on
one face only.
Kendex tools are available in many styles and sizes
for practically every type of machining operation.
8
• Inserts i ndexed in seconds
Si mplicit y Of Des i g n
T h e s im p l e d e sign o f
Kendex [Ools i s indicated
by the exploded view draw
ing. There's nothing com
plicated [0 cause failure or
require frequent adj ustment . •�"'.IIiI•••
Inserts index quickly and accurately in the sturdy,
heat-treated shank, with cuuing edge perfectly
aligned. The shim is fastened directly [0 the holder
,t�
by a shim screw.
I KTS
Se lection Gu ide
I KTCN.C l¢::?1i
---,1!iJ
'·1 �T"
I iJ
I�
K S_
f
L-_ KTD
r----.--
KRA KTF IiLJ
��
�
.
9
,...
Suggestions For Selecting Kendex Tools
A. Rake Angles
1. Vse Negative Rake Tools:
• For general purpose machining of most mate
rials-especially rough or i nterrupted Cuts.
• For hard materials on rigid setups.
• For greatest economy as i n s erts can be
turned over.
2. Vse Positive Rake Tools:
• For machining softer steels and nonferrous
metals.
• For gummy, work-hardening alloys.
lack rigidity.
C. Selecting Inserts
1. Vtility or Precision
• Utility i nserts have top and bottom ground
for rough machining.
• Precision i nserts have all surfaces ground
10
2. Shapes
• Square Inserts: H ave strong structural shape
(900 point angle ) -Used in lead angle and
chamfering tools.
• Triangular Inserts: H ave 600 point angle
3. Radius
• Use s m a l l rad ius for steel and materials
w hich cut w ith a continuous chip.
• Use larger radius for cast iron.
4. G,'ade Selection
• See pages 29 through 34.
D. Chip Breakers
Chip breaker plates in various widths are avail
able to match the size and shape of insert. See
pages 60 and 61. Kenloc inserts with preformed
chip grooves are available for general mach ining
operations. The preformed chip grooves provide
chip control over a wide range of feeds and speeds.
11
-
Kendex Profiling Tools
CHOICE OF INSERTS
11
4'
12
Kendex Ro ller T u rner Too ls
Kendex roller turner tools with posItive rake,
i ndexable "throw-away" inserts are available for
most models of Warner & Swasey, Gisholt, and
Jones & Lamson roller turners.
Style WSK uses s �uare i nserts
for cutting with a 5 lead angle,
and Style WSK-B uses triangular
i nserts for cutting to a square
shoulder. Both are for Warner &
Swasey roller turners.
Styles GSK and JLK designed
for Gisholt and Jones & Lamson
roller turners use triangular i n
serts.
KENDEX ROLLER TURNER TOOL STYLES
TOOL Used in Insert
Shank
CAT. Manufacturer's Cat.
Size
NO. Roller Tool No. No.
Warner & Swasey
WSK2 M-1372 Y2x % x2Y2 SPG-322
WS K2B M-1372 Y2x % x2Y2 TPG-222
WS K 3 M-1 37 3 3A x 1 x3 SPG-422
WS K 3 B M-1373 % x1 x3 TPG-322
WSK4 M-1374 Ys x Ills x 3Y2 SPG·422
WSK4B M-1374 Ys x Ills x 3Y2 TPG· 322
WS K 5 M-1375 I x 1�x4 SPG-633
WS K 5 B M-137 5 1 x 1� x4 TPG-433
Gisholt
51 300A,1400A, I xl x 3Y2 TPG-433
GSK6
( 1 500A, 500A
GS K7 700B,1800 l�xll1.!x4 TPG·433
JL K 3
r Jones & Lamson
X-750,TX·813,
TX-865,TX·873, % x1 x4l1.! TPG·322
TX·87 5
JTX·1013,
JL K4
!TX·I038 1 x 1�x 5� TPG·433
13
Kendex Threading Tools
14
Kendex Heavy D u t y Too ls
15
Kendex Boring Bars
The Kendex principle of i ndexable "throw-away"
inserts is also used in Kendex Boring Bars for all
types of turret lathes, jig borers, chucking machines,
and semiautomatic lathes. Kendex bars are made
with steel shanks or with Kennametal tungsten car
bide shanks. The latter type (K-Bars) takes advan
tage of the high rigidity of Kennametal which is
three times that of hardened steel. The bars use
stand ard Kendex positive rake square or triangular
inserts. Larger sizes are available with fixed or ad
justable cutter heads.
16
Suggestions for Selecting Boring Bars
17
Kendex Steel Shank Boring Bars (cont'dJ
18
K -Ba rs -Kendex Carbide Sh ank
Bori n g Ba rs
19
carbide to mInimize deflection on deep bore jobs.
Inside the shank are "inertia discs" which counter
act chatter and vibration. In addition to the adjust
able heads, this bar can be used with fixed heads and
threading heads.
�o �
soJ�� � C)
30"-('@ � 0 3� � O S
�
::eI
f---::::
�� S �
�10 �
45 0 4S 0
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ki2J � C) L
TWO WAY ADJUSTMENT UNITS
20
One-Way A d j ustment Units-Provide radial adj ust
ment for bore diameter by means of set screw. Units
are designed for setting into pockets milled in heads
or bars and are held in place by a bridge-type clamp.
Three styles with positive rake inserts are available.
• KU-IOO Series with 0° lead angle for boring to a
square shoulder
• KU-200 Series w ith 15° lead angle for straight
through boring
• KU-300 Series with 45° lead angles for chamfering
Two-Way Adjustment Units - Can be adjusted for
bore diameter and shoulder length for close coler
ance machining. Units are held in place by a
"through-shank" screw co permit flexibility in cool
design. Negative and positive rake units are avail
able for extra light, light, medium, and heavy duty
applications. The units are available with:
• 0° lead angle for facing and boring to a square
shoulder
• 5° lead angle for straight-through boring
boring
• 30° lead angle for chamfering or straight-th rough
boring
• 45° lead angle for chamfering or straight-th rough
boring
21
,...
Kenloc HThrow-Away" Insert Tools
The Kenloc tooling system provides the most eco
nomical and versatile indexable insert tooling for all
general purpose machining operations.
A simple yet effective lock pin design, illustrated
on page 23, provides positive locking of the Kenloc
insert.
Kenloc insert with molded chip control grooves
provides up to eight indexable cutting edges.
Kenloc tools are available in a wide range of styles
and shank sizes with cutting angles that conform to
basic industry standards.
The Kenloc tooling system consists of the follow
ing three main types:
1. Kenloc tools with triangular, square, and round
inserts.
2. Kenloc tools which utilize 800 diamond inserts
with radii on all four corners for cutting to a
square shoulder or with a lead angle.
3. Kenloc Pre-Set tools having same geometry as the
Kenloc diamond insert tools, but with four hold
er adjusting screws to permit pre-setting when
used in numerical ly-controlled machines.
Kenloc Tool Features
• Positive insert locking-no shift or flutter
• Low holder profile minimizes chip interference
and tool overhang
• Quick indexing with partial turn of lock cup
• Economical Kenloc inserts with pre-formed chip
control grooves
22
Kenloc Positive Locking Action
Positive locking of
the insert is achieved by
the unique shape of the C---l-
Kenloc pin. As shown
in the diagram, the base
of the pin is moved in a
circle by the off-center
hole in the cup ( A).
Point (B ) is in contact
with the sides of the
hole in the tool holder so that the top of the pin ( C)
moves in a circle also, forcing the insert into positive
contact with backwalls.
Since the locking pin is free to rotate at random
during index ing, any wear on the pin is distributed
and cannot affect the locking efficiency.
Kenloc Tools
23
Kenloc Diamond Insert Tools
These Kenloc tools permit the use of a diamond
insert with radii on all four corners. Six styles of tools
are available which can handle practically every type
of turning and facing operation.
PDN I AF--
P- �-J
i[1J..-
P -J
10·
"s . [jj _
l-- G
L1!JjJ�PJ--{--,
Kenloc Pre-Set Tools
t"-
FOUR ADJUSTING SCREWS FOR PRE-SETTING
24
Kenna meta l Sta n dard Kendex Insert
Nu mberi ng Syste m
Catalog numbers for Kendex Inserts consist of
three descriptive letters followed by three numbers.
The letters denote the shape, rake, and finish (Util
ity or Precision) while the numbers indicate the size
of the insert, thickness of i nsert, and size of nose
radius.
For example, the catalog or style number SNG-32 1
designates the insert characteristics as shown below.
S N G-3 2
Shape . .Nose Radi us in 1 /64ths
of an inch
Rake .. .. .Thickness i n 1 / 1 6ths
of an inch
Type of Finish .. I.e. Dia. or Sq. in 1 / 8ths
of an i nch
BRAZED TOOLS
St yle a n d Size Designation
Catalog numbers for Industry Standard Brazed
Tools indicate style of tool with first letter from A
through G. The second letter is either L or R to
d i stinguish between left- a nd right-hand tool s .
Shank cross-sectional size is indicated b y a number
which follows the letter or letters.
25
,..
Square shank tools have catalog numbers indicat
ing the shank width (or height) in multiples of
l/ 1 6-inch_ For example, AL-4 is a Style A tool, left
hand, with 4/16 or l/4-inch square shank.
For rectangular shanks, the first digit indicates
shank width in multiples of liS-inch, while the sec
ond digit gives the shank height in I/4-inch multi
ples_ Thus a size 44 cool has a shank 4/s or liZ-inch
wide x 4/4 or I-inch high or liz x I-i nch_ Size 90,
which has a I-liz x Z-inch shank section, is the only
tool that does not follow this system of numbering.
The following table shows tool shank dimensions
for all Industry Standard sizes.
SHANK
INDUSTRY STANDARD TOOL STYLE: DIMENSIONS
(inches)
A B C 0 E F G A B C
-
A-16 B-16 C-16 0-16 F-16 G-16 1 1 7
A-20 B-20 C-20 F-20 G-20 1-1/4 1-1/4 8
A-24 B-24
- G-24 1-1/2 1-1/2 8
-
A-44 B-44 C-44 F-44 G-44 1/2 1 7
A-H B-S4 C-H �/8 1 6
A-SS B-S � C-55
- F-S 5 G-SS 5/8 1-1/4 8
A-64
A-66
B-64 C-64
B-66 C-66 - F-64
1'-66
G-64 3/4
3/4
1
1-1/2
6
8
A-BS
A-86
B-85
B-86 C-86 - F-8S
F-86
G-BS
G-86
1
I
1-1/4
1-1/2
R
8
A-88 B-88 1 10
A-90 B-90 1-1/2 2 14
26
Kennametal Indexable Insert
Milling Cutters
These milling cutters bring the proven advan
tages of "throw-away" insert tooling to milling
operations. Three main types are available in diam
eters from 4 to 18 inches for all face milling opera
tions from light finishing to 3/4-inch depth of cut.
Close tolerances built into the cutter body give accu
rate insert location and rigid support. A l l cutters
provide quick indexability-just loosen one screw of
self-releasing wedge.
27
Kennametal Roller DeVibrator
The Roller DeVibrator
is a device normally used
as a follower rest on turn
ing operations to stop
chatter and vibration.
It consists of the fol
lowi ng: housing with
contact w h eel, "inertia
discs" inside the housing,
supporti ng yoke, and
mounting base.
The operating princi
ple is as follows : The contact wheel transmits the
vibration from the workpiece to the inertia discs
which make impacts at random against the inside
wall of the housing. These impacts in turn are trans
mitted back to the workpiece through the contact
wheel to set up a counterforce that damps the
vibrations.
ROllER
ASSEMBLY BASE
28
CUTTING GRADES
A. Grade System
Kennametal has long recognized the basic
characteristics of the metal cutting process
and, as a result, has made available the ac
companying grade system or network of
standard grades in the form of a triangle. This
network of grades provides an optimum
coverage of the entire range of the machining
area and tool life requirements. The Kenna
metal grades in the triangle illustrated on
Page 33 are arranged according to their resist
ance to abrasion, cratering, edge-wear, and
shock. There is a Kennametal grade with
specific characteristics to meet any combin
ation of machining requirements to provide
optimum performance.
However, three basic grades, K21, K68 and
K45 will machine 90% of your jobs.
B. Grade Description
Following is a brief description of the four
teen standard Kennametal Cutting Grades:
1. Crater- Resistant Grade
K7H 93.5 RA; 11.10 density; 150,000 psi
TR. High hardness crater-resistant grade
for high-velocity machining at light to
moderate chip loads.
KSH 93.0 RA; 11.50 density; 200,000 psi
TR. Stronger than K7H and more wear
resistant that K3H. For semi-finishing cuts
on clean steel.
K3H 91.7 RA; 11.10 density; 250,000 psi
TR. General purpose crater-resistant grade
stronger than K5H and more wear-resistant
than KM. For moderate cuts on carbon
and alloy steels of 0.30 C and above, also for
medium to heavy cuts on soft steels with
less carbon.
29
,..
30
K8 92.5 RA; 15.10 density; 200,000 psi
TR. Stronger than K 11 and more wear
resistant than K6. For semi-finishing at
�oderate chip loads and abrasive mate-
31
,...
32
•
��
� �
,,� �
�
'? �- 7
�K165 Kll\
# K7H K8 \'<'�
g KSH IK4S1 IK68�l1
� K3H K4H K6 ��
� K2S
\K211 Kl��
�
� KM
• MAXIMUM SHOCK RESISTANCE.
33
,..
the most resistant to wear. The center col
umn includes grades which have a combina
tion of both crater- and edge-wear resistance.
The nearer to the top of the triangle, the
more abrasion-resistant the grade; while to
ward the base the grades are more shock
resistant. This grade chart will enable any
experienced machinist to select and adj ust
grades to obtain the best performance on
any operation.
34
MACHINING HINTS
Modern materials vary greatly in cutting charac
teristics, and must be machined with suitable tech
niques. The following hints on machining the more
common of them are i ntended as an aid in setting
up j obs initially. On long runs or repetitive j obs, ad
j ustments ma y be made by analysis of tool wear.
Steel
Carbon and Alloy Steels-These have much the same
cutting characteristics. Both cut with a continuous
chip and form a built-up edge on the tool if run at
low speeds. As speed increases, a "critical" point is
reached above which the built-up edge is swept away
and cutting is more efficient, tool life greatly ex
tended, and finish improved. This critical speed is
affected by hard ness of the steel, chip thickness, and
to a lesser degree by the depth of cut. Good cutting
practice is usually 50% to 1 00% above critical speed.
Reference to the table of recommended speeds for
machining steel with Kennametal will show that
soft "gummy" steels, such as boiler plate or SAE
1010, require very high machining speeds to remain
safely above the critical a n d t h u s cut efficiently ,
whereas steel hardened t o 3 0 0 Brinell cuts efficiently
at less than 1/2 the speed. Similarly, light cuts (chip
thickness and depth) require more speed than heavy
cuts.
Because of the strong, continuous chip, steel tends
to crater or erode the top face of the tool, and grades
of Kennametal designed to resist this action are
therefore required. A fiat chip will curl away from
the top face of the tool with comparatively light
force, whereas the same amount of steel in a channel
shaped chip has greater structural rigidity and re-
35
,...
quires more force to deflect. When the tool has a
large nose radius, a curved or channel cross section
is produced in the chip thus requiring higher tool
pressure and power. When the tool has a small nose
radius, a flat ribbon-like chip is produced, tool life
is better, and less power is required. For this reason
a small nose radius is recommended for Ken nametal
steel-cutting tools when the operation makes this
possible.
Stainless Steels-From the standpoint of machining
characteristics, these steels divide into two groups:
The hardenable (magnetic), and the austenitic (non
magnetic) . Hardenable stainless steels machine
much the same as alloy steels of equal hardness, and
the foregoing recommendations will apply. Austen
itic stainless steels such as 1 8-8, type 300, etc., are
work hardening, yet soft and gummy in their tend
ency to tear and to build up on the cutting edge.
The build-up tendency calls for high speed, whereas
the work-hardened chip and machined surface call
for speeds in the lower ranges to prevent excessive
tool wear. The best condition is therefore a compro
mise, with a feed rate heavy enough to get under the
work-hardened surface of the previous stroke or
revolution, and a speed high enough to avoid exces
sive build-up, recognizing that tool life w i l l be
shorter than with equivalent j obs on other steels.
High Manganese Steels-For applications involving
severe impact and wear, steels with 12% to 14% of
manganese are frequently used because of their ex
treme work-hardening properties. These parts can
be successfully machined with grad e K2S Ken na
metal at speeds of 35 to 1 00 feet per minute and
feeds not less than .015/1. If a finishing cut is to be
taken, at least 1/32", and preferably 1/16", stock
should be allowed so that the finishing tool can get
under the work-hardened surface.
36
Cast Iron
Gray Iron-This machines with a crumbling chip
and has very little tendency to build up along the
cutting edge. Machi ning techniques are therefore
quite different than for steel. Because of freedom
from a built-up edge, there is no lower limit or criti
cal speed to be considered, and tool wear is almost
directly proportional to speed of cutting. Speeds up
to 400 ft. per min., depend ing upon feed rate and
depth of cut, are common. For normal cutting, such
as .025" feed and .200" depth of cut, speeds of 275
ft. per min. where pieces per tool grind is important,
and up to 350 ft. per min. where cutting speed is
more important than tool life, are common.
The low-strength chip breaks i nto a crumbly
powder, so a large nose radius permits better finish,
faster feed, and longer tool l ife.
37
,...
speeds and stretching the chip out over a long cut
ting edge to finish the job with a minimum of foot
age passing over the cutting edge. Use of large
diameter rounds or extreme lead angles on longi
tudinal feeds, or broad tools on cross feeds, accom
plish this purpose. K6 or K8 are used for edge-wear
resistance.
38
H i g h Stren g t h Steel s
There is con sid era b l e overlapping o f high
strength steels or ultra-high strength steels (iron
base alloys) and high temperature alloys (iron base,
nickel base, and cobalt base a l l oys) . The high
strength steels are those with tensile strength levels
of 200,000 psi to 400,000 psi from room tempera
ture to a few hundred degrees fahrenheit. The high
temperature alloys also have high tensile strength
but are able to retain their strength to much higher
temperatures.
Most steels in the general category ofhigh strength
steel s can be readily machined with the harder
grades K45, K5H, and K7H which are intended
for machining steel. The cutting edges must be
moderately to heavily honed to insure maximum
edge strength.
A suitable cutting fluid is recommended primarily
to serve as a coolant for removing the high heat
generated in the chip making process. Adequately
powered machine tools should be used as the forces
of cutting are very high due to higher tensile strength
levels. The tool shank should be as large as permis
sible and as sturdy as possible. The workpiece must
be well clamped or chucked and well supported to
avoid loosening due to machining forces.
Depending on the hard ness of the workpiece,
feeds should be reduced by 10 to 20% and speeds
by 20 to 50% of those used for most alloy steels in
order to obtain reasonable tool life.
Positive rake Kendex tools with 150 or 300 lead
angle should be used wherever possible. Negative
rake Kendex tools of the same lead angle should be
used only when it is necessary to avoid excessive
39
chipping and/or breakage of the insert. A positive
rake insert of a tough grade, moderately honed to
avoid edge breakdown, will generally be found
most suitable.
H i g h Te mperatu re A llo ys
The high temperature or heat-resistant alloys have
an excellent combi nation of high-temperature
strength and resistance to oxidation. These mate
rials are difficult to machine due to their high alloy
content, and must be machined at reduced cutti ng
speeds. There are generally five basic reasons for
difficulty in machining these superalloys:
1. Work-hardening
2. High strength levels
3. Abrasiveness
4. High heat generated
5. Low thermal conductivity
All five of these factors result in poor machinabil
ity. Although there are many standard high tempera
ture a l loys , there are even more compo s ition
variations of these with many more heat treatment
or processing variations. However, for the sake of
simplicity, these alloys can be grouped i nto three
major classifications: iron base, nickel base and
cobalt base.
In general, machining recommednations for these
alloys are as follows: *
Iron Base
Roughi,lg General Fi,lishing
Depth of Cut 1 /8 - 3 /8 1 / 1 6- 1 /4 1/32-3/32
Feed . 0 1 0-.040 .008-.0 2 0 .003-.0 1 0
Speed, sfm 3 0- 1 00 5 0- 1 2 5 7 5 - 2 00
Grade KM-K 2 1 K 2 S-K6 K68-K8
40
Nickel Base
Roughing General Finishing
Depth of Cut 1 /8 - 1 /4 1 / 1 6- 3 / 1 6 1 / 3 2-3/3 2
Feed .0 1 0-.0 3 5 .008- . 0 2 0 .003-.0 1 0
Speed, sfm 3 0-90 5 0- 1 00 7 0- 1 7 5
Grade KM-K2 1 K4H-K6 K6B-KB
Co balt Base
Roughing General Finishing
Depth of Cut 1 / 1 6- 3/ 1 6 1 / 3 2 - 1 /8 1/3 2-3/32
Feed .0 1 0-. 0 3 0 .008-. 0 2 0 . 0 0 3 - .0 1 0
Speed, sfm 2 5- 7 5 4 0-90 60- 1 2 5
Grade KM-K2 1 K 2 S-K4 H K45-K6B
*These mach i n ing recommendations are intended as start
ing ranges only as each job requires special attention a n d
fi n a l conditions depend largely on heat treatment and struc
ture of the workpiece as well as part configuration.
41
,...
can last. Don't trade dollars in machine time
for pen nies in tool cost.
6. Use positive rake tools wherever possible.
7. Use negative rake tools only where necessary
and where surface speeds can be kept in the
higher ranges.
8 . Machine tool must be kept rigid.
9. Machine tool should be "overpowered . "
1 0 . Workpiece must b e well clamped.
1 1. Workpiece must be supported to avoid flexing.
12. Depth of cut should be deep enough to avoid
glazing.
13. Feed should be positive to avoid dwelling
a nd work-hardening.
14. Minimum chip discoloration is desirable.
15. Each job requires special consideration. This
requires ingenuity on the part of tool engi
neers.
Above all, it is important to keep in mind that
the same good shop practice that is applied in ma
chining carbon and alloy steels should be observed.
However, in machining high temperature alloys
such practices are ma ndatory.
Because these a lloys are relatively difficult to
machine and each alloy requires special attention,
we invite you to get in touch with your Kennametal
Carbide E ngineer for assistance in esta blishing
optimum tool performance.
42
Kennametal carbides can be used most successfully to machin e these metals
but since most all machining operations are special cases, no overall fixed rules
apply. In general however, it must be kept in mind that feeds are moderate,
speeds and depths of cut are low, and tool life is relatively short. The followin g
data are given as suggested starting points.
Lead Nose Depth
Angle* Radius Grade of Cut Feed Speed
Molybde'lII m (Mo)
.010·
Roughing 1 5 ' · 30' 1 /64 . 1 / 3 2 K6·K6S 1 / 1 6 · I /S ,020 1 00·200
,005-
Finishing 1 5 '-30' 1 /64- 1 /3 2 KS-K I I 1 /32·1(\6 ,0 1 5 1 50-300
Ttmgsten (IV)
.020-
Roughing 3 0 ' -4 5 ' 1 / 3 2 - 3/64 K6-K6B 1 / 1 6- 1 /8 ,040 20-60
,0 1 5 -
Finishing 1 5 ' -3 0 ' 1 /64- 1 / 3 2 KS-K I I 1 /3 2 - 1 / 1 6 ,030 50-SO
Tan/alum (Ta)
.0 1 5 -
Roughing 1 5 '-30' 1 /64 · 1 / 3 2 K2 1 -K2S 1 ( \ 6· 3 / 1 6 ,030 60- 1 00
,00 5 ·
Finishing 1 5 '-30' 1 /64- 1 / 3 2 K4H-K45 1 /64- 1 / 1 6 ,020 80-200
Columbium (Cb)
.0 1 0-
Roughing 3 0 ' -4 5 ' 1 /3 2 - 3/64 KG·K6S 1 /32-1 / 1 6 .030 2 5 ·60
,OOS-
of>.. Finishing 30'-45' 1 /64. 1 / 3 2 KS-K I I 1 /64 · 1 / 3 2 .0 1 5 50-70
�
�
...
...
Suggested Grades and Machining Conditions for Various Work Materials and Types of Cut
F I N I S H I NG R O U G H I N G
BHN RC Sp«d Grade Sp«d Grade Sp«d Grade Sp«d Or.d� Sp«d Grade Sp«d Grade
;:;
250-375
" '" I
:l
0 � � '< � JO(HOO 2ScHOO :;
'" '"
250 800-l S0 225-350
�
300 32 650-850 '" � � � rn=JSO I 200-325
3SHsO � 3 0
i!'
Plain Carbon Steeil,
;:;
.00 43 450 600 250....00
.. 1 75- 0 1 50- 215
'" '"
Alloy Steeb. and
�
400 & SOO Series
. JoCHoO ----rn:J5O '"
I --;so=rn I
:;;
42S . 400-550 1 75-250 1 25-250
I
Stainless Steel.
i2 '"
••
'"
:e
so. 51 300-375 r-rn--m- '"
� � '"
� � '"
----;s:;oo
- f---
I ---.o �
-o:i7S
m
SSO
53
SS
250 375
200-275 I
1 25-200
l OG - I SO
- - I-
ROUGHING FINISHING
BHN R E M A R K S
Sp«d F"'" Grade Sp«d F"'" Grllde
200 & 300 5es'in UM: KI (or heavy rouchina. Ulle K l l (or fine finishina;_ UK
SlainJ", Stech IS()-.2S0 12S�300 OIS 02> KI·Kft 250--600 010� 020 K08·K8 �itive rake toolin& to avoid excessive work hardening.
ArmOf" Plate Steel 250 320 80- 125 010 020 K1S·K411 125-175 .oS OIS K45·K5U 3°'5° Ne,ative land at I ...., II. reed required.
Work harden. KVCTely. UK �itive reed and depth or cut
Hiah Manganeae Steel 1 70-210 35 80 020- 030 K1S-K4H 50-125 015- 020 K45-K51-1 to avoid dwelling.
Hiah Speed Steel 200 320 120 220 01 0- 020 K.UI·K5H 200 350 005- OIS K.5H·K71-1 Hi,hcr ,peed, required ir build·up occur•.
Tool Steel ISO 225 ISO 230 010 020 K311·K511 200-300 005- 015 K5H· K 7 1-1 U.ually require poIitive rake tooling.
TOOL PERFORMANCE
Previous sections of this manual have dealt with
tool selection, choosing the proper grade of Kenna
metal to use, a nd specific recommendations for
speeds and feeds for various materials to be cut.
After having followed these recommendations, tool
performance should be examined to d etermine
whether the number of pieces per cutti ng edge is
adequate; whether the cost per piece is i n line with
other jobs.
Tool performance is an evaluation of the produc
tion cost per workpiece produced. After all measures
of cost and performance have been made, it is the
cost of the finished piece that is most important.
This means that tool performance is not an inde
pendent or arbitrarily established measure, but one
which is a distinct part of the over-all production
operation.
There is a minimum tool performance which must
be achieved and this is generally established from
previous data concerning the job. I nformation that
follows in this manual will aid in checking tool
troubles which can cause unacceptable performance.
But even when the tools are performing satisfac
torily, production costs may be un necessarily high.
Tool life, which is most generally stated i n units
of time, is the key to production economics. With
the advent of the indexable "throw-away" i n sert
Kendex tooling, tool life took on new significance.
Tool change time, which previously had been an
important element in downtime, became a very small
part of the nonproductive part of an operation. The
critical need to " make the tool last," in order to
reduce costly tool changing, was eliminated. How
ever, due to the entrenched practice of measuri ng
tool life in units of time, the potential advantages
46
of Kendex insert tooling has not and is not being
fully real ized . R e cognition of the fact that tool
change time only amounts to one or two minutes
with Kendex insert tooling suggests that shorter
tool life is desirable-if production rates and costs
can be improved. Application of this principle i n
actual practice h a s proven its merit.
The following examples demonstrate the sound
ness of measuring tool performance i n units of "cost
per piece" rather than tool life in minutes.
Machine Cost per Hour $ 8.00 $ 8.00 $10.00 $10.00 $ 9.00 $ 9.00 $ 9.00 $ 9.00
Tool Cosl per Hour $ .04 $ .40 $ .36 $ .76 $ .14 $ .215 $ .14 $ .77
Cosl per 8·H""r Shift $64.32 $67.20 $82.88 $86.08 $73.12 $73.72 $73.12 $78.16
Pieces per Shift 51 181 8 17 94 h(s./pc.. 41hfS.{pc. 8 16
em ,or Ploco I 1.26 I .37 110.36 1 5.0& SI59.16 Im..l 1 '.14 1 4.a
47
Tool Life
2 Hours 1 Hour
$9 . 2 5
Cost per edge -- = $ 1 . 1 6
8
$ 0.58 $ 1.16
48
1 . Machine conditions. 5. Poor chip control.
Cracking or Breaking
1 . Feed tOO heavy. 2. Worn or chipped cutting edges.
3. I m properly applied coolant. 4 . Too much rake or relief.
5. Too much overhang. 6. Lack of rigid ity in set-up.
7. Speed toO slow. 8 . Too much variation i n depth of cut for
size of tip. 9. I n correct grade. 1 0. Chatter. 1 1 . Braze or
grinding strains. 1 2 . Bu ilt-up edges.
49
ChaHer
1 . Tool not on ce nter. 2. I n s u ffi c ie nt relief or. clear a n ce.
3 . Too much rake. 4 . Too much overha n g . 5. Nose radius
too large. 6 . Feed too high. 7 _ Lack of r i g id ity in set-up.
8 . I ns u ffi c ie n t horsepower.
Torn Finish
1 . Speed toO low. 2 . Dull tool. 3 . Chip breaker too narrow.
4. I mproper grind ing.
Wear
1. Speed too high. 2. Feed too light. 3. I n correct grade.
4 . Nose radius toO large. 5. I mpr oper g r ind in g .
Glaze
1 . Dull tool. 2. Feed too light. 3. Nose radius toO large.
4. I ns u ffi c ie nt relief.
Build-Up
1. Speed too low. 2. Finer fi nish g r ind needed. 3. Too little
rake.
Crater
1 . Speed too high. 2. Feed too high. 3 . I n correct grade.
50
TO O L W EAR A N A LYSIS
Check Speed of Work - Relation
of Speed to Feed - Grade of Carbide
51
C H E C K OF C A R B I D E G R A D E : Use th e one m o st
su itable for the job. Kennametal metal-cutting
Grades are classified into four general types of car
bide. with different degrees of hardness in each.
( See pages 29 through 32. )
Check Speed of the Work-To ascertain if speed is
within the proper range for the hardness of material
being machined it should be checked with the table
on pages 44 and 4 5.
Check Relation of Speed to Feed-The table below
can be used to adjust speed and feed on a particular
j ob to balance the two sources of wear (edge abra
sion and top surface cratering) for maximum life.
52
Kendex Too l Care
The ever-increasing use of Kendex i ndexable i n
sert tooling eliminates many potential sources of
tool trouble as encountered with brazed tools. The
mechanical tool, however, must be used correctly
and maintained in good working order if it is to
provide maximum efficiency. The following check
list will help keep such tools working.
1. Use the correct i nsert.
2. Use the most effective chip breaker.
3. Replace damaged shims.
4. Keep the i nsert recess clean.
5. Replace bent or cracked clamps.
6. Check holder carefully after an accident.
7. Do not "over-run" inserts.
53
To a s sure proper use o f Kendex holders, and
tools in general, requires only two or three pre
cautions.
1. Change the i n sert before i t breaks. R u n n i n g an
i n sert for " j ust a few more" pieces is hazardous.
2. Clean the recess, shim, chip breaker, and i n sert
on each i ndex. Dirt in the recess or pocket or
work material welded to the i n sert or c h i p breaker
res u l t in poor seati ng-th is will cause trouble.
3 . Seat i nsert securely and tighten clamp moderately.
When replacing the i n sert in the holder make
sure it seats firmly, so that it does not "rock" i n
a n y d i rection.
U se only the wrench i ntended to tighten the clamp.
Wrench exte n s i o n s are nOt needed.
54
GRIN D ING TOOLS
Genera l Instruct ions
Although Kennametal compositions are extremely
hard, no difficulty need be experienced in grinding
Kennametal single-point tools when proper grind
ing procedures are followed .
The essential requirement is to avoid "thermal
shock " caused by a sudden change in temperature.
The greatest possibility of thermal shock is in brazed
tools due to the difference in expansion rates of car
bide and steel. W h e n crater resistant grades o f
carbide are heated, they expand about one-half as
much as steel. The wear resistant grades expand
one-third as much as steel. Therefore, a brazed tool is
already strained and grinding heat may cause failure.
A dull brazed tool can be res harpe ned several times
by simply touching up on a fine grit diamond wheel.
Only the tip need be ground. However, a tip that has
been chipped or broken requires extensive grinding
of both steel and carbide and a tool may be damaged
in one of two ways:
1. If the surface of the carbide is overheated, while
the interior remains comparatively cool, un
equal expansion will cause "crazing"-a net
work of hairline cracks or checks on the surface.
2. If the steel is overheated while carbide remains
comparatively cool, as when grinding away the
shank below the tip, heat cracks will develop.
This manual gives only general information on
tool grinding. For detailed procedure refer to publi
cations available from grinding wheel manufacturers
such as "Grinding Carbide Tools" published by the
Norton Company.
55
,...
Offhand G ri n ding
Use of proper Grinding Wheels is extremely im
portant. Medium bond silicon carbide wheels. 46 to
60 grit for roughing and 90 to 1 20 grit for finishing,
are generally recomme n d e d . A lumi n u m oxide
wheels are suitable for rough gri nding the shank
steel below the tip but care must be taken to avoid
grinding the tip or overheating the steel.
Diamond cup wheels of 100 to 220 grit, resi noid
or vitrified bonds, are generally used for offhand
finish gri nding of carbide cutting tools. Metal-bond
wheels are normally slower i n their cutting action
but are more durable and the face of the metal bond
wheel will remain flat a nd true much longer than
either the resi noid or vitrified bond types.
FoJlow the recommendations of your wheel manu
facturer as to suitability of wheel for your purpose
and method of dressing.
Wet G ri n di n g
The u s e o f wet gri nding for roughing o f steel
shanks and silicon carbide grinding of parts made
from Kennametal is recommended to minimize the
possibility of overheati ng. Wet gri nding usually
allows the use of a more durable wheel, it is faster
than dry gri nding and reduces the abrasive dust
condition.
A fluid specially compounded for carbide grinding
is generally satisfactory. Many suitable compounds
are available. The coolant should flow liberally o nto
the wheel a nd cover the entire working surface of the
tool. I ntermittent or i nsufficient flow may produce
alternate heating and quenching of the tool and
cause tip to crack due to temperature changes.
56
Regrinding Procedure
A considerable saving in carbide, as well as i n
grinding wheels, can b e made b y regrinding tools
more frequently. If possible, have a regular schedule
for regrinding tools after a certain number of pieces
have been machined or after the tools have been
used over a definite period of time. Do not put off
regrinding until the cutting edge is chipped o r
broken. Some plants consider a roughing tool too
dull when it shows a p proximately O.030-inch edge
wear land. Wear lan d on finishing tools should not
be much greater than the feed. Resharpening a nor
mally-dulled tool requires only a small amount of
grinding with a diamond wheel to provide a sharp
cutting edge.
57
,..
58
A tool crazed on the broad top surface of the tip
will sometimes lose a section back of the cutting
where there is apparently no strain, as shown i n
sketch B.
A crazed tip surface may also develop along the
side of the cutting edge as shown in sketch C. The
breaks run straight down and occur when the tool
is cutting, as though from too high pressure.
Heat Cracks-The second and larger type of crack
in a tool tip is more easily seen. It usually appears
near to, and parallel with, a brazed surface as shown
i n sketch D. Or it may start at the edge of a tip, then
swing arou nd parallel to the braze. This type of
crack is caused by:
1. Unequal expansion of steel and carbide which
can be caused by overheating the shank while
the tip remai ns cool. This ofte n occurs when
steel is being snagged away beneath the tip.
2. Rapid cooli ng after grinding.
3. An i nterrupted flow of coolant which allows
the tool to heat up while cutting and then to
be suddenly quenched when the flow of coolant
is restored.
Whenever a tool shank is blue below the tip from
the heat of grindi ng, a crack of this type will prob
ably be found in the tip. However, the crack may
not become apparent until the tool is in use. Such
cracking can be preve nted by careful wet gri nding.
59
,..
CHIP CONTROL
Chip control and disposal present no great prob
lem on j obs involving irregular or interrupted cuts,
or brittle materials. as the chip will break up with
out mechanical assistance.
However, when machining tough, stringy mate
rials which cut with a continuous chip, a chip
breaker is desirable to coil the chip or break it up
into relatively short lengths for easy disposal. A
properly directed flow of coolant also helps break
the chip coil and helps wash the chips into the pan.
60
Feed, 0.0 1 4 -inch Feed, O.03 6-inch
EFFECTIVE CHIP CONTROL OVER A WIDE RANGE OF FEEDS.
KFND£% rOCUING
,'
MII'
.,I,.,,,, , '''' ... tAUt",.' ,#
Brazed Too l s
Three types o r desi g ns of chip breakers are used:
Parallel, Angular, and Groove as shown i n the ac
companying illustrations. The depth is usually held
fairly constant while the width is varied to obtain
the desired chip control.
61
Gri n d i n g C h i p Breakers
B R A Z E D TOO LS
Chip breaker grooves should be ground on a sur
face grin der, or one desig ned especi ally for the
purpose, with either resinoid or vitrified bonded
diamond wheels only. The wheel should be wider
than the width of chip breaker so that, when the
wheel is reversed on its spindle, there is no position
of the wheel face that does not engage the work.
Wheels II4-inch wide may be vitrified or resinoid
bonded 150 to 220 grit. If the wheel is less than
Ikinch wide, use relatively hard resinoid bonded
wheel in 150 grit size.
Light feed per pass and rapid table traverse are
essential to prevent tip surface from checking. Forty
to sixty table passes per minute, with not over Y3 of
a thousandth per pass vertical feed assures rapid,
safe grinding with maximum wheel life. The wheel
should be kept clean by a flow of soluble oil in water,
or a kerosene-moistened wick.
Correct corner radius
on wheel is b e t w e e n
o n e a n d t wo t i m e s
depth o f the chip
breaker.
62
Boring Tool Angle Chart
EffECTIVE
END RELIEf
TOOL
END
R EUEF
- ---
63
,..
Kf MNAMfTAl
�--- . - " - - , ,.- -