TUNGSTEN CARBIDE TOOLS

Training Manual for Turning

TURNING 1. 2. 3. 4. 5. 6. How To Select The Right Tool Tool Wear and Remedy Tool Angles - Influence upon the Turning Process Chip Formation Chip Breakers Tool Holders

1. 1.1 1.2 1.2.1 1.2.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14

How To Select The Right Tool Turning - Definition Turning Methods (classified according to the tool types) Longitudinal Turning and Facing Tools, Copying Tools Threading - Internal and External Turning Tool, Grooving and Longitudinal Turning, Parting Off, Axial Grooving Factors for the Correct Tool Selection Workpiece - Factors of Influence Workpiece - Stable / Unstable Machines - Factors of Influence Tool Holders Maximum Overhang Length The Clamping System The Selection of the Suitable Indexable Insert Indexable Inserts - Factors of Influence The Cutting Edge Point (Point Angle) Cutting Parameters and Cutting Speed WALTER SELECT

2. 2.1 2.2 2.3 2.4 2.4.1 2.5 2.6 2.7 2.7.1 2.8 2.9 2.9.1 2.10 2.11 2.12 2.13 2.14

Tool Wear and Remedy Tool Wear- Definition The Main Causes of Wear Types of Wear Flank Wear Maximum Flank Wear Crater Wear Notch Wear Oxidation on the Secondary Cutting Edge Notches in the Depth of Cut Plastic Deformation Built-Up Edge Austenitic Stainless Steel Grades Comb Cracks Longitudinal Cracks Crumbling Chip Direction Crumbling due to Vibrations

3. 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 4. 4.1 4.2 4.3 4.4

Tool Angles - Influence upon the Turning Process Clearance Angle Tool-orthogonal Wedge Angle Inclination Angle Included Angle Setting Angle Tool orthogonal Rake Depth of Cut and Chip Section Specific Cutting Force Determination of the Specific Cutting force Components of the Shear Force Power at the Tool Cutting Edge Chip Building Importance for Turning - Chip Building Types of Chips Chip Building Chip Building in Relation with the Workpiece Material

5. 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8. 5.9 5.10 5.11 5.12 5.13

Chip Breakers ISO Designation System Chip Breaking Ranges Chip Breaking Range for a Chip Breaker in Relation to Different Cutting Edge Radii Controlled Chip Breaking with Chip Breakers Classification of the Chip Breaking Ranges according to ISO Selection of the Chip Breakers Double-sided or One-sided Indexable Insert Double-sided Indexable Inserts with Negative Basic Shapes Double-sided Indexable Inserts with Negative Basic Shapes: Summary One-sided Indexable Inserts with Negative Basic Shapes One-sided Indexable Inserts with Negative Basic Shapes: Summary One-sided Indexable Inserts with Positive Basic Shapes One-sided Indexable Inserts with Positive Basic Shapes: Summary

6. 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14

Tool Holders Points of Impact of the Cutting Edge Lever-action Clamping System for Indexable Inserts with Negative Basic Shapes Bracket-type Clamping System for Indexable Inserts with Negative Basic Shapes Lever-action Clamping System for Indexable Inserts with Positive Basic Shapes ISO Designation Code for Tool Holders for External Machining Tool Holders for Longitudinal Turning and Surfacing Tool Holders for Longitudinal Turning or Surfacing Tool Holders for Copying Tool Holders for Forming by Turning and for Copying ISO Designation Code for Tool Holders for Internal Turning Tool Holders for Internal Turning for Indexable Inserts with Negative Basic Shapes, without Internal Coolant Supply Tool Holder for Internal Turning for Indexable Inserts with Negative Basic Shapes, with Internal Coolant Supply Tool holder for Internal Turning for Indexable Inserts with Positive Basic Shapes, without Internal Coolant Supply Tool Holder for Internal Turning for Indexable Inserts with Positive Basic Shapes, with Internal Coolant Supply

Evolution of the Cutting Materials for Turning

,a = high carbon steel b = high speed steel c = stellite ( cast alloy ) d = tungsten carbide e = indexable inserts f = single layer coatings g = multilayer coatings

1 1.1

How to Select the Right Tool Turning - Definition

Turning is a metal removal operation with a geometrically defined cutting edge. A machining production process mainly for manufacturing cylindrical workpieces. The usually one-edged tool is stationary and is guided along the surface to be machined; the rotation (turning movement) is performed by the workpiece. Turning, compared with milling and boring, is the more extensively used high technology metal removal operation. Turning problems today are concentrated mainly on the chip formation and to the machining costs! Turning is a matter of controlled chip breaking and swarf evacuation. This does not simply mean to somehow remove the excess work piece material from the machining area, but much more. The chips must be broken in a controlled way, not least to carry away the heat generated by the machining operation. Coated and uncoated carbide grades were developed at a frenetic pace during the seventies, leading to a continuous productivity improvement. Almost every year, new chip breakers and new carbide / coating combinations are launched into the market, contributing to a continuous reduction of the machining costs.

1.2 1.2.1 -

Turning Methods (classified according to the tool types) Longitudinal Turning and Facing Tools, Copying Tools Longitudinal turning: The tool cutting edge moves parallel to the rotation axis of the workpiece. Facing: The tool cutting edge moves perpendicular to the rotation axis of the workpiece. Copying: The tool cutting edge usually moves parallel and perpendicular to the rotation axis of the workpiece, depending upon the shape of the workpiece. Threading - Internal and External Turning Tool, Grooving and Longitudinal Turning, Parting Off, Axial Grooving Threading: The tool cutting edge usually moves as for longitudinal turning. Grooving: The tool cutting edge usually moves as for facing, depending upon the workpiece shape.

1.2.2 -

11

1.3

Factors Influencing the Correct Tool Selection

Many factors influence the profitability of the turning process, not least the metal removal rate. A range of variables exists in each production company. These variables are further subjected to many variants: Workpiece Machine Tool system Clamping system Basic shape of the indexable insert Chip breaker Machining parameters

In order to find out the most suitable indexable insert, the best tool or even the most appropriate tool range, many questions have to be answered before a decision can be made. Experience shows however, that the best results are achieved when the machining process is planned in such a way that basic metal removal principles are applied and their respective performances are considered. The machining profitability means first of all, to make the best possible use of the production possibilities..

13

1.4

Workpiece - Influencing Factors

The following information about the workpiece is necessary for the tool selection: Workpiece shape Workpiece material Toughness Blank status Clamping - Stability Quality of surface (required) Tolerances (required) Requirements regarding the depth of cut Requirements regarding the feed Requirements regarding the machining time stable - unstable long-chipping - short-chipping high - low rolled - forged - cast Good - Poor turned - ground Tight - Open ap = given f = given T = given

15

1.5

Workpiece - Stable / Unstable

Stable workpiece External machining: tools (tool holders) with negative insert basic shapes. Internal machining: tools (boring bars) up to a ratio D/L 1 : 2.5 with a negative basic shape D/L 1 : 4 with a positive basic shape Unstable workpiece

External and internal: tools with positive insert basic shapes. In case of instability, further measures such as ... Sharp cutting edges Setting angle ( 90 degrees Cutting edge radius as small as possible Reduction of the depth of cut Reduction of the cutting speed Feed depending upon the quality of surface

are necessary.

17

1.6

Machines - Influencing Factors

Profitable machining depends first of all on making the best possible use out of the given production possibilities. To achieve a high profitability, the following factors of influence must be clarified before the tool selection. Machine type, i.e. centre lathe, CNC autolathe, special lathe Tool attachment, shank sections and diameters, right-hand or left-hand tools, number of tool positions, stationary and/or rotating Driving power Workpiece clamping system Possible application of systems with exchangeable front parts

19

1.7

Tool Holders external machining internal machining

Tool Holder system

Tool dimensions

shank section shank diameter shank length setting angle

The following rules should always be followed when selecting turning tools: Always select the largest possible shank section The following factors also determine also the application of the tool clamping system chip section A, meaning depth of cut and feed observe carefully the overhang length for the steel shanks

21

Shank: steel

Shank: heavy metal with steel head

Shank: carbide with steel head

(ap x f)

1.8

Maximum Overhang Length

Maximum overhang length for single edge internal cutting tools (boring bars) Overhang up to 4xD Reduction of the chip section up to 40 % compared with the stable internal machining. Only the depth of cut is reduced. Overhang up to 12xD Further reduction of the chip section of up to 10 %, despite of the application of heavy metal or carbide for the shank material. Important basic factors for the calculation of the machining time! ! ! Clamping length The clamping length of each boring bar should in any case be equal or greater than 3 x D. Slot-type clamping devices are most suitable as they achieve the maximum surface pressure and reduce tendancy towards vibration.

23

1.9

The Clamping System

Lever-action clamping The lever-action clamping is a user-friendly and market accepted clamping system for indexable inserts. High indexing accuracy Unhindered chip ow Easy handling Compatible with other tool manufacturers

Definition of the clamping system in combination with the preselected shank section. The workpiece stability determines the clamping system for indexable inserts with negative or positive basic shapes: Stable machining Unstable machining = = indexable insert with a negative basic shape indexable insert with a positive basic shape

25

1.10

Selecting the Suitable Indexable Insert

The selection of the suitable indexable insert, of the correct geometry and of the appropriate cutting grade is decisive for maximum turning profitability. All components Basic shape of the indexable insert Chip breakers Protecting chamfer Cutting grade Setting angle Machining parameters

must be appropriate for the workpiece material

27

1.11

Indexable Inserts - Influencing Factors

Some important influencing factors should be taken into account for the application of the indexable inserts, in order to have an optimal cutting edge geometry which gives also optimal chip removal results: Rolled or forged skin Toughness and hardness Interrupted cut Setting angle

The cutting parameters are to be defined according to the following sequence: 1. Determine the depth of cut 2. Match the feed 3. Determine the cutting speed

29

1.12

The Cutting Edge Point (Point Angle))

The selected point angle determines the stability of the cutting edge point. Normally, the angle varies between 35 and 90 degrees. The round indexable inserts have however a greater surface at the cutting edge, due to their large radii, and they are thus more stable and applicable for heavy machining operations. As a disadvantage, the round inserts generate high radial pressures which can lead to vibration.

31

Cutting Parameters for Turning Inserts with Negative Basic Shape

Brinell hardness HB

Breakdown of material group and code letters

Material group

Cutting speed vC = m/min

WAK 10 f = mm 0,4 WAM 20 f = mm 0,3 WAP 10 f = mm 0,4 390 320 240 280 200 280 220 200 170 280 120 260 170

Workpiece material approx. 0,15% C approx. 0,45% C Unalloyed steel approx. 0,45% C approx. 0,75% C approx. 0,75% C annealed annealed annealed tempered annealed tempered

0,1

0,6

0,1

0,5

0,1 520 440 320 350 270 380 300 270 240 400 200 320 230

0,6 300 260 200 240 180 240 200 170 150 180 80 220 130

125 190 250 270 300 180 275 300 350 200 325 200 240 180 180 260 150 250 130 480 260 280 200 320 280 180 200 150 270 200 120 150 120 220 250 150 100

Low-alloyed steel

tempered tempered tempered annealed hardened by tempering ferritic / martensitic, annealed martensitic, tempered austenitic, retained pearlitic / ferritic pearlitic (martensitic) ferritic pearlitic ferritic

High-alloyed steel and highalloyed tool steel Stainless steel M Stainless steel Grey cast iron K Grey cast iron with spheroidal graphite Malleable cast iron

450 250

280 160

200 120

250

190

150

1.13

Cutting Parameters and Cutting Speed

Once all factors which are pertinent for the machining operation have been defined, the cutting parameters can to be set. The cutting speed can be defined from the enclosed parameter tables, starting from the workpiece material, via the selected cutting material and the feed. The tables are in the tool catalogues. The cutting speed is defined in relation to the feed. The cutting speeds given in the tables are valid for a setting angle of 9 degrees and a tool life of 15 minutes.

33

1.14

WALTER SELECT

With WALTER SELECT, an easily-understood selection system, you always find the indexable insert suitable for your machining operation. Three faces characterise the different machining conditions. Good machining conditions Moderate machining conditions Unfavourable machining conditions

You are safely led to the most suitable indexable insert, taking into account all other relevant criteria for your machining operation. It's easy: Simply follow step by step the path to your optimal WALTER indexable insert.

35

Type of machining operation

D

Internal machining
L D L D L L D 30 L D 50 L D

External machining

30
unstabe unstabe unstabe unstabe unstabe

50
unstabe qq stable stable qq

Types of indexable inserts positive

80

stable

stable

stable

2,5
qq

4
qq

2,5
qq

4
qq

2,5
qq

4
qq

2,5

2,5

2,5

qq

qq

negative positive
55

qq

qq

qq

qq

qq

negative positive negative positive

90

qq

qq

qq

qq

negative positive
60

qq

qq

qq

qq

negative
35

qq

positive negative positive

qq qq qq qq

qq

qq

qq

qq

stable

L:D

L:D

L:D

L:D

L:D

L:D

qq

qq

qq

qq

80

negative

qq

qq

qq

Hauptanwendung

weitere Anwendung

a) Selection of a suitable turning insert type for a given machining operation The machining operation and the workpiece contour determine whether you will select an indexable insert with a positive or a negative basic shape and which point angle you need. As a rule: A positive basic shape is preferable for internal machining, for applications on small machines; for unstable set up and intricate contours. A negative basic shape is always a good choice for external machining, high chip removal rates and unfavourable machining conditions. Select as a principle the largest included angle acceptable by the workpiece and the system rigidity.

37

Nominal dimension of the insert

Insert types
l 80

Max. suitable depts of cut Rough Medium machining machining

50 % of l. 60 % of l. 75 % of l. 25 % of l. 25 % of l. 30 % of d. 50 % of l. 50 % of d.

ISO indexable inserts for turning

Nominal dimension 03 04 06 07 08 09 10 11 12 15 16 19 20 22 25

positive negative

55

positive negative positive

negative
90

positive negative positive 60 % of l.

60 % of l. 75 % of l. 30 % of l. 30 % of l. 50 % of l. 15 % of l.

60

negative
l 35

positive negative positive

50 % of l. 60 % of l. 75 % of l.

80 l

negative

The required insert nominal size and thus the length of the cutting edge depend upon the type of machining operation. Depth of cut ap is an influencing factor. Doubling the depth of cut ap also means doubling the cutting force Fc. The depth of cut can only be increased to a certain level (the setting angle , and the cutting edge length must be taken into consideration).

b)

39

Rt = r = f =

depth of the profile in mm nose radius in mm Feed in mm

2 f R t = ------------ 1000 = [ m ] 8r

Theoretical values Ra/Rz in Relation to the feed and the insert radius
Insert round radius insert mm mm 0,2 0,4 0,8 1,2 1,6 2,4 6 8 10 12 16 20 25 Ra/Rz in m 0,4/1,6 0,05 0,07 0,10 1,6/6,3 0,08 0,11 0,15 0,19 3,2/12,5 0,13 0,17 0,24 0,29 0,34 0,42 0,49 0,56 0,63 0,69 0,80 0,89 6,3/25 8/32 32/100 f = feed in mm 0,22 0,30 0,37 0,43 0,53 0,62 0,72 0,80 0,88 1,01 1,13 1,26

Feed ranges in relation to the insert radius and machining operationt

rough to medium machining Finishing to medium machining

f = feed in mm 0,040,15 0,070,22 0,100,30 0,200,40

0,38 0,47 0,54 0,66

1,08 1,32

0,250,60 0,350,85 0,401,00 0,501,20

0,20 0,23 0,25

0,31 0,36 0,40 0,44 0,51

1,00 1,10 1,26 1,42 1,58

0,200,60 0,230,70 0,250,80 2,54 2,94 3,33 0,400,80 0,501,00 0,601,25 0,701,50

c)

Select the largest possible cutting edge radius suitable for the workpiece contour, the rigidity of the system and the chip control.

The surface quality is generally expressed as the arithmetic mean value Ra. There is no mathematical connection between the Ra value and the depth of cut. The following table takes into account the relationship between Ra and Rz depending upon the nose radius and the feed. Rough Machining: Select the largest possible nose radius permitted by the rigidity of the workpiece and the machine to ensure a stable cutting edge which retains its strength for as long as possible. Rough machining fmax = 2/3 of the radius Fine to medium machining: The theoretical surface quality can be calculated with this formula:

2 f R t = ------------ 1000 = [ m ] 8r

41

Groups of materials to be machined Steel : Unalloyed and alloyed steel High-alloyed steel Stainless steel, ferritic, martensitic Austenitic Ferritic-austenitic Malleable cast iron, grey cast iron Spheroidal graphite cast iron Aluminium and other non-ferrous metals Non-metallic materials Heat-resistant special alloys with a nickel or cobalt basis, titanium and titanium alloys, highalloyed steels with poor machining qualities Hardened steel, hardened cast iron materials and gravity die cast metals, manganese steel

Code

P M K N S H

Stainless steel and cast steel: Cast iron: NF metals: Problem Materials:

Hard materials:

d) Determine the material group code to be machined. The materials to be machined by chip removal are classified in six groups of workpiece materials, depending upon their machining characteristics. They are designed with a code letter and a code colour. The groups of materials to be machined are subdivided into workpiece material sub-groups which are differentiated according to their chemical composition, their structural constitution, their heat treatment and/or their hardness.

43

. Machining stability, clamping system, Type of workpiece machining operation Smooth cut, previously machined surface Casting or forged skin Variable depth of cut Minimal interrupted cuts Medium interrupted cuts

very good

good

moderate

Severe interrupted cuts

e) Select the face symbol to suit the relevant machining conditions The respective machining conditions result from a combination of machine stability, clamping system and workpiece in relation to the type of the cutting edge action. This can be: Smooth cut, previously machined surface Cast or forged skin Variable depth of cut Minimal interrupted cuts Severe interrupted cuts

45

Chip breaking range for indexable inserts with negative basic shapes
16 12.5 10 8.0 6.3 5.0 4.0 3.2 2.5 2.0 1.6 1.2 1.0 0.8 0.63 0.5 0.4 0.32 0.25 0.20 0.16 0.12 0.1 0.025 0.04 0.063 0.1 0.16 0.25 0.4 0.63 1.0 1.6 2.5 0.032 0.05 0.08 0.12 0.20 0.32 0.5 0.8 1.2 2.0

Chip breaking range for indexable inserts with positive basic shapes
16 12.5 10 8.0 6.3 5.0 4.0 3.2

NR NM NS ap [mm]

2.5 2.0 1.6

ap [mm]

C F

1.2 1.0 0.8 0.63 0.5

B
PS NS

PM

C F

0.4 0.32 0.25 0.20 0.16 0.12 0.1

NF

PF NF

0.025 0.04 0.063 0.1 0.16 0.25 0.4 0.63 1.0 1.6 2.5 0.032 0.05 0.08 0.12 0.20 0.32 0.5 0.8 1.2 2.0

f [mm]

f [mm]

Cm 45 - / Vc = 250 m/min
D-018

f)

Determine the chip breaker index or the ISO range using the required depth of cut and the feed in the ISO chip breaking range diagram: The scale of the ISO chip breaking range diagram is logarithmic, but the diagram itself is linear in order to emphasize the important range for finish machining where chip breaking problems can be experienced. The ISO chip breaking range diagram is divided into six chip breaking ranges but only the A-D ranges are valid. E and F are outside practical machining conditions.

1:4 (f) : (ap) 1 : 16 f : ap

47

ISO Group of workpiece classificamaterials tion range AB B

WALTER chip breaker designation . . . NS 4 . . . NS 8 . . . NM 4 . . . NM 7 . . . NR 7 . . . NS 4 . . . NM 4 . . . NR 7 . . . NS 4 . . . NS 8 . . . NM 4 . NMA WAK 10 WAP 10 WAP 10 WAP 10 WAP 10 WAM 20 WAP 30 WAP 30 WAK 10 WAK 10 WAK 10 WAK 10 WAP 20 WAP 20 WAP 20 WAP 20 WAP 20 WAM 20 WAM 20 WAP 30 WAP 20 WAP 20 WAK 10 WAK 10 WAM 20 WAP 30 WAP 30 WAP 30 WAP 30 WAM 20 WAM 20 WAP 30 WAP 20 WAP 30 WAP 30

ISO Group of workpiece classificamaterials tion range

WALTER chip breaker designation . . . PS 4 . . . PM 5 . . . PS 4 . . . PM 5 . . . PS 4 . . . PM 5 . . . PM 2 WAK 10 WAP 10 WAM 20 WAP 30 WAK 10 WAP 10 WK 1 WAP 20 WAP 20 WAM 20 WAP 30 WAK 10 WAP 20 WK 1 WAM 20 WAP 30 WAM 20 WAP 30 WAP 20 WAP 30 WK 1

P M K N

AB BC AB BC

BC C CD AB

BC CD

g)

Define the recommended cutting materials by means of the workpiece material code, the chip breaker designation and the face symbol By means of the workpiece material group ( which does not give any information regarding the respective tenacity of the workpiece materials nor about the respective workpiece material structure) you go forward into the WALTER SELECT INDEXABLE INSERT definition. The obtained ISO chip breaking range brings you to the recommended WALTER chip breaker. From the WALTER chip breaker, you go then via the face symbol for the respective machining conditions, to the recommended WALTER cutting grade. The cutting parameters for indexable turning inserts, are divided for a positive or negative basic shape, and are further subdivided according to the workpiece material and Brinnell hardness values (HB). The mentioned feed in relation with the hardness (HB) gives the respective cutting speed (vc= m/min).

49

2. 2.1

Tool Wear and Remedy Tool Wear - Definition

Each cutting edge is submitted to a wear process during cut. It is subject to wear until it reaches the end of its life. No great imagination is necessary to understand that much more happens at the cutting edge than is visible to the naked eye. The wear is caused by simultaneous mechanical and thermal stresses on the turning tool. With an increasing cutting temperature, the thermal-related wear causes, such as oxidation and diffusion, prevail. It is necessary to evaluate correctly the magnitude of different influences such as extreme pressures as well as chemical reactions and to deduce from this evaluation the optimum cutting parameters. Tool wear cannot be avoided. Its "dimension" matters..

51

a = diffusion (crater wear) b = mechanical abrasion (VB) c = oxidation (scaling) d = built-up edge

a= cutting speed b = feed c = depth of cut

Wear

Cutting temperature

Cutting temperature Wear

increase of value vc, ap, f

2.2

The Main Causes of Wear

The machining conditions in the metal removal process are usually defined in order to avoid a complete cutting edge failure during an operation. In fact the cutting edge should, after a predefined engagement time, show wear which is an indication of the available life and prevent breakage. The tool life or engagement time is defined in accordance with the predictable wear. The main causes are: Diffusion (a) Mechanical abrasion (b) Oxidation (c) Built-up edge (d)

Premature wear causes production troubles and costs money. Early detection and suitable countermeasures ensure profitable production.

53

2.3

Types of Wear

The end of the working life of a cutting edge is reached when the cutting edge is unable to cope with the metal removal operation for which it has been used. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Flank wear Crater wear Notch wear Max. flank wear Oxidation notch Plastic deformation Built-up edge Comb cracks Longitudinal cracks Crumbling Cutting edge breakage

This can be determined by the surface quality or dimensional accuracy of the workpiece; the capacity to ensure controlled chip flow; or by the wear reaching such dimensions as to prevent reliable cutting edge function. In extreme cases the end of working life is a result of cutting edge breakage.

55

2.4

Flank Wear

Flank wear - abrasive wear The most important wear type which largely increases with the cutting speed, is the mechanical abrasion at the cutting edge. This wear by friction cannot be compared with the usual friction processes because pressures up to approx. 4000 N/mm2 and temperatures of 1200 degrees Celsius can occur at the cutting edge, depending upon the cutting grade and workpiece material. The flank wear is characterised by long straight and sharp-edged wear striae. The flank wear develops parallel to the theoretical cutting edge. The appearance, of wear on a tool flank and on the nose causes: An increase of the cutting forces Increased vibration Higher temperatures A deterioration of the quality of surface A lack of dimensional accuracy on the workpiece due to a cutting edge offset

57

Cause: Too high cutting speed Carbide grade with a too low wear-resistance Non suitable feed (too low feed)

Remedy: Reduce the cutting speed Use a carbide grade with a higher wear resistance Set the feed in a correct relation to the cutting speed and the depth of cut

59

2.4.1

Maximum Flank Wear

To avoid a complete tool breakage and to have still enough reserve for the turning operation, the tool manufacturers recommend a maximum flank wear..

V Bmax = ---

R 2

61

2.5

Crater Wear

Crater wear - diffusion and abrasion During the metal removal operation, diffusions occur between the workpiece material and the rake face of cutting material. The high temperature caused by the chip flowing over the cutting face produces a crater in the cutting material, and leads to weakening of the cutting edge. Excessive crater wear can change the chip formation and consequently the cutting forces thus increasing the risk of insert breakage.. Cause Too high cutting speed or too high feed, or both Too small tool orthogonal rake Wrong coolant supply Carbide grade with a too low wear resistance Remedy Reduce the cutting speed and/or the feed, select a carbide grade with a higher wear resistance Use a tool holder and an indexable insert with a positive tool orthogonal rake Increase the coolant quantity and/or pressure, provide a better supply to the cutting area Use a carbide grade with a better resistance to crater wear (Al2O3)

63

2.6

Notch Wear

The notch wear, or oxidation, just like diffusion is a result of high cutting temperatures. The necessary oxygen has no access to the areas with an extreme temperature. The rake face of the cutting edge is covered by the chip The ank face touches the cut surface on the workpiece along the width of wear land.

The notch is formed only at the end of the depth of cut. Oxides break off and form a notch.. Cause Oxidation wear Remedy Reduce the cutting speed an Al2O3-coated carbide grade a setting angle smaller than 90 degrees

65

2.7

Oxidation on the Trailing Edge

This wear leads to a cracked open surface with pimples and is hardly detectable with the naked eyes on the cutting edge or the cutting edge radius.

Cause Oxidation wear

Remedy Reduce the cutting speed an Al2O3-coated carbide grade a setting angle smaller than 90 degrees

67

2.7.1

Notches at the Depth of Cut

Notches occur due to always recurring depths of cut and because of hardening of , or irregularities on the surface of the workpiece material. Cause Notches Remedy Select a tougher carbide grade Use a more stable protective chamfer Change the setting angle 75

69

Increasing tenacity, decreasing cutting speed Increasing cutting speed, increasing high temperature hardness

2.8

Plastic Deformation

Plastic deformation is a result of thermal and mechanical overloading of the cutting edge. The cutting edge cannot cope with this overstress and becomes deformed. The wedge angle on the cutting edge changes, thus, changing the cutting characteristic of the cutting edge. This can cause upward or downward plastic deformation. Cause Too high machining temperature with consequent softening of the carbide substrate Remedy Reduce the cutting speed Use a carbide grade with a better wear resistance Reduce the chip section (in particular the feed) Reduce the setting angle Provide a coolant supply Damage to the coating Replace the insert in due time

71

2.9

Built-up edge

During the metal removal operation, the workpiece material and the cutting grade of the tool are pressed together at high pressures and simultaneous to heating. The heat is generated by the shaping of the workpiece material (chips) in the shearing zone, as well as by the friction between cutting edge and workpiece. Pressure welding occurs and protrudes at single places or all over the range of the depth of cut on the flank surface. The built-up edge can modify a cutting edge geometry in such a way that a too positive wedge angle and also a too positive tool orthogonal rake appear. These pressure welding detaches itself and particles (carbides) are picked off the cutting edge, thus generating a rough flank surface which causes then further and quicker welding. The following measures can prevent built-up edges: Increase the cutting speed Aim at a smaller protective chamfer on the cutting edge Effective cooling Increase the tool orthogonal rake Positive tool orthogonal rake

73

Austenitic workpiece materials

NM4 - WAM 20

2.9.1

Austenitic Stainless Steel

The most common austenitic stainless steel is the grade 18/8 (18% Cr and 8% Ni). From the machining point of view, the soft-annealed or the cold-drawn conditions are favourable. A disadvantage is the heavy built-up edge which cannot be avoided, even with an extreme modification of the machining parameters. - The solution is to adjust the feed to achieve chip formation (soft, curved helical chip, shape C). - A feed rate of at least 0.1mm/rev must be selected in order to enable good controlled chip breaking. - Consistent coolant supply is necessary to reduce heat, because very high temperatures are generated in the contact area between cutting edge and workpiece. - The roughing indexable insert must be replaced before excessive wear affects subsequencet operations i.e. finishing. - For roughing of steps or shoulders, square inserts with 90 nose angles, and toolholders with 75 setting angles are preferable.

75

Increasing tenacity, decreasing cutting speed Increasing cutting speed, increasing high temperature hardness

2.10

Comb Cracks

The effect of the temperature changes This wear is most common for metal removal operations with interrupted cuts. The cutting edge is subjected to considerable temperature variations between in and out of cut. When the cutting edge with its high temperature exits the cutting area, it is rapidly cooled down by the coolant or by the ambient air, before being heated again during the next operation. This creates tensions which lead to cracks in the cutting edge area. The wear effect depends on the capacity of the cutting material to resist thermal shocks. The cracks run parallel and perpendicular to the cutting edge and lead to crumbling.. Cause Variations of temperature Interrupted cut Non-uniform coolant supply Select a grade with a better resistance against thermal stress Provide a consistant and sufficient coolant supply or no coolant at all Remedy

77

2.11

Longitudinal cracks

The origin of such wear is similar to comb cracks but it mainly appears with extremely heavy machining. Interrupted cuts, heavy depths of cut and low feeds are the causes. The impact point of the chip is too close to the cutting edge. Remedy: Increase the feed

79

ISO

2.12

Crumbling

Crumbling on one or several cutting edges has several causes. Crumbling causes: Built-up edge Vibration Changing chip section Chip impact Interrupted cut Inappropriate cutting grade

They are however always due to a mechanical overload.

81

ISO

Cause Too brittle carbide grade

Remedy Use a tougher carbide grade Chamfer the cutting edge

Chip impact

Chamfer the cutting edge a negative cutting edge geometry Modify the chip direction (modification of the feed, the cutting speed, or the chip breaker...)

83

2.12.1 Chip Direction The chip breaker is used to direct the chip from the turned surface, towards the flank of the cutting edge and the bottom support. With some workpiece materials or in certain parameter situations (depth of cut in relation to the feed) the generated chip impacts onto the lower cutting edge of a double sided indexable insert and damages it. Only a modification of the chip curvature, by means of another chip breaker or with a modification of the parameters vc and f can bring a solution.

85

2.12.2 Crumbling due to Vibration Vibration during the turning operations can lead to crumbling which can in turn cause severe notches. Reduction of vibration: Select a setting angle near 90 Select the smallest cutting edge radius Select a sharp cutting edge (without protective chamfer) Select a positive indexable insert Select a smaller depth of cut Reduce the cutting speed Increase the feed (taking into account surface nish requirement)

87

3. 3.1

Tool Angles - Influence upon the Turning Process Clearance angle

The clearance angle , with the wedge angle, enables the penetration of the cutting edge into the workpiece. The size of the clearance angle is between 530' and 745' for the insert holders. If it were 0, the flank surface would rub on the surface to be machined causing friction.. Too small clearance angles cause: A high temperature rise on the cutting edge Increased ank wear Increased cutting force on the cutting wedge

Too large clearance angles cause: Dimensional inaccuracy of the workpiece caused by ank wear Increased risk of cutting edge breakage Temperature rise at the cutting edge Greater overall wear Risk of notches in the cutting edge Poor workpiece surface quality

The clearance angle measured on the tool is identical with the clearance angle effectively working on the workpiece, only if the point of the tool is set in the centre of the workpiece.

89

a tensile stress b compressive strain

3.2

Tool-orthogonal Wedge Angle

For stability reasons, the tool-orthogonal wedge angle should be as large as possible. For a favourable and economic metal removal operation, it should be as small as possible. It is therefore necessary to find an acceptable compromise for the respective metal removal operation. The tool-orthogonal wedge angle should be selected according to the material to be machined. High-resistant workpiece materials require large tool-orthogonal wedge angles. Soft and/or tough workpiece materials are machined with small tool-orthogonal wedge angles.

3.3

Inclination Angle

The inclination angle defines the spiral direction of the chip. A negative inclination angle eases the cutting edge nose but it has a negative effect on the chip flow. Its dimension corresponds to the tool orthogonal rake for a negative cutting wedge geometry.

91

Nose radius r

Inclination angle

3.4

Included Angle

The stability of the indexable insert improves with an increased included angle. Rough machining operations are performed with large included angles. A forward-running cutting edge always brings more stability than a forward-running nose radius.Use i.e. square, round or rhombic indexable inserts. 3.5 Setting Angle

The correct setting angle reduces the risk of workpiece defletion and vibration on long/unstable workpieces. The setting angle determines the position of the main cutting edge in relation to the workpiece. With a small setting angle, the passive force is increased Medium setting angles (45 - 70) are used for unstable workpieces with their lengths not exceeding L = 6 x D. Larger setting angles (70 - 95) are used for long and unstable workpieces with lengths 6 x D L 12 x D. The larger the setting angle, the smaller the passive force thus the reduction of workpiece deflection.

93

3.6

Tool orthogonal Rake

The cutting edge receives its mechanical and thermal stability from the tool orthogonal rake negative or positive. The dimension of the tool orthogonal rake is critical for the cutting force and for different wear characteristics. Large positive tool orthogonal rakes for non-ferrous materials - such as copper, light metals, aluminium alloys... Medium positive tool orthogonal rakes for steels with a medium resistance of 650 - 1000 N/m2. Small positive to negative tool orthogonal rakes for steel grades above 1200 N/m2 and for short-chipping cast materials.

95

1:4 1 : 16 f : ap

3.7

Depth of Cut and Chip Section

The depth of cut and the feed as well as the cutting speed, have a great influence upon the life tool. The chip section is used as a reference value regarding the appropriate tool application. A favourable chip section is obtained with a ratio of 1:4 to 1:16 between the feed (f) and the depth of cut (ap). This means that for a feed of .4 mm, the depth of cut can be between1.6 mm and 6 mm. The chip sections A, B and C on the picture have identical surfaces. The A chip section is the most unfavourable as the depth of cut is very short (inferior to 1:4). The cutting pressure and the heat generated by the turning process must be absorbed by the engaged part of the cutting edge (tendancy to plastic deformation). The B and C chip sections have identical depth of cut and identical feeds. The tool holder position for C (smaller setting angle, = 45) is more favourable than the tool holder position for B ( = 60), because C gives a wider and thinner chip.

97

FIXED
Applied directly to the rule

VARIABLE
not taken into account in the rule

Workpiece material

Cutting wedge geometry

Shear Force

Cutting speed

Feed

Cutting grade

Depth of cut

Tool wear

3.8

Specific Cutting Force

In the past there were many attempts to define mathematically the shear force in relation to the essential chip removal parameters. The application of the shear force rule according to Kienzle-Victor is the most widely used today. The calculation formula is very simple and therefore best suited for applications in the workshop. The rule was derived from test results and intended in the beginning only for calculating cutting force. Its extension to the components of feed force and of reactive force is possible without difficulty. The main factors influencing shear force can be classified as fixed, and variable which can be corrected. The fixed figures go thus directly into the rule, whereas the variable values are to be considered as correction factors. The shear force rule is: 1 mc

Fc = b h
with

k c1.1

ap b = -----------sin

and h = f sin

99

Typical values of the specific shear force kc as a function of the chip thickness h (linear)

Typical values of the specific shear force kc as a function of the chip thickness h (double logarithmic)

specific shear force kc

chip thickness h (mm)

apecific shear force kc

chip thickness h (mm)

3.9

Determination of the Specific Cutting Force

If the feed f or the chip section h are increased while the depth of cut ap or the chip width b remain constant, the related cutting force

Fc --------------bh
decreases in the linear and in the double logarithmic representations. In the linear representation, the specific cutting force reduces along a curve with an increasing chip section h. If this curve is transferred in a double logarithmic diagram we get a straight line. The specific cutting force Kc1.1 mainly depends on the workpiece material, on the machining conditions and on the tool. The growth figure 1-mc characterises the cutting force behaviour of a workpiece material/cutting grade combintion for different chip thickness values and for a constant cutting speed. The influence of the setting angle is included in the equation for the calculation of the cutting force Fc and of the resultant cutting force or passive force Fp, by the indication of the chip width b and of the chip thickness h. While the cutting force Fc and the resultant cutting force or passive force Fp increase with a smaller setting angle, the feed force Ff drops.

101

F = Shear force Fp = Resultant cutting force or passive force Fc = Cutting force Ff = Feed force Pc = Cutting performance
Nm P c = F c v c = ---------min

3.10

Components of Shear Force

Relatively high forces generated by cutting off, built-up cutting edges and forming of the chip, appear during the chip removal operation. The shear force is reduced in the main cutting force Fc which is parallel to the cutting speed (vc), in the feed force Ff and in the resultant cutting force (passive force) Fp. The values and the directions of the force components mainly concern the machine and device technical design. In general we say that the feed force Ff can take values from 0,15 x Fc to 0,5 x Fc and the resultant cutting force (passive force) values from 0,25 x Fc to 0,4 x Fc. In practice, we generally need only the cutting performance or the machine power which can be determined by means of the cutting force and of the cutting speed. The feed force is usually not calculated due to its relatively small dimension but it is taken into account in the efficiency coefficient of the machine, whose value is quite uncertain, in particular with a partial load.

103

A = chip section in mm2 F = cutting force in N h = chip thickness in mm Pc = power at the cutting edge f = feed ap = depth of cut ap b = ---------sin c h = f x sin A = h x b = (ap x f) F = A x Kc

( 1 mc ) h b k c1.1 v c KNm P c = -------------------------------------------------------------------------- = ------------- = kW sec 60 1000

3.11

Power at the Tool Cutting Edge

In the equation, the chip thickness h is clearly emphasised by the exponential factor (1-mc). 1-mc means: increase of the cutting force related to the chip width relative to the chip thickness. It is generally between 0.6 - 0.8. A f ap Pc b h F = = = = = = = chip section in mm2 feed in mm depth of cut in mm power at the cutting edge in kW chip width in mm chip thickness in mm cutting force in N

105

1 = shear surface 2 = workpiece 3 = cutting edge

4 = rake face 5 = chip

4. 4.1

Chip Building Importance for Turning - Chip Building

The penetration section of the tool into the workpiece is defined by the feed and the depth of cut. During the turning operation, the workpiece is moved along the tool with the cutting speed (vc)and the feed rate (fv). During this process, the tool cuts the chip - in accordance with the chip section. This operation is very strongly influenced by the properties of the workpiece material and is not a smooth continuous process. It starts with pressure on the workpiece material which is stressed until it breaks, depending on the elongation at rupture (elongation in percent) and on other conditions. The chip is altered, meaning it is thicker than its original thickness. The upper chip surface is not smooth but presents upset scales. The lower chip surface is smooth due to the flat pressure as a consequence of the chip gliding on the tool rake. The area between chip and workpiece, meaning between already formed workpiece material and material which has not yet been formed, is the shear surface - it follows a defined angle to the workpiece, the shear angle. The importance of the chip shaping depends on the thickness of the chip before the forming process and on the mechanical properties of the workpiece material. The motion flow of a chip along the contact area on the tool rake is also an important factor in the chip removal machining..

107

Ribbon chips

Snarl chips

Flat helical chips

Oblique helical chips

Long cyl. helical chips

short cyl. helical chips

Spiral helical chips

Spiral chips

Helica chip

Discontinuous chips

GOOD CHIP SHAPES UNFAVOURABLE CHIP SHAPES ACCEPTABLE CHIP SHAPES

4.2

Types of Chips

We distinguish between two types of chips owing chips shearing chips

The flowing chips are unfavourable. They are made of cut off material. Which is continuous such as ribbons. The stress upon the workpiece material was so low that the material coherence remained within the chip. Shearing chips are the desired shape. In shearing chips, the workpiece material was so strongly stressed that the chip falls to pieces immediately after the cutting zone or, after a small stress, above the chip breaker. The building of shearing chips or of flowing chips always depends on the properties of the workpiece material together with the cutting conditions and the execution of the chip breaker.

109

Chip forming
Depth of cut

Feed of the tool holder

4.3

Chip Forming

The chip breaking ability of an indexable insert geometry is often the decisive factor regarding its possibility of application. This ability can be determined in a diagram. The depths of cut and the feeds are put in relation. However, a practical diagram can give a statement only about a chip breaking zone for one geometry one workpiece material one cutting speed

with adjusted depths of cut and a feed range adapted to the geometry. The comparison between the different mechanical properties of a medium carbon steel and an alloyed steel shows that the first named is stronger formed and has a stronger initial curvature. Due to the low resistance of the carbon steel, which is still lower with the deformation, the unalloyed carbon steel breaks easier than the alloyed steel. With identical machining parameters (vc, f, ap) soft steel grades always give more strongly chip forming chips than workpiece materials with a higher resistance.

111

4.4 P M K N S H

Chip Building in Relation with the Workpiece Material = = = = = = constant, long chipping lamellar, stainless steels short chipping, cast material soft chip breaking, aluminium variable chip breaking, as with alloys with a high nickel content chip breaking with hard workpiece materials

113

5. 5.1

Chip Breakers ISO Designation System

Designation and tolerance of the indexable inserts DIN 4987 The definitions in this standard are valid for the designation of standard and non standard indexable inserts made out of carbide, ceramic cutting material and other cutting materials. Any amendment of the symbols used for the designation is prohibited. Symbol 1 6 7 8 9 10 11 12 13 14 15 16 Basic shape of indexable insert Normal clearance angle Tolerance groups Characteristics of the tool rakes and of the fastening features Size Thickness Corner radius Cutting edge Execution, application of the indexable insert R/L Width of chamfer (manufacturer's detail) Chamfer angle (manufacturer's detail) Manufacturer's details about the chip breaker

115

1 Shape of insert

5. 5.1

Chip Breakers ISO Designation System

Designation and tolerance of the indexable inserts DIN 4987 The definitions in this standard are valid for the designation of standard and non standard indexable inserts made out of carbide, ceramic cutting material and other cutting materials. Any amendment of the symbols used for the designation is prohibited. Symbol 1 17 18 19 20 21 22 23 24 25 26 27 Basic shape of indexable insert Normal clearance angle Tolerance groups Characteristics of the tool rakes and of the fastening features Size Thickness Corner radius Cutting edge Execution, application of the indexable insert R/L Width of chamfer (manufacturer's detail) Chamfer angle (manufacturer's detail) Manufacturer's details about the chip breaker

117

4 Type of insert IC mm
3,97 5,0 5,56 7/32"

5 Insert size = Length of the cutting edge / mm C D R S T V W K* IC Zoll

5,32" 06 09 06 1/4" 3/8" 06 09 07 08 11 10 12 1/2" 5/8" 3/4" 12 16 16 19 20 25 1" 25 19 33 15 12 15 22 27 08 10 09 16 16 06 11 11 04

A G N

M R W X

6,0 6,35 8,0 9,525 10,0 12,0 12,7 15,875 16,0 19,05 20,0 25,0 25,4 31,75

Special configuration

32 32 *) For the K shape of isnert K (KNMX,KNUX), only the theoretical length of the cutting edge is mentioned

5. 5.1

Chip Breakers ISO Designation System

Designation and tolerance of the indexable inserts DIN 4987 The definitions in this standard are valid for the designation of standard and non standard indexable inserts made out of carbide, ceramic cutting material and other cutting materials. Any amendment of the symbols used for the designation is prohibited. Symbol 1 17 18 19 20 21 22 23 24 25 26 27 Basic shape of indexable insert Normal clearance angle Tolerance groups Characteristics of the tool rakes and of the fastening features Size Thickness Corner radius Cutting edge Execution, application of the indexable insert R/L Width of chamfer (manufacturer's detail) Chamfer angle (manufacturer's detail) Manufacturer's details about the chip breaker

119

6 Insert thickness, s mm
01 T1 02 03 T3 04 05 06 07 09 10 12 s = 1,59 s = 1,98 s = 2,38 s = 3,18 s = 3,97 s = 4,76 s = 5,56 s = 6,35 s = 7,94 s = 9,52 s = 10,00 s = 12,00

7 Corner radius, r, mm
M0,00 04 08 12 16 24

8 Type of cutting edge

sharp edge

r = round insert r = 0,4 r = 0,8 r = 1,2 r = 1,6 r = 2,4 T

double negative chamfers negative chamfer and rounded off cutting edge

round edge

E
negative chamfer

K S

5. 5.1

Chip Breakers ISO Designation System

Designation and tolerance of the indexable inserts DIN 4987 The definitions in this standard are valid for the designation of standard and non standard indexable inserts made out of carbide, ceramic cutting material and other cutting materials. Any amendment of the symbols used for the designation is prohibited. Symbol 1 17 18 19 20 21 22 23 24 25 26 27 Basic shape of indexable insert Normal clearance angle Tolerance groups Characteristics of the tool rakes and of the fastening features Size Thickness Corner radius Cutting edge Execution, application of the indexable insert R/L Width of chamfer (manufacturer's detail) Chamfer angle (manufacturer's detail) Manufacturer's details about the chip breaker

121

9 Execution of the tool holder

Feed

10 Width of chamfer
010 025 070 150 l = 0,10 l = 0,25 l = 0,70 l = 1,50 l = 2,00

11 Chamfer angle
15 20 = 15 = 20

Feed

200

Feed

Feed

12 Manufacturers option
The ISO code comprises nine symbols. The symbols 8 and 9 are used only if necessary. The manufacturer can attach further symbols, such as i.e. :

... NM 4

... PM 5

5. 5.1

Chip Breakers ISO Designation System

Designation and tolerance of the indexable inserts DIN 4987 The definitions in this standard are valid for the designation of standard and non standard indexable inserts made out of carbide, ceramic cutting material and other cutting materials. Any amendment of the symbols used for the designation is prohibited. Symbol 1 17 18 19 20 21 22 23 24 25 26 27 Basic shape of indexable insert Normal clearance angle Tolerance groups Characteristics of the tool rakes and of the fastening features Size Thickness Corner radius Cutting edge Execution, application of the indexable insert R/L Width of chamfer (manufacturer's detail) Chamfer angle (manufacturer's detail) Manufacturer's details about the chip breaker

123

5.2

Chip Breaking Ranges

The chip breaking ranges combined with the workpiece material are always the key to the range of applications of a chip breaker. - With the indication of the appropriate ranges for the feed and the depth of cut. Very serious errors can occur if the dependence on the cutting edge radius is not taken into account. There are chip breakers for superfinishing, for finishing via roughing up to coarse chip removal.

125

Feed f Workpiece material: Cm 45 Rm = 650 N/mm2 Cutting grade: WTN 33 Cutting speed

Depth of cut

5.3

Chip Breaking Range for a Chip Breaker in Relation to Different Cutting Edge Radii

A chip breaker has always several cutting edge radii in order to be armed for the respective turning operation. However, different cutting edge radii generally mean in most cases also different widths for the protective chamfers, and in turn a different beginning for the controlled chip breaking. The risk of unwanted snarl chips is very high. The danger for the user in determining an unsuitable chip breaker from the respective chip breaking ranges is also very high. Such wrong information may lead to time- and cost-intensive tests as well as to capacity loss.

127

5.4

Controlled Chip Breaking with Chip Breakers

Each chip breaker family have protective chamfers adapted to the respective cutting edge radius with a length defined for the application of the chip breaker. If the effective feed is smaller than the respective protective chamfer, the chip will not run through the chip breaker and will not be carried away from the workpiece but develops into a snarl chip. The chip runs through the chip breaker only if the feed and the chamfer length are identical, thus allowing controlled chip breaking. The chip forming starts with the initial curvature at the first cut and it depends for the rest on the cutting parameter combinations, in particular on the feed f and the depth of cut (ap), on the cutting angles, on the type and the properties of the workpiece material as well as on the size of the cutting edge radius. A rectangular chip section (< f :ap = 1:4) means a unusually hard chip forming while a wide, thin ribbon-shaped chip (> f :ap = 1:16) leads to the formation of unwanted snarl chips. A small chip curvature for thick chips leads to a greater contact length between chip and cutting edge and thus to higher deformation forces and pressures and ultimatley insert failure.

129

Chip breaking ranges for indexable inserts with a negative basic shape
16 12.5 10 8.0 6.3 5.0 4.0 3.2 2.5 2.0 1.6 1.2 1.0 0.8 0.63 0.5 0.4 0.32 0.25 0.20 0.16 0.12 0.1 0.025 0.04 0.063 0.1 0.16 0.25 0.4 0.63 1.0 1.6 2.5 0.032 0.05 0.08 0.12 0.20 0.32 0.5 0.8 1.2 2.0

Chip breaking ranges for indexable inserts with a positive basic shape
16 12.5

NR7

ISO AB = NS4
E
PM5

E
NM7 NM4

10 8.0 6.3 5.0 4.0 3.2 2.5 2.0

ISO B

= NS8

a [mm]

a [mm]

NS4

1.6 1.2 1.0 0.8 0.63 0.5

C F

PS4

ISO AB = PS4
C F

ISO BC = NM4 ISO BC = PM5 ISO C = NM7 ISO CD = NR7

0.4 0.32 0.25 0.20 0.16 0.12 0.1

0.025 0.04 0.063 0.1 0.16 0.25 0.4 0.63 1.0 1.6 2.5 0.032 0.05 0.08 0.12 0.20 0.32 0.5 0.8 1.2 2.0

f [mm]

f [mm]

D-057

5.5

Classification of the Chip Breaking Ranges according to ISO

The ISO project divides the standardised diagram into six chip breaking ranges. The important ranges for turning and for the controlled chip breaking are A-D. The tool manufacturers can classify their own designations for the chip breakers according to ISO and ensure in this way user-friendly transparency.

131

5.6

Selection of the Chip Breakers

There are two possibilities for the selection of indexable inserts from the point of view of chip breaking: The rst one is given by the inherent brittleness of the different workpiece materials which do not require any chip breaker. The second one: indexable inserts with sintered or ground chip breakers.

The main purposes of such indexable inserts are to remove chips from the workpiece material and to break the chips in a controlled way. Therefore the suitable chip breaker depends on the workpiece material and on the machining parameters.

133

Cutting pressure

Cutting pressure

Bottom support

Bottom support

5.7

Double-sided or Single-sided Indexable Insert

The indexable inserts with a negative basic shape are available as single or double-sided inserts. Single-sided indexable insert High chip removal rates but only 50% cutting edges

against

Double-sided indexable insert

Medium chip removal rates and double cutting edge number compared with one-sided indexable inserts

In case of overstress a double-sided indexable insert tends to tilt! Negative indexable inserts according to ISO, as single or double-sided inserts, have very stable cutting edges. Machining with such inserts enables an excellent profitability. The inserts are clamped using their centre hole which enables quick and accurate changing of the insert. The WALTER indexable insert programme is defined according to the requirements from the market. There are indexable inserts for an unusually wide range of applications. They ensure high productivity.

135

Cutting parameters ISOdesignation Depth of cut ap = mm 0,10 - 0,50 0,20 - 1,00 0,10 - 0,50 0,25 - 1,00 Feed f = mm 0,04 - 0,12 0,08 - 0,20 0,06 - 0,16 0,10 - 0,25

DNMG 110402 - NF 5 DNMG 110404 - NF 5 WNMG 080404 - NF 5 WNMG 080408 - NF 5

D-060

5.8 N F S M R

Double-sided Indexable Inserts with Negative Basic Shapes

= negative basic shape = superfinishing = finishing = medium finishing = roughing 1....................5...................9

Shape of the cutting edge positive negative ______________________________________________________ NF5 Double-sided indexable insert Cutting edge sintered on the periphery Sharp, positive cutting edge Chip breaker sintered in the insert Good chip breaking with small feeds and small depths of cut Extremely suited to tolerance accuracy and quality of surface finish

137

Cutting parameters ISO designation CNMG 120404 NS 4 CNMG 120408 NS 4 CNMG 120412 NS 4 DNMG 110404 NS 4 DNMG 110408 NS 4 DNMG 110412 NS 4 DNMG 150604 NS 4 DNMG 150608 NS 4 DNMG 150612 NS 4 SNMG 120404 NS 4 SNMG 120408 NS 4 SNMG 120412 NS 4 TNMG 160404 NS 4 TNMG 160408 NS 4 TNMG 160412 NS 4 TNMG 220404 NS 4 TNMG 220408 NS 4 TNMG 220412 NS 4 VNMG 160404 NS 4 WNMG 060404 NS 4 WNMG 060408 NS 4 WNMG 060412 NS 4 WNMG 080404 NS 4 WNMG 080408 NS 4 WNMG 080412 NS 4
D-061

Depth of cut ap = mm 0,1 1,5 0,2 2,5 0,5 4,0 0,1 1,5 0,2 2,5 0,5 4,0 0,1 1,5 0,2 2,5 0,5 4,0 0,1 1,8 0,2 2,8 0,5 4,5 0,1 1,5 0,2 2,5 0,5 4,0 0,1 1,5 0,2 2,5 0,5 4,0 0,1 1,5 0,1 1,5 0,2 2,5 0,5 4,0 0,1 1,5 0,2 2,5 0,5 4,0

Feed f = mm 0,05 0,20 0,08 0,25 0,10 0,30 0,05 0,20 0,08 0,25 0,10 0,30 0,05 0,20 0,08 0,25 0,10 0,30 0,05 0,22 0,08 0,28 0,10 0,35 0,05 0,20 0,08 0,25 0,10 0,30 0,05 0,20 0,08 0,25 0,10 0,30 0,05 0,22 0,05 0,20 0,08 0,25 0,10 0,30 0,05 0,20 0,08 0,25 0,10 0,30

NS4

Double-sided indexable insert Cutting edge sintered on the periphery Chip breaker sintered in the insert Finishing geometry Good chip control High quality of surface finish Small feeds and small depths of cut

139

Cutting parameters ISO designation CNMG 120404 NS 5 CNMG 120408 NS 5 CNMG 120412 NS 5 DNMG 110404 NS 5 DNMG 110408 NS 5 DNMG 150604 NS 5 DNMG 150608 NS 5 DNMG 150612 NS 5 SNMG 120404 NS 5 SNMG 120408 NS 5 SNMG 120412 NS 5 TNMG 160404 NS 5 TNMG 160408 NS 5 TNMG 160412 NS 5 WNMG 080404 NS 5 WNMG 080408 NS 5 WNMG 080412 NS 5 Depth of cut ap = mm 0,3 3,0 0,6 3,0 1,0 3,0 0,25 3,0 0,3 4,0 0,3 3,0 0,6 3,0 1,0 3,0 0,3 3,0 0,6 3,0 1,0 3,0 0,3 3,0 0,6 3,0 1,0 3,0 0,3 3,0 0,5 3,5 0,6 4,0 Feed f = mm 0,12 0,25 0,15 0,35 0,15 0,35 0,10 0,25 0,10 0,32 0,12 0,25 0,15 0,30 0,15 0,30 0,12 0,25 0,15 0,35 0,15 0,35 0,12 0,25 0,15 0,30 0,15 0,30 0,10 0,25 0,12 0,40 0,16 0,45

D-062

NS5

Double-sided indexable insert Cutting edge sintered on the periphery Chip breaker sintered in the insert Curved cutting edge for compensation of the inclination angle For medium feeds and medium depths of cut Generates low cutting forces

141

ISO designation CNMG 120404 NS 8 CNMG 120408 NS 8 CNMG 120412 NS 8 CNMG 120416 NS 8 CNMG 160608 NS 8 CNMG 160612 NS 8 CNMG 160616 NS 8 DNMG 110404 NS 8 DNMG 110408 NS 8 DNMG 110412 NS 8 DNMG 150604 NS 8 DNMG 150608 NS 8 DNMG 150612 NS 8 DNMG 150616 NS 8 SNMG 120404 NS 8 SNMG 120408 NS 8 SNMG 120412 NS 8 SNMG 120416 NS 8 SNMG 150408 NS 8 SNMG 150412 NS 8 SNMG 150416 NS 8 TNMG 160404 NS 8 TNMG 160408 NS 8 TNMG 160412 NS 8 TNMG 220408 NS 8 TNMG 220412 NS 8 TNMG 220416 NS 8 WNMG 060404 NS 8 WNMG 060408 NS 8 WNMG 060412 NS 8 WNMG 080404 NS 8 WNMG 080408 NS 8 WNMG 080412 NS 8 WNMG 080416 NS 8

Cutting parameters Depth of cut Feed ap = mm f = mm 0,6 2,0 0,8 2,5 1,0 3,0 1,0 3,5 0,8 2,5 1,0 3,0 1,0 3,5 0,6 2,0 0,8 2,5 1,0 3,0 0,6 2,0 0,8 2,5 1,0 3,0 1,0 3,5 0,6 2,0 0,8 2,5 1,0 3,0 1,2 5,0 0,8 2,5 1,0 3,0 1,0 3,5 0,6 2,0 0,8 2,5 1,0 3,0 0,8 2,5 1,0 3,0 1,0 3,5 0,6 2,0 0,8 2,5 1,0 3,0 0,6 2,0 0,8 2,5 1,0 3,0 1,0 3,5 0,12 0,25 0,18 0,40 0,22 0,50 0,25 0,60 0,25 0,45 0,30 0,55 0,35 0,60 0,12 0,25 0,18 0,35 0,22 0,45 0,12 0,25 0,22 0,40 0,25 0,45 0,25 0,45 0,15 0,25 0,20 0,40 0,25 0,50 0,25 0,40 0,25 0,45 0,30 0,55 0,35 0,63 0,12 0,25 0,18 0,35 0,22 0,45 0,22 0,35 0,25 0,40 0,25 0,40 0,15 0,20 0,18 0,35 0,22 0,40 0,15 0,25 0,18 0,40 0,22 0,50 0,25 0,60

D-064

NS8

Double-sided indexable insert Stable cutting edge For small depths of cut and medium to high feeds Excellent chip breaking on a wide range of feeds and depths of cut Machining with interrupted cut, applicable for workpiece surfaces which are difficult to machined Cutting edge sintered on the periphery Chip breaker sintered in the insert

143

ISO designation CNMG 120404 NM 4 CNMG 120408 NM 4 CNMG 120412 NM 4 CNMG 120416 NM 4 CNMG 160608 NM 4 CNMG 160612 NM 4 CNMG 160616 NM 8 DNMG 110404 NM 4 DNMG 110408 NM 4 DNMG 110412 NM 4 DNMG 150604 NM 4 DNMG 150608 NM 4 DNMG 150612 NM 4 DNMG 150616 NM 4 SNMG 120404 NM 4 SNMG 120408 NM 4 SNMG 120412 NM 4 SNMG 120416 NM 4 SNMG 150608 NM 4 SNMG 150612 NM 4 SNMG 150616 NM 4

Cutting parameters Depth of cut Feed ap = mm f = mm 0,4 4,0 0,6 5,0 1,0 5,0 1,2 5,0 0,8 7,0 1,0 7,0 1,2 7,0 0,4 4,0 0,6 4,0 1,0 4,0 0,4 4,0 0,6 5,0 1,0 5,0 1,2 5,0 0,4 5,0 0,6 5,0 1,0 5,0 1,2 5,0 0,8 8,0 1,0 8,0 1,2 8,0 0,16 0,25 0,18 0,40 0,20 0,40 0,25 0,40 0,25 0,50 0,30 0,50 0,35 0,55 0,16 0,25 0,18 0,35 0,20 0,35 0,16 0,25 0,18 0,35 0,20 0,40 0,25 0,40 0,16 0,25 0,18 0,40 0,20 0,40 0,25 0,40 0,25 0,50 0,30 0,50 0,35 0,55

D-065

NM4

Double-sided indexable insert Cutting edge sintered on the periphery Chip breaker sintered in the insert Excellent chip breaking on a wide range of feeds and depths of cut Machining with interrupted cut For difficult workpiece surfaces For stainless austenitic steel grades

145

ISO designation TNMG 160404 NM 4 TNMG 160408 NM 4 TNMG 160412 NM 4 TNMG 160416 NM 4 TNMG 220408 NM 4 TNMG 220412 NM 4 TNMG 220416 NM 4 WNMG 060404 NM 4 WNMG 060408 NM 4 WNMG 060412 NM 4 WNMG 080404 NM 4 WNMG 080408 NM 4 WNMG 080412 NM 4 WNMG 080416 NM 4 WNMG 100608 NM 4 WNMG 100612 NM 4 WNMG 100616 NM 4

Cutting parameters Depth of cut Feed ap = mm f = mm 0,4 4,0 0,6 4,0 1,0 4,0 1,2 4,0 0,8 5,0 1,0 5,0 1,2 5,0 0,4 4,0 0,6 4,0 1,0 4,0 0,4 4,0 0,6 5,0 1,0 5,0 1,2 5,0 0,8 7,0 1,0 7,0 1,2 7,0 0,16 0,25 0,18 0,35 0,20 0,35 0,25 0,40 0,18 0,35 0,20 0,40 0,25 0,40 0,16 0,25 0,18 0,35 0,20 0,35 0,16 0,25 0,18 0,40 0,20 0,40 0,25 0,45 0,25 0,50 0,30 0,50 0,35 0,55

D-065

NM4

Double-sided indexable insert Cutting edge sintered on the periphery Chip breaker sintered in the insert Excellent chip breaking on a wide range of feeds and depths of cut Machining with interrupted cut For difficult workpiece surfaces For stainless austenitic steel grades

147

ISO designation CNMG 120408 NM 5 CNMG 120412 NM 5 CNMG 120416 NM 5 CNMG 160608 NM 5 CNMG 160612 NM 5 CNMG 160616 NM 5 CNMG 160624 NM 5 DNMG 110408 NM 5 DNMG 110412 NM 5 DNMG 150608 NM 5 DNMG 150612 NM 5 SNMG 120408 NM 5 SNMG 120412 NM 5 SNMG 120416 NM 5 SNMG 150608 NM 5 SNMG 150612 NM 5 SNMG 150616 NM 5 SNMG 150624 NM 5 TNMG 160408 NM 5 TNMG 160412 NM 5 TNMG 160416 NM 5 WNMG 080408 NM 5 WNMG 080412 NM 5 WNMG 080416 NM 5

Cutting parameters Depth of cut Feed ap = mm f = mm 0,8 5,0 1,2 5,0 1,5 5,0 0,8 7,0 1,2 7,0 1,5 7,0 2,5 7,0 0,6 4,0 1,0 4,0 0,8 5,0 1,2 5,0 0,8 5,0 1,2 5,0 1,5 5,0 0,8 7,0 1,2 7,0 1,5 7,0 2,5 7,0 0,8 5,0 1,2 5,0 1,5 5,0 1,2 5,0 1,5 5,0 2,0 5,0 0,25 0,50 0,30 0,50 0,35 0,50 0,25 0,50 0,30 0,60 0,35 0,60 0,40 0,60 0,15 0,40 0,20 0,50 0,25 0,45 0,30 0,45 0,25 0,50 0,30 0,50 0,35 0,50 0,25 0,50 0,30 0,60 0,35 0,60 0,40 0,60 0,25 0,45 0,30 0,45 0,35 0,45 0,20 0,45 0,22 0,50 0,25 0,55

D-066

NM5

Double-sided indexable insert for medium feeds and medium depths of cut Cutting edge sintered on the periphery Chip breaker sintered in the insert Stable protective chamfers The universal indexable insert For casting and forging skins Ensures a high productivity and a troublefree application In combination with coated carbide grades: Application for grey cast iron and cast iron with nodular graphite (nodular graphite iron)

149

ISO designation CNMG 120408 NM 7 CNMG 120412 NM 7 CNMG 120416 NM 7 CNMG 160608 NM 7 CNMG 160612 NM 7 CNMG 160616 NM 7 CNMG 190612 NM 7 CNMG 190616 NM 7 CNMG 190624 NM 7 DNMG 110408 NM 7 DNMG 110412 NM 7 DNMG 150608 NM 7 DNMG 150612 NM 7 SNMG 120408 NM 7 SNMG 120412 NM 7 SNMG 120416 NM 7 SNMG 150608 NM 7 SNMG 150612 NM 7 SNMG 150616 NM 7 SNMG 190608 NM 7 SNMG 190612 NM 7 SNMG 190616 NM 7

Cutting parameters Depth of cut Feed ap = mm f = mm 2,0 8,0 2,0 8,0 2,0 8,0 2,0 10,0 2,0 10,0 2,0 10,0 2,0 12,0 2,0 12,0 2,0 12,0 1,5 4,0 1,5 4,0 2,0 5,0 2,0 5,0 2,0 8,0 2,0 8,0 2,0 8,0 2,0 10,0 2,0 10,0 2,0 10,0 2,0 12,0 2,0 12,0 2,0 12,0 0,30 0,45 0,30 0,55 0,40 0,65 0,30 0,50 0,30 0,60 0,40 0,65 0,30 0,60 0,40 0,65 0,50 0,70 0,25 0,40 0,30 0,45 0,25 0,40 0,30 0,50 0,30 0,45 0,30 0,55 0,40 0,65 0,30 0,50 0,30 0,60 0,40 0,65 0,30 0,50 0,30 0,60 0,40 0,65

D-067

NM7

Double-sided indexable insert Medium to high feeds and depths of cut for a double-sided indexable insert Cutting edge sintered on the periphery Chip breaker sintered in the insert Stable cutting edges for turning operations with severe interrupted cut For important casting and forging skins or sand inclusions The geometry for the best profitability for extreme rough machining operations

151

ISO designation TNMG 160408 NM 7 TNMG 160412 NM 7 TNMG 160416 NM 7 TNMG 220408 NM 7 TNMG 220412 NM 7 TNMG 220416 NM 7 WNMG 060408 NM 7 WNMG 060412 NM 7 WNMG 080408 NM 7 WNMG 080412 NM 7 WNMG 080416 NM 7 WNMG 100608 NM 7 WNMG 100612 NM 7 WNMG 100616 NM 7

Cutting parameters Depth of cut Feed ap = mm f = mm 2,0 6,0 2,0 6,0 2,0 6,0 2,0 7,0 2,0 7,0 2,0 7,0 1,5 5,0 1,5 5,0 2,0 6,0 2,0 6,0 2,0 6,0 2,0 8,0 2,0 8,0 2,0 8,0 0,30 0,45 0,30 0,50 0,40 0,55 0,30 0,50 0,30 0,50 0,40 0,60 0,25 0,40 0,30 0,45 0,30 0,45 0,30 0,55 0,40 0,65 0,30 0,50 0,30 0,60 0,40 0,65

D-067

NM7

Double-sided indexable insert Medium to high feeds and depths of cut for a double-sided indexable insert Cutting edge sintered on the periphery Chip breaker sintered in the insert Stable cutting edges for turning operations with severe interrupted cut For important casting and forging skins or sand inclusions The geometry for the best profitability for extreme rough machining operations

153

P Rm=N/mm2
600 10001200 12001500 6001000 VII

K
GGGGG-

N S

WALTER SELECT

...A NF5 NS4 NS5 NS8 NM4 NM5 NM7 .NMG .NMG-G1 = well suitable

A AB B B BC BC C BC B

+ + + + + + + + + + = suitable with limits

= suitable

5.8.1

Double-sided Indexable Inserts with Negative Basic Shapes: Summary

The double-sided turning inserts cover the main part of the requirements for turning steel and cast materials. The controlled chip breaking is ensured within an extremely wide range for long-chipping steel materials. " " from nishing to roughing

The different protective chamfers, clearance angles, tool orthogonal rakes as well as the resulting wedge angles enable a profitable application up to 1500 N/mm2. These indexable inserts are used for steel and casting materials as well as for austenitic steel materials with a high nickel content.

155

ISO designation CNMM 120408 NR 5 CNMM 120412 NR 5 CNMM 120416 NR 5 CNMM 160608 NR 5 CNMM 160612 NR 5 CNMM 160616 NR 5 CNMM 160624 NR 5 CNMM 190612 NR 5 CNMM 190616 NR 5 CNMM 190624 NR 5 DNMM 150608 NR 5 DNMM 150612 NR 5 SNMM 120408 NR 5 SNMM 120412 NR 5 SNMM 120416 NR 5 SNMM 150608 NR 5 SNMM 150612 NR 5 SNMM 150616 NR 5 SNMM 150624 NR 5 SNMM 190612 NR 5 SNMM 190616 NR 5 SNMM 190624 NR 5 SNMM 250716 NR 5 SNMM 250724 NR 5 TNMM 160408 NR 5 TNMM 160412 NR 5 TNMM 160416 NR 5 TNMM 220408 NR 5 TNMM 220412 NR 5 TNMM 220416 NR 5

Cutting parameters Depth of cut Feed ap = mm f = mm 1,5 8,0 2,0 8,0 2,5 8,0 1,5 10,0 2,0 10,0 2,5 10,0 3,5 10,0 2,0 12,0 2,5 12,0 3,5 12,0 1,0 6,0 1,5 6,0 1,5 8,0 2,0 8,0 2,5 8,0 1,5 10,0 2,0 10,0 2,5 10,0 3,5 10,0 2,0 12,0 2,5 12,0 3,5 12,0 5,0 18,0 5,0 18,0 1,0 6,0 1,5 6,0 2,0 6,0 1,0 7,0 1,5 7,0 2,0 7,0 0,30 0,50 0,40 0,65 0,50 0,65 0,30 0,50 0,40 0,70 0,50 0,80 0,60 1,00 0,40 0,70 0,50 0,80 0,60 1,00 0,30 0,50 0,35 0,60 0,30 0,50 0,40 0,65 0,50 0,65 0,30 0,50 0,40 0,70 0,50 0,80 0,60 1,00 0,40 0,70 0,50 0,80 0,60 1,00 0,60 1,20 0,80 1,50 0,30 0,50 0,35 0,60 0,35 0,60 0,30 0,50 0,35 0,60 0,35 0,60

D-069

5.9

Single sided Indexable Inserts with Negative Basic Shapes Single sided indexable insert Cutting edge sintered on the periphery Chip breaker sintered in the insert For rough machining For an optimum combination between safety and small cutting forces Multirange chip breaker Positive geometry for an excellent roughing performance also with thin workpieces

157

ISO designation CNMM 120408 NR 7 CNMM 120412 NR 7 CNMM 120416 NR 7 CNMM 160612 NR 7 CNMM 160616 NR 7 CNMM 190612 NR 7 CNMM 190616 NR 7 CNMM 190624 NR 7 SNMM 120408 NR 7 SNMM 120412 NR 7 SNMM 120416 NR 7 SNMM 150612 NR 7 SNMM 150616 NR 7 SNMM 190612 NR 7 SNMM 190616 NR 7 SNMM 190624 NR 7 SNMM 250716 NR 7 SNMM 250724 NR 7 SNMM 250916 NR 7 SNMM 250924 NR 7

Cutting parameters Depth of cut Feed ap = mm f = mm 1,0 7,0 1,5 7,0 2,0 7,0 1,5 9,0 2,0 9,0 1,5 12,0 2,0 12,0 2,5 12,0 1,0 7,0 1,5 7,0 2,0 7,0 1,5 9,0 2,0 9,0 1,5 12,0 2,0 12,0 2,5 12,0 4,0 16,0 4,0 16,0 4,0 16,0 4,0 16,0 0,20 0,50 0,25 0,60 0,32 0,70 0,25 0,60 0,32 0,70 0,25 0,60 0,32 0,70 0,35 1,00 0,20 0,50 0,25 0,60 0,32 0,70 0,25 0,60 0,32 0,70 0,25 0,60 0,32 0,70 0,35 1,00 0,40 0,80 0,50 1,20 0,40 0,80 0,50 1,20

D-070

NR7

Singlesided indexable insert Cutting edge sintered on the periphery Chip breaker sintered in the insert To achieve a high profitability for roughing operations where large support faces are required This chip breaker works with the highest feed and depth of cut, with an excellent chip breaking Low power requirement

159

P Rm=N/mm2
600 10001200 12001500 6001000 VII

K
GGGGG-

N S

WALTER SELECT

NR5 NR7 = well suitable

D CD = suitable

+ + = sutable with limits

5.9.1

Single sided Indexable Inserts with Negative Basic Shapes: Summary

Compared with the double-sided turning inserts, the variety of the single sided inserts is smaller. This is dictated by the workpiece parameters i.e the amount of heavy machining required. Single sided inserts are economical in the cases where double-sided inserts might tilt and break during the operation, or when high chip removal volumes exceed the capacities of a double-sided turning insert.

161

ISO designation CCGT 060202 PF 5 CCGT 060204 PF 5 CCGT 09T302 PF 5 CCGT 09T304 PF 5

Cutting parameters Depth of cut Feed ap = mm f = mm 0,1 0,6 0,2 0,6 0,1 1,0 0,2 1,0 0,04 0,10 0,06 0,12 0,04 0,10 0,06 0,12

17

PF5

D-072

5.10

Single sided Indexable Inserts with Positive Basic Shapes

Indexable inserts with positive basic shapes are mainly used for internal turning on machining centres and lathes or for turning unstable or small workpieces. Positive indexable inserts combine small cutting forces with a high cutting edge stability. The lever-action clamping system brings stability and it has no protruding clamping element. It enables chip flow without any obstacle and provides a compact execution for the complete tool. The positive insert programme includes modern geometries covering the machining range from roughing to superfinishing. For turning aluminium alloys, the turning insert programme includehs the PM2 geometry for aluminium. PF5 Single sided indexable insert For superfinishing Cutting edge sintered on the periphery with sintered chip breaker Sharp, positive cutting edge Small feeds and depths of cut Highest requirements for tolerance accuracy and quality of surface

163

ISO designation CCMT 060202 PS 4 CCMT 060204 PS 4 CCMT 060208 PS 4 CCMT 09T302 PS 4 CCMT 09T304 PS 4 CCMT 09T308 PS 4 CCMT 120404 PS 4 CCMT 120408 PS 4 DCMT 070202 PS 4 DCMT 070204 PS 4 DCMT 070208 PS 4 DCMT 11T302 PS 4 DCMT 11T304 PS 4 DCMT 11T308 PS 4 SCMT 09T304 PS 4 SCMT 09T308 PS 4 SCMT 120404 PS 4 SCMT 120408 PS 4

Cutting parameters Depth of cut Feed ap = mm f = mm 0,1 1,0 0,1 1,5 0,1 2,5 0,1 1,0 0,1 1,5 0,1 2,5 0,1 1,5 0,1 2,5 0,1 1,0 0,1 1,5 0,1 2,5 0,1 1,0 0,1 1,5 0,1 2,5 0,1 1,5 0,1 1,8 0,1 1,5 0,1 1,8 0,04 0,12 0,05 0,16 0,08 0,20 0,04 0,12 0,05 0,16 0,08 0,20 0,05 0,16 0,08 0,20 0,04 0,12 0,05 0,16 0,08 0,20 0,04 0,12 0,05 0,16 0,08 0,20 0,05 0,15 0,05 0,18 0,05 0,15 0,05 0,18

D-073

PS4

Single sided indexable insert Cutting edge sintered on the periphery Cutting edge specially adapted for finishing operations Good results with austenitic stainless steel grades Small cutting forces with an excellent chip breaking

165

ISO designation TCMT 110202 PS 4 TCMT 110204 PS 4 TCMT 110208 PS 4 TCMT 16T302 PS 4 TCMT 16T304 PS 4 TCMT 16T308 PS 4 VCMT 110302 PS 4 VCMT 110304 PS 4 VCMT 110308 PS 4 VCMT 160404 PS 4 VCMT 160408 PS 4 WCMT 040202 PS 4 WCMT 040204 PS 4 WCMT 040208 PS 4 WCMT 06T302 PS 4 WCMT 06T304 PS 4 WCMT 06T308 PS 4 WCMT 080404 PS 4 WCMT 080408 PS 4

Cutting parameters Depth of cut Feed ap = mm f = mm 0,1 1,0 0,1 1,5 0,1 2,5 0,1 1,0 0,1 1,5 0,1 2,5 0,1 1,0 0,1 1,5 0,1 2,5 0,1 1,5 0,1 2,5 0,1 1,0 0,1 1,5 0,1 2,5 0,1 1,0 0,1 1,5 0,1 2,5 0,1 1,5 0,1 2,5 0,04 0,12 0,05 0,16 0,08 0,20 0,04 0,12 0,05 0,16 0,08 0,20 0,04 0,12 0,05 0,16 0,08 0,20 0,05 0,16 0,08 0,20 0,04 0,12 0,05 0,16 0,08 0,20 0,04 0,12 0,05 0,16 0,08 0,20 0,05 0,16 0,08 0,20

D-073

PS4

Single sided indexable insert Cutting edge sintered on the periphery Cutting edge specially adapted for finishing operations Good results with austenitic stainless steel grades Small cutting forces with an excellent chip breaking

167

ISO designation CCMT 060204 PS 5 CCMT 060208 PS 5 CCMT 09T304 PS 5 CCMT 09T308 PS 5 CCMT 120404 PS 5 CCMT 120408 PS 5 DCMT 070204 PS 5 DCMT 070208 PS 5 DCMT 11T304 PS 5 DCMT 11T308 PS 5 SCMT 09T304 PS 5 SCMT 09T308 PS 5 SCMT 120404 PS 5 SCMT 120408 PS 5 TCMT 110204 PS 5 TCMT 110208 PS 5 TCMT 16T304 PS 5 TCMT 16T308 PS 5 VBMT 110304 PS 5 VBMT 110308 PS 5 VBMT 160404 PS 5 VBMT 160408 PS 5 VBMT 160412 PS 5

Cutting parameters Depth of cut Feed ap = mm f = mm 0,3 2,5 0,8 2,5 0,3 4,0 0,8 4,0 0,3 5,0 0,8 5,0 0,3 2,5 0,6 2,5 0,3 4,0 0,6 4,0 0,3 4,0 0,8 4,0 0,3 5,0 0,8 5,0 0,3 3,0 0,6 3,0 0,3 4,0 0,6 4,0 0,3 2,5 0,6 2,5 0,3 3,0 0,6 3,0 1,0 3,0 0,12 0,25 0,15 0,30 0,12 0,25 0,15 0,32 0,12 0,25 0,15 0,32 0,12 0,25 0,15 0,30 0,12 0,25 0,15 0,32 0,12 0,25 0,15 0,30 0,12 0,25 0,15 0,32 0,12 0,25 0,15 0,30 0,12 0,25 0,15 0,32 0,12 0,20 0,15 0,30 0,12 0,25 0,15 0,30 0,12 0,30

D-074

PS5

Single sided indexable insert Cutting edge sintered on the periphery For moderate stress Universal application with wide chip breaking range Stable protective chamfer suitable for thin forging and casting skins, slightly interrupted cuts

169

D-075

PM2

Single sided indexable insert Sintered on the periphery Tool orthogonal rake 23 Polished tool rakes to avoid sticking particles Application with aluminium alloys and similar soft non-ferrous workpiece materials Good chip flow PVD-coated insert for superfinishing in turning with very small feeds and depths of cut, applicable for steel materials

171

ISO designation CCMT 060204 PM 5 CCMT 060208 PM 5 CCMT 09T304 PM 5 CCMT 09T308 PM 5 CCMT 120404 PM 5 CCMT 120408 PM 5 CCMT 120412 PM 5 DCMT 070204 PM 5 DCMT 070208 PM 5 DCMT 11T304 PM 5 DCMT 11T308 PM 5 DCMT 11T312 PM 5 SCMT 09T304 PM 5 SCMT 09T308 PM 5 SCMT 120404 PM 5 SCMT 120408 PM 5 SCMT 120412 PM 5 TCMT 16T304 PM 5 TCMT 16T308 PM 5 TCMT 16T312 PM 5 VCMT 110304 PM 5 VCMT 110308 PM 5 VCMT 160404 PM 5 VCMT 160406 PM 5 VCMT 160406 PM 5 VCMT 160412 PM 5

Cutting parameters Depth of cut Feed ap = mm f = mm 0,4 2,5 0,6 2,5 0,4 3,0 0,6 4,0 0,4 3,0 0,6 5,0 0,8 5,0 0,4 2,0 0,6 2,0 0,4 3,0 0,6 4,0 0,8 4,0 0,4 3,0 0,6 4,0 0,4 3,0 0,6 5,0 0,8 5,0 0,4 3,0 0,6 4,0 0,8 4,0 0,4 2,5 0,6 3,0 0,4 2,5 0,6 3,0 0,6 3,0 0,8 4,0 0,12 0,25 0,16 0,30 0,12 0,25 0,16 0,35 0,12 0,25 0,16 0,40 0,20 0,50 0,12 0,20 0,16 0,25 0,12 0,25 0,16 0,30 0,20 0,35 0,12 0,25 0,16 0,35 0,12 0,25 0,16 0,40 0,20 0,50 0,12 0,25 0,16 0,30 0,20 0,40 0,12 0,20 0,16 0,25 0,12 0,25 0,15 0,25 0,16 0,30 0,20 0,35

D-076

PM5

Single sided indexable insert For moderate roughing operations For interrupted cut Forging and casting skins Austenitic stainless steels Universal indexable turning insert Cutting edge sintered on the periphery Chip breaker sintered in the insert

173

P Rm=N/mm2
600 10001200 12001500 6001000 VII

K
GGGGG-

N S

WALTER SELECT

PF5 PS4 PS5 PM2 PM5 ..MT = well suitable

A AB B BC B = suitable + + + +

= suitable with limits

5.10.1 Single sided Indexable Inserts with Positive Basic Shapes: Summary Single sided positive indexable inserts are used on low-powered machines or for unstable workpieces for classical turning operations. Their main range of applications remains as; hollowing out ,internal fine turning, on machining centres or boring-mills. These indexable inserts are also used with extended length tools.

175

+ +

U
-6

+ dg 7

S-T-U-V contact

S V

-6

U contact

0 + -

-6 95 -10
h

+
0
30

U contact
a

S-T-U-V contact
D-078

S contact

U contact

V contact

dg7 a

V contact

6. 6.1

Tool Holders Points of Impact on the Cutting Edge

The point of impact has a great significance for the stress on the milling and turning cutting edges. With the following combinations, we obtain: Axial and radial angles 0 degree Positive axial angle, radial angle 0 degree Axial angle 0 degree, positive radial angle = = = surface contact S-T-U-V linear contact S-V linear contact T-U linear contact S-T

Negative axial angle, radial angle 0 degree =

Such types of contacts are unfavourable because a large part of the chip section is generated by the first contact. Negative radial angle, positive axial angle = V contact Favourable : Helical chip geometry for milling, the cutting edge radius (nose) is spared. Turning, internal machining with positive insert basic shape.

177

+ +

U
-6

+ dg 7

S-T-U-V contact

S V

-6

U contact

0 + -

-6 95 -10
h

+
0
30

U contact
a

S-T-U-V contact
D-078

S contact

U contact

V contact

dg7 a

V contact

Positive radial angle, positive axial angle = S contact Unfavourable : The cutting edge radius makes the first contact, risk of breakage but lowest power requirement.

Negative radial angle, negative axial angle = U contact Favourable : The best protection for the cutting edge but highest power requirement if indexable inserts without chip breakers are used. For indexable inserts with chip breakers, the power drops by 1% (medium tool orthogonal rake for turning 12 degrees in the chip breaker, and 6 degrees once mounted) per degree of positive tool orthogonal rake

179

6.2 -

Lever-action Clamping System for Indexable Inserts with Negative Basic Shapes For indexable inserts with centre holes The indexable insert is clamped by a knee lever which draws the inserts against both support faces of the insert seat. The long clamping movement of the knee lever compensates the sintering tolerances dened by ISO.

The lever-action clamping ensures: High indexing accuracy Chip ow without any obstacle, no protruding clamping elements Easy handling (clamping, releasing, changing the mounting parts) Limited spare part requirements Clamping possibilities for all current ISO shapes and dimensions Market-orientated system Mounting parts compatible with the competitors'

181

6.3 -

Bracket-type Clamping System for Indexable Inserts with Negative Basic Shapes For indexable inserts with centre holes The clamping bracket clamps the indexable insert against the wedge and downwards onto the bottom support and against the steady tubular rivet Bracket-type clamping for copying operations The large clamping movement compensates sintering tolerances The bracket brings an additional security in case of extreme stress on the cutting edges and of vibration.

183

Prestress about 0.2 mm

Prestress = 0

6.4 -

Lever-action Clamping System for Indexable Inserts with Positive Basic Shapes For indexable inserts with centre holes The indexable insert is clamped by a knee lever, just the same as the negative clamping system The long clamping movement compensates the sintering tolerances The prestress tolerance is absolutely compensated for positive indexable inserts with centre holes The positive and frictional locking is always given compared with screw clamping Easy handling of the indexable inserts even in the overhead position of the tool holder The tool holder with positive knee lever-action clamping is easily accessible from the rear No protruding clamping elements

185

90

90
45 45

C
Top clamping

90

60

75

90

B
75

C
95 95

G
107 30

M
Top and hole clamping
93

50

63

P
Hole clamping

J
45

L
93

N
60

Q
85

Width of shank b is shown in mm. Figures after the decimal point are ignored. Integers are preceded by a 0 Example: b = 8 mm = 08. For cartridges CA.

C/D/E M/V
l

R
l

S
l
72.5 72.5

S
Screw clamping

75

60

R
X

T
l

Approach angle not designated according standard. description necessary Shank width

Clamping system

Approach angle

Size of insert

P
Insert shape
80

G
Clearance angle of insert
Clearance angle

N
Hand on tool

25 25
Shank height The height of the cutting edge h1 is shown in mm. Figures after the decimal point are ignored. Integers are preceded by a 0 Example: h1= 8 mm = 08. 32 40 50 60 70 80 90 100 110 125 140 150 160 170 180 200 250 300

M 22
Lenght of toolholder = A = B = C = D = E = F = G = H =J = K = L = M = N = P = Q = R = S = T

C
55

B
5

R
7

D R
90

C E
20

S
60

F
25

T
35

N
0

h1

350 400 450 special 500

=U =V =W =X =Y

P
11

6.5

ISO Designation Code for Tool Holders for External Turning

It is prohibited to amend the symbols - letters and figures - defined for the designation. The designation symbols 1-9 must be mentioned in the given sequence. Symbol Symbol Symbol Symbol Symbol Symbol Symbol Symbol Symbol 1 2 3 4 5 6 7 8 9 The clamping system of the horizontally mounted indexable inserts Basic shape of the indexable insert Code letters for the shape of the tool holder Normal clearance angle of the indexable insert Code letters for the characteristics of the tool holder version Code figures for the height of the tool holder Code figures for the width of the tool holder Code letters for the length l1 Code figures for the size of the indexable insert

187

Tool holders for longitudinal turning and facing

6.6

Tool holders for longitudinal turning and facing

The universal tool holders which we meet on almost each CNC machine are the tool holders PCLN R/L PWLN R/L (PCLC (PWLC R/L) R/L)

and

They have not the most stable setting angle but they are preferred due to their versatility. The more stable tool holders PCSN R/L PSSN R/L

and

with a setting angle of 45 are used for roughing operations on forged and cast skins with severe interrupted cuts, meaning in the cases giving a wide but thin chip section with a forward-running cutting edge.

189

Tool Holders for Longitudinal Turning or facing

45 91+1

75

75

PTGN R/L PTGC R/L

PSDN N PSDC N 91+1

PSBN R/L PSRC R/L 75

PCBN R/L

75

PTFN R/L PTFC R/L

D-084

PSKN R/L PSKC R/L

PCKN R/L

6.7

Tool Holders for Longitudinal Turning or facing

Further tool holders are available for longitudinal turning and facing with different basic shapes of the indexable inserts (negative or positive) and different ISO standard shank sections for the different turning operations. Shank sections according to ISO. 1212 positive basic shape 1616 2020 2525 3225 3232 4040 negative basic shape

191

Tool Holders for Longitudinal Turning or facing

45 91+1

75

75

PTGN R/L PTGC R/L

PSDN N PSDC N 91+1

PSBN R/L PSRC R/L 75

PCBN R/L

75

PTFN R/L PTFC R/L

D-084

PSKN R/L PSKC R/L

PCKN R/L

- Negative basic shape: - Radial angle (inclination angle) - Axial angle - Positive basic shape: - Radial angle - Axial angle (inclination angle) (tool orthogonal rake) (tool orthogonal rake)

negative -6 negative -6

positive positive

0 0

193

Tool Holder for Copying

6.8

Tool Holder for Copying

Which tool holder is used with which insert basic shape, T or D, depends on various technical and economic points of view. Economic decision based upon the insert basic shape: Form T = 3 or 6 cutting edges Form D = 2 or 4 cutting edges Technical decision based upon the insert thickness: Form T = 4.76 mm Form D = 6.35 mm (Form D has a better heat absorbtion) Technical decision based upon the copying angle: Between setting angle + point angle towards the copying angle, there must be a 2-3 clearance angle. If this is not the case, the tool turns with its "back". Then, the copying angle is decisive, 25 or 30. - negative basic shape: - radial angle (inclination angle) - axial angle (tool orthogonal rake) - positive basic shape: - radial angle (inclination angle) - axial angle (tool orthogonal rake)

negative -6 negative -6

positive positive

0 0

195

Tool Holders for Forming by Turning and for Copying

107 30'

72 30'

93

107 30'

PDHC R/L

PRGC R/L

PRDC N

PVVB N

PVJB R/L

PVHB R/L

D-086

6.9

Tool Holders for Forming by Turning and for Copying

Round inserts are easily used for forming by turning and for manufacturing deep die sinking. Round indexable inserts enable to turn radii with the plunge-cut method at their final dimensions as they are defined in the construction drawings. For forming by turning and copying, i.e. to make relief grooves for grinding operations, we use indexable inserts with a V basic shape. Point angle 35, meaning the smallest point angle according to ISO.

- positive basic shape: - radial angle - axial angle (inclination angle) (tool orthogonal rake) positive positive 0 0

197

S
Solid steel design

R = r.h. cutting

C
Top clamping

90 90

F F

45

S
U
L = l.h. cutting

A
Solid steel design with internal coolant supply

M
Top and hole clamping

75

K
L
95

93

C
Tungsten carbide shank with steel head

P
Hole clamping
95

60

W
Y
Toolholder design

E
Tungsten carbide shank with steel head, internal coolant supply Type of shank

S
Screw clamping

107 30

85

Clamping system

Approach angle

A 20 Q P C L C R 09
Diameter of shank Diameter of shank is shown in mm. Figures after the decimal point are ignored. Integers are preceded by a 0 Length of toolholder Insert shape Clearance angle of insert Cutting edge length 32 40 50 60 70 80 90 100 110 125 140 = = = = = = = = = = = A B C D E F G H J K L 150 = M 160 = N 170 = P 180 = Q 200 = R 250 = S 300 = T 350 = U 400 = V 450 = W special = X 500 = Y
Clearance angle
80

C
55

B
5

C/D/E M/V
l

D R
90

C
7

R
l
20

E F
25

S
60

S
l

T
35

N
0

P
11

T
l

6.10

ISO Designation Code for Tool Holders for Internal Turning

The designation symbols 1-9 must be mentioned in the given sequence. Symbol Symbol Symbol Symbol Symbol Symbol Symbol Symbol Symbol 1 2 3 4 5 6 7 8 9 Construction details of the tool holder Code figures for the shank diameter Code letters for the length The type of fastening for horizontally mounted indexable inserts Basic shape of the indexable insert Code letters for the shape of the holder Normal clearance angle of the indexable insert Code letters for the execution of the tool holder Code figures for the size of the indexable insert

199

Tool Holders for Internal Turning

6.11 -

Tool Holders for Internal Turning for Indexable Inserts with Negative Basic Shapes, without Internal Coolant Supply Tool Holders with clamping and support at surfaces on the cylindrical shank for internal machining on CNC and conventional lathes without internal coolant supply. Milled relief groove for larger chip volumes The clamping and support at surfaces are used as an orientation for cutting off to a specic length and for the alignment Lever-action clamping With carbide support bottom where the design enables it Decision for a longer series according to ISO Shank diameter Length 25 T = 300 32 U = 350 40 V = 400 Basic shapes of the indexable inserts C, D, S, T Radial angle (inclination angle) negative -10 Axial angle (tool orthogonal rake) positive -6 For maximum overhang (diameter : length) d : l = 1 : 2,5

201

Tool Holders for Internal Turning

6.12

Tool Holder for Internal Turning for Indexable Inserts with Negative Basic Shapes, with Internal Coolant Supply Tool Holders with cylindrical shank for internal machining on CNC and conventional lathes with internal coolant supply. Coolant supplied very close to the cutting edge A milled part on the head of the tool holder is used as an orientation for cutting off to a specic length and for the alignment Lever-action clamping Carbide bottom support Decision for a shorter series according to ISO Shank diameter Length 20 Q = 180 25 R = 200 32 S = 250 40 T = 300 Basic shapes of the indexable inserts D, W Radial angle (inclination angle) negative -10 to -15 Axial angle (Tool orthogonal rake) - 6 For maximum overhang (diameter : length) d : l = 1 : 3,5

203

Tool Holders for Internal Turning

6.13 Tool Holders for Internal Turning for Indexable Inserts with Positive Basic Shapes, without Internal Coolant Supply Tool Holders with clamping and support at surfaces on the cylindrical shank for internal machining on CNC and conventional lathes without internal coolant supply. The clamping and support at surfaces are used as an orientation for cutting off to a specic length and for the alignment Mostly lever-action clamping, where the design does not permit it, screw clamping With carbide support bottom where the design enables it Decision for a longer series according to ISO Shank diameter Length 12 Q = 180 16 R = 200 20 S = 250 25 T = 300 32 U = 350 40 V = 400 Basic shapes of the indexable inserts C, D, S, T Radial angle (inclination angle) negative -10 bis -15 Axial angle (tool orthogonal rake) positive - 6 For maximum overhang (diameter : length) d : l = 1 : 3,5

205

Tool Holders for Internal Turning

6.14

Tool Holders for Internal turning for Indexable Inserts with Positive Basic Shapes, with Internal Coolant Supply Tool Holders with cylindrical shank for internal machining on CNC and conventional lathes with internal coolant supply. Coolant supplied very close to the cutting edge A milled part on the tool holder front part is used as an orientation for cutting off to a specic length and for the alignment Mostly lever-action clamping, where the design does not permit it, screw clamping With carbide bottom support where the design allows it Decision for a shorter series according to ISO Shank diameter Length 12 K = 125 16 M = 150 20 Q = 180 25 R = 200 32 S = 250 40 T = 300

207

Tool Holder for Internal Turning

Basic shapes of the indexable inserts C, D, S, T, V, W Radial angle (inclination angle) Axial angle (tool orthogonal rake) For maximum overhang (diameter : length) d:l=1:4

negative - 6 bis -12 positive 0

209