Sandvik Ebook
Sandvik Ebook
• Theory B4
• Selection procedure B7
• System overview B 11
• Troubleshooting B 36
B3
A Theory
Parting off
B
Chip evacuation is essential
Parting and
workpiece.
• Typical chips are clock-spring shaped,
E narrower than the groove.
• The insert geometry shrinks the chip
width.
Drilling
F
Parting off – definition of terms
n
Boring
H
Other information
Machinability
B4
Theory
A
Turning
Feed rate reduction is often advantageous for performance
when machining towards the centre to minimize the pressure
on the cutting edge.
B
Parting and
grooving
• Cutting speed declines to zero at the
C
centre.
Threading
D
100 – 0% of vc
Milling
Feed reduction towards centre E
To reduce pip size, the feed should be reduced by up to
75% when approaching the centre, around 2 mm before
the part comes off.
Drilling
F
H
Other information
Machinability
B5
A Theory
C
n = spindle speed (rpm)
n vc = cutting speed (m/min)
Threading
E
Face grooving– definition of terms
The feed has a great influence on chip formation, chip
Drilling
H
Other information
Machinability
B6
Selection procedure
A
Turning
Production planning process B
Parting and
grooving
Dimension and quality
of the groove or face
C
1 Component
Workpiece material,
Threading
chip evacuation
Machine parameters
2
Milling
Machine
E
Type of tool:
- Spring-clamp
- Screw-clamp
3
Drilling
Choice of tool
- Insert type
How to apply
G
Tool holding
B7
A Selection procedure
Parameters to be considered
B Component
•A
nalyse the dimensions and quality
demands of the groove or face to be
Parting and
machined.
grooving
Material
P M K
• achinability
M
N S H
Milling
• Clamping
• Chip breaking
E
• Hardness
• Alloy elements
Drilling
F
2. Machine parameters
Condition of the machine
•S tability, power and torque especially for
Boring
larger diameters
• Component clamping
G • Tool changing times/number of tools in
turret
• Chip evacuation
Tool holding
H
Other information
Machinability
B8
Selection procedure
A
3. Choice of tools
Turning
Example of different machining methods
Multiple grooving
B
•M
ultiple grooving is the best method for
rough grooving when the depth is bigger
Parting and
than the width.
grooving
•M
ake a "fork". This will improve chip flow
and increase tool life.
C
Threading
D
Plunge turning
•P
lunge turning is the best choice when
machining steel and stainless steel and
Milling
when the width of the groove is larger
than the depth.
• Good chip control. E
Drilling
F
Ramping
•R
amping avoids vibration and minimizes
Boring
radial forces.
•R
ound inserts are the strongest inserts G
available.
• Double the number of cuts/passes.
Tool holding
H
Other information
Machinability
B9
A Selection procedure
4. How to apply
Turning
ar
Milling
5. Troubleshooting
E Some areas to consider
B 10
System overview
A
System overview
Turning
External parting and grooving
B
1. Parting-off solid bars and tubes 4. Shallow to deep grooving
2. Turning and recessing 5. Face grooving
Parting and
3. Undercutting 6. Profiling
grooving
4 C
Threading
6
D
1
4
Milling
3 4
2
E
Drilling
Internal grooving F
3. Profiling
G
3
Tool holding
1 2
H
1
Other information
Machinability
B 11
A System overview
Different systems
Turning
Insert type
B
Q-Cut Q-Cut U-Lock
Application CoroCut2 CoroCut1 CoroCut3 151.2 151.3 154.0
Parting and
Parting
grooving
(Cut off)
Medium Deep Shallow Deep
C
Grooving
Internal,
Threading
small dia.
Face grooving
D
Turning
Milling
Profiling
E
Undercutting
Drilling
Circlip groov-
F ing
Boring
Second
Shallow parting – Ø ≤12 mm
choice
H
Other information
Machinability
B 12
System overview
A
Turning
Different systems
B
Parting and
grooving
≥25 C
≥12
≥4.2 ≥10
Threading
D
Milling
E
Drilling
F
G
Tool holding
H
Other information
Machinability
B 13
A System overview
Inserts
Turning
Overview
B
Application
Parting and
grooving
Parting
C Machining condi- (Cut off)
Grooving Turning Profiling Profiling
tion
Threading
Finishing CF GF TF
D
Medium CM GM TM RM AM
Milling
Roughing CR
E
Optimizer RO
Drilling
Sharp CS RS
F
ER treated
GE RE
Boring
G
Tool holding
H
Other information
Machinability
B 14
Parting and grooving – how to apply
A
Turning
B
Parting & grooving
and how to apply
Parting and
grooving
• Parting & grooving general and how to apply B 16
C
Threading
• General grooving and how to apply B 25
Milling
• Profiling and how to apply B 31
E
• Turning and how to apply B 33
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
B 15
A Parting and grooving – how to apply
Best stability
Threading
•O
verhang (ar) should be as small as
possible.
D
• largest seat size should be used.
• ar = 8 x la max
Milling
E
Internal machining
Shank type:
Drilling
to 7 x dmm.
G
Tool holding
Inserts:
• Use smallest possible width
• Use light cutting geometries.
H
Other information
Machinability
B 16
Parting and grooving – how to apply
A
Turning
System considerations
B
Deep parting – Ø ≤112 mm
Parting and
grooving
Medium parting – Ø ≤40 mm
Threading
D
Milling
clamp blades with single parting are screw-clamp for economic parting in
edge inserts. holders with 2-edge mass production.
inserts. E
Drilling
Tool block with spring-clamp tool blade for
tool overhang adjustment. F
H
Other information
Machinability
B 17
A Parting and grooving – how to apply
Features/Benefits
• Quicker insert change
B
• Cut off larger diameter
• Adjustability
Parting and
grooving
• Deep grooving
• Double ended
C • Radial feed only
Threading
•E
xtremely small insert widths
G - grooving down to 0.5 mm
- parting down to 1 mm.
• Cutting depths up to 6 mm.
Tool holding
B 18
Parting and grooving – how to apply
A
Parting-off bars
Turning
Overhang should not exceed 8 x la (width
of insert).
Max ar = 8 x la B
(width of insert) Use as narrow an insert as possible:
- To save material
Parting and
- Minimise cutting force
grooving
- Minimise environmental pollution.
Threading
D
Material savings
Milling
E
Drilling
F
Positioning of the tool
Use maximum deviation of ±0.1 mm from
Max ±0.1 mm
centre line.
Boring
B 19
A Parting and grooving – how to apply
C
Hand of insert
Three types of insert with different entering
Threading
angles:
Hand of insert
- Right hand (R)
- Neutral (N)
D - Left hand (L)
Milling
E
Insert geometry
Neutral entering angle
Drilling
• Increases strength
• Higher feed/productivity
F rε • Better surface finish
laa • Straighter cut
rε ϕr = 0 • Pip stays on part falling off.
Boring
• Smaller PIP
• Better chip control
• Lower feed rate
H Large corner radius
• Increased feed rate
Other information
B 20
Parting and grooving – how to apply
A
Turning
EasyFix sleeves
B
Parting and
accurate machining with less
grooving
vibration and precise height.
Threading
D
Recommended overhang
Milling
dmm
E
Carbide reinforced
dampened bars
Drilling
l <7 x dmm
dmm F
l ≤5 x dmm G
dmm
Tool holding
H
Other information
l ≤3 x dmm
Machinability
B 21
A Parting off – how to apply
Parting off
Pip reduction by using different front angles
Turning
D
Milling
Note!
A front-angled insert will give reduced
E chip control due to the direction of the
chip flow. (A neutral insert directs the chip
Example of front angles on
1-, 2- and 3-edge inserts: straight out of the groove).
5°, 10°, 8°, 12°, 15°, 20°
Drilling
H
Other information
Machinability
B 22
Parting off – how to apply
A
Parting-off tubes
Turning
Parting-off tubes
Use insert with the smallest possible B
width (la) to save material, minimise cutting
force and environmental impact.
Parting and
grooving
C
Threading
Make sure that the lowest possible cutting
forces are generated. Use inserts with the
smallest possible width and sharpest cut- D
ting edges.
Milling
Practical hints E
Max ±0.1 mm
•C
entre height is impor-
tant, ±0.1 mm.
Drilling
• If sub spindle is used,
pull away the component
approx. 1 mm before F
centre.
Ø1 •R
educe feed by up to
75% approx. 2 mm
Boring
0.25 x fn
Tool holding
H
Other information
Machinability
fn
B 23
A Parting off – how to apply
E
Drilling
F
Boring
H
Other information
Machinability
B 24
Grooving – how to apply
A
General grooving
Turning
•S
ingle cut grooving is the most
economic and productive method to B
produce grooves.
• If the depth of the groove is bigger than
Parting and
grooving
the width, multiple grooving is the best
method for rough grooving.
•A
screw-clamp tool holder should be
C
selected for grooving operations.
Threading
D
Milling
E
Single cut grooving
•E
conomic and productive method to
Drilling
produce grooves.
• F inishing geometry has width tolerance
F
of ±0.02 mm and works well in low
feeds.
•W
iper inserts give extremely high quality
surface on the side of the groove.
Boring
G
Tool holding
H
Other information
Machinability
B 25
A Grooving – how to apply
Multiple grooving
Turning
C
Threading
D
Practical hints
When producing high quality grooves, there is often a
need for chamfered corners.
Milling
E
•O
ne way is to use the corners on the in-
A sert, for example, of a finishing grooving
insert, to chamfer, see illustration A.
Drilling
F
Boring
B •A
better way to make grooves with
G chamfer in mass production, is to order
a Tailor Made insert with the exact
chamfer form, see illustration B.
Tool holding
H
Other information
Machinability
B 26
Circlip grooving – how to apply
A
Circlip grooving
Turning
Circlips on shafts and axle components
are very common.
B
•C
irclip grooving can be performed with
three-edge inserts or two-edge grooving
Parting and
inserts.
grooving
• F or internal grooving there is also a wide
choice of inserts and boring bars.
C
Threading
Systems to choose from
D
3-edge inserts 2-edge inserts
• F or best economy, use 3-edge inserts in
widths 1.15 - 4.15 mm.
•O
r 2-edge inserts in widths
Milling
1.85 - 5.15 mm.
E
internal inserts Carbide rod inserts
• Internal inserts are available for min.
hole diameter 10 mm and with circlip
widths 0.73–1.70 mm.
Drilling
•M
in hole diameter for carbide rod inserts
is 4.2 mm and circlip widths F
are 0.78 - 1.98 mm.
Boring
B 27
A Face grooving – how to apply
Face grooving
Turning
D
Milling
F
Boring
•C
urved tool for face • Curved tool for face •E
xchangable cutting
G grooving, shank 0º style. grooving, shank 90º blades make it possible
style. to make special tool from
standard tools.
Tool holding
H
Other information
Machinability
B 28
Face grooving – how to apply
A
Turning
• T ool is fed axially towards
the end surface of the
part. B
• T ool must be adapted to
the bending radius of the
Parting and
groove.
grooving
•M
achine largest diameter
and work inwards for
best chip control. C
Threading
D
Right hand (R) tool
Milling
Choice of A and B curve, right or left hand tool E
Choose the correct tool – A or B curve, right or left hand
style - depending on machine set-up and workpiece rotation.
www.tool-builder.com
Drilling
F
Boring
G
Tool holding
H
Other information
Machinability
B 29
A Face grooving – how to apply
1
2
C
2 If the insert support rubs workpiece
outside dia:
- maybe the dia. range is wrong
Threading
Roughing Finishing
E
2
1
Drilling
First cut (1) always starts Machine the first cut (1) within the given
on the largest diameter diameter range.
and works inwards. The
Boring
B 30
Profiling – how to apply
A
Profiling
Turning
When machining components with complex
shapes, profiling inserts offer great oppor-
tunities for rationalisation. B
•M
odern parting and grooving tool sys-
Parting and
tems can also perform turning.
grooving
•A
screw-clamp tool holder should be
selected for turning and profiling
operationd in view of achieving maximum C
stablility.
•A
neutral tool holder is suitable for both
opening up or completing a recess.
Threading
• T he round shape inserts have dedicated
geometries for these operations.
D
Milling
E
Drilling
F
Boring
Ramping
G
Tool holding
•U
se round inserts for outstanding chip control and good
surface finish.
• In unstable set-ups, use ramping to avoid vibrations.
H
Other information
Machinability
B 31
A Turning – how to apply
Profile turning
Turning
component radius.
grooving
• If you must have the same insert radius as the com-
ponent radius, use micro stops to make the chip short
C and avoid vibrations.
Threading
F
Boring
G
Tool holding
H
Other information
Machinability
B 32
Turning – how to apply
A
Turning
Turning
The most common applications for wide
grooves or turning between shoulders
are multiple grooving, plunge turning or B
ramping. All three methods are roughing
operations and have to be followed by
Parting and
a separate finishing operation. A rule of
grooving
thumb is that if the width of the groove is
smaller than the depth – multiple grooving
should be used and vice versa for plunge C
turning. However, for slender components,
the ramping method may be used.
Threading
D
•U
se holders with smallest possible over-
hang, screw clamping and insert with rail
Milling
shape if possible.
•U
se a stable, modular tooling system if
possible. E
Drilling
Roughing F
Boring
G
Tool holding
B 33
A Turning – how to apply
Finishing
Turning
C
Threading
Axial turning
E Surface finish
•Y
ou get the best wiper effect when you
Ra max ”find” the right combination between
feed (fn) and blade deflection.
F
a value below 0.5 µm will be generated
•R
with high bearing.
Boring
G
Tool holding
H
Other information
Machinability
B 34
Undercutting – how to apply
A
Undercutting
Turning
• When a clearance is needed.
• T hese applications require dedicated inserts with round B
cutting edges that are sharp and accurate.
• The tolerance of these inserts is high: +/– 0.02 mm.
Parting and
grooving
C
Threading
D
Tools for undercutting
Angled Angled 20° Angled 45°
7° ,45° and 70°
Milling
E
Drilling
F
•H
older for external under- •H
older for internal under- •H
older for external under-
cutting. Insert with two cutting. Insert with two cutting. Insert with one
cutting edges. cutting edges. cutting edge.
Boring
G
Tool holding
H
Other information
Machinability
B 35
A Troubleshooting
Troubleshooting
Turning
Tool wear
B
Problem
Parting and
grooving
More positive
geometry ++
D
Tougher grade ++
Milling
More wear
E resistant grade ++ + +
Increase cutting
+
Drilling
speed
F
Decrease cut-
ting speed + + ++
Boring
Reduce feed
G rate ++ + +
Tool holding
Choose stronger
geometry + ++
H
Other information
B 36
Troubleshooting
A
Problem Solution
Turning
Bad surface
• Use a short and stable • Check speed / feed
tool. guidelines. B
• Take away the chips – • Use wiper geometry.
use geometry with good • Check tool set-up.
Parting and
chip control.
grooving
C
Bad surface on aluminium
Threading
• Select the sharpest • Select a special soluble
geometry. oil for the material.
• Use geometry with good
chip control. D
Milling
Bad chip breaking
• Change geometry.
• Select a higher feed. E
• Use dwelling (pecking).
• Increase coolant.
Drilling
Vibration
F
• Use a stable set-up. • Check tool condition.
• Check speed / feed • Check tool set-up.
guidelines.
• Use shorter overhang.
Boring
• Change geometry.
G
Poor tool life
Tool holding
B 37