Technical Info
55Pages

TECHNICAL INFORMATION Technical Guidance | Spare Parts | Index

Technical Guidance References Technical Guida

Technical Guidance Basics of Turning Cutting Force Cutting Speed and Cutting Force Principal force (N) Calculating Power Requirement Pc : Net power requirement (KW) f : Feed rate (mm/rev) ap : Depth of cut (mm) η : Machine efficiency Cutting speed (m/min) Rake Angle and Cutting Force K c : Specific cutting force (N/mm2) l Calculating cutting force l Rough value of specific cutting force (Kc) Cutting force (N) Specific cutting force (N/mm2) Chip area (mm2) Depth of cut (mm) Feed rate (mm/rev) v c : Cutting speed (m/min) Rake angle (degree) Feed Rate and Specific Cutting Force Calculating...

Technical Guidance Tool Failures and Tool Life Forms of Tool Failures Cat. 1~5 Flank Wear Resulting from Mechanical 6 Chipping 7 Fracture causes Resulting from Chemical reactions Cause of Failure Due to the scratching effect of hard grains contained in the work material. Fine breakages caused by high cutting loads or chattering. Due to the impact of an excessive mechanical force acting on the cutting edge. Crater Wear Swaft chips removing tool material as it flow over the top face at high temperatures. Plastic Deformation Cutting edge is depressed due to softening at high temperatures....

Technical Guidance Tool Failure and Remedies Trouble Shooting Guide for Turning Damage Excessive flank wear Cause - Grade lacks wear resistance. - Cutting speed ist too fast. - Feed rate ist far too slow. - Select a wear resistant grade. P30 a P20 a P10 K20 a K10 a K01 - Use an insert with a larger rake angle. - Decrease the cutting speed. - Increase feed rates. Tool Edge Failure Cutting edge fracture Build-up edge - Select a more crater-resistant grade. - Use an insert with a larger rake angle. - Select an appropriate chipbreaker. - Cutting speed is too fast. - Feed rate and depth of cut...

Technical Guidance Chip Control Type of Chip Generation a b Type of Chip Control c Feed rate Large feed rate Shape Influence factor Application Condition Continuous chips Chip is sheared Chips appear to with good surface and separated by be torn from the finish. the shear angle. surface. Steel, Stainless steel Small feed rate Chips crack before reaching the cutting point. NC lathe (For automation) General lathe (For safety) Steel, Stainless steel Steel, Cast iron (Very low Cast iron, Carbon (Low speed) speed, very small feedrate) Work deformation Rake angle D.O.C. Cutting speed Good : C...

Technical Guidance Basics of Milling Parts of a Milling Cutter External diameter of cutter body External diameter of boss Hole diameter Width of key way Cutter Body Axial rake angle Back locating face Approach angle Setting ring True rake angle Front relief angle Overall height Inclination angle Insert Chip pocket Relief angle Diameter of cutter Locator Setting ring Wiper flat clearance angle Major cutting edge Inward dish Chamfered corner (if trail angle) or wiper flat (if 0°) Radial rake angle l Calculating cutting force ap . ae . vf . Kc 60 5 106 5 η Work- –––s––– piece Alloy steel No. l...

Technical Guidance Basics of Milling Functions of the Various Cutting Angles Functions Controls chip removal direction, effects adhesion of the chips and thrust force etc. Approach angle True rake angle (Effective rake angle) The effect of the small approach angle is to reduce the chip thickness and cutting force. Controls cutting performance and ability to retain a cutting edge Influences Rake angles can vary from positive to negative (large to small) with typical combinations of positive and negative, positive and positive or negative and negative configurations. Controls chip thickness...

Technical Guidance Basics of Milling Relation Between Engage Angle and Tool Life Insert Rotation Relation to tool life Engage angle denotes the angle by which the full length of the cutting edge comes in contact with the workpiece, with reference to the feed direction. The larger E is, the shorter the tool life. To change the value of E: 1) Increase the cutter size 2) Shift the position of the cutter Small diameter Cutting area by tool life (m3) Large diameter Cutting area by tool life (m3) Relation to cutter position Relation to cutter diameter Workpiece feed direction Engagement angle...

Technical Guidance Tool Failure and Remedies Trouble Shooting Guide for Milling Excessive Flank Wear Basic Remedies P30 a P20 a K20 a K10 Cutting Conditions Excessive Crater Wear Cutting Edge Failure Tool Design Unsatisfactory Machined Surface Finish - Reduce cutting speeds. - Reduce depth-of-cut and feed rate. Cutting Conditions Tool Design Others Unsatisfactory Chip Control Tool Design Cutting Conditions Tool Design Cutting Conditions Steel Finishing Cast Iron Non-Ferrous Alloy ACK200 (Coated Carbide) DA1000 (SUMIDIA) Roughing ACP100 (Coated Carbide) ACK200 (Coated Carbide) DL1000 (Coated...

Technical Guidance Basics of Endmilling Parts of an Endmill Body Neck Cutter sweep Neck diameter Land width Relief width Diameter Neck length Length of cut Radial relief Radial primary relief angle Radial secondary relief angle Margin width Shank diameter Center hole Shank length Overall length Rake face land width Rake angle Helix angle Radial cutting edge End cutting edge End gash Rounded flute bottom Center hole Flute depth Axial primary relief angle Chip pocket Axial secondary relief angle Ball radius Concavity angle of end cutting edge Calculating Cutting Conditions vc : Cutting speed...

Technical Guidance Basics of Endmilling Up-cut and Dowm-cut Up-cut Workpiece Workpiece Feed l Surface roughness Feed dir. l Condition Workpiece: C50 Endmill: GSX21000C-2D (ø10 mm, 2 teeth) Flank wear width (mm) Relation Between Cutting Condition and Deflection Down-cut Up-cut Cutting conditions: vc = 88 m/min (n = 2.800 min-1) v f = 530 mm/min f z = 0,1 mm/tooth ap = 15 mm ae = 0,5 mm Side milling Work material: Pre-hardened steel (40HRC) Cutting data: vc = 25 m/min ap = 12 mm ae = 0,8 mm Work material: Pre-hardened steel (40HRC) Cutting data: vc = 25 m/min Up ap = 8 mm cut side ae = 8 mm...