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Technical Info

Product catalog summary

Technical Guidance Overview

This document provides comprehensive technical guidance on machining processes, focusing on turning, milling, endmilling, and drilling. It includes detailed sections on tool failures, chip control, and machining of various materials such as hardened steel, cast iron, and hard-to-cut materials.

Basics of Turning

This section covers the fundamentals of turning, including the calculation of power requirements, cutting force, and cutting speed. It emphasizes the importance of rake angle, feed rate, and nose radius in determining cutting force and surface finish.

Tool Failures and Remedies

Common tool failures such as flank wear, crater wear, and chipping are discussed, along with their causes and remedies. Recommendations include selecting appropriate insert grades, adjusting cutting speeds, and optimizing feed rates.

Chip Control

The document outlines methods for improving chip control, such as adjusting feed rates and using inserts with larger nose radii. It highlights the impact of chip control on machining safety and surface finish.

Basics of Milling

This section explains the components of a milling cutter and the significance of various cutting angles. It provides formulas for calculating cutting speed, feed rate, and power requirements. The effects of rake angle combinations on chip removal and cutting performance are also detailed.

Tool Life and Wear

Tool life is analyzed in relation to cutting speed and wear patterns. The document includes graphs illustrating the progression of tool wear over time and provides strategies for extending tool life.

Technical References

Includes charts for steel and non-ferrous metal symbols, hardness scale comparisons, and finished surface roughness. These references support the technical guidance provided throughout the document.

Conclusion

The document serves as a comprehensive guide for optimizing machining processes, addressing common tool failures, and improving overall efficiency and safety in machining operations.

Milling Inserts and Surface Finish

The document discusses the use of milling inserts with wiper flats, which are designed to improve surface finish by having some teeth elevated to act as wiper inserts. It highlights the influence of different face angles on surface finish and the relationship between the number of engaged cutting edges and cutting force.

Tool Life and Engage Angle

The engage angle, which is the angle at which the cutting edge contacts the workpiece, affects tool life. A larger engage angle shortens tool life. Adjustments can be made by increasing cutter size or shifting its position.

Chip Control and Tool Design

Recommendations for improving chip control include selecting cutters with good chip removal features, reducing the number of teeth, and using high rake cutters with sharp edges. The document also suggests using irregular pitched cutters and improving workpiece and cutter clamp rigidity.

Tool Failure and Remedies

Common tool failures such as chattering, edge chipping, and unsatisfactory surface finish are addressed with specific remedies. These include selecting appropriate cutter types, adjusting cutting speeds, and reinforcing cutting edges.

Endmilling Techniques

The document covers the basics of endmilling, including the parts of an endmill and the calculation of cutting conditions such as cutting speed, feed rate, and depth of cut. It also discusses the differences between up-cut and down-cut milling and their effects on tool deflection and wear.

Drilling Guidance

Drilling guidance includes the importance of point angle and burr control, web thickness, and thrust. It provides recommendations for reducing chisel width by thinning and controlling cutting force for low rigidity machines.

Run-out Accuracy

Ensuring run-out accuracy is crucial for preventing drill breakage and maintaining hole precision. The document advises on maintaining peripheral run-out accuracy when the tool or workpiece rotates.

Chip Control Issues

For unsatisfactory chip control, the document suggests increasing cutting speeds and feed rates, and adjusting coolant pressure if using internal coolant.

Troubleshooting Guide for Drilling

Tool Design and Cutting Conditions: Adjustments such as increasing back taper, reducing margin width, and altering cutting speeds and feed rates are recommended to address issues like margin wear, drill breakage, oversized holes, poor surface finish, and non-straight holes.
Cutting Fluid: Use fluids with higher lubricity to improve performance and reduce wear.
General Recommendations: Refer to the general catalogue for specific cutting conditions and maintain drill run-out below 0.02 mm.

Technical Guidance on Machining

Surface Roughness and Cutting Speed: High cutting speeds stabilize surface roughness, and varying feed rates can improve surface finish by spreading notch wear.
Coolant Influence: Continuous cutting shows minimal coolant impact on tool life, but interrupted cutting can lead to thermal cracking.
Material-Specific Recommendations: Different tool materials and cutting speeds are recommended for various work materials like hardened steel, cast iron, and alloys.

Tool Failure and Remedies

Thermal Cracks: Dry conditions are recommended to prevent thermal shocks. Reducing cutting speed and force can help.
Chipping and Flaking: Use tougher grades and strengthen cutting edges. Adjust cutting conditions to reduce impact shocks and back forces.
Wear Management: Select wear-resistant grades and adjust cutting speeds and feed rates to manage flank and crater wear.

Material Specifications

Material Equivalents: Lists of JIS, AISI, and DIN standards for various materials, including steels, stainless steels, and cast irons, are provided for reference.

Overview: The document provides detailed information on various cutting tools and inserts, including indexable inserts, endmills, and SUMIBORON inserts. It also outlines safety instructions and the services offered by Sumitomo Electric Industries through their Tool Engineering Centers worldwide.

Specifications: The document lists numerous types of cutting tools and inserts, such as indexable inserts, SUMIDIA inserts, and multi-drills. Each tool type is associated with specific codes and parameters, indicating their design and application.

Safety Instructions: The document emphasizes the importance of safety when handling cutting tools. Key precautions include wearing protective equipment, ensuring proper tool clamping, and adhering to recommended usage conditions to prevent injury from sharp edges, flying debris, or tool breakage.

Tool Engineering Services: Sumitomo Electric Industries offers comprehensive support through their Tool Engineering Centers. Services include training, test cuts, technical consulting, and tooling proposals. These centers are strategically located worldwide to assist in improving manufacturing processes and solving machining problems.

Global Network: The document highlights Sumitomo's global presence, with a robust sales and production network aimed at delivering high-quality products and services to meet market demands worldwide.

Catalog excerpts

TECHNICAL INFORMATION Technical Guidance | Spare Parts | Index

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Technical Guidance References Technical Guida

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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 Cutting...

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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. Thermal...

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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 are...

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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 type,...

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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 Relation...

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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 and...

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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 Engagement...

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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 Carbide)...

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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 (m/min)...

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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 Downcut...

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All SUMITOMO ELECTRIC Hartmetall GmbH catalogs and technical brochures

Archived catalogs

CBN / PCD Tools
113 Pages
Drilling Tools
69 Pages
Turning Tools
237 Pages
Milling Tools
219 Pages
Cutting Materials
35 Pages