Table Of ContentCUTTING TOOLS
R.EDWARDS
THE INSTITUTE OF MATERIALS
Book 583
First published 1993by
The Institute of Materials
1Carlton House Terrace
London SW1Y 5DB
© 1993The Institute of Materials
All rights reserved
ISBN 0901716480
Typeset from the author's disk by
Inforum, Rowlands Castle, Hants
Printed and bound in Great Britain at
The University Press, Cambridge
Dedication
This book is dedicated to Dr. Thomas Raine who decided to employ me
in 1946 in the Physical Metallurgy Group of the Research Department
of the Metropolitan Vickers Electrical Company Ltd. Trafford Park
Manchester.
He encouraged and made it possible for me to take my MSc and PhD
degrees and gave me all my basic grounding in hard metal. I will always
be indebted to him.
R. Edwards
v
Acknowledgements
Grateful thanks are due to the following people and companies for their
help in providing some of the information and illustrations included in
this book and also for interesting and stimulating discussions on specific
subjects.
John Ashley - Kennametal V.K.
Paul Bossom - De Beers
John Haddock - Hydra Tools International PIc.
Ian Hall- Cerasiv U.K.
David Hammond - Hammond & Company
Ken Foster Hudson - Foster Hudson Ltd.
Dr. David Jack - Sandvik U.K.
J.W. Lynch - International Twist Drill
John Rennie - The Rennie Tool Co. Ltd.
P.S. Thicke - Deloro Stellite Ltd.
Special thanks must be given to Mr. Horst Woehrle of Plansee Tizit,
Austria. The author was associated with this company for almost 45
years until his retirement in November 1990.The majority of the photo-
graphs used in this book have been provided by Plansee Tizit and the
author is most grateful to them for the help he has received.
vi
Contents
Foreword xi
1. Introduction 1
2. Cutting Materials 3
2.1 High Speed Steels 4
2.2 Stellite 8
2.3 Hardmetals 9
2.4 Cermets 16
2.5 Ceramics 18
2.5.1 Sialons 18
2.5.2 Aluminium Oxide Based Ceramics 19
2.5.3 Silicon Nitride 21
2.6 Cubic Boron Nitride (CBN) 22
2.7 Polycrystalline Diamond (peD) 24
3. Brazed Tools and Indexable Inserts 27
3.1 Brazed Tools 27
3.2 Indexable Inserts 28
4. Coatings 36
4.1 Single Layer Coatings 36
4.2 Two Layer and Transitional Coatings 38
4.3 Multi Layer Coatings 39
4.4 Coating Structure 40
4.4.1 Coatings for Turning 41
4.4.2 Coatings for Milling 42
4.5 PVD Coating on Hardmetal 44
4.6 How do Coatings Work? 45
vii
viii Cutting Tools
4.7 Why Don't Coatings Break? 47
4.8 Design of Coatings 47
5. Machining Processes 50
5.1 Turning 50
5.1.1 Cutting Parameters 50
5.1.2 Cutting 'Mechanisms' 56
5.1.3 Chip Control 62
5.1.4 Cutting Edge Condition 66
5.1.5 ISO Application Groups 68
5.1.6 Workpiece Materials 71
5.1.7 Coolants 84
5.1.8 Types of Failure of Hardmetal Cutting Tools 86
5.1.9 Turning Tools 92
5.1.10 Boring Tools 107
5.1.11 Cartridges 112
5.1.12 Other Special Turning Applications 113
5.1.13 General Points and Advice 116
5.2 Parting and Grooving 117
5.3 Threading 124
5.3.1 Clamped Tooling 125
5.3.2 Thread Milling 129
5.4 Milling 130
5.4.1 Integral Shank Tools 131
5.4.2 Adaptor and Arbor Mounted Tools 134
5.4.3 Special Milling Cutters 136
5.4.4 Factors Involved in Milling 138
5.4.5 Cutting Parameters 141
5.4.6 Milling with Ceramics and CBN 150
5.4.7 Hardmetal Insert Problems 151
5.5 Drilling 152
5.5.1 Twist Drills 153
5.5.2 Gun Drills 155
5.5.3 Short Hole Drills 158
5.6 Modular Tooling and Quick Change Systems 161
6. Practical Machining Examples 168
6.1 Aluminium and Al Alloys 168
6.2 Brass, Bronze, Copper 171
6.3 Grey Cast Iron 173
Contents ix
6.4 Ductile Cast Iron 175
6.5 Hard Cast Iron 177
6.6 Free Machining and Low C Steels 179
6.7 Alloy and Medium to High C Steels 181
6.8 Tool Steels 182
6.8.1 Soft Condition 182
6.8.2 Hard Condition 183
6.9 Austenitic Stainless Steels 185
6.10 Ferritic and Martensitic Stainless Steels 187
6.11 Heat Resisting Alloys 188
6.12 Titanium and Ti Alloys 190
6.13 Plastics and Non-metallics 191
6.14 Hardmetal 192
Hardmetal Cutting Tools and Associated Standards 194
Further Information and Reading 197
