APPLICATION GUIDE Heat resistant super alloys
High pressure coolant machining for better productivity and results More information Useful information and application techniques can be found in our catalogues, handbooks and application guides, such as PluraGuide. CoroGuide web is an internet-based catalogue including a cutting data module (also available on CD) where you can find cutting data recommendations for your specific application. Visit our websites for the latest news! www.sandvik.coromant.com www.aero-knowledge.
Contents Introduction 1. Heat resistant super alloys – HRSA Alloy groups 2 3 4 4. Milling 60 Production planning process 61 Typical components 61 Machining strategy 62 64 Machinability/raw material condition 5 Cutter concept Common component types 7 Milling process with indexable inserts 65 Coolant requirement 8 Face milling with carbide inserts 68 End milling/90 degree approach 77 Ceramic milling 82 Solid carbide – CoroMill Plura in HRSA machining 88 97 2.
Introduction This application guide concentrates on optimizing machining of heat resistant super alloys (HRSA). For one of the most challenging material groups to machine, optimized tools are naturally a prerequisite, but equally important is how to apply them. We will guide you through the most common materials and machining applications.
1. Heat resistant super alloys – HRSA Heat resistant super alloys (HRSA) are a family of alloys utilised in various industry segments: Aerospace engine – combustion and turbine sections. Stationary gas turbines – combustion and turbine sections. Oil and gas – marine applications. Medical – joint implants. The properties which make them attractive are: • Retension of strength and hardness at high temperatures. • Corrosion resistance.
Alloy groups HRSA materials fall into three groups: nickel-based, iron-based and cobalt-based alloys. The physical properties and machining behaviour of each varies considerably, due both to the chemical nature of the alloy and the precise metallurgical processing it receives during manufacture. Whether the metal is annealed or aged is particularly influential on the subsequent machining properties.
With such a wide spread of materials under the generic heading of HRSA the machining behaviour can vary greatly even within the same alloy group. In fact the same material can have numerous machining recommendations.
Comparison of wear depending upon material hardness and insert grade CNMX 1204A1-SM – vc 50 m/min, fn 0.25 mm/r, ap 1.5 mm Hard material Soft material S05F GC1105 6 min GC1105 12 min S05F 7 min 3.5 min Chip hammering Raw material production method Depending upon the size, shape and strength requirements of the component, various production methods for the blank material will be adopted. The production method varies the machinability of the material and will change the wear characteristics.
Common component types Typical HRSA components, and an indication of the different machining methods involved for each include: Aerospace and gas turbine – nickel based Component Turning Milling Drilling Others Discs 60% 10% 5% 25% Casings 45% 40% 15% Rings 95% 5% Blades Blisks Impellers 10% 50% Shafts 70% 5% 25% Turning Drilling 40% Medical – CoCr Component Milling Cup 90% 10% Head 90% 10% Others 7
Coolant requirements Coolant should be applied in all operations excluding milling with ceramics. The volume should be high and well directed. High pressure coolant HPC (up to 80 bar) shows positive results in terms of tool life and consistency. Dedicated HPC-tools with fixed nozzles give parallel laminar jets of coolant with high velocity accurately directed at the right zone between insert and chip.
2. Turning of nickel-based materials – aerospace engine and stationary gas turbines Classification of machining stages The production cycle for the machining of a HRSA component can be broken into three distinct stages, each with specific demands on the tooling and the machined surface. FSM – First stage machining – up to 10 mm depth of cut The forged components often have rough, uneven skin or scale.
ISM – Intermediate stage machining – 0.5 to 5 mm depth of cut At this stage the material is mainly in the final hard/aged condition, (the hardness is typically 36 to 46 HRC) having undergone some form of heat treatment after FSM. Material to be removed The ISM process involves profiling of the component with varying depths of cut at moderate tolerances, where productivity is important but insert security is equally vital. In this area, ceramics offer the best productivity where stability allows.
Typical wear mechanisms With carbide grades two wear mechanisms dominate – plastic deformation and notch wear. It is important to identify which is the most prominent before selecting the correct grade and strategy. Notch wear on main cutting edge is a mechanical wear which is concentrated at the depth of cut.
Top slice wear – this type of wear is common for ceramics in HRSA. Small slices of the cutting tool material are lost around the insert’s top face. When the flank of the insert is worn, the workpiece pressure against the periphery will be high enough to break small slices away along the edge line.
Insert shape selection Entering angle – kr With a standard C/D/SNMG style insert for roughing, the entering angle is constant regardless of depth of cut. CNMX CNMG DNMG However, with round inserts the entering angle varies from 0 to 90° depending upon the ratio between depth of cut and diameter. SNMG RCMT Effect of entering angle Notch wear on the inserts is the major problem when machining HRSA.
Selecting the right insert for the job Best productivity FSM - to shoulder - pocketing LSM Thin walls 14 Depth of cut ISM
Xcel insert – high productive machining into a corner Examples of machining Casing Ring A tooling solution for semi-rough turning into shoulders, combines a host of design advantages combing the benefits of a square and rhomboid insert into one single tool: • reduced notch wear and increased feeds compared to rhombic inserts. • reduced radial forces and constant chip thickness compared to round inserts.
The inserts fit into a standard CNMG holder but require a new shim to accommodate their design. New shims 5322 234-07 for T-Max P lever design holders 5322 234-08 for CoroTurn RC holders Tool life test – Inconel 718 (46 HRC) – ap 1.7 mm, fn 0.
Turning of heat resistant super alloys Xcel allows productivity to be doubled in nickel-based HRSA, through increased cutting data and a longer-lasting tool life. Data Competitor Xcel Insert: Competitor CNMX 12 04 A2-SM grade GC1005 Feed: Cutting speed: Number of components/edge: 0.2 mm/r 32 m/min 1 piece 0.3 mm/r 50 m/min 2 pieces Material: NIMONIC PE 16 Ring, diameter 650 mm Cutting depth: 1.7 mm Result Over 100 % productivity increase Time in cut reduction: 8 min to 3.
Round inserts and CoroCut®inserts with -RO geometry Round inserts are the strongest inserts available, and allow high productivity. Typically aerospace components are large, with large radii and blending profiles Entering angle – designed to eliminate high stress points allowing round inserts to be used. kr The best performance is achieved when the entering angle remains under 45°. This gives a depth of cut of 0.15 x insert diameter (the maximum depth of cut should be no greater than 0.25 x diameter).
Chip thickness iC The chip thickness varies with round inserts, and depends upon the entering angle. With low ap/iC ratios, the feed can be increased in order to raise the chip thickness to a desired level. fn kr Recommended chip thicknesses hex for HRSA are: Carbide 0.1 to 0.35 mm Ceramic 0.08 to 0.15 mm Depth of cut to diameter ratio ap/iC hex fn = 3 0.75 0.6 0.45 0.3 0.15 4 1 0.8 0.6 0.4 0.2 5 1.25 1 0.75 0.5 0.25 6 1.5 1.2 0.9 0.6 0.3 8 2 1.6 1.2 0.8 0.4 10 2.5 2 1.5 1 0.5 12 3 2.4 1.
Application hints ‘Wrap-around’ is a problem which occurs with round inserts when plunging or profiling into corners. Due to high angular engagement creating high cutting pressures, the feed needs to be reduced. To reduce this problem, optimized programming strategies together with smaller insert radii should be used. Recommendations 1) Never plunge straight into cut. 2) Roll in and out of cut.
Cutting tool materials Wear mechanisms per area Grade selection when machining HRSA should not be considered in terms of finishing and roughing. Plastic deformation (PD) is present in all operations, however the formation of notch wear is driven by the entering angle of the insert. Depth of cut (ap) mm 8 Toughness/PD – interrupted cut PD demanding – continuous cut 5 PD and notch demanding 0.
Ceramic insert grades Ceramic cutting materials offer excellent productivity in roughing operations in FSM and ISM. Their application differs greatly compared to carbide due to their: • High temperature resistance – allows high cutting speed to be applied to produce a highly plasticised and sheared chip. • Low toughness – can lead to edge frittering, top slice and notch wear.
Grade application areas Notch wear resistance Bulk toughness CC6060 CC6065 CC670 Programming consideration Programmed direct into corner/plunging Skin, scale, ovality Material consideration Programmed with roll-in, roll-out of corner High quality forging Pre-machined material Intermediate stage machining – 46 HRC First stage machining – 26 HRC Cutting parameters 400 The feed should be selected to give a chip thickness which is high enough to not workharden the material but not be too high to cause
Application hints for round inserts Trouble shooting – wear mechanisms Top slice Notch wear Reason Remedy Reason Remedy Too high cutting pressure Reduce feed Sensitive cutting tool material Careful programming techniques Specific to HRSA Reduce entering angle Reduce ap on round insert Use CC670 Use CC6060, CC6065 Application hints for ceramic inserts Insert selection Low Productivity High Low Radial forces High • Where possible use round or square inserts with a small entering angle an
Notch wear Notch wear can be minimized with good planning and some general advice: mm mm • Use round inserts whenever possible – ensure the relationship between depth of cut ap and insert diameter does not exceed 25%. 6.35 9.52 12.70 19.06 25.40 0.9 1.4 1.9 2.8 3.8 • Use 45º entering angle when depth of cut exceeds 25% of iC. • “Roll over action” in programming to eliminate the need for pre-chamfering and minimize the notch wear.
Carbide insert grades GC1105 S05F A TiAlN PVD coated fine-grain carbide with good hot hardness and toughness properties. It is optimized for inserts with 95º entering angle but is an all-round grade giving effective performance through FSM, ISM and LSM areas. A CVD coated fine grain carbide with excellent hot hardness properties. It is optimized for applications with a 45º approach (square, round, CoroCut RO and finishing).
Surface roughness, Ra mm Surface finish comparison 3 S05F H13A 2.5 2 1.5 1 0.5 = New insert = Worn insert 0 0.15 0.25 Surface integrity tests have shown that S05F, applied at vc 40 m/min, gives extremely consistent deformation depth and residual stress profiles, when comparing new and worn inserts. The dimensional accuracy and lack of any coning/taper is also seen to eliminate the need for re-cutting or spring passes.
Spiral cutting length (SCL) – predictive machining SCL was introduced by Sandvik Coromant for the machining of HRSA due to the typically short tool life. One insert normally machines one pass and is then indexed. It is important to be able to predict for: • Roughing – adding a stop in the program to change the insert • Finishing – cutting data which ensures that the pass is completed with a predictable wear so as not to have to change during the cut or recut the pass.
SCL recommendations All cutting trials for these data recommendations are in Inconel 718 (46 HRC) and have been found to be true for other nickel alloys in the same hardness – Udimet 720, Waspaloy. LSM/finishing CNGG 120408-SGF 1105 CNMG 120408-SF 1105 CNMG 120408-SF S05F SCL m CNMG 120408-SM 1105 2750 SCL m 2500 2250 2000 2000 1750 1750 1500 1500 1250 1250 1000 1000 750 750 500 500 250 250 0 0 40 60 80 Cutting speed m/min 40 60 80 Cutting speed m/min ap 0.25 mm – fn 0.
Roughing vc m/min ap mm fn mm/r Tool life min SCL m Q cm3/min Qtot cm3 95º CNMG 120408-SMR 1105 50 2 0.25 5 250 25 125 45º CNMX 1204A2-SM S05F 50 2.7 0.35 9 450 47 425 SNMG 120408-SMR S05F 50 3 0.35 9 450 53 473 SNMG 190616-SM S05F 50 5 0.35 9 450 88 788 RCMT 1204M0-SM S05F 50 2 0.5 5 250 50 250 45º >45º RNGN 120700 T01020 6060 30 250 2 0.
Geometries and chip breaking Recommendation for tool geometry: Application area Feed range, mm Edge rounding Geometry requirements Geometry recommendation General turning Double sided FSM 0.20 to 0.4 Direct pressed – primary land Medium 0.15 to 0.25 Medium to small Direct pressed positive rake angle Positive QM MM QM Direct pressed ground Small TF 5E MR SMR Xcel 0.1 to 0.
Chip breaking diagrams Cutting speed 65 m/min, Inconel 718 – 44 HRC kr 45° – ISM SNMG 120408-SMR ap mm CNMX 1204A2-SM ap mm 2.5 2.5 1.5 1.5 0.5 0.5 0.2 0.25 0.3 Round inserts – ISM/LSM 0.35 fn mm/r 0.2 0.25 RCMT 1204M0-SM ap mm N123J2-0600-RO ap mm 2.5 1.0 0.3 0.35 fn mm/r 0.75 1.5 0.5 0.5 0.25 0.2 32 0.25 0.3 0.35 0.4 fn mm/r 0.15 0.2 0.25 0.3 0.
kr 95° – ISM CNMG 120408-SM ap mm CNMG 120408-SMR ap mm 2.0 2.0 1.0 1.0 0.5 0.5 0.25 0.25 0.15 0.2 0.35 0.15 kr 95° – LSM DNGG 150608-SGF ap mm 2.0 2.0 1.0 1.0 0.5 0.5 0.25 0.25 0.2 0.15 0.25 fn mm/r CNGG 120408-SGF ap mm CNMG 120408-SF ap mm 2.0 2.0 1.0 1.0 0.5 0.5 0.25 0.25 0.15 0.35 fn mm/r VBGT 160408-UM ap mm 0.15 0.2 fn mm/r 0.2 0.25 fn mm/r 0.15 0.2 0.2 0.25 fn mm/r 0.
Recommended starting choices for nickel based HRSA General turning 1st choice FSM 2nd choice Cutting speed, m/min GC1105 GC1115 30–40 CC670 CC6065 Feed, mm/r Depth of cut, mm 0.3–0.4 Up to 10 150–200 0.15–0.2 Up to 5 Insert style Metal Comments removal rate, cm3/min SNMG 15, 120 19 -SMR Use 45° approach to reduce chip thickness and notching. 200 Use 45° approach to reduce chip thickness and notching – first choice on good quality forgings. RNGN 19 SNGN 19 ISM CC6060 CC6065 200–300 0.
Grooving and profiling 1st choice ISM GC1105 GC1125 40– 60 0.1–0.15 2nd choice Cutting speed, m/min Feed, mm/ rev Machining stage Depth of cut, mm Insert style For rough grooving - use largest rad possible. TF 5E S05F GC1105 40– 60 0.2–0.4 For profiling. Max ap 0.15 x D RO 4P CC670 200–400 0.05–0.1 For rough grooving under good conditions. LSM GC1105 GC1125 40– 60 0.1–0.15 150.23 0.25 to 0.5 For finish grooving. Use 0.
Tailor Made Within many of Sandvik Coromant’s product families, the available range of inserts and tools is not limited to those specifically listed in the catalogues. Tooling designed to individual customer requirements is available through the Tailor Made service, allowing customers to specify their cutting tool requirements for particular machining operations.
Engineered solutions for the aerospace industry We have developed engineered solutions to specific application requirements in the aerospace industry. The solutions will be developed to a specific component – contact your Sandvik Coromant technical representative for more details. CoroCut®angled inserts for grooving Thin walls and complex shapes for components in the aero engine leads to a requirement for grooving and profiling inserts within tightly confined spaces.
Standard inserts and blanks for do-ityourself grinding An assortment of both left and right handed CoroCut 90º inserts are available as standard in grade GC1115. GS RS Standard assortment: • Right- and left-handed 90º design • Seat sizes H and L • Width (la) 2, 3 and 4 mm • GS and RS geometry For do-it-yourself grinding, blanks are available as standard in grades H13A, H10F and H10. 90° blanks RG...-BG LX...
Deep grooving and profiling Discs and spool components have deep cavities which have to be machined from solid or finish machined after welding. The long depth to width ratio required for the tool means that there is a high tendency to vibration. The blade solution is developed to optimize this difficult application offering maximum rigidity and minimized vibration allowing high productivity where long slender tools are required. • Dampened mechanism incorporated in the blade.
S-RCMX -SM Fits in ceramic holders which reduces both the number of tools required and tool change over: • Finishing operations • Mixed production of titanium and HRSA Secure solution with chip breaker giving excellent productivity and chip control. S-RCMX 060600-SM, dia 6 mm S-RCMX 090700-SM dia 9 mm S-RCMX 120700-SM, dia 12 mm S05F – first choice HRSA H13A – first choice titanium S-SNMM-SR An optimized geometry for machining HRSA materials, with forged skin, in the soft condition (26 HRC).
CSGX Ceramic grooving inserts Fits in RCGX/RPGX ‘V bottom’ holders. CSGX 060608 T01020 670, width 6.35 mm CSGX 090708 T01020 670, width 9.75 mm CSGX 120708 T01020 670, width 12.7 mm High metal removal – effective use in: • Machining into corner after square insert • Wide grooving – use turret method Seal-fin Special tool holder for standard inserts.
Sandvik Coromant component feature solutions FSM – 26 HRC Removal of skin. kr 75º for larger depth of cut (ap). Insert Geometry S-SNMM 190616 SR S-SNMM 250924 SR Grade Cutting speed, m/min GC2015 20 GC2015 20 Depth of cut, mm Feed, mm/r Tool life, min* Metal SCL, removal m rate, cm3/ min 10.00 15.00 0.60 0.60 20 20 120 180 Depth of cut, mm Feed, mm/r Tool life, min* Metal SCL, removal m rate, cm3/ min 8.00 5.00 0.40 15 0.25 5 400 400 *For Inconel 718 (26 HRC).
ISM – 46 HRC Max. ramping angle Roughing with high depth of cut. 40° for DSDNN 25° for DSSNL/R Insert SNMG 190616 SNMG 120408 Geometry Grade Cutting speed, m/min Depth of cut, mm Feed, mm/r Tool life, min* Metal SCL, removal m rate cm3/ min SM SMR S05F S05F 50 50 5.00 3.00 0.35 0.35 8 8 87.5 52.5 Cutting speed, m/min Depth of cut, mm Feed, mm/r Tool life, min* Metal SCL, removal m rate, cm3/ min 2.00 2.00 0.2 0.2 4 3 100 1000 100 750 400 400 *For Inconel 718 (46 HRC).
ISM – 46 HRC Profiling and pocketing. Ceramic. RNGN 120700 6060 150.23 9.5 mm 670 RCGX 090700 6060 vc 300 m/min vc 300 m/min vc 300 m/min ap 2.0 mm la 9.5/6 mm ap 1.5 mm fn 0.15 mm/r fn 0.07 mm/r fn 0.15 mm/r RCGX 090700 6060 vc 300 m/min ap 1.5 mm fn 0.15 mm/r Q 68 cm3/min Carbide. Insert RCMT 10T3M0 RCMT 1204M0 Geometry Grade Cutting speed, m/min Depth of cut, mm Feed, mm/r Tool life, min* Metal SCL, removal m rate, cm3/ min SM SM S05F S05F 50 50 1.50 2.00 0.35 0.50 5 5 26.
ISM – 46 HRC Profiling and pocketing. CoroCut. Use trochoidal turning method described on page 20. Insert N123L2-0800 N123J2-0600 N123H2-0400 Geometry Grade Cutting speed, m/min Depth of cut, mm Feed, mm/r Tool life, min* Metal SCL, removal m rate, cm3/ min RO RO RO S05F S05F S05F 50 50 50 1.20 1.00 0.60 0.50 0.40 0.30 6 6 6 33 22.5 10.5 300 300 300 *For Inconel 718 (46 HRC).
ISM – 46 HRC Wide grooving. Insert 150.23-0635 150.23-0950 CSGX 090708 N123K2-0600-0004 N123L2-0800-0008 Geometry Grade Cutting speed, m/min Depth of cut, mm Feed, mm/r Tool life, min* Metal SCL, removal m rate, cm3/ min T01020 T01020 T01020 TF TF CC670 CC670 CC670 GC1105 GC1105 300 300 300 50 50 6.35 9.50 9.50 6.00 8.00 0.07 0.07 0.07 0.12 0.15 3 3 3 8 8 133.4 199.5 199.5 36 60 Cutting speed, m/min Depth of cut, mm Feed, mm/r Tool life, min* Metal SCL, removal m rate, cm3/ min 3.00 3.
ISM – 46 HRC Seal-fin grooves special holders, standard inserts. N123E2-0200-RO S05F vc 50 m/min ap 0.5 mm fn 0.25 mm/r Blade grooves on disc/spool. N123H2-0400-0004-TF 1105 N123G2-0300-RO S05F vc 40 m/min ap 0.5 mm fn 0.1 mm/r vc 50 m/min fn 0.25 mm/r CoroCut engineered insert GC1105 vc 50 m/min ap 0.5 mm fn 0.25 mm/r Grooves on stator vanes. CoroCut 90° insert GC1115 CoroCut 90° insert GC1115 vc 30 m/min vc 30 m/min la 2 mm ap 0.25 mm fn 0.1 mm/r fn 0.
ISM – 46 HRC Operation 1a Operation 1b Rings Operation Insert Geometry 1a 1b CNMG 120412 SM N123G2-0300-0004 GF Operation 1c Grade Cutting speed, m/min Depth of cut, mm GC1105 GC1105 50 1.0 50 0.20 0.08/0.12 Operation 1d Operation Insert Geometry Grade Cutting speed, m/min Depth of cut, mm Feed, mm/r 1c 1d DNMG 150612 DNMG 150612 SM SM GC1105 GC1105 50 50 1.0 0.25 0.20 0.
ISM – 46 HRC Thin walls/unstable. Insert CNMG 120408 CNMG 120408 Geometry Grade Cutting speed, m/min SM SM GC1105 50 GC1105 50 Depth of cut, mm Feed, mm/r Tool life, min* Metal SCL, removal m rate, cm3/ min 1.50 1.00 0.20 0.20 5 5 15 10 250 250 *For Inconel 718 (46 HRC). Internal machining. Bar type selection Steel dampened boring bars DNMG 150608-SM 1105 vc 50 m/min, ap 2 mm, fn 0.15 mm/r DNMG 150608-SM 1105 vc 50 m/min, ap 2 mm, fn 0.
LSM – 46 HRC Round inserts. Insert Geometry Grade Cutting speed, m/min Depth of cut, mm Feed, mm/r Tool life, min* Metal SCL, removal m rate, cm3/ min RCMT 1204M0 RCMT 10T3M0 RCMT 0803M0 SM SM SM S05F S05F S05F 40 40 40 0.25 0.25 0.25 0.50 0.45 0.40 20 20 20 5 4.5 4 800 800 800 *For Inconel 718 (46 HRC). CoroCut. Thin wall components.
3. Turning of cobalt-based materials – medical Material properties + r esistant to wear (hard material 45-50 HRC). + can be cast into complex shapes. + high corrision resistance. + stronger than stainless steel. – twice the weight of stainless steel. – very brittle under impact loading. The cobalt-based alloys in the medical area are mainly of two types: CoCrMo and CoNiCrMo.
Process considerations Component condition Machining limitations The forgings are manufactured from castings or bar stock. This has some impact on the process, whilst the cast blank has less material to remove, the tough skin, with a certain degree of ovality, can cause difficulties if the insert is not fully engaged on the first pass. Bar stock requires much more material to be removed and normally there is a drilling operation to remove the bulk, see engineered solution page 58.
Typical wear mechanisms Notch wear A mechanical wear which is concentrated at the depth of cut. This wear reduces the tool life drastically and produces a burr on the component. Remedy: It is an application related wear which is easiest solved by changing the entering angle (insert shape) rather than insert grade. Abrasive wear Mainly caused by the hard particles in the workpiece material rubbing or grinding the edge.
Insert shape selection From the wear mechanisms it can be seen that a reduction in entering angle (kr) has two clear advantages: • Notch wear reduced giving longer more predictable wear with improved productivity. kr iC ap • Reduced chip thickness – with a V or D style insert the chip thickness (hex) is the same as the feed and the cutting length is the same as the depth of cut. Using a depth of cut below the radius reduces the chip thickness relative to feed and increases the cutting edge length.
Optimized tools for internal machining To capture the advantages offered by applying large radii, Sandvik Coromant has developed a range of tools which will pioneer traditional processes, giving both increased productivity and tool life. Available styles: Insert style Insert size, mm Boring bar diameter, mm DCMT DCMT Round Round 7 11 8 10 16 20 16 20 vc 70 m/min, fn 0.1 mm/r, ap 0.5 mm, material cobalt chromium Holder: A20M-ADXCL 11-R Insert: DCGT 11T308-UM 1115 1 component.
Round insert geometries • R300-0828E-PL 1030 or 1010 • R300-0828E-PH, 1030 • R300-1032E-PL 1030 or 1010 • R300-1032E-PH, 1030 + periphery ground. + direct pressed. + light cutting. + need of stable fixture. + low vibration/cutting forces 0.1 mm 0.2 mm 15° 15° Effect of feed Effect of speed Facing to centre – Cobalt chromium Dc 46 mm, vc 70 m/min, ap 0.5 mm, GC1030 Facing to centre – Cobalt chromium Dc 46 mm, fn 0.1 mm/r, ap 0.
Recommended starting choices for cobalt based HRSA Machining Feature stage 1st choice Rough turning Internal External Metal removal rate cm3/min Cutting speed, m/min Feed, mm/r Depth of cut, mm PH PL GC1010 GC1030 50–80 0.1– 0.15 Up to 1.5 12 R300-08 SM SM GC1105 S05F* 40–60 0.1– 0.15 Up to 1.0 9 RCMT 10 RO RO GC1105 S05F* 40–60 0.1– 0.15 Up to 1.0 9 N123J2-0600 PL GC1010 50–80 0.1– 0.15 0.1–0.3 3 R300-08 UM UM GC1105 GC1115 40–60 0.08– 0.1 0.1–0.25 1.
Carbide insert grades • GC1105 – Unique thin PVD (TiAlN) coating on hard fine grained substrate. – Excellent adhesion to the substrate even on sharp edges, good hot hardness. • GC1115 – Unique oxide PVD coated on micro-grained carbide. – Good resistance against built-up formation and crater wear. Ideal for more unstable conditions. • GC1125 – PVD coated micro-grained carbide. – Good resistance to thermal shock and notch wear. First choice for parting-off operations.
Sandvik Coromant component feature solutions Cups with small radius requirement and/or unstable fixturing (min. dia = 34 mm) Cups with no radii restrictions and/or stable fixture (min. dia = 34 mm) Roughing Holder: A20M-SRXDR 08-R Insert: R300-0828E-PL 1030 Cutting data: vc = 50–80 m/min, fn = 0.1–0.15 mm/r, ap ≤ 1 mm Roughing Holder: A20M-SRXDR 08-R Insert: R300-0828E-PL 1030/1010 Cutting data: vc = 50–80 m/min, fn = 0.1–0.15 mm/r, ap ≤ 1.
Milling of HRSA materials When milling super alloys, there are certain process requirements which must be observed. •M illing of high-temperature alloys often requires more rigid and powerful equipment than the milling of carbon steels. •C utter accuracy in both radial and axial directions is essential to maintain a constant tooth load and a smooth operation, and to prevent premature failure of individual cutter teeth.
Production planning process To optimise a machining operation all aspects of the application should be considered: • Type of operation? • Tool paths? • Conventional or climb milling? • Cutting tool type and material? • Change of operation sequence? Optimising the above is of course necessary, however, to achieve an optimised process these must be combined with process and application ‘know how’ to achieve secure productive machining.
Typical components – aerospace Combustion casings Discs Rings Blades/blisks Mounting brackets Machining strategy Features Spindle speed Most HRSA components are critical parts of the aircraft engine with complex features to be machined. For example when machining an engine casing the most time consuming operation is machining the band between the bosses. Careful planning and application of modern cutting tool materials can dramatically reduce cycle time.
Power/torque requirement Basically, the power requirement varies with the amount of metal to be removed, average chip thickness, cutter geometry and speed. The greater the metal removal rate (Q cm3/min) the higher the power requirement.
Cutter concept Modern milling is a very universal machining method. During the past few years hand in hand with machine tool developments, milling has evolved into a method that machines a very broad range of configurations. The choice of cutter concept is no longer straightforward – in addition to all the conventional applications, milling is a strong contender for producing holes, threads, cavities and surfaces that used to be turned, drilled, or tapped etc. (See hole making chapter).
The cutter diameter is more or less selected by the operation and the machine capability. The choice of ceramic insert, carbide inserts or solid carbide is determined by productivity calculations, surface requirements and process limitations (machine, fixturing etc). The kr/insert style (round, 45º, or 90º) and number of teeth selected will have a dramatic effect on the machining strategy and ultimately on the tool life and Q.
Milling with indexable inserts Cutter diameter and position in face milling Entry into and exit from the workpiece considerations The selection of milling cutter diameter is usually made on the basis of the workpiece width with the power availability of the machine also being taken into account. The position of the cutter in relation to the workpiece engagement and the number of teeth in contact are all vital factors for successful operation.
When profile milling the positioning of the cutter can be pre-defined, however for face milling where the position of the cutter is more flexible it can be prone to misapplication. 1) a e should not be greater than 75% of the cutter diameter, and not less than 30% – at least 2 teeth in contact (if zn > 2). Roll on entry 2) T he cutter should be off-centre giving as close to zero chip thickness as possible on exit from cut.
Face milling with carbide inserts Effect of insert style Chip thickness, cutting forces and tool life are affected by the choice of insert style when milling HRSA materials.
Typical wear patterns in HRSA milling Flank wear Rapid flank wear causing poor surface finish or out of tolerance. Cause: Cutting speed too high or insufficient wear resistance. Remedy: Reduce cutting speed. Select a more wear resistant grade. Cause: Chip thickness too low. Remedy: Increase feed. Notch wear Notch wear causing poor surface finish and risk of insert breakage. Cause: Work hardening materials. Remedy: Select round insert/reduce ap.
CoroMill®300 – positive round face milling concept Three main geometries are available for CoroMill 300 cutters when machining HRSA materials: Good conditions E-PL High edge sharpness and precision. Positive geometry with edge reinforcement. First choice with S40T. First choice E-MM High edge sharpness and precision in combination with security. First choice for applications with S40T. Difficult conditions CoroMill® 300 M-MM Good choice for general conditions.
Effect of cutting speed, vc Surface speed together with the material hardness are the most important factors in determining tool life when machining super alloys. Cutting temperatures for HRSA materials are typically 750 to 1020ºC. These temperatures are sufficiently high that oxidation and work-hardening become contributing factors to total tool wear. The results below show that an increase of 5 m/min cutting speed reduces tool life and total material removed by approximately 30%.
Effect of feed per tooth, fz As with other workpiece materials, feed and depth of cut are also important for tool life when machining HRSA materials.
Effect of geometry/fz The graph below shows the effect of the geometry depending upon the feed/tooth. Tool R300-063Q22-12H, zn 7, Dc 51 mm, vc 30 m/min, ae 36 mm, ap 2 mm, Material: Inconel 718 (44 HRC) Minutes in cut Total metal removed, cm3 40 = Average time in cut 610 = Average volume removed 30 420 20 280 10 140 0 S40T R300-1240E-PL hex 0.12 mm fz 0.16 mm/tooth S40T R300-1240E-PL hex 0.18 mm fz 0.24 mm/tooth S40T R300-1240E-PL hex 0.24 mm fz 0.
Effect of ap/entering angle Selecting the correct cutting depth/entering angle when face milling in HRSA materials has an effect on tool life and productivity. Despite limitations on depth of cut when using round insert cutters these are still the most productive method when milling HRSA. Unlike typical titanium aerospace frame components HRSA components tend Depth of cut to diameter ratio ap/iC 0.25 0.2 0.15 0.1 0.05 Depth of cut for insert diameter, in mm Entering angle κr 8 2 1.6 1.2 0.8 0.
Effect of hardness with grade and geometry, E-PL 1030 It can be seen that in harder materials new grade and geometry E-PL 1030 withstands the heat created during cutting much better than E-PL S40T. The harder substrate combined with optimised micro geometry has better resistance to notch wear and plastic deformation. Tool R300-063Q22-12H, Dc 51 mm, fz 0.24 mm/tooth, hex 0.
Effect of material hardness Small variations in material hardness will have a significant effect on tool life. Tool R300-063Q22-12H, Dc 51 mm, fz 0.24 mm/tooth, hex 0.18 mm, ap 2 mm, ae 36 mm, vc 30 m/min Material: Inconel 718 min 30 25 20 15 10 5 0 40 43 46 HRC R300-1240E-MM 2040 Summary – Face milling using carbide inserts in HRSA materials • CoroMill 300 (round insert cutter) gives optimum performance. • Grade S40T/GC1030 has the best performance.
CoroMill®390 – end milling/90 degree approach 90 degree entering angle is the least favourable design for milling in HRSA due to the high notching tendencies. However shoulder milling and profiling operations are demanded by the component features e.g. mounting brackets, casings, rings (scallops), circular interpolation of larger holes, slotting etc. Grade, geometry and cutting data should be selected based upon the percentage radial immersion. Edging/finishing – low radial immersion ae = 12.5% of Dc.
CoroMill® 390 End milling – increased immersion ae = 25 to 75% of Dc. Grade GC1030 M-PL – Grade S30T E-PL + Application – increased radial immersion/extreme conditions Tool R390-025A25-11H zn 4, Dc 25 mm, vc 35 m/min, ae 19 mm (75% of Dc), ap 5 mm, hex 0.07 mm, fz 0.
Effect of chip thickness, hex Tool R390-025A25-11H zn 4, Dc 25 mm, vc 25 m/min, ap 5 mm, Material: Inconel 718 (44 HRC) Minutes in cut Total metal removed, cm3 200 50 = Average time in cut 40 = Average volume removed 160 30 120 20 80 10 40 0 hex 0.07 mm hex 0.13 mm hex 0.07 mm hex 0.1 mm hex 0.13 mm fz 0.11 mm/tooth fz 0.20 mm/tooth fz 0.07 mm/tooth fz 0.1 mm/tooth fz 0.13 mm/tooth ae 3.1 mm (12.5% of Dc) ae 12.
Effect of cutting speed, vc Careful consideration must be made when selecting cutting speed for end milling in HRSA materials. Reduce cutting speed if radial emersion is increased. Tool R390-025A25-11H zn 4, Dc 25 mm, ap 5 mm, Material: Inconel 718 (40 HRC) Total metal removed, cm3 Minutes in cut 125 = Average time in cut 250 = Average volume removed 100 200 75 150 50 100 25 50 0 vc 25 m/min vc 30 m/min vc 35 m/min vc 25 m/min vc 30 m/min vc 35 m/min hex 0.07 mm, fz 0.11 mm hex 0.
Immersion ratio (ae/Dc) The diagram below shows that milling with large percentage radial immersion, has restricted tool life at the aggressive condition of 75% ae/Dc. Tool R390-025A25-11H, Insert GC2040 E-ML, zn 4, Dc 25 mm, vc 30 m/min, ae 12.5 mm (50% of Dc), hex 0.1 mm, ap 5 mm, Material: Inconel 718 (40 HRC) Minutes in cut 50 Total metal removed, cm3 = Average time in cut 200 = Average volume removed 40 160 30 120 20 80 10 40 0 fz 0.12 mm ae 6.25 mm (25% of Dc) fz 0.1 mm ae 12.
Summary – end milling/90 degree approach in HRSA materials Edging/circular interpolation of existing hole •G rade S30T performs better at lower immersion ratios. • F or grade S30T the geometry E-ML performs better on average regardless of the cutting conditions employed. •a e = 12.5% of Dc, fz 0.11 mm (hex 0.07 mm) CoroMill® 390 Increased immersion/slotting/ circular ramping •A t higher immersion ratios grade S30T E-ML has the best performance. •a e = 50% of Dc, fz 0.1 mm (hex 0.
S-R120R D3 Pitch, (X) Dc Size D5m l1 50 63 63 70 70 72 12 50 63 80 Coromant Capto S-R120R-038C5-12X03 3 38 S-R120R-051C6-12X04 4 51 S-R120R-068C6-12X05 5 68 Insert Clamp Key Shim Shim screw Key for shim screw RNGN 120700 RNGN 120400 5412 034-021 5412 034-021 5680 049-01 5680 049-01 176.1-851 3213 010-206 174.
Coolant and ceramic milling When milling using ceramic inserts, coolant should normally not be used. In most operations the use of coolant has a negative effect on tool life. This is due to the increase in thermal shock with cooling and heating of the cutting zone as the insert enters and then exits the workpiece. This increases the chance of top slice of the ceramic. However, a small amount of MQL (Minimum Quantity Lubrication) could have a positive effect when reducing heat in the machining process.
Effect of feed per tooth, fz As with round carbide inserts the chip thickness varies and depends upon the entering angle. With low ap/iC ratios the feed can be increased in order to raise the chip thickness to the desired level. Selecting the correct hex value when milling with ceramic inserts is critical. Always modify the feed depending upon the entering angle, max chip thickness (hex).
Grade choice and effect of milling direction D3 63 mm, zn 4, vc 1000 m/min, ae 32 mm, fz 0.11 mm/tooth, hex 0.07 mm, ap 1.5 mm (no coolant) Material: Inconel 718 (40 HRC) Minutes in cut 5 4 3 2 1 0 RNGN 670 RNGN 6080 RNGN 6060 RNGN 670 RNGN 6080 RNGN 6060 Down/climb milling Up/conventional milling The diagram shows that: • New Sialon grade CC6060 gives the outstanding performance. •U p/conventional milling provides a longer tool life and more consistent wear compared to down/climb milling.
Solid carbide – CoroMill®Plura in HRSA machining Due to the high hot hardness and toughness of HRSA they are one of the most difficult to machine materials placing great demands on the tool. The outcome is traditionally, low cutting speeds and hence lower productivity/higher machining costs. However low radial cuts are required to keep the chip thickness small and allow for the higher feed rate.
Processes using HSM techniques Trochoidal milling A roughing/high material removal method used when in a confined space or slot. A continuous spiraling path feeding in the radial direction to form a groove or a profile. It requires specialised programming and machine capabilities. Slicing A semi-roughing technique used to produce a profile. Multiple passes to reduce the radial immersion. It requires a machine with high spindle speed and dynamic capability.
Application recommendations Down milling It is almost always more favourable to apply down milling rather than up milling. When the cutting edge goes into contact in down milling, the chip thickness has its maximum value, in up milling the chip thickness is zero. The tool life is generally shorter in up milling due to the fact that there is considerably more heat generated due to the rubbing action that takes place on entry. The radial forces are also considerably higher in up milling.
Tool holding One of the main criteria when deciding both the tool and holding device is to have as small a run out as possible. This keeps a uniform chip thickness on each cutting edge and hence has an even load distribution. The total indicator run out (TIR) should not be more than 10 microns. A good rule of thumb is that ‘For every 10 microns in added run out the tool life reduces by 50%’! A CoroGrip® power chuck or shrink fit should be used due to: Minimised run out - increased tool life.
Wear mechanisms Typical wear observed on CoroMill Plura tools in the case of Inconel is micro chipping rather than flank wear. The edge line starts frittering before it leads to total cutting edge failure. The transition from micro chipping to failure is exponential, therefore once this wear is observed the tool should be immediately indexed. This can be monitored with the power/load gauge or by sound. Tool R216.24-12050-AK26P 1620, vc 75 m/min, hex 0.04 mm, ap 10 mm, ae 0.5 mm, fz 0.
Helix angle An end mill’s helix angle is defined as the angle of the cutting edge relative to the centreline of the tool. The helix influences tool performance mainly by affecting chip flow and cutting forces by determining the length of engagement of the cutting edge for a given depth of cut. The greater the helix angle, the longer the cutting edge length allowing longer tool life and also giving a more gradual entry and exit into and from the workpiece.
Corner geometry The main wear observed in the case of HSM in Inconel is micro chipping at the cutting edge. A radius end mill, due to increased strength is always better compared to a chamfer or sharp corner. Comparison between chamfer and radius end mill vc 100 m/min, ap 10 mm, hex 0.02 mm, ae 0.5 mm, fz 0.05 mm/tooth Material: Inconel 718 = Total metal removed Minutes = Tool life 80 80 73 70 70 60 60 52 50 50 40 40 27 30 20 20 10 0 cm3 30 20 10 R216.24-12050-GAK26P 1620/R3 R216.
Chip thickness (hex) The low radial engagement reduces the chip thickness compared to the feed per tooth. Using the optimised chip thickness is pivotal in optimisation of finishing, slicing or trochoidal milling. Equally the tool life drops by as much as 50% when the chip thickness is increased from 0.04 to 0.052 mm (25%). The best results are achieved at 0.04 mm thickness. It can be seen in the diagram that a reduction of chip thickness reduces the material removed due to rubbing rather than cutting.
Radial cut (ae) For roughing applications it can be seen in the diagram that the maximum total material removed, when running with a constant speed and chip thickness, can be achieved with ae = 1.0 mm. This equates to 8% ae/Dc and should be used as a base when roughing operations are required. Total metal removed and tool life vs radial cut R216.24-12050-GAK26P 1620, vc 75 m/min, ap 10 mm, hex 0.04 mm Material: Inconel 718 min 100 90 80 70 60 50 40 30 20 10 0 cm3 87 22 0.5 94 90 18 16 0.
First choice recommendations for HSM It can be seen in the diagram that R216.24-12050-GAK26P 1620 is the optimised cutter for HSM in Inconel. Total metal removed and tool life vs radial cut Material: Inconel 718 vc 100 m/min, ae 0.5 mm, ap 10 mm, fz 0.05 mm/tooth, hex 0.02 mm min cm3 80 80 = Total metal removed = Tool life 60 60 40 40 20 20 0 R215.36-12050- R215.3C-12030- R216.24-12050AC26L 1620 AC26H 1610 GAK26P 1620 R216.24-12050- R216.34-12050- R216.
Exchangeable-head – CoroMill®316 in HRSA machining CoroMill 316 is a complement to our existing solid carbide programme. Insert geometry is based on CoroMill Plura tools. •R oughing, semi finishing and finishing applications in general machining.
Component/Feature based solutions Engine casing Feature Rough mill sole plate Material Cutter Cutter diameter, D3 Insert Number of teeth, zn Cutting speed, vc Spindle speed, n Table feed, vf Feed per tooth, fz Depth of axial cut, ap Depth of radial cut, ae Metal removal rate, Q Inconel 718 R300-050Q22-12H 50 mm R300-1204E-PL 1030 5 35 m/min 223 r/min 311 mm/min 0.25 mm 2.5 mm 38 mm 27.
Feature Machine radius Material Cutter Cutter diameter, Dc Insert Number of teeth, zn Cutting speed, vc Spindle speed, n Table feed, vf Feed per tooth, fz Depth of axial cut, ap Depth of radial cut, ae Metal removal rate, Q Inconel 718 R216-20B25-050 20 mm R216-20T3E-M 2040 2 50 m/min 447 r/min 143 mm/min 0.
Feature Sole plate hole – Ø 59 mm – 20 mm deep Method Material Cutter Circular ramping from solid Inconel 718 CoroMill 300 R300-035C3-12H 35 mm R300-1240E-MM 2040 4 25 m/min 227 r/min 76 mm/min 0.
Feature Slotting Method Material Cutter Trochoidal milling Inconel 718 R216.24-08050 EAK19P 1620 8 mm 4 75 m/min 3000 r/min 200 mm/min 0.05 mm 8 mm 0.67 mm 5.64 min 1.0 cm3/min Cutter diameter, Dc Number of teeth, zn Cutting speed, vc Spindle speed, n Table feed, vf Feed per tooth, fz Depth of axial cut, ap Depth of radial pitch, w Time Metal removal rate, Q Feature Blisk machining Roughing Finishing Method Material Cutter Plunge milling Inconel 718 R230.
Recommended start cutting data Face milling Type Application Tool choice Max. depth of cut ap mm Radial cut ae mm Cutting speed vc m/min Feed fz mm/tooth 30 30 25 25 0.18 0.25 0.25 0.30 Low to Round medium ap CoroMill®300 R300-0828E-PL GC1030 R300-1240E-PL G1030 R300-1240E-MM GC2040 R300-1648E-MM GC2040 Medium to kr 45° large a CoroMill®245 R245-12T3E-ML GC2040 3 30 0.20 Against kr 90° shoulder CoroMill®390 R390-11T308E-ML GC2040 5 30 0.10 p 1 2.
Ceramic milling Type Application Low to Round medium ap Tool choice Ceramic milling RNGN 120700E CC6060 Max. depth of cut ap mm 2.0 Radial cut Cutting speed ae mm vc m/min 70% of Dc 1000 Feed fz mm/tooth 0.10 Open slot milling Cutter Width mm 6–8 8–10 10–15 15–20.5 20.5–26.5 Diameter mm 80–200 80–200 80–200 100–315 160–315 CoroMill®331 - side and face cutters N331 insert size N/L/R331.1A-04-WL N/L/R331.1A-05-WL N/L/R331.1A-08-WL N/L/R331.1A-11-WL N/L/R331.
Hole making in HRSA alloys Hole types and hole making methods Hole making in HRSA can be split up into 5 distinct areas: > Ø 16 mm through holes for assembly In aerospace engines: casings, flanges, rings, discs, shafts, etc usually have identical, relatively small holes drilled in large numbers. These are often in diameters and with limitations suited to solid carbide drills. For critical parts the hole is often made in up to 5 steps to guarantee quality and consistency. 1. drilled 2.
Ø 20 to Ø 80 mm through holes in thin wall or unstable components Aerospace casings, which are large thin wall components with large diameter boss holes, use circular ramping to produce the hole. This method, although not as quick as drilling, has the advantages of producing low axial cutting forces providing the most reliable process.
Tools for hole making Drilling Solid carbide CoroDrill Delta-C R846 hole dia 3.0 to 20.0 mm Indexable insert CoroDrill 880 hole dia 14.0 to 63.5 mm Deep hole CoroDrill 800 T-Max 424.10 hole dia 25 to 65 mm hole dia 63.5 to 130* mm Trepanning T-Max U 416.7 hole dia 60 to 110* mm Circular ramping from solid CoroMill Plura R216.
Circular ramping from solid Milling of holes is a flexible process able to produce a range of hole sizes with each cutter. It produces low axial cutting forces and copes well with interrupted entrances and exits which are a problem when machining into curved surfaces such as casings. Cutter and hole diameter The ramping process requires a cutter which is capable of axial cutting. The diameter selection is very important when using cutters which are not centre cutting.
Circular milling of existing hole Hole diameters can be finish machined using circular milling as an alternative to boring depending on the surface finish requirement. The feed rate (vf) must be reduced compared to straight line milling due to that in internal applications. • T he periphery of the tool will be moving faster than the centre line of the tool. Programming of the feed rate (mm/min) on most milling machines/CAM systems is based on the centre line of the spindle.
Back chamfering/deburring When machining aerospace engine components, one tricky but often neglected operation is deburring holes. By using a CoroMill 327 or CoroTurn XS back chamfering tool it is possible to increase productivity while providing a repeatable, mechanised, safe process – eliminating the need for manual deburring and special tools. The CoroTurn XS tool must be used with a Coromant Capto adaptor to provide the correct clearance when used in rotating applications.
Thread milling Many holes in a typical aerospace engine casing require threads. Machining the thread in smaller holes can prove to be a difficult operation. This can be performed using a tap to machine the thread. However in HRSA materials this can cause problems with chip jamming resulting in tap breakage and ultimately scrapping of an expensive component.
CoroMill®328 For larger holes over 39 mm, CoroMill 328 offers inserts for metric and UN threads. Inserts are pocket-mounted for safe and stable positioning, with 3 cutting edges per insert and high-pitch cutter bodies. CoroMill 328 is available in versatile grade GC1025, for all material types. CoroMill 328 has Weldon, arbor and bore with keyway mounting.
Recommended start cutting data Short hole drilling Drill dia. Dc mm Tool choice Cutting speed vc m/min 3–16 CoroDrill®Delta-C R846 Grade GC1220 20-30 0.06–0.12 CoroDrill®880 Peripheral insert= -LM H13A Central insert = -LM 1044 20–30 0.04–0.10 12–63.5 Feed fn mm/r Deep hole drilling Drill dia. Dc mm 25–43 43–65 63.
Circular ramping from solid Cutter concept Cutter diameter Min. hole dia. Dm min mm Insert choice Max. depth Cutting speed of cut/pitch vc m/min ap mm Feed* fz mm/tooth CoroMill®390 end mill 16 20 25 32 40 26 34 44 58 74 R390-11T331E-ML 2040 2 30 0.10 CoroMill ®300 25 32 34 35 40 42 50 52 63 66 80 38 52 56 58 68 72 88 92 114 120 148 R300-1240E-MM 2040 2 30 0.20 *Reduce feed when programming tool centre feed.
Component/feature solutions Shaft Inconel 718 20.
Hole making in the aerospace industry – aero engine OPERATION A Ø 12 mm, hole 20 mm deep OPERATION B Ø 120 mm, hole 1500 mm deep 1. Drilling CoroDrill Delta-C R846 – Ø 11.00 mm R846-1100-30-A1A 1220 vc 25 m/min fn 0.1 mm/r 1. Drilling T-Max 424.10 DHD, Ø 110 mm Insert grade B2D1 vc 43 m/min fn 0.23 mm/r 2. Finish boring Alternative 1 CoroMill Plura R216.24 – Ø 12.00 mm R216.24-12050CAK26P 1620 vc 40 m/min fn 0.2 mm/r 2.
Component/feature solutions Casing Waspalloy CMC 20.22 2m m Ø 60 mm 20 mm Ø2 B A 5 mm Ø 8.
Hole making in the aerospace industry – aero engine OPERATION A Ø 22 mm, hole 20 mm deep OPERATION B Ø 60 mm, hole 20 mm deep 1 Drilling CoroDrill 880 – Ø 21.00 mm Central insert – LM 1044 Peripheral insert – LM 1044 vc 30 m/min fn 0.05 mm/r 1. Circular ramping – hole Ø 59 mm CoroMill 300 – Ø 35 mm R300-12400E-MM 2040 vc 25 m/min fz 0.2 mm/tooth ap 2.0 mm 2. Circular milling – hole Ø 22 mm CoroMill Plura R216.24 – Ø 12.00 mm R216.24-12050CAK26P 1620 vc 75 m/min ae 0.5 mm fz 0.1 mm/tooth ap 10 mm 2.
Technical data Turning Terminology and units Dm = Machined diameter mm fn = Feed per revolution mm/r vc = Cutting speed m/min κr = Entering angle degree n = Spindle speed r/min Rmax = Profile depth µm Tc = Machining time min rε = Insert nose radius mm = Depth of cut Q = Metal removal rate cm3/min ap lm = Machined length mm hex = Max chip thickness mm Pc = Net power kW SCL = Spiral Cutting Length m N/mm2 k c 0,4 = Specific cutting force for chip thickness 0.
Milling Terminology and units Dcap = Cutting diameter at actual depth of cut, ap mm hm = Average chip thickness mm lm = Machined length mm zc = Effective number of teeth ap = Cutting depth mm kc1 = Specific cutting force (for hex = 1 mm) piece N/mm2 r/min ae = Working engagement mm n vc = Cutting speed m/min Pc = Cutting power net Q = Metal removal rate cm3/min κr = Entering angle Tc = Machining time min mc = Rise in specific cutting force (kc) as a function of chip thickness
HRSA – Material cross-reference list Material Commercial Hardness Brinell HB Code Nominal composition approximate content in % condition designation Ann. Aged Ni Cr Co Fe Mo C Mn - - - - - - 76.01) 52.01) 62.01) 70.01) 52.01) 30.0-38.0 20.0 20.0 21.0 16.0 18.0 20.0-25.0 5.0 20.0 0.72) 1.02) 5.02) 1.02) 8.0 1.03) 19.0 - Balance 6.0 9.0 3.0 4.0-4.8 0.11 0.06 0.1 0.08 0.05 0.082) 1.03) 0.63) 0.53) 0.352) 0.352) 1.
Si Al Ti Others 1.02) 0.42) 0.52) 0.352) 0.352) 0.52) 0.22) 0.6-1.0 0.62) 0.42) 0.8 0.5 - 0.4 2.42) 0.42) 2.5 0.9 0.4-1.0 3.7 1.5 5.109 - 0.23 1.2 5.5 6.2 0.21 1.2 4.7 1.0 2.66 9.0 1.0 2.3 0.019 0.2 0.1 1.02) 3.8 4.3 3.0 5.5 4.7 6.0 5.4 - 2.5 3.3 5.0 2.5 4.7 2.5 0.06 1.0 - 3.5 3.5 4.05 10.5 6.3 0.352) 0.4 1.02) 1.0 0.6 2.75 0.22) 0.4 0.82) 0.25 0.1 4.5 0.3 0.52) 0.52) 1.8 0.25-0.5 0.75-1.5 0.52) 0.52) 2.02) 1.02) USA SAE - USA AMS UK France Germany BS ANFOR Werkst.
350 42.5 275 Balance 250 42.0-43.0 350 Balance - Balance - Balance - 58.0b 12.5 19.0-21.0 15.5-17.5 16.0-20.0 19.0 18.0-21.0 19.0 310 - 350 - - 300 - 63.3 4.5 61.6 67.5 60.7 79.3 69.4 15.5 15.5 12.5 19.5 11.0 20.0 9.0 MC S2.0.Z.AG CMC 20.22 10.0 10.0 10.0 20.0 2.0 16.5 2.01) 2.0 15.0-21.0 19.0-21.0 18.0-22.0 13.0-15.5 2.5 1.7 0.3 4.5-5.5 3.0-5.0 0.15 0.15 0.15 0.15 0.1 0.1 0.1 0.05 0.131) 0.11) 0.121) 0.12-0.2 - 1.01) Balance 19.0-21.0 0.71) 2.01) Balance 12.0-16.0 1.
Si Al Ti Others 1.0 2.5 5.5 1.5 1.5 4.25 1.75 1.75 2.5 4.3 2.0 1.2 2.5 1.3 2.4 1.01) 1.0-1.8 1.8-2.7 0.17 0.5 0.9 1.8 0.26 1.01) 1.0-2.0 2.0-3.0 0.391) 1.01) 0.9-1.5 1.9-2.7 1.6 1.01) 4.5-4.9 0.9-1.5 0.42) 1.01) 4.5-5.5 3.5-4.5 0.42) USA SAE - USA AMS UK France Germany BS ANFOR Werkst. Nr Germany DIN 1706 Others 5551 - 3146 Hr 410,601 Hr 2, 202 HR 3 HR4 NC 20 TA NC 20 K17 TA NC20TA Nc20ATV NCKD20ATV NCK15ATD 2.4916 2.4675 2.4631 2.4632 2.4631 2.4632 2.4634 2.
Material Commercial Hardness Brinell HB Code Nominal composition approximate content in % condition designation Ann. Aged Ni Cr Co Fe Mo C Mn J1650 Haynes 25* Haynes 188* Undimet 188* Undimet L-605* - - - - - - In aged condition HS6* HS21* J1570* - - - 350 MC S3.0.Z.AG MC S3.0.Z.AG CMC 20.32 CMC 20.3 Annealed or solution treated 27.0 10.0 22.0 20.0-24.0 9.0-11.0 20.0 Balance 20.0 51.01) 22.0 39.01) 20.0-24.0 Balance 19.0-21.0 Balance 3.02) 3.02) 3.02) 3.
Si Al Ti Others 0.42) 0.35 0.2-0.5 0.42) - 3.8 - 15.0 14.03 15.0 16.0 0.6 - - 0.25 - 1.0 - USA SAE USA AMS 5537C - 5759 5772 - - 5373 5385 - UK France Germany BS ANFOR Werkst. Nr 3531 - KC20WN KC22WN - LW 2.4964 - Germany DIN 1706 Others CoCr20W15Ni CoCr22W14Ni - R30605 R30188 R30188 R30605 CoCr28Mo - R30006 R30021 - 3.15 5508 0.3 5718 Z12 CND12 LW 1.4939 0.5 0.8 0.7 0.15 0.6 1.0 0.2 0.1 0.
Notes 126
Notes 127
Notes 128
Acknowledgement Some sections of this article present the findings of technical investigations carried out by the AMRC* which are sponsored by Sandvik Coromant. *The Advanced Manufacturing Research Centre (AMRC) is a partnership which builds on the shared scientific excellence, expertise and technological innovation of industrial partners and world-class research within the University of Sheffield’s Faculty of Engineering.
APPLICATION GUIDE Heat resistant super alloys Head office: AB Sandvik Coromant SE-811 81 Sandviken, Sweden www.sandvik.coromant.com E-mail: info.coromant@sandvik.com C-2920:034 ENG/01 © AB Sandvik Coromant 2010.08 This folder is printed on recycleable paper.
