Cutting%20Tool%20Selection%20Guide

8/7/2019 Cutting%20Tool%20Selection%20Guide

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Cutting Tool Selection

Quick Reference Training Program


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Toll-Free Telephone: 800-333-8311 Internet: www.cpmt.com 2005 By Climax Portable Machine Tools Inc.

Bringing the solution to you.

Presented by:

Carbide Tool Bit Overview

Carbide Tool Bit Benefits Very hard

Will withstand high temperatures

Replaceable inserts

Readily available

Pre-sharpened from factory

Carbide Tool Bit Drawbacks

Rubs material rather than cuts material

Brittle

Requires more rigidity

Requires more horsepower

Usually wrong tool geometry (for portable tools) from tool supply house

Generally cant re-sharpen


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Presented by:

High Speed Steel (HSS)

Tool Bit Overview HSS Tool Bit Benefits

Cuts freely

Easy to re-sharpen

Tool geometry easily changed

Very tough

Requires little tool pressure

Readily available

Pre-sharpened from factory

HSS Tool Bit Drawbacks

Must use proper SFPM cant take the heat Viewed as slower

Operator needs to understand tool geometry


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Presented by:

Carbide Vs. High Speed Steel Bits

High Speed Steel tool bitgeometry

Carbide tool bitgeometry


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Presented by:

Tool Holder Examples


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Presented by:

Tool Geometry Angle Definitions

Top Rake: Evacuates chiproles chip out

Heel or Clearance Angle: This is the clearance between the cutter and

the surface that has just been cut. Insures that the cutting edge (and notthe back side or heel of the cutter) contacts the work piece first

Lead Angle: This is formed by the leading edge of the cutter and aplane perpendicular to the cutter feed motion

End relief angle: The clearance below the end of the tool

Side Relief Angle: The clearance below the cutting edge

Back Rake: This is a shear angle that also evacuates the chip or roles

the chip out Nose Radius: The nose radius stretches the cutting edge. It increases

the amount of cutting edge in contact with the work

See Diagram On Next Page


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Presented by:

Tool Geometry


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Presented by:

How Tool Geometry Affects The Cut

Negative Lead Angle

Zero Lead Angle

Positive Lead Angle


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Presented by:



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Presented by:


Top Rake

The Larger top rake dimension equals

A larger entrance angle

The larger radius is used for materials thatresist bending (have a high shear modulus).Set back must be increased in relation to the

radius to the control entrance angle

A smaller top rake dimension equals asmaller entrance angle

Top Rake


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Presented by:

Nose Radius Vs Tool Pressure


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Presented by:

The Basics Of Chip Formation

Metal is cut by material harder thanitself being forced through it.

The sharper the tool, the easier it is toforce through. Sharpness can beimproved by adding different angles tothe tool (Tool Geometry).

The faster the tool is forced through,

the rougher the surface that is left.


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Presented by:

Tool Bit Wear


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Presented by:

Tool Bit Wear


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Presented by:

Roughing Vs Finishing Bit Overview


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Presented by:

Finishing Bit Detail

10

10 5

5


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Presented by:

Roughing Bit Detail

10

15

15

510


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Presented by:

Surface Feet Per Minute Vs. Bar RPM

SFPM vs. Bar RPM; Bore Diameters

0

50

100

150

200

250

300

0 25 50 75 100 125 150 175

Bar Speed (rpm)

CuttingSpeed(sfpm)

2

3

4

6

8

10

12

18

2417.9 ci r

14.1 cir

11.3 c ir

8.9 cir

7.3 cir

5.9 cir 3.6 cir

2

3

4

6

810121824

Note: Motor Sizes show n BB5000 Only

Bore Diameter (inches)


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Presented by:

Tool Recommendations For Various

Combinations of Cutting Speeds & RPMBar Speed

(rpm) 1 2 3 4 6 8 10 12 18 24 30 36 48 60

5 1 3 4 5 8 10 13 16 24 31 39 47 63 79

10 3 5 8 10 16 21 26 31 47 63 79 94 126 157

20 5 10 16 21 31 42 52 63 94 126 157 188 251 314

30 8 16 24 31 47 63 79 94 141 188 236 283 377 471

40 10 21 31 42 63 84 105 126 188 251 314 377 503 628

50 13 26 39 52 79 105 131 157 236 314 393 471 628 785

60 16 31 47 63 94 126 157 188 283 377 471 565 754 942

70 18 37 55 73 110 147 183 220 330 440 550 660 880 1100

80 21 42 63 84 126 168 209 251 377 503 628 754 1005 1257

90 24 47 71 94 141 188 236 283 424 565 707 848 1131 1414

100 26 52 79 105 157 209 262 314 471 628 785 942 1257 1571

125 33 65 98 131 196 262 327 393 589 785 982 1178 1571 1963

150 39 79 118 157 236 314 393 471 707 942 1178 1414 1885 2356

175 46 92 137 183 275 367 458 550 825 1100 1374 1649 2199 2749

HSS Recommended. Best range for field machining.

HSS/Carbide Recommended. Must have rigid set-up

Carbide Recommended. Must have rigid set-up, no interrupted cuts.

Carbide Recommended. Must have rigid set-up, light finish cuts only.

Not Recommended for field machining

Model 1 2 3 4 6 8 10 12 18 24 30 36 48 60

BB2000 1.4 4

BB3000 1.4 6

BB4000 1.8 10

BB5000 2.5 24

BB6000 6 36

BB7000 8 40

BB8000 16 80

Recommended range for optimum results

Recommended only with very rigid set-up

Not Recommended

Cutting Speed - Surface Feet Per Minute (SFPM)Bore Diameter (inches)

Bore Diameter (inches)


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Presented by:

Calculating SFPM & RPM

Formula for calculating SFPM or RPM

SFPM x 12 = Pi x Dia x RPM

Example 1:

50 SPFM (High Speed Steel) x 12 = 3.141 (Pi) x 4 (dia) x ? (RPM)

600 = 12.5 x ? (RPM)

600 12.5 = 47 RPM

Example 2:

100 SFPM (Carbide) x 12 = 3.142 (Pi) x 4 (dia) x ? (RPM)

1200 = 12.5 x ? (RPM)

1200 12.5 = 96 RPM


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Presented by:

Formula for determining Machining Time(for turning or boring)

Machining Time =

Example:

4 Dia = Not needed

10 Long = Length of cut.01 Feed = Inches / Rev

30 RPM = Revolutions/Min

Machining Time =

=

Machining Time = 33.33 minutes

Overall LengthRPM x Feed

Calculating Machining Time

1030 x .01

10.30


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Presented by:

Chip Characteristics

Metal chip color is a good

indicator of proper machine speed

(RPM & Feed Rate)

Objective is to produce straw

colored chips

Blue color chips indicate excessivemetal heat and boring rate

Silver chips indicate an

opportunity to increase overallboring rate


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Presented by:

Tool Bit SharpeningWhen To Sharpen?

Speed & feed are correct, but still getting blue colored chip

Tool begins to chatter

Base metal looking torn Vs. smooth

Machine is vibrating & working hard


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Presented by:

Tool Bit SharpeningSharpening Techniques

Match existing angle to wheel relationship

Cool often (water bucket)

Check with protractor

Use stone to take off ragged edges


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Presented by:

Cutting LubricantsOverview

Use of cutting oil will prolong tool life

If oil is used, insure proper ventilation

Use extreme care when applying oilsquirt can is

recommended

Cutting oil is messyuse oil sparingly based on

application

Apply with squirt can while machine is running

Use brush to apply prior to machine start up


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Toll-Free Telephone: 800-333-8311 Internet: www.cpmt.com


Presented by:

Cutting FluidsBenefits & Cautions

Benefits of Using Cutting Fluids

Lubrication of tools to improve the flow of chips at the cutting face

Cooling of the tool & work piece for improved dimensional stability

Reduction in built-up edge

Improvement in surface finish

Helps flush away chips.very important during horizontal boring Cautions

Unsteady flow of coolant could cause cracking of carbide tools

Damaging thermal variation in the cutting tool can be intensified whenutilizing cutting fluid during an interrupted cutting process

Carbide inserts cannot stand the thermal shock associated with coolantbeing turned on and off.

Cutting%20Tool%20Selection%20Guide

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