sandvik technical guide

Utfyllnadsbild till I-kap.indd 1 2009-08-19 10:05:07

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Tailor Made product program

Formulas and de�nitions

Thread charts

Measuring surfaces

Hole tolerances

FAQ

INFORMATION/INDEX

MTG09 Information_Index_I01-13.indd 1 2009-11-30 09:57:18

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Information/Index – Tailor Made

In addition to a comprehensive standard program, we can offer tools to your dimensions on standard tool terms. In our Tailor Made offer, you are free to specify your own dimensions without paying the price of a special tool.

Download the Tailor Made Tool Selection Guide in PDF-format at: www.coromant.sandvik.com

For further details, contact your nearest Coromant sales representative.

• Quick quotation

• Easy to order

• Competitive delivery

Additional tool options designed for your specific requirements


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Information/Index – Tailor Made

The product families available as Tailor Made options are:

Parting and Grooving• CoroCut inserts • T-Max Q-Cut inserts • CoroCut/T-Max Q-Cut holders • T-Max Q-Cut MBS holders

Threading• CoroThread 266 inserts • U-Lock inserts

Face milling• CoroMill 200 round insert cutters • CoroMill 210 plunge cutters • CoroMill 245 face milling cutters • CoroMill 290 square shoulder cutters • CoroMill 300 round insert cutters • CoroMill 390 square shoulder cutters • CoroMill 490 square shoulder cutters • CoroMill Century inserts

Side and face milling• CoroMill 331 side and face milling inserts • CoroMill 331 side and face milling cutters • CoroMill 331 cutters with fixed pockets • T-Max Q-cutter inserts • T-Max Q-cutters

Cast iron face milling - Automotive• Sandvik Auto-AF adjustable cutters • T-Line milling inserts • T-Line milling cutters • Sandvik Auto cylinder boring cutters

End milling• CoroMill 390 end mills • CoroMill 390 long edge milling cutter • CoroMill 490 end mills • CoroMill 790 Al end mills

Short hole drilling - Delta drillsApplications • CoroDrill Delta-C 840 drills • CoroDrill Delta-C 850 Al drills • CoroDrill Delta-C 415.5 drills • Coromant Delta drills

Short hole drilling - U drillsApplications • CoroDrill 880 drills • CoroDrill 880 step and chamfer drills • Coromant U drills • Coromant U step and chamfer drills • T-MAX U drills

Deep hole drilling• T-MAX drill heads


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vc = n =

Tc =

hm =

Q = Pc =

kc = kc1 × hm × 1 -

Dm × π × n vc × 1000

Im

360 × fn × ap

vc × ap × fn × kc

γ0

1000 π x Dm

fn × n

iC × π × arccos 1 -

vc × ap × fn 60 × 10³

100

Dm

ap

fn

vc

n

Pc

Q

hm

hex

Tc

Im

kc

kc1

mc

kr

γ0

rε

-mc

2 × ap

iC

hm =

hex =

fn × sin kr

fn × sin kr

hex = fn × 4 ap 2 ap

iC iC

( (

( (

(

√ - ( ²

fn2 × 125

Dm × π lm

Dm1 + Dm2

rε

1000 fn

2

×

π

1000×

lm1

fn

×( ( lm2 =

Dm1 + Dm2

Dm1 – Dm2

2

2

π

1000×

lm2

lm1

fn×(

(( (

((

√²

² +

*)

*)

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Formulas and definitions

Turning

Cutting speed (vc) Spindle speed (n)

Net power (Pc)

(m/min)

(cm³/min)

(rpm)

(kW)Metal removal rate (Q)

Specific cutting force (kc)Machining time (Tc)(N/mm²)(min)

(mm)

Average chip thickness (hm)

Round inserts

(mm)

Max. chip thickness (hex)

Round inserts

Insert shapes: C, D, S, T, V, W(mm)

Note: arccos in degrees

Insert shapes: C, D, S, T, V, W(mm)

(μm)

(m)

(m)

(m)

Profile depth (Rmax)

External or internal (straight) turning

Facing

Taper cutting

Rmax =

SCL =SCL =

SCL

Rmax

SCL =

Spiral Cutting Length m

μmProfile depth

Nose radius

Chip rake angle

Entering angle

Correction factor for actual hm

Specific cutting force valid for hm = 1 mm

Specific cutting force

Maximum chip thickness

Average chip thickness

Machined length

Machining time

Metal removal rate

Net power

Spindle speed

Cutting speed

Parameter Meaning

Machined diameter

Depth of cut (D.O.C.)

Feed per revolution

Metric unit

mm

mm

mm/r

m/min

rpm

kW

cm³/min

mm

mm

min

mm

N/mm²

N/mm²

degree

mm

In parting and grooving, fnx (radial feed) and fnz (axial feed) are also used.

Information/Index – formulas and definitions

Spiral Cutting Length (SCL)

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∆apx =ap

nap - 1

∆apx

×ap

nap

j = 0.3

= 1

= x - 1

√× √ j

∆apx 1 =

∆apx 2 =

∆apx 3 =

∆apx 4 =

∆apx 5 =

∆apx 6 =

0.94

0.94

0.94

0.94

0.94

0.94

5

5

5

5

5

5

√

√

√

√

√

√

×

×

×

×

×

×

√

√

√

√

√

√

0.3 = 0.23

1 = 0.42

2 = 0.59

3 = 0.73

4 = 0.84

5 = 0.94

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Thread turning

Parameter Meaning

Radial infeed

Actual pass (in a series from 1 to nap)

Total depth of thread

Number of passes

1st pass

2nd pass

3rd pass

Metric unitFormulas to calculate infeed for each pass in a reduced series.

Example:

Conditions Calculations Results

External threading

Pitch: 1.5 mm ap: 0.94 mm nap: 6 passes

1st pass, infeed

= 0.23 mm

2nd pass, infeed

0.42 - 0.23 = 0.19 mm

3rd pass, infeed

0.59 - 0.42 = 0.17 mm

4th pass, infeed

0.73 - 0.59 = 0.14 mm

5th pass, infeed

0.84 - 0.73 = 0.11 mm

6th pass, infeed

0.94 - 0.84 = 0.10 mm

mm

mm



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vc = n =

fz =

vf =

Dcap × π × n vc × 1000

vf

1000 π × Dcap

n × zc

fz × n × zc

Dcap

fz

vf

zn

zc

fn

ap

vc

ae

n

Pc

Mc

Q

hm

hex

kr

Dm

Dw

vfm

Q =

Pc =ap × ae × vf × kc

60 × 106

ap × ae × vf

1000

kc = kc1 × hm × 1 -

kc = kc1 × hm

γ0100

-mc

-mc

( (

hm =360 × sin kr × ae × fz

π × Dcap × arccos 1 -2 × ae

Dcap( (

hm =180 × sin kr × ae × fz

π × Dcap × arcsinae

Dcap( (Mc =

Pc × 30 × 10³

π × n γ0

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Table feed or feed speed (vf)

Cutting speed (vc)

Metal removal rate (Q)

Spindle speed (n)

Feed per tooth (fz)

(mm/min)

(m/min)

(cm³/min)

(rpm)

(mm)

Net power requirement (Pc)(kW)

Average chip thickness (hm). For straight cutting edge.

Side milling

Torque (Mc)(Nm)

Note: arcsin in degrees

Note: arccos in degrees

(mm)

Face milling If the workpiece is placed central to the milling cutter.(mm)

Specific cutting force (kc)(N/mm²)

If γ0 is unknown, use γ0 = 0°, which becomes:

Cutting diameter at actual depth of cut, ap

Feed/tooth

Table feed

Total number of teeth in cutter

Number of effective teeth

Feed/rev


Cutting speed

Working engagement

Spindle speed

Net power

Torque

Metal removal rate

Average chip thickness

Maximum chip thickness

Entering angle

Machined diameter (component diameter)

Unmachined diameter (component diameter)

Table feed of the tool at Dm (macined diameter)

mm

mm

mm/min

pcs

pcs

mm

mm

m/min

mm

rpm

kW

Nm

cm³/min

mm

mm

degree

mm

mm

mm/min

Parameter Meaning Metric unit


Milling

Chip rake angle


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Dcap = Dc +2 × ap

tan kr

fz =

fz =

hex × iC

hex × Dcap

2 × ap × iC − ap²

2 × sin kr × Dcap × ae − ae²

fz =

fz =

hex

D3 × hex

sin kr

Dcap

√

√

fz =

fz =

hex × iC × Dcap

4 × ap × iC − ap² × Dcap × ae − ae²√ √

Dcap = Dc +√iC² – (iC − 2 × ap)²

√Dcap² – (Dcap – 2 × ae)²

Dcap = √D3² – (D3 – 2 × ap)²

D3 × hex

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Face milling round insert (ae >Dcap/2) mm.

Side milling (ae <Dcap/2) straight edge mm.

Face milling (centered work-piece) straight edge and side milling (ae >Dcap/2) mm.

Feed per tooth (mm/tooth), cutter centered.

Feed per tooth (mm/tooth), side milling.

Max. cutting diameter at a specific depth mm.

Slide milling (ae<Dcap/2) and round insert (ap<iC/2) mm.



Formulas for specific milling cutters Cutters having a straight cutting edge

Cutters with round inserts

Ball nose end mills



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vfm = n × fz × zc

vf =vfm × (Dm – Dcap)

Dm

fz = hex

Dm² – Dw² 4 (Dm – Dcap)

fz =

fz =

=sin b

sin b

vfm = n × fz × zc

hex hex

hex

√ 1 – cos² b

b = arccos 1 -

b = arccos 1 -

Dcap

Dcap

Dvf = Dm-Dc Dvf1 = Dvf

2

vf =vfm × (Dm + Dcap)

Dm

(

(

(

(Dw² – Dm² 4 (Dm + Dcap)

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Calculated version

Internal circular ramping (3-axes) or circular milling (2-axes)

Peripheral feed (mm/min)

Tool centre feed (mm/min)

Radial depth of cut (mm)

Feed per tooth (mm)

Feed per tooth (mm)

When widening a hole

In a solid workpiece where

Dw = 0 and ae eff = Dm 2

Circular ramping in solid workpiece

Circular ramping or circular milling to widen a hole

Circular milling with a roll into cut tool path, Dvf1

External circular ramping (3-axes) or circular milling (2-axes)

Calculated version

Peripheral feed (mm/min)

Tool centre feed (mm/min)

Feed per tooth (mm)


eff

2 × ae eff

ae eff =2 × ae eff

ae eff =


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vc

n

Q

fn

fz

vf

Tc

Im

Dc

Pc

Mc

Ff

vc =Dc × π × n

1000

Pc = Mc =fn × vc × Dc × kc Pc × 30 × 10³

240 × 10³ π × n

zc

ap

fz

vf = fn × n fn = zc × fz

Pc =

Ff ≈ 0.5 × ap × fn × kc × sin kr

ap × fn × kc × vc

60 × 10³

vf = fn × n

n =vc × 1000

π × Dc

Q =Dc × fn × vc

4

fn =vf

n

Tc =lmvf

kc = kc1 × (fz × sin kr) × 1 - γ0

ap

100

Dc

-mc (

(

(

(

Ff ≈ 0.5 × kc × × fn × sin krDc

2

CoroDrill® 880

1 -

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Cutting speed (vc)

Net power requirement (Pc) Torque (Mc)

(m/min)

(kW) (Nm)

Penetration rate (vf)(mm/min)

Spindle speed (n)(rpm)

Metal Removal rate (Q)(cm³/min)

Feed per revolution (fn)(mm/r)

Machining time (Tc)(min)

Specific cutting force (kc)(Nm/mm²)

Feed force (Ff)(N)

For solid drills: (CoroDrill Delta-C, type 840) fz = fn/2 kr = 70° γ0 = 30°

For indexable insert drills: (CoroDrill 880) fz = fn kr = 88° γ0 = 15°

Parameter Meaning

Cutting speed

Spindle speed

Metal removal rate

Feed per revolution

Feed/edge

Penetration rate

Machining time

Machining drilling length

Drill diameter

Net power

Torque

Feed force

Metric unit

m/min

rpm

cm³/min

mm/r

mm

mm/min

min

mm

mm

kW

Nm

N

Boring and trepanning

Penetration rate Feed per revolution (fn)

Net power (Pc)

Feed force (Ff)

(mm/min) (mm/r)

(kW)

(N)

For other formulas, see Drilling

*) Note: zc = 1 for step-boring

Parameter Meaning

Number of effective teeth *)


Feed per tooth (insert)

Metric unit

pcs

mm

mm/r


Drilling


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New cutting data calculator Self-explanatory and very easy to use

• Calculator metric/inch

• Size 80x125x15 mm

The Sandvik Coromant cutting data calculator is designed to solve most calculation problems encountered in the metal cutting area.

The calculator is self-explanatory and very easy to use. Users include programmers, operators, machinists, supervisors, foremen, designers and more.

As a user, you simply decide what parameter you want to calculate, choose the appropriate formula from the menu in the display and enter the input as prompted by the calculator. This means that the user does not need to memorize any metal cutting formulas.

The Sandvik Coromant cutting data calculator also functions as a standard mathe matical calculator. Calculations can be done in metric or inch.

The Cutting Data Module is available on the internet free of charge at: http://www.coroguide.com or at: www.coromant.sandvik.com

Input

• Material• Grade

Output• Diameter• Hole depth

Plura guide

Tool selection, cutting data and programming of the CoroMill Plura and CoroMill 316.

Available on CD-ROM, order No: C-2948:063.

Software for calculationsCutting Data Module

Turning, milling, drilling and boring Example CoroDrill® 880


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4

10

12

25

60

CoroCut® MB

T-Max U-Lock 166®T-Max U-Lock® 166

CoroThread™ 266 CoroThread™ 266

T-Max Twin-Lock®

CoroMill® Plura

CoroMill®327

CoroMill®328

CoroTurn® XS

CoroCut® XS

T-Max Twin-Lock®

CoroMill® 3284

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Information/Index – thread charts

Overview – threading

0.2 – 2 mm

0.5 – 3 mm 32 – 8 t.p.i.

0.5 – 8 mm 32 – 3 t.p.i.

0.5 – 2 mm 32 – 18 t.p.i.

0.5 – 2.5 mm 32 – 11 t.p.i.

0.5 – 2 mm 32 – 14 t.p.i.

0.5 – 8 mm 32 – 3 t.p.i.

10 – 5 t.p.i.

0.7 – 3 mm 27 – 10 t.p.i.

1 – 4.5 mm 24 – 5 t.p.i.

1.5 – 6 mm 16 – 4 t.p.i.

Pitch

Pitch

External threading Internal threading

Right / Left

10 – 5 t.p.i.

1.5 – 5 mm 16 – 5 t.p.i.

Thread charts

Min. hole (mm)


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Dc

M14M16M18M20M22M24M27M30M33M36M39

2.002.002.502.502.503.003.003.504.004.004.00

12.0014.0015.5017.5019.5020.9023.9026.4029.4032.0035.00

880-D1200880-D1400880-D1550880-D1750880-D1950880-D2090880-D2390880-D2640880-D2940880-D3200880-D3500

CoroDrill® 880

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Thread hole recommendations

• Many tables containing recommended tapping drill sizes are not valid for modern drills, such as the CoroDrill Delta-C, which normally produces a slightly smaller but more accurate hole than conventional HSS drills. Using conventional drill diameter recommendations may lead to tap breakage.

• For larger hole sizes use CoroDrill 880-drills.

• For chamfering, use a drill with chamfering capability (CoroDrill Delta-C type 841) or the CoroMill Plura chamfering end mill, CoroMill 327 or CoroMill 328. For more information, see page D 126.

Metric ISO Threads

Tap Threading

Thread Pitch Drill diameter Dc mm Recommended drills



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M4 × 0.7M4 × 0.7M5 × 0.8M5 × 0.8M6 × 1.0M6 × 1.0

M8 × 1.25M8 × 1.25

.201" 1/4-20 UNC

.260" 5/16-18 UNC

.272" 5/16-24 UNF

.315" 3/8-16 UNC

0.70.70.80.81.01.0

1.251.25

Dc

3.353.404.254.305.005.106.606.856.908.00

R841-0335-30-A1AR841-0340-30-A1AR841-0425-30-A1AR841-0430-30-A1AR841-0500-30-A1AR841-0510-30-A1AR841-0660-30-A1AR841-0685-30-A1AR841-0690-30-A1AR841-0800-30-A1A

M10 × 1.5M10 × 1.5M12 × 1.75M12 × 1.75

M14 × 2.0M14 × 2.0

M16 × 2.0M16 × 2.0M18 × 2.5

M20 × 2.5

MF6 × 0.75MF8 × 1.0MF8 × 0.75MF10 × 1.0MF10 × 0.75MF12 × 1.5MF12 × 1.25MF14 × 1.5MF16 × 1.5MF16 × 1.0

.453" 1/2-20 UNF

.482" 9/16-12 UNC

.532" 5/8-11 UNC

.650" 3/4-10 UNC

.689" /4-16 UNF

.421" 1/2-13 UNC

1.51.51.751.75

2.02.0

2.02.02.5

2.5

0.751.00.751.00.751.51.251.51.51.0

8.608.7010.3010.4011.5012.1012.2513.5014.1014.2515.5016.5017.50

5.307.007.309.009.2510.5010.8012.5014.5015.00

R841-0860-30-A1AR841-0870-30-A1AR841-1030-30-A1AR841-1040-30-A1AR841-1150-30-A1AR841-1210-30-A1AR841-1225-30-A1AR841-1350-30-A1AR841-1410-30-A1AR841-1425-30-A1AR841-1550-30-A1AR841-1650-30-A1AR841-1750-30-A1A

R841-0530-30-A1AR841-0700-30-A1AR841-0730-30-A1AR841-0900-30-A1AR841-0925-30-A1AR841-1050-30-A1AR841-1080-30-A1AR841-1250-30-A1AR841-1450-30-A1AR841-1500-30-A1A

M4 × 0.7M5 × 0.8M6 × 1.0M8 × 1.25M10 × 1.5M12 × 1.75M14 × 2.0M16 × 2.0

.516" 9/16-18 UNF

0.70.81.81.251.51.752.02.0

3.704.655.557.409.3011.2013.1015.10

R841-0370-30-A1AR841-0465-30-A1AR841-0555-30-A1AR841-0740-30-A1AR841-0930-30-A1AR841-1120-30-A1AR841-1310-30-A1AR841-1510-30-A1A

M8 × 1.25M7M6M5M4

M10 × 1.5M12 × 1.75M14 × 2.0M16 × 2.0M20M24

MF6 × 0.5MF8 × 0.75MF12 × 1

.335" 3/8-24 UNF

.217" 1/4-28 UNF

1.251.01.00.80.7

1.51.752.02.02.53.0

0.50.751.0

6.756.005.004.203.30

8.5010.2512.0014.0017.5021.00

5.507.2511.00

R841-0675-30-A1AR841-0850-30-A1AR841-1025-30-A1AR841-1200-30-A1AR841-1400-30-A1A

R841-0550-30-A1AR841-0725-30-A1AR841-1100-30-A1A

CoroDrill® Delta-C

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Inch and Metric ISO Threads

Tap threading

Thread Inch sizes Pitch Recommended drills

Fine threads

Rolled thread

Thread milling

Fine threads



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Ra = 2 µm

Ra = 2 µm

It

Ir

In = 5 x Ir

Ra

Ra

3.2

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The surface texture generated on the workpiece can be described by three basic parameters:

• P-profile Primary profile, an overall profile.

• W-profile Waviness profile

• R-profile Surface roughness profile. The R-profile is calculated by using a cut-off filter to remove the longwave components from the P-profile. The R-profile is therefore an intentional modification of the P-profile.

Measuring surfaces

The surface textures appear very different yet still show the same Ra-value.

When measuring surface textures, the evaluation is usually based on one, specified reference length. If the reference length is not determined in the component design drawing, then the person who measures the surface texture must determine the reference length.

Basis for evaluation

Measuring lengths lt = the total length (comprises the starting, evaluation and

stopping length).ln = the evaluation length (comprising five reference lengths is

standard).lr = the reference length.

Parameters based on the R-profile:

The most common parameters in the R-profile are:

Mean roughness of the profile A mean value of all deviations from a straight line within the evaluation length, irrespective of the vertical direction. This means that it is impossible, using an Ra-value, to determine whether the deviations are peaks or valleys. Ra is not significantly affected by individual deviations, which means that there is also a risk of missing a large peak or a scratch.

The most common Ra-values for metal surfaces are between 0.02 μm and 3.5 μm – the lower the value the finer surface (0.02 μm = mirror blank).

Mean line

Evaluation of the arithmetical mean deviation of the assessed profile.

Information/Index – measuring surfaces

Example of drawing indication:


I 15

A

B

C

D

E

F

G

H

I

Rt

Rt

Rz1

In1

Rz2

In2

Rz3

In3

Rz4

In4

Rz5

In5

Rz=Rz1 + Rz2 + Rz3 + Rz4 + Rz5

5

Rz

Rp1 Rp2 Rp3 Rp4 Rp5

Rp=Rp1 + Rp2 + Rp3 + Rp4 + Rp5

5

In0 20 40 60 80 100%

c

Rp

Rmr

Rz8

Rt4

Rp2

Rmr70%/c =1

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Information/Index – measuring sufaces

Total profile height The total height of the profile is the sum of the height of the largest profile peak height and the largest profile valley depth within the evalution length (which normally comprises five reference lengths). A single Rt-value (which is not combined with Rz or Ra) is one of the most rigid demands in the R-profile.

Maximum profile height (average) The maximum height of the profile is the mean value of the individual profile heights, Rz, obtained between the largest peak height and the largest valley depth within the reference lengths included in the evaluation length. Normally, there are five reference lengths, but the number can vary with modern measuring equipment. The Rz-value in the reference length that shows the highest deviation is called the Rzmax or Rmax.

Maximum peak height (average) The maximum profile peak height is the mean value of the largest individual profile peak heights, Rp, obtained within the reference length. The surface roughness parameter, Rp, together with, Rz, can provide information about the surface characteristics.

The material ratio (Abbot-Firestone curve) The most suitable method for obtaining a measurement of the ”wearability” of an item is to assess the material ratio of the surface. Rmr is given in %. Evaluating the material ratio is a simple method used to indicate the level of a surface defect.

Profile depth

Reference level

Material ratio






I 16

A

B

C

D

E

F

G

H

I

IT6

IT5

0.008

0.005

0.012

0.018

0.030

0.048

0.075

0.120

0.180

0.009

0.006

0.015

0.022

0.036

0.058

0.090

0.150

0.220

0.011

0.008

0.018

0.027

0.043

0.070

0.110

0.180

0.270

0.013

0.009

0.021

0.033

0.052

0.084

0.130

0.210

0.330

0.016

0.011

0.019

0.013

0.022

0.015

0.025 0.029

0.018 0.020

0.025 0.030 0.035 0.040 0.046

0.039 0.046 0.054 0.063 0.072

0.062 0.074 0.087 0.100 0.115

0.100 0.120 0.140 0.160 0.185

0.160 0.190 0.220 0.250 0.290

0.250 0.300 0.350 0.400 0.460

0.390 0.460 0.540 0.630 0.720

IT7

IT8

IT9

IT10

IT11

IT12

IT13

D>3–6 D>6–10 D>10–18 D>18–30 D>30–50 D>50–80 D>80–120 D>120–180 D>180–250

Ø

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Information/Index – hole tolerances

• The lower the IT-number, the closer the tolerance.• The tolerance for one IT class increases at larger diameters.

Diameter range, D (mm)

Hole tolerances

The dimensions of a hole can be divided into three parameters:• The nominal value (the theoretically exact value)• The tolerance width (designated IT acc. to ISO)• The position of the tolerance (designated by capital letters

acc. to ISO)

Dmax minus Dmin is the tolerance width also called IT.

Hole tolerances

Bearings

Examples

Holes for threading with fluteless taps

Normal tap holes

Tool width

Nominal

Nominal value: 15.00 mm

Tolerance width: 0.07 mm (IT 10 acc. to ISO)

Position: 0 to plus (H acc. to ISO)

One example:


I 17

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B

C

D

E

F

G

H

I

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Information/Index – hole tolerances

Running fit Slide fit Drive fit Interference

Play (bearings) Grip (=negative play) (fixed joints)

Most common

Hole larger than axle Axle larger than hole

Axleø20 mm h7

Holeø20 mm h7

Axle tolerance position is designated by lower case letters that correspond to the hole tolerances. The figure below provides a complete picture:

Hole and axle tolerances

The hole tolerance is often connected to the tolerance of an axle that should fit the hole.

Example:


I 18

A

B

C

D

E

F

G

H

I

A 3

A 93

A

A

A

A

A

A

A

A

A

A

A

A

B

B

B 3

B 49

B

B

B

B

B

B

B

B

B

B

C

C

C

C

C 3

C 37

C

C

C

C

C

C

C

C

D 80

D

D 84

D

D 95

D

D 3

D 133

D 102

D

D 103

D

D

D

E

E

E

E

E

E

E

E

E 3

E 49

E

E

E

E

F

F

F

F

F

F

F

F

F

F

F 3

F 37

F

F

G

G

G

G

G

G

G

G

G

G

G

G

G 3

G 59

H

H

I

I

H

H

I

I

H

H

I

I

H

H

I

I

H

H

H

H

H

H

I

I

I

I

I

I

A 89

A

A

B

B 47

B

C

C

C 34

D

D

D

E

E

E

F

F

F

G

G

G

H I

H I

H I

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Information/Index – FAQ

Where to find information about different topics

FAQ

Where can I find cutting data?

• Note that cutting speed and feed recommendations are to be found in the Main catalogue, with one exception i.e. feed recommendations for milling tools, see page D 192.

• However, cutting data recommendations how to avoid or solve a problem are included in this gude.

What method and tool should I use?

The first part of each product chapter, called Application, give guide lines regarding choice of tools and how to apply them in order to achieve a good result.

I have choosen a product now I need more information about it?

Specific information about a product can be found in the latter section of each chapter. called Products:

• Turning, turn milling

• General turning (incl. all CoroPlex tools)

• Parting and grooving


• Threading, thread milling

• Thread turning

• Milling

• Milling

• Drilling, circular ramping

• Drilling

• Boring and reaming, circular milling/ramping

• Boring and reaming

• Tool holding/Machines


Chapter

Chapter

Trouble shooting

Each product chapter has a section called trouble shooting.

• General turning


• Thread turning

Chapter

I 19

A

B

C

D

E

F

G

H

I

A

A 150

A 22

A

A

A

A 72

A

A

A 82

A 89

B

B 70

B 9

B

B

B

B

B

B

B

B 48

C

C 51

C

C

C

C

C

C

C

C

C 35

D

D 192

D 32

D 10

D

D

D 80

D

D

D

D 128

E

E 66

E 16

E

E

E

E

E

E

E

E 46

F

F 63

F

F

F

F

F

F

F

F

F 34

G 22

G

G

G 26

G

G

G 28

G

G

G 32

G

H

H

H

I

I

I

H

H 11

H 16

I

I

I

H

H 3

H 37

I

I

I

H

H 10

I

I

A

A

A

A

B

B

B

B

C

C

C

C

D 128

D

D

D

E

E 44

E

E

F

F

F 34

F

G

G

G

G 57

H I

H

H

H

I

I

I

A4

A 149

A

A

A

A

B

B 67

B

B

B

B

C

C 50

C

C

C

C

D

D 200

D

D

D

D

E

E 50, E 58, E 62

E

E

E

E

F

F 62

F

F

F

F

G

G

G

G

G

G

H I

H I 2

H I 4

H

H

H

I 11

I 14

I 16

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Machine tools

Cutting tool materials

Workpiece materials

• Turning centers

• Grade information

How to machine different workpiece materials

• Machining centers

• Grade overview table (type of coatings etc.)

New material classification including:• kc values• description of different work piece materials• influence of alloying elements etc.

• Multi-task machines/machining

• Basic information – what is PVD, CVD, ceramics etc.

• Cross referens list – new MC vs CMC vs local standads

• Small part machines/machining

• Insert wear types

Chapter

Chapter

Chapter

• Milling

• Drilling

• Boring and reaming


Additional information

• Manufacturing economics

• Tailor made and extended offer

• Formulas

• Thread holes

• Measuring surfaces

• Hole tolerances

Chapter

I 20

A

B

C

D

E

F

G

H

I

A B C D E F G H I

A 5

A 4

A 6–A 9

A 12

A 14, A 48–A 52, A 59–A 61

A 37

A 17, A 63

A 62

A 91

A 92

A 67

A 68

A 80

A 18, A 94–A 99

A 19, A 100, A 112

A 21, A 151

A 24, A 27, A 29, A 33, A 36, A 39, A 45

A 40

A 89–A 92

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General turning

Page

Page

Choice of tool, insert and tool holding

How to apply and use the tools

• I like to maximize the productivity, what should I consider when I make the choice of tools?

• What should I think about when setting up my application?

• I need a brief description of the turning tool concepts available.

• How do feed, speed and depth of cut effect the tool life?

• What type of insert shape should I choose?

• I must avoid to change insert in the middle of a finishing cut. How can I predict the tool life?

• What determines the size of the nose radius?

• What can I do to minimze the tool deflection in internal turning?

• How can I improve chip control?

• How can I reduce vibration problems?

PageTool mounting, setting and maintenance

• How can I ensure that the center height of the insert is correct?

• I have a CoroTurn SL (570) bar. How much can it be cut off?

• How do I measure the tool offset in a Multi-task machine?

• Can a boring bar with flats be used in an EasyFix sleeve? – Yes, it's possible to use it but you will not find the correct centre height of the bar because

there is no groove in a bar with flats.

• When and how can I use a wiper insert ?

• How do I choose the right insert:

– geometry?

– grade?

– geometry and grade?

• I consider to do hard part turning instead of grinding. How should it be done?

• Have all the CoroTurn 107 and CoroTurn 111 bars coolant holes? – Yes, all the bars have a coolant hole except for the smaller dimension damped bars.

PageTool wear component quality

• See Trouble shooting

I 21

A

B

C

D

E

F

G

H

I

A B C D E F G H I

B 15, B 17

B 21

B 9, B 20, B 30

B 8

B 6, B 46

B 17

B 18

B 22

B 7

B 47–B 48

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Parting and grooving

PageChoice of tool, insert and tool holding

• What geometry is best for pip and burr free parting off?

• I need a flat bottom when producing a radial groove. What geometry should I choose?

• What type of insert and geometry is best for hard part machining?

PageHow to apply and use the tools

• Should I use cutting fluid when parting off?

• How can vibrations be avoided?

• What should I think about when parting into a drilled hole?

• How can I avoid problems with burrs?

• What is the best method for rough grooving? Multiple grooving or plunge turning?

• Is there a Wiper radius on CoroCut parting and grooving inserts and what are the benefits? – Yes, on geometries TF and CF there is a Wiper radius giving a positive effect on the surface finish in parting and

grooving.

• Can I double the feed with a Wiper insert for Parting and Grooving? – No. The main reason to have a wiper on TF and CF geometries is to achieve much better surface finish. If the feed

rate increases too much, chipforming will be too hard and have a negative influence on tool life.

• What is Wiper effect in axial turning with a CoroCut insert? – When making turning operations with the TM or TF geometries you have to increase the feed rate in axial direction,

to bend/tilt the holder/insert to get clearance. This is what we call Wiper effect resulting in excellent surface finish and productivity.

• What should I use to make use of the Wiper Technology in face grooving operations? – Use CoroCut geometry TF. Futhermore the TF geometry will steer the chip out from the work piece, resulting in a very

secure operation with the best surface finish.


• How to mount a spring clamped insert correctly?

PageTool wear and component quality

• See Trouble shooting.

I 22

A

B

C

D

E

F

G

H

I

A B C D E F G H I

C 6

C 8, D 96

C 5, C 13

C 12

C 10, D 95, I 11

C 27, C 33, D 97

C 16

D 97

D 99

C 14

C 18

C 19

C 21, C 26, C 32

D 98

C 19

C 35

C 34

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Threading


• How is a thread defined?

• When should thread milling be prefered to thread turning?

• What is the difference betwwen full profile, V-profile and multi-point threading?

• What is the difference between A, F and C-geometries?

• I need a brief description of the threading tool concepts available.

• What is the difference between right and left hand external threads ?

• How do I select shim to obtain the right inclination angle?

• What cutter diameter should I choose to get an accurate thread profile?

• Where can I find the RPRG value for a CoroMill Plura?


• What is the difference between flank, incremental and radial infeed?

• How should cutting fluid be applied?

• How to achive the best chip control?

• What are the main considerations to obtain a good thread quality?

• What type of machine tool is required for thread milling?


• What should be considered when setting up a thread turning tool?

PageTool wear

• Abnormal flank wear on one side of the edge?

Component quality

• The thread profile is not correct?

Page

I 23

A

B

C

D

E

F

G

H

I

A B C D E F G H I

D 16

D 6–D 8

D 13, D 134, D 184

D 192–D 195, H 14

G 42

D 20

D 25

D 26

D 30, D 130

D 28

D 32–D 41

D 31, D 52, D 59

D 117

D 102–D 114

D 41, D 94, D 121

D 145

D 185

D 39, D 129

D 29, D 131

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Milling


• I like to maximize the productivity?

• I need a brief description of the milling applications and tools available.

• I need information about insert geometries?

• I need information about choice of grades?

• How do I choose the correct holder for my milling cutter?


• How does the chip thickness effect the feed recommendation?

• What does it mean to ”roll into cut” ?

• How can I avoid vibration when milling a corner?

• How can I minimize the risk of vibrations when milling?

• Does cutting fluid have an effect on the tool-life?

• What should I consider when milling different types of material?

• Which method gives less deflection when milling thin walls?

• What is the most efficient way to machine deep down in cavities?

• How to make holes with milling tools?

• What are the advantages of trochoidal milling?


• How should I set the CoroMill Century?

• I need information how to regrind my CoroMill Plura endmill?

PageTool wear

• A large notch wear limits the tool life. What can I do?

Component quality

• I can not reach the expected surface finish for my operation. Why?

Page

I 24

A

B

C

D

E

F

G

H

I

A B C D E F G H I

E 5

E 6, E 42

E 52–E 53

E 16–E 17

E 36

E 22

G 49

E 7, E 15

I 16

E 32, E 35, E43

E 34

E 19

E 32–E 33

E 64–E 65

E 48, E 46

E 8

E 44

A B C D E F G H I

G 52

F 25, F 47, F 52

F 18➤

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Drilling

Page

Page

Choice of tool, insert and tool holding

How to apply and use the tools

• Should I choose an indexable insert or a solid carbide drill?

• What to think about when setting up the drill in a machine?

• What geometry and grade should I choose when machining different materials with a CoroDrill 880?

• What should I consider when drilling in different workpiece materials?

• What type of drill should I use for plunge drilling?

• Can I drill into an angled surface?

• How do I choose the correct holder for my drilling tool?

• How can I improve chip evacuation?

• What does H8-tolerance mean?

• Can I produce a hole that is larger than the drill?

• Can I use my CoroDrill 880 for a boring operation?

• How should I make the pilot hole before drilling with CoroDrill 805?


• How do I set my adjustable drill adaptor?

• Where do I find information how to regrind my CoroDrill Delta-C drill?

PageTool wear

• There are chipping on the edges. What can I do?

Component quality

• What is important to achive a good hole quality?

• The drilled hole is oversized, what can be the problem?

Page

Boring


• How do I choose the correct tool holder for my boring tool?

• What geometry and grade should I choose for fine boring?

• What geometry and grade should I choose for rough boring?

I 25

A

B

C

D

E

F

G

H

I

F 5, F 31

F 6–F 7

F 6, F 16

F 41–F 42

F 46, F 52

F 12

F 19, F 31

F 29

F 30

F 34

F 30

F 20

F 38, F 42, F 47

F 10

F 18

F 32

F 39, F 43, F 45

F 28–F 29

F 54

F 13

H 10

F 12

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• When is reaming to be prefered instead of fine boring?

• Should I choose multi edge boring, step boring or single edge boring?

• Should I choose CoroBore 820 or Duobore?

• When should I choose Silent Tools?

• What is the precision of the adjustability of CoroBore 825 and fine boring head 391.37A?


• What are the recommendations regarding cutting fluid when boring?

• What should I think about when machining a blind hole?

• What is the best method to achieve close hole tolerance with a fine boring tool?

• Can I make an external operation with a boring tool?

• How to overcome vibrations?

• What to think about when machining back boring?

• How do I get the best performance with CoroBore 820?

• Should I adjust cutting data when boring with long overhangs?

• What cutting data should I use when applying a boring tool?

• What to think about when machininig large diameter holes?

• What is the maximum run-out for a reamer?


• How do I set up my rough boring tool for multi edge boring, step boring or single edge boring?

• How do I set the diameter on my adjustable CoroBore 825 or fine boring head 391.37A/B?

• The fine boring head 391.37B have a balance weight? How should this weight be set?

• What maintenance is required on my boring tool?

PageTool wear

• How do I analyze insert wear?

Component quality

• What shoud I think about to achieve a good hole quality?

Page

I 26

A

B

C

D

E

F

G

H

I

G 7

G 5

G 20

G 7

G 7

G 28

G 7

G 7

G 114

G 103

G 100, A 126

G 86, A 124, A 147, B 58, C 40

A 127

G 36

G 22

G 12–G 15

G 13–G 15

G 16

➤

A B C D E F G H I

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Tool holding/Machines

PageChoice of tool holding

• What can I benefit from a quick change system?

• Is the Coromant Capto coupling both a quick change and modular system? – Yes, modular gives you the ability to build tools with standard articles to the correct length to suit the application

and machine tool and quick change gives you a faster set-up and a better machine utilization.

– Faster set-up and better machine utilization

• What type of holder system is suitable for my machine?

• Can I use the same Coromant Capto coupling tools on other machines as well? – Yes, for all machine types new and existing. There is only one version of the coupling

• Can I use Coromant Capto coupling tools also in machines with other interfaces? – Yes, with basic holders it is possible to convert from the most common interfaces to Coromant Capto.

• I have bought a new Multi-Task machine. How should I equip my machine? – In this type of machines it is important to use a system like Coromant Capto to fulfill all requirements for the large

variation of demand (turning, milling and drilling) effective for both stationary and rotating applications.

• Can I use my existing special shank tools if I have standardized on Coromant Capto system in my machine? – Yes, by using the range of square shank tool adaptors.

• Can the Coromant Capto coupling be used for other purposes? – Yes, for e.g. fixturing and work piece holding

• I need information about:

– HydroGrip

– CoroGrip

– Silent tools adapters

– CoroTurn SL

– Easy fix

• I have choosen a turning/milling/drilling/boring/tapping tool, what type of holders are available?


• How to apply a clamping unit in to a turning centre? – Depending on the machine interface we have several standard or machine adapted units.

• How does the tool holder run-out affect vibrations and machining quality? – Reduced life time and bad surface finish is always a consequence of bad run-out. Use direct integrated tools or

Hydro-Grip chucks for round tools.


• I need information about max rpm and balancing?

• I use the older type of collet chuck with Coromant Capto coupling and the clamping does not work properly? – Use a stop scew to eleminate that the tool is inserted past the drawbar ejecting surface

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• A cutting unit remains stuck in the clamping unit/spindle. What should I do?

• My CoroGrip tool holder seems not to clamp my milling cutter with the right force. How could I check the function?

• How can I check the draw bar movement of an assembled clamping unit?

• I need an assembly fixture for my modular tooling

sandvik technical guide

Documents