A More Efficient Way to Cut Near-Net Parts - milling insert

Workpiece is held in a chuck, mounted on a face plate or secured between centers and rotated while a cutting tool, normally a single-point tool, is fed into it along its periphery or across its end or face. Takes the form of straight turning (cutting along the periphery of the workpiece); taper turning (creating a taper); step turning (turning different-size diameters on the same work); chamfering (beveling an edge or shoulder); facing (cutting on an end); turning threads (usually external but can be internal); roughing (high-volume metal removal); and finishing (final light cuts). Performed on lathes, turning centers, chucking machines, automatic screw machines and similar machines.

Crystal manufactured from boron nitride under high pressure and temperature. Used to cut hard-to-machine ferrous and nickel-base materials up to 70 HRC. Second hardest material after diamond. See superabrasive tools.

Sumitomo’s holders for CGA-style inserts have a top clamp that pulls an insert back into the pocket, and the holders also use a side screw to help enhance stability and tool life. “We only offer it for hard grooving,” said Rich Maton, assistant manager, engineering department for Sumitomo. “If you have an insert that is moving in the pocket, over time the insert will wear and tool life will vary, which is especially significant for the high-productivity requirements of the automotive industry, where going from 50 to 100 or 150 pieces per edge makes a huge impact.”

To provide the rigidity needed for machining hardened steel parts, INDEX’s C100 and C200 turning machines feature the SingleSlide, a slideway with two degrees of freedom in one plane.

CBN works well in such hard materials because instead of cutting the material, CBN molts the material at the tool/workpiece interface.

Hardness is a measure of the resistance of a material to surface indentation or abrasion. There is no absolute scale for hardness. In order to express hardness quantitatively, each type of test has its own scale, which defines hardness. Indentation hardness obtained through static methods is measured by Brinell, Rockwell, Vickers and Knoop tests. Hardness without indentation is measured by a dynamic method, known as the Scleroscope test.

“To enhance efficiency, our new M5Q90 tangential milling cutter features fully engineered cutter bodies matched with dedicated PCD insert geometries that feature a positive cutting angle to reduce cutting force and load on the machined component,” explains Emmanuel David, global automotive product manager at Sandvik Coromant.

Toolholders for grooving inserts should be as short as possible to minimize overhang, which increases rigidity. And while solid, or integral, holders are typically better suited for hard grooving, according to Matthew Schmitz, national product manager—GRIP Products for Iscar Metals Inc., Arlington, Texas, Iscar offers modular systems as well.

No matter what kind of groove they are making, shops that previously relied on grinding for finishing hardened steel parts can improve productivity by transitioning to grooving with PCBN tools. They achieve comparable tolerances while dramatically reducing machining time. CTE

Some common groove features for hardened steel parts are simple square, profile and plunge grooves. Typically, grooved parts require a fine surface finish because there is a mating part or an O-ring or snap-ring groove. “The applications are split between internal and external operations, but the majority of applications require finishing passes,” said Mark Menconi, product specialist for Mitsubishi Materials, Schaumburg, Ill. “The finishing passes range from a slight touch-up with a low DOC near 0.010 " to a full finishing pass near a 0.020 " DOC.”

A type-S117 HORN PCBN-tipped insert finishes the width of the groove on this gear. Stock removal is approximately 0.15mm to 0.2mm. To obtain a fine surface finish, the insert has a wiper flat on both side-cutting edges.

Angle between the side-cutting edge and the projected side of the tool shank or holder, which leads the cutting tool into the workpiece.

“Customers don’t always want to change the insert when going from harder to softer, so we have to find the next best tool for the operation,” said Duane Drape, national sales manager for HORN USA Inc., Franklin, Tenn. “If they use carbide, they have problems with the insert wearing too quickly on the harder outer casing. If they are cutting the softer area with CBN that was made for cutting very hard material, it would be destroyed. So we work on a compromise. We may work with a very hard carbide with a super lubricated coating or a soft CBN grade with an edge prep that is suitable for cutting rather than for hard machining.

When cutting softer steel, say 45 to 50 HRC, with carbide, ceramic or PCBN, chips should be as short as possible. This effectively removes heat from the material during the cutting process because the heat stays with the chip.

Crystal manufactured from boron nitride under high pressure and temperature. Used to cut hard-to-machine ferrous and nickel-base materials up to 70 HRC. Second hardest material after diamond. See superabrasive tools.

Capable of both face and shoulder milling, the M5Q90 is also suitable for many applications in the general engineering and aerospace sectors.

Fluid that reduces temperature buildup at the tool/workpiece interface during machining. Normally takes the form of a liquid such as soluble or chemical mixtures (semisynthetic, synthetic) but can be pressurized air or other gas. Because of water’s ability to absorb great quantities of heat, it is widely used as a coolant and vehicle for various cutting compounds, with the water-to-compound ratio varying with the machining task. See cutting fluid; semisynthetic cutting fluid; soluble-oil cutting fluid; synthetic cutting fluid.

M5Q90 cutter bodies are designed according to customer specifications, and therefore meet the requirements of high-productivity machining – the tool can operate in high-speed conditions in excess of 20,000 rpm. However, all cutter bodies offer the same design of tip seat, coolant channel, lead angle and rake angle. Inserts are always kept in stock.

About the Author: Susan Woods is a contributing editor for CTE. Contact her by phone at (847) 973-2271, or by e-mail at susan@jwr.com.

Rigid machine tools with adequate power are a must for hard grooving. “The more rigid and powerful machine you have, the more aggressively you can cut hardened material,” Economan said. “For applications involving machining materials harder than 50 HRC, many light-duty machine tools won’t hold up to the demanding cutting conditions. This holds true when the machining requirements exceed what the machine is capable of, as far as horsepower, torque and especially rigidity.”

Cutting tool material consisting of natural or synthetic diamond crystals bonded together under high pressure at elevated temperatures. PCD is available as a tip brazed to a carbide insert carrier. Used for machining nonferrous alloys and nonmetallic materials at high cutting speeds.

Over the past decade, finish grooving hardened steel parts using polycrystalline cubic boron nitride inserts has increasingly replaced grinding. “Typically, grinding is a more stable process that provides more accurate tolerances than grooving,” said Tyler Economan, proposal engineering manager for INDEX Corp., Noblesville, Ind. “However, people are trying to do more complete machining on workpieces if the turning machine is capable of completing the necessary processes.”

Part of the reason CBN is run dry is because, while it can take the heat, it does not operate as well with temperature fluctuations. “When a CBN insert actually interfaces with the material, heat is created at the tip of the tool,” Economan said. “But because the CBN doesn’t like shifts in temperatures, it is difficult to adequately cool it to where you can maintain a more constant temperature.The hard CBN is very brittle and could crack due to temperature changes.”

Chip control is not an issue for 58-HRC and harder applications. Dry grooving is the norm, and the chips are more like dust or very small particles, which can be removed with a manual air blast. “If a chip touches anything, it usually just falls apart,” said Sumitomo’s Maton, adding that chips won’t mar parts upon contact. “If you grab a pile of chips, they would just crumble in your hand.”

Iscar’s Schmitz also suggests running the cutting tool “upside down.” He explained: “Mounting a tool in a machine so the insert is facing upward during the cut is the machine tool builder’s preferred way to mount tools because the rotation of the part exerts downward pressure on the machine ways or rails, stabilizing the machine tool. But as the insert goes across that material, a chip forms and may remain on top of the insert and the workpiece. If I take that tool and flip it upside down so I no longer see the insert, the chips are flowing away from the working zone and I’m using gravity to my advantage.”

Machining operation in which metal or other material is removed by applying power to a rotating cutter. In vertical milling, the cutting tool is mounted vertically on the spindle. In horizontal milling, the cutting tool is mounted horizontally, either directly on the spindle or on an arbor. Horizontal milling is further broken down into conventional milling, where the cutter rotates opposite the direction of feed, or “up” into the workpiece; and climb milling, where the cutter rotates in the direction of feed, or “down” into the workpiece. Milling operations include plane or surface milling, endmilling, facemilling, angle milling, form milling and profiling.

Steel containing specified quantities of alloying elements (other than carbon and the commonly accepted amounts of manganese, sulfur and phosphorus) added to cause changes in the metal’s mechanical and/or physical properties. Principal alloying elements are nickel, chromium, molybdenum and silicon. Some grades of alloy steels contain one or more of these elements: vanadium, boron, lead and copper.

Sumitomo’s holder for CGA-style inserts has a top clamp and a side screw to enhance stability and tool life when grooving hardened steel.

Angle of inclination between the face of the cutting tool and the workpiece. If the face of the tool lies in a plane through the axis of the workpiece, the tool is said to have a neutral, or zero, rake. If the inclination of the tool face makes the cutting edge more acute than when the rake angle is zero, the rake is positive. If the inclination of the tool face makes the cutting edge less acute or more blunt than when the rake angle is zero, the rake is negative.

For induction-hardened, or casehardened, parts, the outer, hardened surface, can be as much as 1.5mm thick, and up to 58 to 60 HRC, while the undersurface is typically much softer. In situations like this, it is important to ensure the majority of the cut happens below the hardened, outer surface.

Rigidity is important for setups and workholders. Because grooving involves significant edge contact, it produces significant tool pressure. When fixturing hardened workpieces, wide clamps can distribute the clamping surface. “You definitely need to support the area being machined,” said Paul Ratzki, marketing manager for Sumitomo Electric Carbide Inc., Mt. Prospect, Ill. “With hard material, you have much greater vibration and tool pressure, which can cause the part to fly out of the machine, or chip or even break the CBN insert.”

Metal-removing edge on the face of a cutter that travels in a plane perpendicular to the axis. It is the edge that sweeps the machined surface. The flat should be as wide as the feed per revolution of the cutter. This allows any given insert to wipe the entire workpiece surface and impart a fine surface finish at a high feed rate.

“The inserts, which are easy to handle and adjust, offer reduced cost per part along with high accuracy and repeatability,” adds Jacques Gasthuys, global automotive application engineer.

Mitsubishi Materials USA Corp.’s GY series Tri-Lock modular system reportedly offers rigidity equal to that of an integral insert holder. The system secures the grooving blade to the holder in three directions: the periphery and front and top sides. Two features decrease insert movement during grooving. The convex “V” formation eliminates side-to-side movement, and the safety keys eliminate forward movement caused by cutting forces when plunging.

Engagement of a tool’s cutting edge with a workpiece generates a cutting force. Such a cutting force combines tangential, feed and radial forces, which can be measured by a dynamometer. Of the three cutting force components, tangential force is the greatest. Tangential force generates torque and accounts for more than 95 percent of the machining power. See dynamometer.

Machining operation in which material is removed from the workpiece by a powered abrasive wheel, stone, belt, paste, sheet, compound, slurry, etc. Takes various forms: surface grinding (creates flat and/or squared surfaces); cylindrical grinding (for external cylindrical and tapered shapes, fillets, undercuts, etc.); centerless grinding; chamfering; thread and form grinding; tool and cutter grinding; offhand grinding; lapping and polishing (grinding with extremely fine grits to create ultrasmooth surfaces); honing; and disc grinding.

The M5Q90 completes the Sandvik Coromant offer for machining aluminum automotive parts, complementing the M5B90, M5C90, M5F90, CoroMill Century/590 and M5R90 tooling solutions.

Iscar Metals offers GITM Groove Turn inserts in two PCBN grades: IB10H for medium- to high-speed continuous machining of hardened steel and B20H for interrupted cutting of hardened steel.

Another option is changing the cutting parameters. “Once you cut through that casehardening, you can be more aggressive,” said Index’s Economan. “If the case depth only goes down to 0.005" or 0.0010", then after that you should increase the cutting parameters to appropriate levels with either the same tool or a different one.”

Casehardening is a simple method of hardening low-carbon steel whereby carbon is added to the outer surface of the steel to a specific depth. Problems can arise when the groove depth exceeds the thickness of the casehardening because the grooving insert transitions from a harder material to a softer one. Therefore, toolmakers have developed several grades for various types of materials.

Machining grooves and shallow channels. Example: grooving ball-bearing raceways. Typically performed by tools that are capable of light cuts at high feed rates. Imparts high-quality finish.

Number of axes along which a robot, and thus the object it is holding, can be manipulated. Most robots are capable of maneuvering along the three basic Cartesian axes (X, Y, Z). More sophisticated models may move in six or more axes. See axis.

Main body of a tool; the portion of a drill or similar end-held tool that fits into a collet, chuck or similar mounting device.

Various work materials that are through-hardened include HSS, die steels, bearing steels and alloy steels. Only ferrous metals are casehardened and that process is typically reserved for low-carbon steel. Casehardening produces a hard, wear-resistant exterior over a tough core. Parts made from hardened steels include arbors, axles, link components, driving pinions, camshafts, gears, bushings, transmission shafts and bearings.

To boost the first-stage roughing operation on newly cast aluminum parts for the automotive industry, cutting tool and tooling systems specialist Sandvik Coromant is introducing its M5Q90 tangential milling cutter. Designed to complete "cubing" (first machining of faces after casting) in a single operation without creating burrs, the new tool is fitted with PCD tangential inserts that provide a smooth and stable cutting action to lower power consumption and eliminate vibration. This concept ensures reliable performance, improved tool life, exceptional surface finish, high metal-removal rate and an increased number of parts per insert.

“Modular holders are going to be used where you see a lot of catastrophic failure,” Schmitz said. “Instead of replacing the entire holder, you just replace a less-expensive component.”

Modular holders also provide many options. “Iscar’s Modular-Grip system mounts various products. You can use one shank with seven different blades to run seven product lines, or any number of blades for the same product line but with different widths,” Schmitz said.

Grooving hardened steel requires harder and more wear-resistant cutting tools with appropriate tool geometry. The trick is to know whether to apply carbide, ceramic or PCBN inserts. “For an application less than 50 HRC, I almost always choose carbide,” Schmitz said. “Ceramics are a very economical choice for applications from 50 to 58 HRC. CBN should not typically be considered until the hardness reaches 58 HRC. This is where it performs best.”

“You can cut 45- to 50-HRC material effectively with CBN, but you have to adjust the geometry,” Drape continued. “Typical CBN is manufactured with a negative land on the cutting edge. On softer materials with that negative land, the CBN is going to get pulled out of the material and then you lose tool life. If I use a softer CBN and adjust the geometry, I can have very good success cutting 45- to 50-HRC material.”

PCBN grades are evolving to cover a wider application range. Harder grades allow for elevated speeds while tougher grades can run in more unstable environments. Different grades of PCBN are also available for continuous or interrupted cutting. Because PCBN is brittle, a sharp cutting edge would start to chip when machining hardened steel, according to Sumitomo’s Maton. “We have to protect the edge, especially when interrupted cutting where the edge prep is much larger and at a greater angle than when continuous cutting.”

Iscar Metals has advanced its Groove Turn PCBN product line with the newly created IB10H and IB20H grades. IB10H is a fine-grain PCBN intended for continuous cutting, while IB20H, composed of fine- and medium-grain particles, offers a good balance between wear and impact resistance to withstand more severe cutting conditions. The failure mode with any PCBN should be gradual edge wear—not sudden cracking or rupturing.

Available in two major types: tungsten high-speed steels (designated by letter T having tungsten as the principal alloying element) and molybdenum high-speed steels (designated by letter M having molybdenum as the principal alloying element). The type T high-speed steels containing cobalt have higher wear resistance and greater red (hot) hardness, withstanding cutting temperature up to 1,100º F (590º C). The type T steels are used to fabricate metalcutting tools (milling cutters, drills, reamers and taps), woodworking tools, various types of punches and dies, ball and roller bearings. The type M steels are used for cutting tools and various types of dies.

Generic term covering several processes applicable to steel that change the chemical composition of the surface layer by absorption of carbon, nitrogen or a mixture of the two and, by diffusion, create a concentration gradient. Processes commonly used are carburizing, quench hardening, cyaniding, nitriding and carbonitriding.

Cutting tool material consisting of polycrystalline cubic boron nitride with a metallic or ceramic binder. PCBN is available either as a tip brazed to a carbide insert carrier or as a solid insert. Primarily used for cutting hardened ferrous alloys.

Cutting tool material consisting of polycrystalline cubic boron nitride with a metallic or ceramic binder. PCBN is available either as a tip brazed to a carbide insert carrier or as a solid insert. Primarily used for cutting hardened ferrous alloys.

Loosely, any milling tool. Horizontal cutters take the form of plain milling cutters, plain spiral-tooth cutters, helical cutters, side-milling cutters, staggered-tooth side-milling cutters, facemilling cutters, angular cutters, double-angle cutters, convex and concave form-milling cutters, straddle-sprocket cutters, spur-gear cutters, corner-rounding cutters and slitting saws. Vertical cutters use shank-mounted cutting tools, including endmills, T-slot cutters, Woodruff keyseat cutters and dovetail cutters; these may also be used on horizontal mills. See milling.

Process of increasing the surface hardness of a part. It is accomplished by heating a piece of steel to a temperature within or above its critical range and then cooling (or quenching) it rapidly. In any heat-treatment operation, the rate of heating is important. Heat flows from the exterior to the interior of steel at a definite rate. If the steel is heated too quickly, the outside becomes hotter than the inside and the desired uniform structure cannot be obtained. If a piece is irregular in shape, a slow heating rate is essential to prevent warping and cracking. The heavier the section, the longer the heating time must be to achieve uniform results. Even after the correct temperature has been reached, the piece should be held at the temperature for a sufficient period of time to permit its thickest section to attain a uniform temperature. See workhardening.

“Hard,” however, is a moving target. Some consider materials from 40 to 55 HRC to be hard, while, for others, hard is 58 to 60 HRC and harder, which is where PCBN comes in.

Distance between the bottom of the cut and the uncut surface of the workpiece, measured in a direction at right angles to the machined surface of the workpiece.

Aluminum cylinder heads and engine blocks will be among the principal components to benefit, typically in automotive foundries or Tier 1/Tier 2 suppliers. By way of example, the cubing operation on a cast cylinder head would involve machining the camshaft face, inlet/outlet face and combustion face. Typical cutting data using M5Q90 might include a speed of 2,500 m/min. (8,202 sfm) and feed per teeth of 0.20 mm (0.008 inch). Users also benefit from high-precision coolant channels that provide the option for either emulsion or MQL application.

If desired, the cutter body tool life can be further extended in engineered solutions with PCD inserts protected by rows of carbide inserts, a configuration that also serves to increase the depth of cut capability. While the basic tool with PCD inserts offers 2–4 mm (0.079–0.157 inch) depth of cut in full engagement, this can be boosted to in excess of 4 mm (0.157 inch) using the engineered solution with protective rows of carbide inserts.

Sumitomo has introduced BNC30G, a coated PCBN grade for parts with interruptions. For continuous grooving, the toolmaker recommends its general-purpose BN250 grade. “With the continuous cut, you’re in the cut for a long time, generating a great amount of heat, so you need a high wear-resistance grade,” Maton said. “With interrupted cutting, you are coming in and out of the cut, banging the corner of the insert. Therefore, you need a very tough grade to withstand the interruption, and a coating helps the tool last longer.”