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.

Every machine shop has to decide whether to make cutters or buy them. A similar decision exists for regrinding cutting tools in-house or paying a company to perform the service.

Coating processes: Two principal coating processes are used for indexable inserts to provide cutting edges with fundamentally different properties for machining:

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About the Author: The late Edward F. Rossman, Ph.D., was an associate technical fellow in manufacturing R&D with Boeing Integrated Defense Systems, Seattle. Rossman’s Shop Operations column is adapted from information in his book, “Creating and Maintaining a World-Class Machine Shop,” published by Industrial Press Inc., New York. The publisher can be reached by calling (212) 889-6330 or visiting www.industrialpress.com.

Carbide and high-speed-steel tools coated with thin layers of aluminum oxide, titanium carbide, titanium nitride, hafnium nitride or other compounds. Coating improves a tool’s resistance to wear, allows higher machining speeds and imparts better finishes. See CVD, chemical vapor deposition; PVD, physical vapor deposition.

While the metallurgic term “carbide grades” refers specifically to tungsten carbide (WC) sintered with cobalt it’s used for various applications such as Nozzles, Dies, Rollers, Crush Rolls, and Cutting Tools. The same term has a broader meaning in machining: sintered tungsten carbide combined with coatings and other treatments. For example, two turning inserts made of the same carbide material but with a different coating or post-treatment are considered different grades.

The high material removal rates and long life for these tools are achieved through an incomparable balance of wear resistance and toughness. Relatively thin insert coatings -- 0.00004 in. to 0.0007 in. -- protect inserts from the heat, corrosion and abrasion that shorten their lives.

Another consideration is tool coatings: what coatings to use, when to apply coated tools and whether a tool is recoated after resharpening.

Many cutters are dynamically balanced in their toolholders before going to the machine tool. Balancing might employ drilling holes in the holder or adding screws to it to ensure proper balance.

ISEM SHYHA · 2010 · 17 — The data indicated that a maximum operating feed rate of 0.2 mm/rev was advisable for the stepped drill configuration to avoid tool fracture, while conventional ...

Each of these processes give rise to different tensions in the coating material. Chemical vapor deposition develops tensile stress in the substrate, while physical vapor deposition tends to develop compressive stress. These stresses provide different desirable characteristics for the insert.

A small percentage of toolmakers grind and produce most of their own cutting tools from solid-carbide blanks. In addition to producing their own standard cutters, these toolmakers must design specials for specific jobs.

Some relatively small-diameter cutters require a long reach into a deep section of a part and the tools flex too much to make efficient cuts. The usual solution is to use a tapered-shank cutter for more rigidity, but the cost is quite high. A lower-cost solution is to create a “telescope” of shrink-fit toolholders to maintain the needed rigidity to extend the cutters. The cost is kept low because standard shrink-fit holders are used and only the tool tip needs replacement when worn.

Apr 7, 2020 — But many such tools are indexable. What to do? M · macardoso. H-M ... I remembered this thread so today I tried threading at 75 rpm with a carbide ...

Recent developments include CVD processes for depositing TiCN and Al2O3 in ways that lower stress levels and develop fewer tendencies for crack formation in the coated surface of the insert. After the heat of the CVD-coating processes a network of cooling cracks tend to form, resembling a dry riverbed. The resulting tensile stresses, due to the different coating materials involved in the several layers, can negatively reduce the toughness properties of the insert.

In operation, tool life is targeted for a specific number of minutes, and then all cutters are resharpened. Shops that grind their own new cutters also resharpen them because the grinding equipment can perform both tasks. However, some shops report lower tool life from resharpened cutters.

All coatings have flaws in their surface uniformity caused by coating droplets and non-uniform grain size. Most modern grades add a post-treatment after the coating process. This treatment is usually:

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I don't know of anywhere that does it on a small a scale. It might be worth going to an LBS, a large chain one is probably the best bet, they ...

To maintain the production of high-quality parts, new cutters are often used for finishing, and resharpened cutters are relegated to roughing. Two shops that grind their own claim they are able to produce a more accurate cutter than one that’s purchased.

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Carbide Grade Selection describes the different carbide tool grades and explains how to select the proper grade for a cutting operation. Carbide grades are classified by two systems. The ANSI C-system lists grades of C1 through C8. The ISO classification system designates carbide grades as P, M, and K, followed by a number that further describes the qualities of the carbide. Carbide grade is often dependent on the type of metal used: tungsten, titanium, or tantalum. Grades have different levels of hardness, toughness, and wear resistance. Coating carbide tools can increase wear resistance and part quality.

Just as there is no official standard for grade application ranges, there is no formal standard for grade designations. That said, most major carbide inserts suppliers follow common guidelines in their grade designations. The "classic" designation follows a six-character format BBSSNN, where:

When milling titanium alloys at less than 70 sfm, I do not recommend applying coated tools. This slow milling speed applies mostly to roughing with cobalt tools. If it is important to coat a new cutter, then it is equally important to use the same coating after resharpening the tool. Recoating presents a logistical problem because most shops are not capable of coating tools. The usual practice is to overnight cutters to a coating company.

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.

The CVD-coated insert typically has a thicker coating and has a high degree of wear resistance and coating adherence. The PVD-coated insert has a thinner coating, high toughness and is more suitable for sharper cutting edges.

Dec 23, 2022 — Stainless steel is an extremely hard material. Low-carbon steel bits, like those used to drill into wood, do not perform when applied to ...

Oct 2, 2017 — Feed Rate and Chip Load Calculations · Chip load per tooth is the appropriate amount of material that one cutting edge of the tool should remove ...

An increase in cobalt content results in increased toughness (TRS) while hardness and wear resistance are reduced. This opposite development of the two desirable parameters, hardness, and toughness can be countered by reducing the carbide grain size. The result is an increased hardness because of the finer grain of the carbide which at the same time permits a high binding metal content as the grain structure offers a large surface area on which to bind:  It also creates a high toughness. Consequently, superfine grain carbide grades offer increased hardness while maintaining toughness.

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It is also easier to manage the balancing process if all cutters are handled in the same manner. Balancing should be done dynamically using equipment that rotates the holder/cutter assembly because static balancing is not adequate. CTE

Substances having metallic properties and being composed of two or more chemical elements of which at least one is a metal.

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CVD is the dominant coating process, partly because it is the only process capable of satisfactorily depositing layers of Al2O3.

Shrink-fit toolholders are my choice for milling titanium alloys. Any cutter that runs faster than 8,000 rpm must be balanced, but I prefer balancing toolholder/cutter assemblies for all spindle speeds to extend spindle life. One unbalanced cutter run at a high speed can quickly damage a $50,000 spindle and shut a machine down for 2 weeks while waiting for a replacement spindle.

About 80 percent of the inserts used in machining today are coated cemented carbide grades. These tool inserts earned and maintained that growing market share because of their broad application for removing large amounts of material while they sustain a long tool-life.

In general, smaller tungsten carbide grain sizes allow for the manufacture of carbides with a finer microstructure. A prerequisite for this is the prevention of grain growth during the sintering process by adding suitable doping (process of adding some impurity atoms) components in the right amount, adjusted to the cobalt content.  The cobalt content is determined based on the required performance specifications for the carbide. Since the specific surface of a carbide depends reciprocally on its grain size, a finely grained carbide can adsorb more binder than a coarsely grained TC.

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20201127 — Cutting stainless steel requires a specialized saw blade with high-speed steel (HSS) or carbide teeth. These blades are designed to withstand ...

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