“I don’t see the double negative very much anymore because it requires a lot of horsepower, and most machines now are lighter-duty machines,” Stusak said.

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Another option for facemilling is a cutter with a double-positive design — that is, positive axial and radial rake angles. He said this arrangement allows freer cutting, which reduces cutting forces and lowers horsepower consumption. In addition, the double-positive design directs chips away from the workpiece.

The third type of facemilling cutter is the positive-negative, or shear-milling, design, which features a positive axial rake and a negative radial rake orientation. Stusak said the positive-negative design produces lower cutting forces than the others, as well as freer cutting action. In addition, the design directs chips away from the workpiece, which helps with evacuation. The design works well with most materials.

The DOC should not exceed 66 per cent of the cutting edge's length for insert shapes S and C, 50 per cent of the cutting edge's length for insert shapes T and D, 25 per cent of the cutting edge's length for insert shapes W and V, and 40 per cent of the insert's diameter for shape R.

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Iscar Metals’ customers in the aerospace industry “use the double positive every day and twice on Sunday,” he said, adding that the double-positive design is the best for nonferrous and difficult-to-machine materials.

When it comes to cutting angles, the rake can make or break your facemilling process. Rake angles impact key parameters, such as chip flow, metal removal rate and tool life. So rake angles need to be chosen with an eye to the requirements of each application.

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Whether the application calls for rough turning, medium turning, or finish turning, the decision on what technology to use should come well before the material is loaded onto the machine or into the bar feeder.

Common cutter designs for facemilling use different combinations of positive and negative rake angles. As the name suggests, a double-negative milling cutter has a negative axial and negative radial rake angle. This arrangement makes a cutter very rigid and maximizes insert strength, said Bryan Stusak, national milling product manager at Iscar Metals Inc. in Arlington, Texas. Typically, he said, it also allows more inserts to be placed around the periphery of a cutter than other designs.

To help insert recognition, the American National Standards Institute (ANSI) developed B212.4-2002 to allow machinists, purchasing departments, and tooling sellers to quickly and easily describe the shape, dimensions, and important parameters of turning inserts.

Single-point cutting tools remove workpiece material by using one of the insert’s cutting edges. But how do you differentiate one insert from another? It starts by understanding their designation.

He said Greenleaf’s engineers consider different options to come up with a rake angle combination that gives the customer the best possible combination of properties.

A large nose radius can use higher feed rates, larger DOCs, and handle more radial pressure. A small nose radius takes only small cutting depths, has a weaker cutting edge, and can handle only a small amount of vibration. Our example insert has a radius of 2, meaning it has a nose radius of 1/32 in.

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On the downside, Stusak pointed out that the double-negative design directs chips toward the workpiece and sometimes creates a burr. The design also subjects the workpiece, inserts and machine spindle to high cutting forces.

The eighth, ninth, and 10th positions in ANSI’s guide are optional and represent the cutting edge condition (aka edge prep, such as sharp, rounded, or chamfered); cutting direction (left, right, or neutral); and information on the insert’s chipformer (FP -- finishing sharp, UN -- universal medium, and HP – high positive).

ISOturning insertnomenclature

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.

Cutting tool materials based on aluminum oxide and silicon nitride. Ceramic tools can withstand higher cutting speeds than cemented carbide tools when machining hardened steels, cast irons and high-temperature alloys.

Triangle carbideInsertsizes

Our example has a G in this place. This indicates that the insert has a cylindrical hole and has a double-sided chipformer.

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For parallelogram- and rectangular-shaped inserts, width and length dimensions are used instead of the I.C. In these cases, a two-digit number designates the insert’s size. The first digit is how wide the insert is (in eighths of an inch) and the second digit is how long the insert is (in quarters of an inch).

For turning inserts, it comes in the form of a 10-place string of numbers and letters, (the first seven are required and the last three are optional), with each describing a portion of the tool.

The fifth position in ANSI’s designation is either a one-digit or a two-digit number that shows the I.C. size (in eighths of an inch) for round, square, triangle, trigonal, pentagonal, hexagonal, octagonal, and rhombic inserts. If it’s a one-digit number, the eighths of an inch make a whole number.

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.

Millinginsertspecification

Turning on a lathe is an operation in which a stationary single-point cutting tool meets a rotating workpiece to produce axially symmetrical shapes. Sounds pretty easy, right? Well, it typically is, if the correct cutting parameters and inserts are chosen for the job.

These measurements and tolerances can get tricky and change based on the insert's shape, so it’s a good idea to consult the literature that accompanies your tooling purchase to get this right.

Also boosting the popularity of the positive-negative design is the fact that it allows the use of both double- and single-sided inserts. Since double-sided inserts can be flipped, as well as turned, they can offer twice as many cutting edges as single-sided inserts. For example, Fellner said Kennametal’s KSOM single-sided inserts have eight cutting edges while the company’s equivalent double-sided design has eight cutting edges per side for a total of 16.

The space provided by this clearance keeps the insert from rubbing against the part. If the insert does have a 0-degree clearance angle (N), chances are it is being used in a roughing operation. The different clearances are:

To do this it’s important to have at least some understanding of the American National Standards Institute (ANSI) turning insert designations. ANSI developed this system of numbers and letters (B212.4-2002) to allow machinists, purchasing departments, and tooling sellers to quickly and easily describe the shape, dimensions, and important parameters of turning inserts. It essentially gets everyone on the same page.

The fourth place in an insert’s designation is another capital letter. This one helps describe more of the insert’s design features, such as its fixing holes, countersinks, and any chipformer features. There are 14 standard types (A, B, C, D, G, J, M, N, Q, R, T, U, W, X).

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.

Insertnose radius chart

Insert choice requires taking into consideration a whole host of variables, including an insert’s size, shape, and overall design features. In most cases, the tool is held in a fixed position in a tool body and the workpiece rotates in the lathe’s turning axis.

The answer is 0.24mm/rev. Cutting time (Tc). Input the values. Cutting time (Tc). Tc(min): ...

Also known as the clearance, the second place shows the angle between the flank and top surface of the insert. Each relief angle is denoted by a capital letter. In our example, the insert has a 0-degree relief angle.

A rake angle is a function of both the shape of the insert and its orientation in the pocket. Once a facemilling cutter is made, insert orientation cannot be changed. Fellner said, however, that shops can change a cutter’s rake angles to meet the requirements of different jobs by changing the shape of the inserts being used.

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Some inserts, like round ones (R), have high edge strength, while some rhombic-shaped inserts (D and V) have a sharp point, which is good for finishing operations. Trigonal inserts (W) often are used for rough machining because of their larger point angle. Each has its place. The shape of the insert also determines how many separate edges can be indexed to as each wears out. The common insert shapes are:

Kennametal, for example, offers inserts with different geometries for general-purpose machining, light machining and heavy roughing.

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“If customers say they need to make sure they’re not getting any chip wash across the face of their part, we’re going to go positive to try to get those chips away,” Peters said. “But we’re going to be upfront with them and tell them they’re going to get those chips away, but they’re giving up a little strength at the cutting edge, which means they may not get that same tool life that they’re looking for.”

In addition, the double-negative design allows heavy feed rates and the most indexes because it accommodates double-sided inserts, said Josef Fellner, global product manager for indexable milling at Pittsburgh-based Kennametal Inc. He said this design is the best bet for shops looking for high metal removal rates and a good choice for facemilling ceramics, cast iron and high-temperature alloys.

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The success or failure of a turning job often depends on decisions made early in the process -- before the cutting even begins -- about a small piece of carbide, cermet, ceramic, or diamond.

Rake angles also can be positive, zero or negative. A rake angle is positive when the sum of the tool’s wedge angle and the clearance angle between the insert and workpiece surfaces is less than 90 degrees. Positive rake angles make tools sharper and more pointed, which reduces their strength. Positive angles also lower cutting forces and power requirements.

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Stringy portions of material formed on workpiece edges during machining. Often sharp. Can be removed with hand files, abrasive wheels or belts, wire wheels, abrasive-fiber brushes, waterjet equipment or other methods.

Inserttypes

“A lot of companies are looking for something that can cover them on everything — not just one material or one application,” Peters said. “If you’re looking for something (like that), we would suggest a positive negative.”

On the other hand, Stusak said, double-positive inserts tend to be single-sided, and the cutting edges are weaker than their double-negative counterparts. He said double-positive cutters tend to pull on the workpiece and actually can lift it if it’s not fixtured properly.

Inserts can be designed with or without holes; have cylindrical, single-countersink, or double-countersink holes; and come with multiple chipformer styles. If the insert has a designation of X in this location, it has a special design.

William Leventon is a contributing editor to Cutting Tool Engineering magazine. Contact him by phone at 609-920-3335 or via email at wleventon@gmail.com.

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“If you have a machine that doesn’t have a lot of horsepower,” he said, “we may change the axial rake to give you less cutting force so you’ll be able to use that machine in most circumstances.”

“We’re going to try our best to make sure we’re right in that sweet spot (where) we’re not necessarily giving up on cutting-edge strength, but we’re also not throwing all the chips into the face of the part.”

The first place shows the shape of the insert. There are 17 standard indexable insert shapes, and each is given a capital letter. In our example, C indicates that the insert is a rhombic-shaped insert of 80 degrees.

Insert measurements and tolerances can get tricky and change based on the insert's shape, so it’s a good idea to consult the literature that accompanies your tooling purchase to get this right.

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ISOinsertnomenclature pdf

“Most people are more concerned about cost per edge than anything, and double-sided inserts have a cost-per-edge advantage over single-sided inserts,” Stusak said.

Space provided behind a tool’s land or relief to prevent rubbing and subsequent premature deterioration of the tool. See land; relief.

Machininginsertnomenclature

There are 14 tolerance classes, the third place, that show how each insert indexes. Each class is denoted by a capital letter. Letters for tolerances are A, B, C, D, E, F, G, H, J, K, L, M, U, and N, which describe the size of the cornerpoint, thickness, and the inscribed circle (I.C.) of the insert. An I.C. is the largest circle that can be drawn inside the given shape.

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Aluminum containing specified quantities of alloying elements added to obtain the necessary mechanical and physical properties. Aluminum alloys are divided into two categories: wrought compositions and casting compositions. Some compositions may contain up to 10 alloying elements, but only one or two are the main alloying elements, such as copper, manganese, silicon, magnesium, zinc or tin.

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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In addition to the best rake angle combination for an application, the exact axial and radial rake angles themselves must be chosen. Normally, these decisions are left to the tooling supplier.

The other type of rake angle is the angle between the tooth face and cutter radius, measured in a plane perpendicular to the cutter axis. Known as the radial rake angle, this angle is important in determining cutting-edge sharpness and strength.

For cutters with indexable inserts, the rake angle is the inclination of an insert’s cutting face. There are two types of rake angles. The axial rake angle is the angle between the cutting edge and the axis of the cutter. This angle affects the facemilling process in several ways. It directs chip flow and impacts cutting-edge strength. In addition, toolmakers use the axial rake angle to control power consumption, said Nate Peters, senior tool design engineer at Greenleaf Corp. in Saegertown, Pennsylvania.

Other than shape, an insert’s size is one of the variables that is easily noticed. In our example, the 4 indicates that the insert’s size is 1/2 in.

When the sum of the tool’s clearance and wedge angles is exactly 90 degrees, the rake angle is zero. And it’s negative when the sum of those angles is greater than 90 degrees. Negative rake angles blunt tools and give them a stronger cutting edge than tools with positive rake angles. In addition, negative rake angles increase the cutting force and the power required for a cut. They also can increase friction, resulting in higher cutting temperatures, and improve surface finish.

Form of milling that produces a flat surface generally at right angles to the rotating axis of a cutter having teeth or inserts both on its periphery and on its end face.

He believes that this rake angle configuration is better suited for older, more powerful machines with high metal removal rates than the machines commonly found at shops today.

Insert thickness is measured from the bottom of the insert to the top of the cutting edge. It also is shown as a one- or two-digit number (indicating the number sixteenths of an inch). Much like the size designation, it is a one-digit number when it describes a whole number. In our example, the insert’s thickness, 3, means that it is 3/16 in. thick.

Peters recommends double-positive cutters for facemilling steel and aluminum alloys while Fellner said these cutters commonly are used for soft, gummy materials and lower-rigidity setups.

Carbideinsert identificationchart PDF

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“I’ve had some customers that understand these concepts very well,” Stusak said. “They’ll say, ‘I want this particular design,’ and they understand why they want it. But 95% of them are not going to understand these details. So it’s really up to the tool manufacturer representative to specify what tool design is best for the application.”

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.