n A

RN 5, /

A0A09
2695 a
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 Best
Available
Copy
8etAvalilable COPY
 QUICK INDEX OF PAGE NUMBERS
MATERIAL GROUPS AND MACHINING OPERATIONS

MACHININGOPERATION 7.1 7.2 7.3 7.4 7.5 8.1 8.2 8.3 8.4
Gear Gear Gear Gear Gear Surface Surface Surface Surface
Hobbing Cutting, Shaping Shaving Grinding, Grinding - Grinding - Grinding - Griding -
Straight Form Horizontal Horizontal Horizontal Vertical
andSpiral Spindle, Spindle, Spindle, Spindle,
Bevel Reciprocating Reciprocating Reciprocating Rotary
Table Table - Table- Table
CBN Wheels Diamond
MATERIAL GROUP Wheels

1. FreeMachmninCarbonSteels Wrought 7.3 7.31 7.47 7.60 7.89 8-3 8-29 - 8-43
2 CarbonSteels,Wrought 7.6 7-32 7.49 7.71 7-89 83 8-29 - 3-43
3. Carbonand Ferritc Alloy Steels(HighTemp. Service) 7-8 7-34 7.51 7-73 - 83 - - 8-43
4. FreeMachining Alley Steels.Wrought 7.9 734 7-51 7.73 7-90 8"4 8-30 - 8-44
5 Alloy Steels,Wrought 7.10 7-35 7-52 7.74 7-90 8-4 8-30 8.39 844
Wrought
6. HighStrength Steels, 7.12 7-36 7-54 7.76 7-91 84 831 - 844
7.Maragrng Steels.
Wrought 7.13 736 7.54 7.76 7-91 8-5 8-31 - 845
8. Tool Steels, Wrought 7-13 7-36 7.54 7.76 7-91 8-5 8-31 8-39 845
9.Nitridiog Steels,Wrought 7.15 7-38 7-56 7.78 - 8-8 8-32 - 8-46
10.Armor Rate. Ship Plate, Aircraft Plate.
Wrought - - - - 8-8 - - 846
11.Structural Steels,Wrought -. ..- - - 8-46
12.FreeMachining Stainless Steels, Wrouglt t 7.15 738 7.56 7.78 - 8- - - 847
13.Stainless Steels.
Wrought 1 7.16 7-38 7.57 7.79 - 8-7 8-33 8.39 8-47
14. Precipitation Hardening StainlessStels Wrought 7-19 7.40 7.59 7-81 - 88 - - 8-48
15.Carbon Steels,Cast 7.19 7-40 7-59 7-81 - 8-8 8-33 - 848
16.Alloy Steels, Cost 7-20 7.40 7-60 7-82 8-8 8-33 - 848
17.Tool Steel Cast - - - - 7-92 89 8-34 - 8-49
18.Stainles Steels, Cast 7-21 7-41 7-61 7-83 - 8-10" - 8-50
19.Precipitation Hardening StainlessSteels,
Cast 7-23 742 7-62 7-84 - 8-11 - 8-51
20. Austenitic Manganese
Steels, Cast . . . ....
21.GrayCastIrons 7.23 7-42 7-62 7-84 - 8-11 8-34 8.39 8-51
22. CompactedGraphite CastIrons - - - 8-11 - - 8-51
23. Ductile CastIrons 7.24 743 7-63 7-85 - 8-11 8-35 - 8-51
24.Malleable Cast'lrons 7-_5 744 7-64 7-86 - 8-12 835 - 8-52
25. White CastIrons (Abrasion Restant) - - 8-12 8-35 - 8-52
2. High Slicon Cast Irons - - - - - 812 - - -
27. Chromium Nickel Alloy Castings - - - 8-12 - - -
28.Aluminum Alloys, Wrought 727 7-44 7.66 7-87 - 8-13 - - 8-52
29.Aluminum Alloys, Cast 7-27 7-45 7-65 7-87 - 8-13 - - 8-53
30. Magnesium Alloys, Wrought - - - - 8-13 - - 8-53
31. Magnsum Alloys, Cast - - - - 814 - - 8-53
32. Titanium Alloys, Wrought - . . . 8-14 - - 8-54
33. Titanium Alloys, Cast - . . . 8-15 - . - -54
34, CopperAlloys, Wrought 7-27 745 7.68 7-87 - 8-15 - - 8-5
35. Copper Alloys, Cast 7-28 746 7.67 7.88 - 8-16 - - 8-56
36. Nickel Alloys, Wrought andCast - . . . 8-17 - - 8-56 -

37. Beryllium Nickel Alloys.Wrought andCast - . ... - 8-17 - - 8-57

38. Nitinol Alloys, Wrought - - - - - 8-18 - - -
39. HighTemperature Alloys, Wrought andCast .- - 8-18 8-36 - 8-58
40. Refractory Alloys, Wrought, Cast. P/M .- 8-20 . - -
41. Zinc Alloys, Cast - - - -. ....
42. LeadAlloys, Cant - - -
43. Tin Alloys, Cart - - - -
44. Uranium, Wrought - 8-21 - - -
45. Zirconium Alloys, Wrought -- - - 8-22 - - -
46. Manganese,
Wrought - - - -.

47.Powder Metal Alloys - - - - 22 - - -

48. Machinable Carbides . . . . .I 8-24 - 8-40 -
49.Carbide - - - 8-24 - 840 -
50. FreeMachining Magnetic Alleys - 8-24 - - -

51.Mgnetic Alloys - 8-24 8-38 840-

52. Free'Wcining Controlled Expansion Alleo - - - - - 8-25 - - -
53. Controlled Expansion Alloys - . .. 8-25 - - -
54. Carbon%and Graphite . . . . . 8-2S - 8.40 -

55. Glas an Ceramics - .. 8-25 - 41

5.Plastics . .. 8-28 - - -
57. Compostes . . . . ... 8-42
58.Flame
(Thermal) Sprayed
Materials 8-2 - 842 -
59. Plet materials . . . . . 6-27 - - -
60. PreciousMtals. . . . .....
61. Rubber . . . . . 2 _ _ _
 QUICK INDEX OF PAGE NUJMBERS
MATERIAL GROUPS AND MACHINING OPERATIONS

MACHINING OPERATION 8.5 8.6 8.7 8.8 8S 8.10 8.11 8.13 8.14
Cylindrical Ciliodrica: Cylindrical internal Internal Internal Ce'iterteus Abrasive Thread
Grinding Grnding - Grinding - Grinding Grinding - Grinding - Grinding Belt Grinding
CBNWheels Diamond CBNWheels Diamnd Grinding
Wheels Wheels

1.FreeMacining Carbon Steels,Wroughit 8601 8-93 - 8.101 8.133 - 8-143 8-177 8.179
2.Carbon Steels.Wrought 8.81 ".31 - 8.101 8.133 - 8-143 8-177 84179
3.Carbonand Frriic loyStels (High Temp.Service) 8061 - - 84101 - - 8-143 84177 8.179
4 FreeMachinin~g Allay Steels,
Wrought 8-2 8&94 - 8.102 '1134 - 8-144 8.177 8-180
5.Alloy Steels, Wrought 8-62 8-4 - 8.102 8.134 - 8-144 8.177 8&180
6 HighStrength Steels. Wrought 8-63 894 - 8103 8 135 - 8145 - 8.181
7.Maragmng Steels,Wrought 8-03 8-9 - 8.103 8.135 - 8145 - 8-181
8.Tool Steels, Wrought 8063 895 - 8.103 8.135 - 8-145 8.177 8-181
9.Nitidig Steels. Wrought 8M6 895 1 - {8-10D5 8.136 - 8-147 - 8-183
Wrough
10.Armor Plate. Ship Plat, Aircralt Plate, t 8-65 - - 8.105 - - -

11.Structural Steels, Wrought - - - - - - -

12.FreeMachining Stainless Steels,Wrought 8-866 - 84106 - 8-147 8.177 8-183
Wrought
13.StainlessoSteels, 8886 - - j8.106 t8-136 &8148 8.177 8.1841
14.Precipitation Hardening Stainless
Steels,Wrought 8-87 - - 8.107 - - 8.149 8.177 8.110
15.Carbon Steels, Cant 8-M 8.95 - 8.108 8136 - 8.150 84I77 8185a
16.Alloy Steels, Calt d48 896 - 84108 8&13 - 50 8-177 8.185
17.Tool Steels. Cast 8469 8-6 - 8.109 8.137 - 8.150 8-177 8.188
18.Stainless Steels.Cast 1-70 - - 8.110 -- J8.151 8.177 8-187
19. freepitation Hs3rdeningStainlessSteels,
Cast 871 - - 8.111 - ]8.152 8.177 8.18
20. Aitenitic Manganese Steels,Cant - - - 8.111 -- I - - -

21.Gray CastIrons 871 - - 8.111 8163

& 8-177 8.188
22. Compacted Graphite CanIrons 8.71 - I 8-112 -I8-153 - 8.1813
23. Ductile CastIrons 872 - - 8-112 - -- 8.154 8-177 8.189
24.Malleable Cars Irons
25.WhiteCantIrons (Abrasion Resistant) -~8-72
8.72 -
-
-
- J8-113 8.112 -
-
-
-
8.154
8-154
8-177
-
8.189
-
26. High Silicon CastIrons 873 - - j8.113 - 8155
& -
27.Clirorniuns.Nickell Alloy Castings j -73 - - 8.113 - 8155 - -

28, Aluminum Alloys, Wrought 873 - - 8.113 - - 8.155 8.177 -

29. Alumninum AloysCast

30. MagnairAlloys, Wrought
1f874 8.73 -
-
-
-
8.114
8.114
-
-
- 8.155
B-8156
8.177
8.177
-

31.Magnesium Alloys, Cast 8-74 - - 8.114 - - 8.188 8-177 -

f 32. TitaniusmAlloys, Wrosigh'. 8.74 - - 8-115 - 8.156 8.177

33. Titanium Allayn Cast 875 - -8.115 - - 8.157 8177 -
34.Copper Alloys, Wrought 8.78 - - 8-1186 - 8.158 8-178A
35. Copper Allows,Cast 8.77 - - 8.117 - - 8150 8.178 -

36. Nickel Alloys.Wroughtand Cast 8.78 - .. 8.118 - - 8-16D - 8-199

37.BerylliumNicel Alln,Wrought ansdCast 8.79 - - 8.119 - - 8.181 - 8.180
38. NitinclAlloys,Wrought 8-79 - - 8.119 - - 8161 - - 1
39. High Temperature Allay;sWrought ad Can 84180 - - 8.120 - - 8-182 8.178 8.181
40. RefrcrllanWrought Calt,P/M 8M8 - - 8.123 - - 8-164 - -

41. ZincAlloys, Cadt- - - - - 8.178 -

42. Lead Alloys,Cut- - - -- - - -

43. Tin Alloyt Cast- - - - -- - - -

44. iraeium.LWrought 8.4 - - - - 8.188 -

45. Zirconium Alloys.Wroght -e 8.124 8166

& -

46. Mainga-Ae. Wrought - - -- - - - -

47.Fbnoeler MmtalAlloys -4 8-124 -- 8.188 8193

&
48. Machinale Carb ides 8436 - 8.97 8-127 - 8.139 - - 8194
49. Carbidms 8o7 - 8.7 8.127 - 8.139 8.18 84194
50. FraeeMachining Maglivetic Alloys17 - 8-127 -- 8.188 -

51. Magnetic Alloys 9V8 I 8.07 8-127 - -130 &.108 8-194

52. Free Machilnig Controlled EspamnmonAlloys em8 8.128 - - 8.188 -
63. CaorofeliedExpansion Aloys 8418 -8.128 - - 8.170 - -

54. Carbons andGraphita 8.88 8.07 8-120 - - 8.170 - -

8.8. -lw 8.96ermit 8.129 - 8-139 &1570 - -

Plstc 889 8.129 - - 8.171 - -

58. Fl"t (ThurinsO

Sprayed Matimal s4o-*9 8-130w 8-141 8-172
sq a W-b8-2 8-132 -- 8.173 -

so. -rciu - - -- -
JRu"e 4 8.132 -- 817 - -

W-
MACHINING
DATA
HANDBOOK
The data contained in this publication have been derived from many sources including
tests conducted under conditions which njav or may not exist where such data are used.
Changes in conditions of processing (machining, fabrication, heat treatment. etc.) and
differences in material properties from those described herein may make some or all of
the data used inappropriate under the circumstances. Users of the enclosed information
are thus cautioned that the information contained herein should be used only as a guide
where the user judges it to be appropriate. Metcut Research Associates Inc.. contractor
to the Unitea States Government. disclaims any and all responsibility for use of the infor-
mation contained herein by readers and users of this publication.

The findings in this publication are not to be construed as an official Department

of Defense position. unless so designated by other authorized documents.

Mention of any trade names or manufacturers in this publication shall not be

construed as advertising nor as an official endorsement or approval of such products
or companies by the United States Government. A

-,-= _
 MAIDININO
TA
3rd Edition

VOLUME TWO..

Compiled by the
Technical Staff
of the
Machinability Data Center
A DoD Information Analysis Center
Sponsored by the
Army Materials and Mechanics Research Cent

MDRC
MACHINABLITY DATA CENTERS
Metcut Research Associates Inc.DT
3980 Rosslyn Drive
C_ __I

Cincinnati, Ohio 45209ELLErT

J ;~ivun;~eJS
~ DHEC 21980 e-J
A"c'-so o
198

;A'
MDC MACHINABILITY DATA CENTER
MDC is a DoD information analysis center sponsored by the Army Materials and Mechancs Research
Center (PMRC). Arsenal Street. Watertown, MA 02172. and operated under Defense Logistics Agency
contract DLA900-77-C-3197 by Metcut Research Associates Inc.

Information Services Provided by MDC

MDC serves both government and industry by providing material removal data and information. MDC's
services include providing analyzed data in response to technical inquiries, presenting seminars, and com-
piling and marketing data publications on subjects of current interest to the manufacturing industry. MDC
also maintains a selected mailing list for providing notification of the availability of new information and
services from the Center.

Scope
The Machinability Data Center (MDC) collects. evaluates. stores, and disseminates material removal in-
formation. including specific and detailed machining data. Emphasis is given to engineering evaluation for
the purpose of developing material removal parameters. such as speeds. feeds, depths of cut. tool material
and geometry. cutting fluids and other significant variables. Data are being processed for all types of mate-
rials and for all kinds of material removal operations. such as turning. milling. drilling. tapping, grinding.
electric. -:-.harge machining. electrochemical machining. etc.

MDC has a data file of over thirty-two thousand selected documents pertaining to material removal tech-
nology. This data file is supported by a computer system for retrieval of information based upon the sp,-
cific material (with definite chemical. physical. and mechanical properties) and the specifiG material re-
moval operation being used. Computerized search techniques are employed utilizing a combination of
search parameters to produce source data. Information retrieval can be refined to the extent necessary to
satisfy the requirements of a specific inquiry by controlling the input search paraneters,

For information: Contact the Machinability Data Center. 3980 Rosslyn Drive. Cincinnati. OH 45209.
Telephone: (513) 271-9510. TWX: 810-461-2840.

ISBN 0-936974-00-1 (Set)

ISBN 0-936914-02-8 (Volume 2)
Library of Congress Catalog Card Number: 80-81480
Metcut Research Associates Inc.
3980 Rosslyn Drive
Cincinnati. OH 45209 I
1966. 1972. 1980 by Metcut Research Associates Inc. All rights reserved
First Edition published 1966. Second Edition 1972. Third Edition 1980
No part of this book may be reproduced. stored in a retrieval system, or transmitted. in any form or by any
means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written per-
mission of the publisher.
Printed in the United States of America

Typeset in Helvetica and Bookman by Dayton Typographic Service Inc.. Dayton, Ohio
Graphics by Repro Art Service Inc.. Cincinnati, Ohio
Printed and bound by The Johnson &Hardin Co.. Cincinnati, Ohio

I
I
 CONTENTS
Volume 2

Section 7. Gear Cutting and Gear Grinding Operations ............................... ....... 7-1
7.1 Gear Hobbing .............................. ................................... ...... ......... 7-3
7.2 Gear Cutting. Straight and Spiral Bevel...................................................... 7-31
7.3 Gear Shaping ....................................................................... ........... 7-47
7.4 Gear Shaving ............................... ............................................... 7-69
7.5 Gear Grinding. Form .......................... ................................................... 7-89

Section 8. Grinding Operations... ................................................................. 8-1

8.1 Surface Grinding-Horizontal Spindle. Reciprocating Table............................... 8-3
8.2 Surface Grinding-Horizontal Spindle. Reciprocatinig Table-
Cubic Boron Nitride Wheels........................................................... _... 8-29
8.3 Surface Grinding-Horizontal Spindle, Reciprocating Table-Diamond Wheels ........ 8B-39
8.4 Surface Grinding-Vertical Spindle, Rotary Table...........................................8-43
8.5 Cylindrical Grinding.......................................................... ...... ......... 8-61
8.6 Cylindrical Grinding-Cubic Boron Nitride Wheels ............................ ........... 8-93
8.7 Cylindrical Grindirgq-Diamond Wheels ................................. ... 8-97
8.8 Internal Grinding .................... ......... ...... ............................ ...... ... 8B-101
8.9 Internal Grinding-Cubic Boron Nitride Wheels ........................................... 8-133
6.10 Internal Grinding-Diamond Wheels .... .................................. 8-139
8.11 Centerless;Grinding........................... .................................. 8-143
8.12 Centerless Grinding-Work Traverse Rates ................................................. 8-175
8.13 Abrasive Belt Grinding ........... ..............-........................................... 8-177
8.14 Thread Grinding ... .. ...................................................................... 8-179

Section 9. Introduction to Nontraditional Machining ........................................... 9-1

Section 10. Mechaicl Nontraditional Machining Operations .............................. 10-1

10.1 Abrasive Flow Machining-AFM ................................................. ........... 10-3
10.2 Abrasive Jet Machinng-AJM...................... ...................................... 10-15
10.3 Hydrodynamic Machining-HDM ................................................... ....... 10-21
10.4 Low Stress Grinding-LSG........................... ....................................... 10-37
10.5 Thermally Assisted Machining-TAM......................................................... 10-39
10.6 Total Form Machining-TFM .................................................................. 10-41
10.7 Ultrasonic Machining-USM ................................................ ................. 10-43
10.8 Water Jet Machining-WJM ................ ... ............................................ 10-65

Section 11. Electrical Nontraditional Machining Operations.................................. 11-1

11.1 Electrochemical Deburring-ECD ............................................................ 11-3
11.2 Electrochemical Discharge Grinding-ECDG ............................................... 11-5
11.3 Electrochemical Grinding-ECG ............................................................. 11-9
11.4 Electrochemical Honing-ECH............................................................... 11-23
11.5 Electrochemical Machining-ECM........................................................... 11-25
11.6 Electrochemical Polishing-ECP............................................................. 11-63
11.7 Electrochemical Sharpening-ECS.......................................................... 11-65
11.8 Electrochemnical Turning-ECT .............................................................. 11-67
11.9 Electro-streamM-ES......................................................................... 11-69
11.10 Shaped Tube Electrolytic Machining-STEMm............................................. 11-71

V
CONTENTS
Volume 2

Section 12. Thermal Nontraditional Machining Operations ......... ........................ 12-1

12.1 Electron Beam Machining-EBM ...._...... ................................... I......... 12-3
12.2 Electrical Discharge Grinding-EDG.... ..-.................. .. ................. 12-11
12.3 Electrical Discharge Machining-EDM .................................................... 12-15
12.4 Electrical Discharge Sawing-EDS ... .................................................... 12-47
12.5 Electrical Discharge Wire Cutting-EDWC ................................................ 12-49
12.6 Laser Beam Machining-LBM............................... .................................. 12-55
12.7 Laser Beam Torch-LBT ......... ................................................ . ....... 12-71
12.8 Plasma Beam Machining-PBM .......................-
............... 12-97

Section 13. Chemical Nontraditional Machining Operations ......................

........... 13-1
13.1 Chemical Machining-CHM ............. ............................................... 13-3
13.2 Electropolishing-ELP ..................................................................... 13-17
13.3 Photochemical Machining-PCM............................................................ 13-19
13.4 Thermochemical Machining-TCM ......................................................... 13-25

Section 14. Tool Materials.......................................................................... 14-1

14.1 General Guidelines for Selection of Tool Materials ........................................ 14-3
14.2 High Speed Steels ..................................................................... 14-4
14.3 CastAlloys .................................................................................... 14-6
14.4 Carbides......... ....... .................................................................... 14-7
14.5 Microgramn Carbides...................................................................... ...... 14-15
14.6 Coated Carbides............................................................................... 14-16
14.7 Ceramic Tool Materials ............................. 14-17
.........................................
14.8 Diamond Tools ................... ............................................................ 14-18

Section 15. Tool Geometry...........................................................................1-

15.1 Turning and Boring Tools, Single Point..................................................... 15-2
15.2 Threading Tools, Single Point .................................................. .......... 15-4
15.3 Die Threading Tools. Thread Chasers ....................................................... 15-6
15.4 Face Mills....................................................................................... 15-8
15.5 Side and Slot Mills-Arbor Mounted.......................................................... 15-10
15.6 End Mills-Peripheral and Slotting. Higit Speed Steel ..................................... 15-12
15.7 Drills, High Speed Steel Twist ................................................................ 15-14
15.8 Oil-Hole or Pressurized-Coolant C.4;3j, High Speed Steel.................................. 15-16
15.9 Spade Drills. High Speed Steel............................................................... 15-16
15.10 Gun Drills, Carbide ....................... ................................................... 15-18
15.11 Reamers, Highl Speed Steel ........................... _:.................................... 15-19I
15.12 Reamers, Carbide ......................... ................................................... 15-20
15.13 Boring Tools, Carbide ....... ................................................................. 15-21
15.14 Taps, High Speed Steel....................................................................... 15-23
15.15 Planing Tools................................................................................. 15-25
15.16 Broaches, High Speed Steel .............................................. ................... 15-27
15.17 Tool and Cutter Angles-Approximate Equivalents ........................................ 15-28

Section 16. Cutting Fluids*......................................................................... 16-1

16.1 Cutting Fluid Selection and Use.............................................................. 16-3
16.2 Cutting Fluid Recommendations............................................................. 16-17
16.3 Cutting Fluid Key.............................................................................. 16-65

*For the detaild contenits of this section. see the title page of thissectior-.

Vi
 CONTENTS
Volume 2

Section 17. Power and Force Requirements..-................... ...................... 17-1

17.1 Determining Forces in Machining ............................................................ 17-3
17.2 Determining Power Requirements in Machining............................................ 17-7
17.3 Estimating Forces in Turning ........................................................... 17-23
17.4 Estimating Torque and Thrust in Drilling..................................................... 17-27

Section 18. Surface Technology* ............................................................... 18-1

18.2 nrdint Surface Texture ....... . ...................................................... 18-5
18.1 ntduooSurface ehnouogy..........................................................................18-5
...................................... 18-39
18. SrfceIntegrity ........................................

Section 19. Machining Guidelines* ............................................................ _.19-1

19.1 General Machining Guidelines .................................................... ........... 19-3
19.2 Guidelines for Drilling.......................................................................... 19-5
19.3 Tool Life........................................................................................ 19-11
19.4 Types of Machinability Data ................................................................... 19-15

Section 20. Grinding and Abrasive Machining* ............................................. 20-1

20.1 Grinding Wheels ........ ........................................................... I.......... 20-3
20.2 Grinding Guidelines .................... ................................................ 20-13
20.3 Surface Roughness and Tolerances........................................................ 20-17
20.4 Grinding Formulas and Charts .......................................................... 20-21
20.5 Abrasive Machining............................................................................ 20-33

Section 21. Economics In Machining and Grinding*........................................... 21-1

Section 22. Machine Chatter and Vibration* . . . . . . . . . . . . . . . . 22- 1

............................

Section 23. Numerical Control Machining* . . . . . . . . . . . . . . . . . . .......................

.. ... ... .. .. 23-1 -

23.1 NC Machining Guidelines. ................................................................. 23-3

23.2 NC Vocabulary............................................................................... 23-9

Section 24. Computer-Aided Manufacturing Technologies*5 .............

. . . . . . . . . . . . . . . . . . . . 24-1

Section 25. Machining Standards ................................................................. 25-1

25.1 Machining Standards by Subject ........................................................... 25-3
25.2 Alphabetical List of Machining Standards ................................................. 25-9
25.3 Sources of Machining Standards .......................................................... 25-23

Section 26. Materials Index......................................................................... 26-1

26.1 Numerical List of Materials.................................................................. 26-3
26.2 Alphabetical List of Materials............................................................... 26-17
26.3 Chemical Composition by Material Group................................................. 26-37

Section 27. Glossary................................................................................. 27-1

Section 28. Subject Index........................................................................... 28-1

'FortMe detailed cofftents of thi section. see tUe title 0

ofgthIS section

vii
 MACHINING
DATA
HANDBOOK

.. -.. .__-_____--..
.. .. . .
I___l
 SECTION 7
GEAR CUTTING AND
GEAR GRINDING OPERATIONS

7.1 Gear Hobbing ............................ ............................................................................................ 7-3

7.2 Gear Cutting, Straight and Spiral Bevel ...................................................................................... 7-31
7.3 Gear S haping ............................... ............................................................................................ 7-47
7.4 Gear 'having ........................... ............ ........................................ 7-69
7.5 G ear G , nding, Form ........................................................................ .......................................... 7-89

tI
!I
iA
i4
i4

lI

1*1

7-1

NO-----~=i----
 pkRECEMWi PAcE BLANK-40 FIL,44D

Gear Hobbing 7.1

DIMTRLFEED* PER [
IAMTRAL
DAD UBE REVOLUTION HOB I 9S5TOOL
PITERIA NUMBENDIIOROOF SPEED MATERIAL
HARD- OF WORKPIECE
MATEIAL
ESS ONDIIONCUTS
in fpm AISI

1. FREE MACHIN4ING CARBON 3-10 2 .060 230

STEELS, WROUGHT 11-10 1 .060 230 M
Low Carbon Resulfurized I-191.6 4 2M
1116 100 Hot 20-48 1 .050 250
117t old48 & Finer 1 .030 280
1118 150 or I
1119 Aneled .A ' 1 5~
1211 -

1212 iW2'
1-2 2 .060 230
3-10 1 .060 240
11-19 1 060 265 M2.M7
150 20-48 1 050 275
to Cold 48 & Finer 1 .030 300
200 Drawn 13 W_5
-07O ~ _

Low Carbon Resulfurlzed 1-2 2 .060 240

1233-10 1 .060 250
1213 11-19 1 060 265 M2.M7
1215Ho 20-48 1 .050 275
to Rolled 48 & Finer 1 .030 300
150 or .-

Annealed

060 270
11-19 1 060 285 M2 M7
150 20-48 1 050 295
!0Cold 48 & Finer 1 .030 330
200 Drawn r4 WM-

Low Carbon Result urized 122.6 9

1108 11-19 1 .060 220 M2, M7

1109 100 Hot 2 481 .050 240
1115 Roiled 48 & Finer10326
150 or t0
Annealed -- 1. r

1-2 2 .060 200

150 20-48 1 .050 250

to Cold 48 & Finer 1 .030 270
200 Drawn -

For hobbing Class 9 (per AGMA 390 03) or better gears, it may be See section 16 for Cutting Fluid Recommendations.
necessary to reduce speeds and feeds by 50% and/or take 2 cuts. $Feeds are based on the largest standard recommended thob diameter.
To meet finish requirements it may b-2necessary to try both conven- When using a smaller hob diameter, the Feed must be reduced pro-
tional and climb cutting portionally.

7-3
7.1 Gear Hobbing

FEED* PER
DIAMETRAL REVOLUTION HOB HSS TOOL
PITCH NUMBER OF SPEED MATERIAL
1
MATERIAL HARD- CONDITION -7 ;n-5 OF WORKPIECE
MN- g CUTS in fpm AISI
I22 060 170
10 2 .060 180
1. FREE MACHINING CARBON
STEELS, WROUGHT (cont.)
Hot t1-19 1 060 190 M2. M7
Medium Carbon Reaulfurizd
Rolled. 20-48 1 .050 200
1132 1144 175
Normalized. 48 & Finer 1 .030 220
1137 1145 to
i1q 1146 225 Annealed II M -
1140 1151 orCold
1141 Drawn = "

2754 Qunoe 48&Oier1P00

1-2 2 .060 6
120
31-10 1 .060 140
11-19 1 .060 145 M2.M7
20-48 1 .050 150
275 Quencned 48 & Finer 1 .030 165
325 Tempered -:. '' .&-...
_[ -,

1-2 2 .060 7
3-10 1 .060 20
11-19 1 .060 20 M3,M42
20-48 1 .050 2
325 Quenched 48 & Finer 1 .030 250
o a b gnly
375 Tempered i=

Lo Crbn eaedi
LwCroLodd3-10
to 1-2 2
1
ana .065 23
.065 25
1L8Hot 11-19 1 .060 27 M2. M7 :
111-17 100 Rolled, 20-48 1 .050 29
48 & Finer 1 .0300_:
to Normalized,

Drawn Ar-

1-2 2 .065
3-10 1 .065 22
Hot 11-19 1 .060 20 M2, M7 A
150 Rolled, 20-48 t 1 05027
to Normalized, 48 & Finer 1 .03028

or Cold _
Drawn

1-2 2 .060 14
3--10 1 .05018
10L18_ Hot 11-19 - 1 ~ .050 '20 M2 M7 P-
---
20 Rle.20-48 1 .050 22
Normalized, 48 & Finer 1 .03020
20 Annealed

or Cold
Drawn

For bobbing Class 9 (per AGMA 390 03) or better gears. it may !)e See section 16 for Cutting Fluid Recommendations.
recessary to reduce speeds and feeds by 50% and/or take 2 cuts. *Feeds are based on the largest standard recommended hob diameter. AR
To meet finish requirements it may be necessary to try both convert- When using a smaller hob diameter, the Feed must be reduced pro-
tional and climb cutting. portionally,

7-4
 Gear Hobbing 7.1
FEED* PER
DIAMETRAL REVOLUTION HOB HSS TOOL
HARD- PITCH NUMBER OF SPEED MATERIAL
MATERIAL NESS CONDITION XOF WORKPIECE
CUTS
Shn
Sin fpm 5
AISI'
_ nM, _ IW Aifi tSIO fi
1-2 2 .065 255
Low Carbon Leaded
12113 3-10 1 .065 265
11-19 1 060 295 M2. M7
12114 Hot
Rolled. 20-48 1 .050 305
12115 100
48 & Finer 1 .030 340
to Normalized.
150 Annealed 3. ' i
or Cold
Drawn
eA ----
1-2 2 .065 210
3-10 1 .065 240
Hot 11-19 1 060 275 M2, M7
Rolled. 20-48 1 .050 285
150
48 & Finer 1 .030 320
to Normalized,
200 Annealed 3r1 "R _m W.
&& .
Drawn ?X 1t;

1-2 2 .060 165

3-10 1 .060 190
Hot 11-19 1 .060 225 M2. M7
Rolled. 20-48 1 050 240
200
to Normalized, 48 & Finer 1 .030 275
250 Annealed
or Cold & -==-- i.
Drawn - \-

Medium Carbon Leaded 1-2 2 .060 200

1L53-10 1 .060 210 2
10L45 Hot 11-19 1 .060 225 M2. M7
10150 o
20-48 1 .050 240
11137 125 Rolled,
48 & Finer 1 .030 260
11141 to Normalized,
11144 175 Annealed . o 2
Drawn
or Cold i

1-2 2 .060 190

3-10 1 060 200

Hot la-19 1 .060 210 M2, M7

Rolled. 20-48 1 .050 225
175
48 & Finer 1 .030 240
to Normalized,
d R
225 AnnealeaacowI
or Cold

;1-2 2 .060 180

Hot Rolled, 3-10 1 .060 190
Normalized, 11-19 1 .060 200 M2, M7
225 Annealed, 20-48 1 .050 205
to Cold Drawn 48 & Finer 1 .030 220
275 or
Quenched
and
i Tempered

For hobbIng Class 9 (per AGMA 390.03) or better gears. It may be See section 16 for Cutting Fluid Recommendations.
necessary to reduce speeds and feeds by50% and/or take 2 cuts. *Feeds are based on the largest standard recommended hob diameter.
To meet finish requirements it may be necessary to try both conven- When using a smaller hob diameter. the Feed must be reduced pro-
tional and climb cutting. portionally.

7-5
_____________
iP- ---- r---~-----
 7.1 Gear Hobbing
1' FEED* PER

DIAMETRAL REVOLUTION OB HSS TOOL

HARD- PITCH NUMBER OF SPEED MATERIAL

MATERIAL NESS CONDITION OF WORKPIECE
CUTS in 1pm AISI

1-2 2 060 130

1. FREE MACHINING CARBON
STEELS, WROUGHT (cont.) Hot Rolled. 3-10 1 .060 140
Normalized, 11-19 1 .060 150 M2, M7
Medium Carbon Leaded
275 Annealed. 20-48 1 .045 160
(cont.)
Cold Drawn 48 & Finer 1 030 175
(materials haled on preceding page) to
325 or
and
Quenched F i -
Tempered ' "

1-2 i 2 .060 8
3-10 1 045 9
11-19 1 .045 25 M3,. M42
20-48 1 025 20
325 Quenched 48 & Finer 1 .025 290
to and -
375 Tempered

I2. CARBON STEELS, 1-2 2 .07020

3-10 1 .070
WROUGHT
Low Carbon Hot 11-19 1 .060 25 M2, M7

Rolled 2048 11 .050

.03029
1005
1006 1019
1020 85
to Normalized, 48 & Finer

10215 125 Annealed

10110

1012 1026
1013 1029 1-2 2 070
1015 1513 3-10 1 070
1016 1518 Hot 11-19 1 .060 200 M2, M7
1017 1522 125 Rolled. 20-48 1 .050 210
1018 to Normalized, 48 & Finer 1 .030 220
175 Annealed
Drawn

1-2 2 .07014
3-10 1 .070 170
Hot 11-19 1 .060 190 M2, M7
175 Rolled, 20-48 1 .050 200
to Normalized. 48 & Finer 1 .030 210
225 Annealed -
or Cold
Drawn

1-2 2 .06010
3-10 1 .06016
11-19 1 .060 15 M2, M7

225 Annealed 20-48 1 .050 195

or 48 & Finer 1 .030 200
to

For bobbing Class 9 (per AGMA 390.03) or better gears, it may be See section 16 for Cuffing Fluid Recommendations.
necessary to reduce speeds and feeds by 50% an, /or take 2 cuts. 'Feeds are based on the largest standard recommended hob diameter.
To meet finish requirements it may be necessa : try both conven- When using a smaller hob diameter, the Feed must be reduced pro-
tional and climb cutting portionally.

7-6

_________
-- ~- P*.~~-~~------- - ii
 Gear Hobbing 7.1

FEED PER
DIAMETRAL REVOLUTION HOB HSS TOOL
PATERIAL OF OF SPEED MATERIAL
HARD- CONDITION
NESS CUTS
NESS WORKPIECE
hnin fpm AISI

Carbon 1-2 2 .070 165

Medium
1526 3-10 1 .070 175
1030 1044
1527 Hot 11-19 1 .060 185 M2.M7
1033 1045
125 Rolled. 20--48 1 .050 200
1035 1046 1536
to Normalized, 48 & Finer 1 .030 210
1037 1049 1541
1038 1050 1547 175 Annealed 2P ONE m
1039 1053 1548 or Cold , , A
1040 1055 1551 Dran
1042 1524 1552 Iv - it "
1043 1525 1-2 2 .070 '
135 ',x#..

3-10 1 .070 145

Hot 11-19 1 .060 165 M2, M7

175 Rolled, 20-48 1 050 185
to Normalized. 48 & Finer 1 .030 200

225 Annealed . - -

Drawn

1-2 2 .063 110

Hot Rolled. 3-10 1 G50 125
Normalized. 11-19 1 .050 150 M2.M7
20--48 1 .050 165
225 Annealed.
48 & Finer 1 .030 175
to Cold Drawn
275 or
Quenched
andI
Tempered
1- 2 2 .045 95
Hot Rolled. 11-19
3--10 1
1 .045
.045 120
110 M2.M7
Normalized, 20-48 1 .045 130
275 Annealed 48 & Finer 1 .030 140

_ ie 4
to or
325 Quenched
and
Tempered

1-2 2 .045 70
3-10 1 .045 80
11-19 1 .025 100 M3,M42
20-48 1 .025 105
325
to Quenched
and 48 & Finer 1 .025 120

375 Tempered

High Carbon 1-2 .070 125

1090 070 135 M2, M7
1060
1064 1075
1078 1H90 11-19 1 .060 155
1064 1078 1095
Rolled. 20--48 1 .050 175
1065 1080 1561 175
tO Normalized, 48 & Finer 1 .030 190
1069 1084 1566
1070 1085 1572 225 Annealed
C All Eil 1_1
1074 1086orCl

For hobbing Class 9 (per AGMA 390,03) or better gears. itmay be See section 16 for Cutting FluidRecommendations.
necessary to reduce speeds and feeds by 50% and/or take 2 cuts. *Feeds are based on the largest standard recommended hob diameter.
To meet finish requirements Itmay be necessary to try both conven- When using a smaller hob diameter, the Feed must be reduced pro-
tional and climb cutting. portionally.

7-7

-:-' -- 3,
7.1 Gear Hobbing
i FEED* PER

DIAMETRAL REVOLUTION HOB .HSSTOOL

HARD- PITCH NUMBER or" SPEED MATERIAL

MATERIAL NESS CONDITION OF WORKPIECE
cUTs in 1pm AISI
___ __ __ _ hn _ ___ 2M____ Iriirw~w ~~ m s
1-2 2 .060 00
2. CARBON STEELS,
Hot Rolled. 3-10 1 050 115
WROUGHT (cont.)
Normalized. 11-19 1 050 140 M2.M7
High Carbon (cont.)
Annealed, 20-48 1 050 155
(materials fisted on preceding page) 225
165
Cold Drawn 48 & Finer 1 030
to
275 or Ma I R- -
Quenched _ 25 3 z -r4
and A~~44~ t-
Tempered __ C Z

1-2 2 .045 85
Hot 3-10 1 .045 100
Rolled. 11-19 1 .045 110 M2. M7
20-48 1 .045 120
275 Normalized.
to Annealed 48 & Finer 1 .030 130
325 or -
Quenched
and
1
Tempered as a. -
1- 2 2 .045 65
2-10 1 045 75
11-19 1 .025 95 M3. M42
20--48 1 .025 100
325 Quenched 48 & Finer 1 .025 115

Tempered
35
~--~ a m 4N.~ __

1-2 2 .07 165

3. CARBON ANC VZ;ni lt
3-10 1 .070 175
ALLOY STEELS (HIGH
TEMPERATURE SERVICE) 11 19 1 060 185 M2 '
ASTM A369. Grades FPA. FPB. 150 2D-48 1 050 200
As 48 & Finer 1 .030 210
FP1.FP2.FP12 to

1-2 2 .070 135 [

ASTM A369. Grades FP3b. 3-10 1 .070 145

FP1 1 1119 1 .060 165 M2.M7
Annealed 20--48 1 .050 185
150 or 48 & Finer 1 030 200
to Normalized
200 and 4-
Tempered

1-2 2 .060 10/

ASTM A369. Grades FP5. FP7. 3-10 1 .050

FP9,FP21, FP22 11-19 1 .050 150 M2,M7
Annealed 20-48 1 .050 165
150 or 48 & Finer 1 030 175
Normalized .,
10
200 and - - -
To-, -,red :

For hobbing Class 9 (pa, AGMA 390.03) or better gears, it may be See section 16 for
Curing Fluid Recommendations.
necessary to reduce speeds and feeds by 50% and/or take 2 cuts, *Feeds are based on the largest standard recommended hob diameter.
To meet finish requirements it may be necessary to try both conven- When using a smaller hob diameter. the Feed must be reduced pro-
tlonal and climb cutting. portionalty.

7-8
 - _ . = - _ - _- -w - -2 _-,
. _ .- '- .V-

Gear Hobbing 7.1

IFEED* DIAMETRAL
PER
REVOLUTION HOB HSS TOOL
HARD PITCH NUMBER OF SPEED MATERIAL
NESS OF WORKPIECE

Ih CUTS
1-2 2 .060 145
4. FREE MACHINING ALLOY
3-10 1 .060 155
STEELS, WROUGHT
Hot 11.19 1 .060 165 M2. M7
Medium Carbon Resulfurized
20-48 1 .050 180
4140 150 Rolled.
4140Se to Normalized, 48 & Finer 10320
4142Te 200 Annealed z" ; : MF
4145Seor Cold
4147Te Drawn >
4150 MA
1-2 2 .060 120
3-10 1 .060 130
Hot 11-19 1 .060 140 M2.M7

20-48 1 .050 160

200 Rolled.
48 & Finer 1 .030 180
to Normalized.
250 Annealed
or Cold
Drawn . ,4-

1-2 2 .045 90
3-10 1 .045 100
11-19 1 .045 110 M2. M7
275 Quenched
2520-48 48 & Finer 1 .045
.030 120
130
to and
325 Tempered

1-2 2 .045 65
3-10 1 .045 75
11-19 1 025 95 M3. M42
325 Quenched
3520--48 48 & Finer 1 .025
.025 100
135
to and
375 Tempered

1-2 2 .060 170

Medium and High Carbon
3-10 1 .060 180
Leaded 11-19 1 .060 190 M2. M7
41L30 413 3-0Hot
43L40
20-48 1 .050 200
41L40 51L32 150 Rolled,
Normalized, 48 & Finer 1 .030 220
41L45 52L100 to
41L-47 86L.20 200 Annealed
41L50 86L40 or Cold

S1-2 2.0 14
3-10 I.060 15
Hot 11-19 1 .060 170 M2..M7

200 Rolled, 20--48 1 .050 185

to Normalized. 48 & Finer 1 .030 200
250 Annealed

For hobbing Class 9 (per AGMA 390.03) or better gears, it may be See section 16 forCutting Fluid Recommendations.
necessary to reduce speeds and feeds by 50% and/or take 2 cuts. *Feeds are based on the largest standard recommended hob diameter.
To meet finish requirements it may be necessary to try both conven- When using a smaller hob diameter, the Feed must be reduced pro-
tional and climb cutting. portionally.

_ _7-9

"- -,_... __
Z.
7.1 Gear Hobbing

FEED PER
DIAMETRAL REVOLUTION HOB HSS TOOL
HARD- PITCH NUMBER OF SPEED MATERIAL
MATERIAL NESS CONDITION - - OF WORKPIECE
CUTS
Iin fpm AISI
B. .n. .... . J ... . ... .

1-2 2 045 120

4. FREE MACHINING ALLOY
3-10 1 .045 140
STEELS, WROUGHT (cont.) 11-19 1 045 145 M2. M7
Medium and High Carbon 20-48 1 045 150
Leaded (cont.) 275 Quenched /8 & Finer 1 030 165
-
(materials listed on preceding page) to and A3 jt2t 15. 3-
325 Tempered---- --

1-2 2 045 70
3-10 1 .045 90
11-19 1 .045 110 M3. M42
20-48 1 045 120
325 Quenched 48 & Finer 1 .030 130
to and ~- 15~-
375 Tempered ~ ~ ~ ~ ;.~

1-2 2 .060 160

5. ALLOY STEELS, WROUGHT
Low Carbon 3-10 1 060 170
11-19 1 060 180 M2. M7
4012 4615 4817 8617 Hot
Rolled. 20-48 1 .050 190
4023 4617 a820 8620 125
4024 4620 5015 8622 to Annealed 48 & Finer 1 .030 210

4118 4621 5115 8822 175 Cold

or Ft2 .A5
MUM
4320 4718 5120 9310 Cd2S ;_ -- ___ -
4419 4720 6118 94B15 O W_W_ I-z
--
4422 4815 8115 94817 '21_01

1-2 2 .060 130

3-10 1 .060 140
Hot 11-19 1 060 150 M2.M7
Rolled. 20-48 1 .050 170
48 & Finer 1 .030 190
to 2 5or Annealed g -.. _ -
Cold 1 -
HM-_ 5

ii1-2 2 .060 105

3-10 1 .060 115

Hot 11-19 1 .050 130 M2. M7

225 Rolled. 20--48 1 .050 150
to Normalized. 48 & Finer 1 .030 165
275 Annealedoa -
or Cold -

Drawn 5

1-2 2 .045 90
3-10 1 .045 100
11-19 1 .045 ;10 M2. M7
Normalized 20-48 1 .045 120
275
IC or
Quenched 48 & Finer 1 .030 130
325 and ;iWEMER
Tempered- -'yg N

For hobbing Class 9 (per AGMA 390.03) or better gears, it may be See section 16 for Cutting Fluid Recommendations.
necessary to reduce speeds and feeds by 50% and/or take 2 cuts. *Feeds are based on the largest standard recommended hob diameter.
To meet finish requirements it may be necessary to try both conven- When using a smaller hob diameter. the Feed must be reduced pro-
tional and climb cutting portionaltly

7-10
I
- - -- ~t=~.
 Gear Hobbing 7.1

DIAMETRAL FEED* PER

REVOLUTION HOB HSST"OOL
HARD- PITCH NUMBER OF SPEED MATERIAL
MATERIAL CONDITION OF I
> : . CUTS
MODUL-in ,pm AISI
Bhn ______ _____ ___ 4mp
12 2 045 65
(cont.)I STEELS, WROUGHT
5. ALLOY 3-10 1 .045 70
(cont.) 11-19 1 025 75 M3.M42
Low Carbon (cont.) Normalized 20-48 1 .025 90
(materials iisted on preceding page) 325 or 48 & Finer 1 .025 100
to Quenched
35and ~ ~ : # rt %.-1t-
Tempered ~ ~ - tt.t ~ 3 5 t

Medium Carbon 1-2 2 060 125

3-10 1 .060 *35
1330 4427 81845 Hot 11-19 1 050 145 M2.M7
1335 4626 8625
'75 Rolled. 20-48 1 .050 160
1340 50840 8627
Annealed 48 & Finer 1 .030 180
1345 50B44 8630 to
4027 500dA 27 225 o 2 13 .-
7 - -g
Cold ,-225
4uvd 50846 8640 Dan__ ~ ~ l2z -~s~~
rJC -

4032 50850 8642 --- r--- - %t

~ r a
-z
4037 5060 8645 w'- ~ ~
4042 50860 86845 ... .
4047 5130 8650 1-2 2 .060 100
43 5123-10 1 .050 10
4130 5132 8655 Annealed. 11-19 1 .050 125 M2.M7
4135 5135 8660 Normalized. 20-48 1 .050 140
4137 5140 8740 225 Cold Drawn 48 & Finer 1 .030 155
4140 5145 8742 to or , -
4142 5147 9254 275 Quenched
4145 5150 9255an
4147 5155 9260
4150 5160 94B30 Temere
4161 51B60 ___-____.. , .__
4340 6150 .045 85
3-10 1 .045 95
11-19 1 045 10 M2. M7
Normalized 20-48 1 .045 110
275 or 48 & Finer 1 .030 120
to Quenched 5 -- -- -
35and .7 -A

Tempered gag.:__

1-2 2 .045 60
3-10 1 .045 65

Normalized 11-19 1 025 75 M3.M42

325 or 4820-48
& Finer 1
1 .025
.025 80
95

375 and
Tempered -__

High Carbon 1-2 2 .060 115

3-10 1 .060 125
50100 Hot 1119 1 .050 135 M2.M7
51100Ho
Rolled. 20-48 1 .050 150
52100 175
48 & Finer 1 .030 170
M-50 to Annealed
or
2259
Cold i --- ~1T
Drawn --

For hobbing Class 9 (per AGMA 390.03) or better gears. it may be See section 16 for Cutting Fluid R-commendations.
necessary to reduce speeds and feeds by 50% and/or take 2 cuts -Feeds are based on the largest standard recommended hob diameter.
To meet finish requirements it may be necessary to try both conven- When using a smaller hob diameter. the Feed must be reduced pro-
lional and climb cutting. portionally.

7-11

r -. -- ~
7.1 Gear Hobbing
FEED* PER
DIAMETRAL REVOLUTION Ho HSS TOOL
HARD- PITCH NUMBER OF SPEED MATERIAL
MATERIAL NESS CONDITION OF WORKPIECE
r ~ ~~Bhn i CUTS f in '." fpm * AISI _"

5. ALLOY STEELS, WROUGHT 12 2 060 90

(cont.) 3-10 050 100
Normalized. 11-19 050 15 M2, M7
High Carbon (cont.)
Cold Drawn 20-48 1 .050 130
(materials listed on preceding page) 225
1o or 48 & Finer 1 .030 145

275 Quenched 02A

and gc > Z;4-2
3' R 4 ?~
Tempered i1~

1-2 2 .045 80
3-10 1 045 90
11o19 1 r d045 100 M2. M7
Normalized 20-48 1 .045 105
275 or 48 & Finer 1 .030 115
to Quenched -- ~
325 and
Tempered
# r4z Z 2r

1-2 2 .045 55

3-10 1 045 60
Normalized 11-19
20-48 11 .025
025 70
75 M3. M42
325 or 48 & Finer 1 025 90

10 Quenched -r-t
- -7iv$ ;J -
and si- '-
Tempered cZ!h J7-- -1VOW

6. HIGH STRENGTH sTES, 1-2 2 .060 80

3-10 1 .050 95
WROUGHT 11-19 1 .050 105 M2. M7
300M 98BV40 20-48 1 .050 110
4330V D6ac 225 48 & Finer 1 .030 120
4340 Hl1l to Annealed
4340Si H13 300c _

-- . -

1-2 2 .045 65
-- 10 1 .045 80
11-19 .045 90 M2, M7
20-48 1 .045 95
to 48 & Finer 1 .030 105
350

1-2 2 .045 60
HP 9-4-20 3-10 1 .045 70
HP P 4-25 11-19 1 .025 80 M3,M42
HP 9-4-30 20-46 1 .025 85
HP 9-4-45 325 48 & Fine. 1 .025 95
to Annealed g~
375

For hobbing Class 9 (per AGMA 390.03) or better gears. it may be See section 16 for Cutting Fluid Recommendations.
necessary to reduce speeds and feeds by 50% and/or take 2 cuts. *Feeds are based on the largest standard recommended hob diameter.
To meet finish requirements it may be necessory to try both conven- When using a smaller hob diame'er the Feed must be reduced pro-
tional and climb cutting. portionally.

7-12
 Gear Hobbing 7.1

FEED PER
DIAMETRAL REVOLUTION NOB .SS TOOL
HARD- PITCH NUMBER OF SPEED MATERIAL
MATERIAL NESS CONDITION-' OF WORKPIECE
CUTSin fpm AISI

1-2 2 .045 120

7. MARAGING STEELS,
3-10 1 045 130
WROUGHT
11-19 1 .945 145 M2. M7
120 Grade 20--48 1 .045 155
180 Grade 275 48 & Finer 1 030 170
to Annealed ~~~-4
325 325 -i 2. _/J
5 ,;- : .15 .

- 1-2 2 0o45 100

ASTM A538. Grades A. B. C 3-10 I 045 110
200 Grade 11-19 1 .4b ;20 A &A7

250 Grade 20-48 1 .045 130

300 G-ade 275 48 & Finer 1 030 140
350 Grade to Annealed ' -
HY230 325

~A

8. TOOL STEELS, WROUGHT 1-2 2 045 40

3-10 1 .045 45
High Speed 045 55 M2. M7 .41
11-19 1
M1 20-48 1 045 60
M2 200 48& Finer 1 .030 80
M6 to Annealed I., -
M10 250

T6

High Speed 3-10 1 .045 40

M3-i M34 M46 11-19 1 .025 50 M2. M7
M3-2 M36 M47 20-48 1 .025 55
M4 M41 T4 225 48 & Finer 1 .025 75
M7 M42 T5 to Annealed -
M30 M43 T8 275 _

M33 M44 TIS

Hoor--2 2 .060 70
SHot Work 3-10 1 .060 75
H10 H23 11-19 1 .060 85 M2.M7
$11 $23 20-48 1 050 90
$H12 24 150 48 & Finer 1 .030 110
H13 H25 1o Annealed Sp,
H14 $26 200 -7
H19 H42
H21 I~__

! 1-2 2 .060 55 -= -
3-10o 1 .060 60
11-19 1 .060 70 M2. M7
;20 -48 1 .050 75
200 48& Finer 1 .030 95

250

_ _ _ __ i -
For hobbing Class 9 (per AGMA 390.03) or better gears, it may be See section 16 for Cutting Fluid Recommendations.
necessary to reduce speeds and feeds by 50% and/or take 2 cuts. *Feeds are based on the largest standard recon'mnended hob amcler.
To meet finish requirements it may be necessary to try both conven. When using a smallor hob diameter,. the Feed must be reduced pro-

II
ional and climb cutting portionally.

7-13

- %
7.1 Gear Hobbing

t AD
|
! DIAMERAFED
PITCH
PIRI iER
NSUMBER IREVOLUTION
OF PAR SPEED
HOG MATRIAL
HSS TOOL
__--- OF O SPED MAERA
MATERIAL HARD- NESSlCONDITION __ WORKPIECE
NES U1S 1 in fpm I AISI

1 2 .045 45
a. TOOL STEELS, WROUGHT 3-10 i .045 50
(conL) 11-19 1 025 60 M3.M42
Hot Work (coaL) 20--48 1 025 65
(materials listed on preceding raye) 325 Quenched 1 48 & Finer 1 1 .025 85
toand ts r14 f
37b Temrpereo"j-'- - - r-I !4YW

Cold Work 1-2 2 060 55

A2 D-^ .060 70 M2.M7
A3 D4 2 -A 1 O50
9-5
_ 48 . Finer 1 .330 95
A6 7 I AnealedN

I 'Ar tI '!
A7201 .0-07

,5,
022

52

15483& Fm 1 .030 110

$6l to Aneale s.060 I

Ss1548 & Finer 1 .030 110

3--0 .060 17
P2 11-19 .060 85 M2.M7
P4 20--46 1 .050 15
P5 100
P3 tc Annealed
S 1-2 2 .060 95

48 &Fier 1 .030 125

P203-10 Ito Annealed 1 .060 75
P2119
20
1 .060 85 M2. ?7
P4 20---48 1 .050 19

F~or
hobbingj Class 9 (per AGMA 390 03) or better gems. II may tie Sesectlon 16 tot Ct.ng Fluid Recoewnfiriont
nacesa.ary to reduce apdeda and feeds by 50% and/or take 2 cu. "Feeda are based on the largest standJard recommen-ded bob, diameter.
To meet finoti requirements it may be nececsalry to try both convert- When usingj a smaller bob (fameter the ForJd m.,st be reduced pro-
tion al and climb cutti ng port.ionaly.

7-14

I -
 Gear Hobbing 7.1

DIAMETRAL IREVOLUT ION HOB HSS TOOL

PITCH NUMBER I
OF OFRD- SPEED MATERIAL
MAEILCONDITION
NESS If=*.C
I ~.0UE ~in fpmn AISI
__ _ _ _ - n _ _ _ _1m gnm~ !SO'
Special Purpose I}
123-10
1-2 2 I 060
06
65
70
L2_ 91060 80 1,12.1.17
16 20-48 n5 :
15 48 Fine 1 030 105,

12 22 106.0 21

Special Purpose .na~r I . I

F21 11--19 060 65 1 14214

F2200 I20-48 101 05
to Annealed j 48 &Fine- 1 030 I 90 1
2502-13 f 210 15

12-2S 1 00 1

Water Hardening 312 1100

SAEJ438b. TypeSWI08. I1-C50
W I0Y2,W I10. W112. W209. ISO 248 1 060me 145
'00 2M
W2 10. W310 to Anae K
200

9. NWTRKMG STEELS, 1-22.05 18

WRUH 3-10
1-91G5
1.4 1 o
10 F214
NftralOov *25
Nrlralloy
Nalratu"
.35
!3' Mod.t
200 Anneale ~ 5aFe 1.312
_

NrtraLtoyj 225 250 ~2~3 ~2 ~ t S

N"ta1oy 230 ~~Z~ ~_ S4S2
Nitratloy EZ 4 1.15-__ 4=
Naralloy N
Nvitex 1 -_5

10 Ouenched _____

Temred M As ?_EZ

12. FREE IAACHMu. 1-2 2 .060 In-

STANKESS STEELS, 3-10 1 .060 205
WROUGH7 11-19 1 06 220 14217
Fwritc 13520-81.523
430F to Anealed ~i~-s
1
430F Se 85 -. CZ--

-~~~
_ 12

For hobbng Class 9 (per AGMA 3 O 03) or fl(W gears. it may be See section 16 lot Cutti7g Fluid Recormenidatiorts
necessary 1oreduce speeda and feeds by 50% and/or take 2 cutS *Feeds are bjaed on the largest standlard recommvended hob diamseter.
To meet fish requiremefts it may be necessary to try both corrver- When usng a smaller hob, diameter. the Feed tJ be reduced Pro-
ttonal and climb cutting Porbionaly-

7-15
7.1 Gear Hobbing
FEED PER
DIAMETRAL REVOLUTION HOB HSS TOOL
HARD- PITCH NUMBER OF SPEED MATERIAL
MATERIAL NESS CONDITION OF WORKPIECE
CUTS
y4'9MODULEV : in fpm AISI
.6 22 125h~w _____

12. FREE MACHINING 1 2 2 .060 125

STAINLESS STEELS, 3f- 19 1 060 170 M2. M7
WROUGHT (cont.) 20-48 1 .050 185
Austenitic 135 48 & Finer 1 .030 200
-
203EZ 303Pb to Annealed2
303 303 Plus X 185 tI 2 t& .4t4% 4 4
303MA 303Se

1-2 2 060 115

3-10 1 .050 135
11-19 1 050 155 M2 M7
20-48 1 050 175
225
Cold 48 & Finer 1 .030 195
to
275 Drawn y -s w~~~ M~it~(%

Martensitic 1-2 2 .060 175

3-10 1 .060 205
416 11-19 1 .060 220 M2.M7
416 Plus X 20-48 1 .050 235
416Se 135 48 & Finer 1 .030 250
420F
42OF
44OF Se
to
185
Annealed
-IN.z 1-- W-

440F Se5 -- .
-
9 _ -*

1-2 2 .060 165

3--10 1 060 195
11-19 1 060 210 M2, M7
Annealed 20-48 1 050 225
to or 48 & Finer 1 .030 240
240 Cold

1-2 2 .045 100 .

3-10 1 045 135
11-19 1 .045 155 M2.M7
275 Qut.,,hed 4820-48
& Finer 1 .030
.045 175
160

325 Tempered EX

13. STAINLESS STEELS, 1-2 2 060 125

WROUGHT310 11-19 11 .060
060 135
150 M2, M7
WeROUGHT

135 48& Fner 1 .030 170

405 434
to Annealed
409 436
429 442 186
430 446

For hobbing Class 9 (per AGMA 390 03) or better gears. it may be See section 16 for Cutting Fluid Recommendations.
necessary to reduce speeds and leeds by 50% and/or take 2 cuts. *Feeds are based on the largest standard recommended hob diameter.
To meet finish requirements it may be necessary to try both conven. When using a smaller hob diameter, the Foed must be reduced pro-
tional and climb cutting, portlonally.

7-16
 Gear Hobbing 7.1

FEED* PER
DIAMETRAL REVOLUTION HOB HSS TOOL
HARD- PITCH NUMBER OF SPEED MATERIAL
MATERIAL NESS CONDITION - OF WRPEC
~MODQLE~
6UEin
CUTS
fpm AISI
___________________ Bhn ________ __ __ ni- >nninIO
Auutenitic 1-2 2 .060 95
21 383-10 1 .060 105
201 308 11-1t9 1 060 120 M2, M7

301 347 135 20-48 1 050 130

30
4 o Annealed 48 & Finer 1 .030 140
304 384 185 ~ ~ 2 s51~~~~;2
304L 385 ~~;j, ~ . 5. 32
'i2-

1-2 2 060 90
3-10 1 .050 100
11-19 1 .050 115 M2. M7
225 20-48 1 050 125
to Cold 48 & Finer 1 .030 135
275 Drawn ~ 1~ ~~i 52-'<

Austenitic 1-2 2 .060 85

3-10 1 .060 95
302B 314 11-19 1 .360 110 M2, M7
309 316 2481 .050 120
309S 316L 135204 48 & Finer 1 030 130
310 317to Anae
310S 330 tvAne'd

122 .060 70
3-10O 1 .050 80
11-19 1 .050 90 M2. M7
2520-48 1 .050 105
to Cold 48 & Finer 1 .030 120
275 Drawn _4 i

Austenitic 12 2 060 60
Nitronic 3231010070O
Nitronic 3311110580 M.7-a
N~tronic 40 210
Nitronic 50 to Annealed48&Fnr 1.310
Nitronic 60 250

Martentic j Iz.60
t 13
403 111 1 00 45 M2 M
410
420 135

422 to Annealed
501 175

For hobbing Class 9 (per AGMA 390.03) or better gears. itmay be See section 16 for Cutting Fluid Recommendations.
necessary to reduce speeds and feeds by 50% and/or take 2 cuts *Feeds are based on the largest standard recommended hob diameter
To meet finish requirements it may be necessary to try both convent. When using a smatter hob diameter. the Feed must be reduced pro-
tional an lm utn.portionaily.

L~.. 7-17
7.1 Gear Hobbing
I I FEEO* PER
HARD-
IDIAMETRAL
PITCH NUMBER
REVOLUTION
OF
HOB
SPEED
HSS TOOL
MATERIAL
MATERIAL NESS CONDITION . OF WORKPIECE
AWU CEu
, CUTS in pm AISI
Bhn __ _ __ _ -~~mm - rmr ISO,
13. TILS TES 1-2 2 060 100
WROUGHT (cont.) 11-19 1 060 120 M2M
Martensitic (cont.) 20 48 1 050 145 MM
(materials listed on preceding page) 175 248 ie8 1 030 160
to Annealed 48-1ie 2 1 0010
22525;,1_

1-2 2 045 60
3-10 1 045 80
11-19 1 045 95 M2, M7
20-48 1 045 105
275 Quenched 48 & Finer 1 030 120
to and253 .s2 , 6--
325 Tempered i - 24 -

Martensitic 1-2 2 060 70

3-10 1 050 90
414 11-19 1 050 105 M2. M7
431 20-48 1 050 115
Greek Ascoloy 225 48 & Finer 1 .030 130
to Annealed__21
275 V &wwnkX

1-2 2 .045 55
3-10 1 .045 75
11-19 1 .045 90 M2, M7
20-48 1 045 100
275 Quenched 48 & Finer 1 030 115
to and __-3 ~ ~ ~ 9~
325 Tempered ~ M

Martensitic 1-2 2 060 60

3-10 1 .050 80
440A 20-19 1 .050 95 M2, M7
44B2-81 .050 105
440C 225 48 & Finer 1 .030 120
t0 Annealed -

275 _- --

1-2 2 .045 50
3-10 1 .045 70
11-19 1 045 85 M2, M7
20-48 1 .045 95
275 (',enched 48 & Finer 1 .030 110
to andMD
325 Tempered-

For hobbrng Class 9 (per AGMA 390.03) o~rbetter gears. it may be See section 16 for Cutting Fluid Recommendaions.
necessary to reduce speeds and feeds by 50%and/or take 2 cuts. *Feeds are based on the largest standard recommended hob diameter.
To meet finish requirements it may be necessary to try both conven- When using a smater hob diameter, the Feed must be reduced pro-
tional and climb culling. portionalty.

7-18
 -- * % 9 Mn-ww rr- f' r

Gear Hobbing 7.1

FEED* PER
DIAMETRAL REVOLUTION HOB HSS TOOL
HARD- PITCH NUMBER OF SPEED MATERIAL
MATERIAL NESS CONDITION '-; cxs- OF WORKPIECE

S- in fpm i AISI
Shn -. - 'I - I ISO
1-2 2 060 65
14. PRECIPIrATION
3-10 1 060 85
HARDENING STAINLESS
11-19 1 060 100 M2 M7
STEELS, WROUGHT
20-48 050 110
15-5 PH 150
Solution 48 & Finer 1 030 125
16-6 PH to
17-4 PH 200 Treated 150 ?20-
2 - -

17-7t PH 1-51102
17-14 Cu Mo 2-5I1030, S4, S2
AF-71 14
AFC-77 5&Fne 175 _________ ____
-1 -,__

Almar 362 (AM-362) 1-2 2 .045 60

AM-350 3-10 I .045 80
11-19 1 .045 95 M2. M7
AM-355
275 Solution 20-48 1 045 105
AM-363
to Treated 48 & Finer 1 .030 120
Custom 450
Custom 455 325 or2 - -i v i---
HNMV Hardened ~~/22 c-~o~ ~ 2 '~-~--'

PH 13-8 Mo Z 5f S

PH 15-7 Mo ________ tSPer1 t-5- 37 ___

Stainless W 1-2 2 .045 50

3-10 1 .045 70
11-19 1 025 85 M3, M42
20-48 1 .025 95
325 Solution
48 & Finer 1 .025 110
to Treated
35or ' t~ Z_~r1 fffikt~ SY-52~
Hardened AiI1: Of110:0-
j 5t -tirS4 t

15. CARBON STEELS, CAST 1-2 2 .060 170

3- ,c 1 .060 200
Low Carbon
Anoealed. 11 19 .0160 215 M2. M7
ASTM A426: Grade CP1 100 rcmahzed 20-48 1 .050 230
1010
1020 to C 48 & Finer 1 030 245

150 Normalized
and h;
" S- ti "
Tempered AN S0

Medium Carbon 1-2 2 .060 130

ASTM A352 Grades LCA. LCB. 3-10 1 .060 150
Annealed. 11-19 1 .060 165 M2, M7
LCC
125 Normalized 20-48 1 .050 180
ASTM A356. Grade 1
or 48 & Finer 1 .030 195
1030 to
1040 175 Normalized
Tempered " X

1-2 2 .060 110

3-10 1 060 125
Annealed, 11-19 1 .060 145 M2, M7
Normalized 20-48 1 .050 150
175
or 48 & Finer 1 .030 165
to
Normalized r
225
and ~j
Tempered - Iat . - as

For hobbing Class 9 (per AGMA 390.03) or better gears, it may be See section 16 for Cutting Fluid Recommendations.
necessary to reduce speeds and feeds by 50% and/or take 2 cuts. *Feeds are based on the largest standard recommended hob diameter.
To meet finish requirements it may be necessary to try both conven- When using a smaller hob diameter, the Feed must be reduced pro-
tional and climb cutting portionally.

7-19

- .. - - -
 4. f

7.1 Gear Hobbing

FEED PER
DIAMETRAL REVOLUTION HOB HSS TOOL

HARD- PITCH NUMBER OF SPEED MATERIAL

MATERIAL NESS CONDITION OF WORKPIECE
A4&/- s CUTS
in fpm AISI
Bhin

15. CARBON STEELS, CAST 1-2 2 045 85

(. 3-10 1 .045 95
(cont.) ( 11-19 1 .045 115 M2. M7
Medium Carbon (cont.) 20-48 1 .045 120
(materials listed on preceding page) 250 Quenched 48 & Finer 1 .030 130
to and _ __ - jgtr.-
300 Tempered . -2 '_-"

. .. . 30..
16. ALLOY STEELS, CAST 1-2 2 .060 130
Low Carbon 3-10 1 060 150
Annealed. 11-19 1 060 165 M2. M7
ASTM A217 Grade WC9
ASTM A352. Grades LC3. LC4 150 Normalized 20-48 1 .050 175
ASTM A426 Grades CP2. CPS. to or 48 & Finer 1 .030 190
-
200 Normalized Rt:it 2-AO }
CP5b. CP 1. CP 2. CP15. .
and Piz
CP21. CP22
1320 2320 4120 8020 Tempered A;t25-- s- _

2315 4110 4320 8620 -k -V 4

1-2 2 .060 110
3-10 1 .060 130
Annealed, 11-19 1 060 145 M2. M7
Normalized 20-48 1 050 155
200
48 & Finer 1 .030 170
to or
225 Normalized ';MI ,-t I
__$$Y$
__
and W _ _

Tempered t_ -4r

1-2 2 .045 90
3-10 1 045 100
11-19 1 .045 110 M2, M7
250 Quenched 20-48
48 & Finer 1
1 .045
030 120
130
to and
300 Tempered ~ 2 2 ~ t t

Medium Carbon 1-2 2 060 110

ASTM A27: Grades N1. N2. 3-10 1 .060 130
U-60-30, 60-30.65-35. Annealed. 11-19 1 .060 145 M2, M7
70-36. 70-40 175 Normalized. 20-48 1 .050 155
to or 48 & Finer 1 .030 170
ASTM A148: Grades 80-40.

120-95. 150-125. 175-145 and

ASTM A216:
ASTM Grades WCA. Tempered
WOB.A217:
WOO.Grades WC1. ..ADM
:

WC4. WC5. WC6 1-2 2 .060 95

ASTM A352: Grades LC1. LC2. Normalized. 3-10 1 .060 110
LC2-1 Normalized 11-19 1 .060 125 M2. M7
ASTM A356: Grades 2. 5. 6. 8. 225 and 20--48 1 .050 140
9. 10
ASTM A389: Grdes C23. 024
ASTM A486: Classes 70. 90.
to
250
Tempered
or
Quenched
.
48 & Finer 1 .030

7 t
155
3
120 and
(materials c-tinued Tempered . '
on next I- je) L
For hobbing Class 9 (per AGMA 390.03) or better gears, It may be See section 16 for Cutting Fluid Recommendations.
necessary to reduce speeds and feeds by 50% and/or take 2 cuts, *Feeds are based on the largest standard recommended hob diameter.
To meet finish requirements it may be necessary to try both conven- When using a smaller hob diameter, the Feed must be reduced pro-
tional and climb rutting portionally.

7-20
 Gear Hobbing 7.1
FEED PEP T
DIAMETRAL REVOLUT!ON HOB I HSS TOOL
PITCH NUMBER OF SPEED MATERIAL
MATERIAL HARD- CONDITION OF
NESS OF ~~CUTS WORKPIECE m I As
in fpm AISI
____________ Wi8n ________ I___ -, ____ i IS -_

16. ALLOY STEELS, CAST 1-2 2 .045 80

(cont.) 3-10 1 045 90
Medium Carbon (cont.) 11-19 1 045 105 M2,M7
20-48 1 .045 10
(materials contnued from 250 Quenched 48 & Finer 1 030 120
preceduig page) to and - gi-
ASTM A487- Classes 1N, 2N, 300 Tempered __ -t 4
___

4N. 6N. 8N, 9N, 1ON, ON,10, . ! 5 in _

20,40, 40A, 6Q,70.80,
9Q0100
1330 4130 80830 8640 1-2 2 .045 70
1340 4140 8040 9525 3-10 1 .045 75
2325 4330 8430 9530 11-19 1 045 85 M2,M7
2330 4340 8440 9535 20-48 1 .045 90
4125 8030 8630 300 Quenched 48 & Finer 1 .030 100
to and -WW
350 Tempered - &Q- 4 A'

1-2 2 045 55
3-10 1 .045 60
i1-;9 1 .025 70 M3. M42
20-48 1 .025 75
350 Quenched 48 & Finer 1 .025 85
to and - . -
400 Tempered . .

1-2 2 .060 120

18. STAINLESS STEELS,CAST
3-10 1 .060 130
Ferritic
ASTM A217: Grades C5.C12 11-19 1 060 145 M2.M7
ASTM A296: Grades CB-30, 135 20-48 I 155
CC-5o. CE 48& Finer 1 .030 165
CA-6NM. CD4MCu 185 Ww'
_ -
ASTM A297: Grade HC
ASTM A487: Class CA6NM -
ASTM A608: Grade HC30 NR .41

Austenitic 1-2 2 .060 90

100 20M
310 1 .060
ASTM A296. Grades CF-16F,
CN-7M, CN-71MS 1119 1 .060 120 M2.M7
5 GaeC
A TVA-1I20-48 1 .00130
ASTM A351 Grade CN-M 140 Annealed 48 & Finer 1 .030 150
to or
170 Normalized ..

For hobbing Class 9 (per AGMA 390.03) or better gears, it may be See section 16 for Cutting Fluid Recommendations. Sit
necessary to reduce speeds and feeds by 50% and/or take 2 cuts. *Feeds are based on the largest standard recommended hob diameter.
To meet finish requirements it may be necessary to try both conven- When using a smaller hob diameter, the Feed must be reduced pro-
tional and climb cutting portionally.

7-21
7.1 Gear Hobbing
FEED* PER
DIAMETRAL REVOLUTION HOB HSS TOOL
HARD- PITCH NUMBER OF SPEED MATERIAL
MATERIAL NESS CONDITION -' s OF WORKPIECE
:- CUTS
AA moou . CUTS:n fpm AISI
Bhn _ ~ /lv
1-2 2 .060 90
18. STAINLESS STEELS, CAST
(cont.) 3- 10 1
1
060
.060
100
11-19 115 M2, M7
Austenitic 20--48 1 050 125
ASTM A296 Grades CF-3, 135 Annealed 48 & Finer 1 030 135
CF-B. CF-SC. CF-20 to or 51 S~~~i~
ASTM A351. Grades CF-3. 185 Normalized
CF-3A, CF-S. CF-8A. CF-BC /2 7 -. ,z-
ASTM A451
C PF3A . C PFGrades CPF3.
. C PF8A . : :'2-t5
.--,- S r
1
z

CPF8C, CPF8C (Ta Max) .5& lr t -- -15 1'-s 411-

ASTM A452. Grades TP 304H.
TP 347H

-MA-i Z---

1-2 2 060 80
Auteniic 3-10 1 060 90
ASTM A296: Grades CF-3M. 11-19 1 060 105 M2. M7
CF-8M. CG-8M. CG-12, 20-48 1 050 115
CH 20, CK-20 135 Annealed 48 & Finer 1 .030 125
ASTM A351: Grades CF-3M, to or t-s X j W 7 ' ;_
CF-3MA. CF-8M. CF-1OMC, 185 Normalized 4
CH-6, CH-10, CH-20. CK-20. = - . - ---- t -

HK-30. HK-40. HT-30 ~S gpg4

ASTM A451- Grades CPF3M, t1o.b-5, I
CPF8M. CPF1OMC, CPH8, t - -

CPH 10. CPH20. CPK20

ASTM A452. Grade TP 316H

ImI

Austenitic Autntc3-10 1-2 2 .060 75

1 .008
ASTM A297: Gra Jes HD. HE. 11-19 1 .060 100 M2.
HF. HH. HI, HK HL. HN. HP. 1-1
20-48 1
1 .060
.050 85
110 M M7

HT, HU 160 48 & Finer 1 .030 120

ASTM A608: Grades HD50. to As Cast
HE3S. HF3O. 8830. 8833. 210NE
1-135. 81<30. HK4O. 8130. 1M- -zB.:~~~4 ~~ <l~%
HL40. HN40, HT60. HU50 - - _- - -

Martensitic 1 2 2 .060 95
ASTM A217: Grade CA-15 11-19 1 .060 125 M2.M7
ASTM A296. Grades CA- 15. 20-48 1 .060 135
CA-iSM. CA-40 135 48 & Fintr 1 .030 145
ASTM A426. Grades CP7. CP9. to Annealed I ,-P
CPCA15 175
ASTM A487: Classes CA15a.
CA- 15M

For hobbing Class 9 (per AGMA 390.03) or better gears, it may be See section 16 for Cutting Fluid Recommendations.
necessary to reduce speeds and feeds by 50% and/or take 2 cuts. 'Feeds are based on the largest standard recommended hob diameter.
To meet finish requirements it may be necessary to try both conven- When using a smaller hob diameter, the Feed must be reduced pro-
tional and climb cuffing. portionally.

7-22
 Gear Hobbing 7.1

FEED' PER
DIAMETRAL REVOLUTION HOD HSS TOOL
HARD- PITCH NUMBER OF SPEED MATERIAL
MATERIAL NESS CONDITION ,. T'_ OF WORKPIECE

18. STAINLESS STEELS, CAST 1-2 2 .060 80

(cant.) 3-10 1 .060 105

Martensitic (cont.) Annealed. 11-19 1 060 115 M2 M7
175 Normalized 20-48 1 .050 125
(materials listed on preceding page)
48 & Finer 1 030 140
to or
225 Normalized r

and
Tempered M'rhQs~% - v=

1-2 2 .045 50
3-10 1 .045 70
11-19 1 .045 80 M2. M7
20-48
48 & Finer 1 .045 90
275 Quenched 1 .030 105
to
325
and
Tempered
~A 4 4 P K
=t 4 f Wt'

19. PRECIPITATION 1-2 2 .045 45

HARDENING STAINLESS 11 019 1 .025 70 M3 M42
20-48 1 .025 75
STEELS, CAST
325
ASTM A351: Grade CD-4MCu 85
to Solution 48 & Finer 1 .025
ACI Grade CB-7Cu
ACI Grade CD-4MCu T
17.4 PH 1 .06 3

1-2 1 .00 155

21. GRAY CAST IRONS
10 1 .050 10
Ferritic
11-19 1 00 210 M2.M7
ASTM A48. Class 20
SAE J431c: Grade G;800 120 20&-48 1 015 240
10 o Annealed
Aneld48 - N-
& Finer 1.015 240

150

1-2 1 .060 100

Pearlitic- Ferritic
ASTM A48: Class 25 3-10 1 .050 110
11-19 1 .030 130 M2, M7
SAE J431c: Grade G2500 1 .015 135
1020-48
16 48 & Finer 1 .015 150
-- 0
toAs Cast
200

Pearlitic 1-2 1 060 75

ASTM A48: Classes 30. 35.40 113-19 1 .030 95 M. M7
11-19 1 .030 9 M0
SAE J431c: Grade G3000 1
190 2-81.1
19 48 & Finer 1 .015 120

220

For hobbing Class 9 (per AGMA 390.03) or better gears, it may be See section 16 for Cutting Fluid Recommendations
necessary to reduce speeds and feeds by 50% and/or take 2 cuts *Feeds are based on the largest standard recommended hob diameter.
To meet finish requirements It may be necessary to try both conven- When using a smaller hob diameter, the Feed must be reduced pro-
tional and climb cutting. portionally.

7-23
7.1 Gear Hobbing
FEEDIPER
DIAMETRAL REVOLUTO 0B HSS TOOL
HARD- PITCH NUMBER OF SPEED MATERIAL
MATERIAL NES CONDITION ___a OF 0ORKPIECE
NSS ;& E CUTSinfm AS
Bhn __ infpRAS
21. GRAY CAST IRONS (cont.) 1-2 2 .060 60
Pearlitic, + Free Carbides 3-10 1 .050 65
ASTM A48 Classes 45. 50 11-19 1 .030 75 M2. M7
SAE J431c- Grades G,1500. 220 20-48 1 .020 80
G4000 to
I48
As Cast
&Finer 1 015 90
--

Pearlitic or Acicular + Free 1-2 2 060 40

Carbides 3-10 1 050 45
ASTM A48. Classes 55. 60 11-19 1 030 55 M2.M7
As Cast 20-48 1 .020 60
250 or 48 &Finer 1 015 70
to Q u en c h ed -_X w _ M_ -.

Tempered - V

345611-19 1 .030 120 M2. M7

Fo obig
lss9(prAGA3 0.0orbttr0ar.imyb4 Seseto 16 for Cutn70iecmedtos
0

nv-~~~ - -____-o _
 Gear Hobblng 7.1

FEED* PER
DIAMETRAL REVOLUTION HOB HSS TOOL
HARD- PITCH NUMBER OF SPEED MATERIAL
MATERIAL NESS CONDITION OF WORKPIECE
CUTS n AS,

Bhn in 01m IS
1-2 1 .060 60
Pearlitic- Martensitic
ASTM A536 Grade 100-70-03 3-10 1 050 65
11-19 1 030 70 M2.M7
SAE J434c Grade 07003 20-48 1 .020 80
240 Normalized 48 & Finer 1 .015 90
to and . .~
300 Tempered

11-2 1 .060 35
Martensitic
ASTM A536 Grade 120-90-02 3-10 1 .050 50
SAE J434c Grade DQ&T 20-48 1 .020 70
270 Quenched 48 & Finer 1 .015 80
to and E R --M'
330 Tempered 07 XN___M1- MNE-M

Austenitic (NI-RESIST 1-2 11 035 45

50
Dutl)3-10 .030
Ductile) 11-19 1 .020 60 M2. M7
20-48 1 .020 65
ASTM A439- Types D-2. D-2C. 006
D-3A. D-5 120 2-4
48 & Finer 1 .015 75
ASTM A571: Type D-2M to Annealed -
200

1-2 1 .035 40
Aumfenitic (NI-RESIST
Dutl)11-19 3-10 11 .030
.020 45
55 M2. M7
ASTM A439: Types D-2B. D-3.
.
-4. -B to
140 Anae
Annealed 48 & Finer 1 .015 70
275 0:1

24. MALLEABLE CAST IRONS 1-2 1 .060 2

Ferritic 3-10 1 .050 225
11-1 1 .030 260 M2. M7
ASTM A47: Grades 32510,
110 20-48 1 .020 270
35018
to Malleablized 48 & Finer 1 .015 300
ASTM A602: Grade M3210
SAEJ158: Grade M3210 160

1-2 1 060 125

Pearlitic
3-10 1 .050 150
ASTM A220: Grades 40010.
11-19 1 .030 175 M2, M7
45006. 45008, 50005
160 Malleablized 20-48 1 .020 180
ASTM A602: Grade M4504,
to and 48 & Finer 1 .015 200
M5003
SAE J158: Grades M4504. 200 Heat -- a --.

M5003 Treated

For bobbing Class 9 (per AGMA 390 03) or better gears. It may be See section 16 for Cutting Fluid Recommendations.
necessary to reduce speeds and feeds by 50% and/or take 2 cuts. *Feeds are based on the largest standard recommended hob diameter.
To meet finish requirements It may be necessary to try both conven- When using a smaller bob dfameter. the Feed must be reduced pro-
tional and climb cutting portionally.

7-25
7.1 Gear Hobbing
FEED PER
DIAMETRAL REVOLUTION HOB HSS TOOL
HARD- PITCH NUMBER OF SPEED MATERIAL
MATERIAL NESS CONDITION OF WORKPIECE
UI.:CUTS
r .. C. -:in fpm AIst
Shn 112 -S_:00l 2I S~0_
24. MALLEABLE CAST IRONS 1-2 1 CSO 100
(cont.) 3-10 1 050 120
Pearlitic (cont.) V1-19 1 030 140 M2. M7
Malleabized 20-48 1 .u20
u 150
(malenals listed on preceding page) 200
to and 48 & Finer 015 160

Tempered
ASTM Martensite121.009
A220- Grade 60004 3-10 1 050 110

ASTM A602 Grade M5503 1-19 1 030 130 W2 M7

SAE J158. Grade M5503 200 Malleabhized 20-48 J-t , -. - 1:
- -- .020 r 140
37:-
to and 48 & Finer 1..... .015 & ISO
S -2.-
255 Heat
Treated

Tempered Martensite 1-2 1 ,060 85

ASTM A220. Grade 70003 3-10 1 j .050 105
ASTM A602 Grade M7002 11-19 1 .030 125 M2. M7
SAE J158. Grade M7002 220 Maileablized 20-48 1 .020 135
to and 48 & Finer 1 1 145
-eat 4. 1t -

Treated wR KRM

Tempered Marwensite -2 1 .060 85

ASTM A220. Grade 80002 260 ~Healti 3-10 ~ 1 1 .050 100
ASTM A602: Grade M8501 11-19 1 .030 125 M2,M7
SAE J158: Grade M8501 240 Malleablized 20-48 1 .020 130
to and 48 & Finer 1 .015 140

Treated -

Tempered Marteite -2 1 .060 70

Heal mg N.2 1
ASTM A220: Grade 90002 20
A602:
ASTMJ158 Grade M8501 11-19 1 .033 110 M2. M7
SAE Grade M8501 250 Malleablized 20--48 1 .020 120
to and 48 & Finer 1 .015 130

Treated I W-1
I

For obbmg Class 9 (per AGMA 393.03) or bel1er gears. itmay be See section Cuting Fluid
16 for Recomrrendetions.
necessary to reduce speeds and feeds by SC0% and/or take 2 cuts *Feeds are hase on the largest strldard recommended hob diamet.
To meet finish requirements it may be neccssarv to try both conven. When using a smaller hob diameter. the Feed must bereduced po
porbonally.
ionaland climb cutting&

7-26
 Gear Hobbing 7.1
F FEED-PER
DIAMETRAL REVOLUTION HOB HSS TOOL

HARD- PITCH NUMBER OF SPEED MATERIAL

MATERIAL NESS CONDITION OF WOKPIECE
'hn_ CUTS
C in fpm AISI

1 1 850
13-0
28. ALUMINUM ALLOYS, 1-2 00
WROUGHT 1 050 900
11-19 1 030 1000 M2.M7
CC 2218 5252 253 30 20-48 1 020 1050
1060 22!9 5254 6262 to Cold 48 & Fine, 1 015 1150
1100 2618 5454 6463 80 Drawn251 -=5O
1145 3003 5456 6951 500kg ~1t> --- IA2 - 27
1175 3004 5457 7001
'-
1235 3005 5652 7004 i w.
- - <4 t5--- ..........
2011 4032 5657 7005 I --. -"- =--io
2014 5005 6053 7039 1 2 1 060 800
2017 5050 6061 7049 3-10 1 050 850
2018 5052 6063 7050 11-19 1 .030 950 M2.M7
2021 5056 6066 7075 75 Solution 20--48 1 .020 1000
2024 5083 6070 7079 to Treated 48 & Finer 1 .015 1100
2025 5086 610' 7175 150 and '-' r-.- 4=jw--
2117 5154 6151 7178 500kg Aged I " - -EO

29. ALUMINUM ALLOYS, CAST 1-2 1 .060 700

113-19 1 .030 850 2. 7
Sand and Permanent Mold
A140 319.0 3570 A712.0 40 20-48 1 .020 900
201.0 328.0 359.0 D712.0 to 48 & Finer 1 .015 1000
2080 A332.0 84430 7130 100 As Cast .t -z .t
213-0 F3320 514.0 771.0 500kg
2220 333.0 A514.0 850.0
2240 354.0 B514 0 A8500 -
2420 355.0 5200 8850.0
295 0 C355 0 53510
82950 3560 705.0 10 1 050 70
3080 A356.0 7070 11-19 1 .030 850 M2 M7
Hidurniniur RR-350 701 .3 50 M.M
70 Solution 20-48 1 .020 900
to Treated 48 & Finer 1 .015 1000
125 and R I M1jr - -i-=
_
500kg Aged

34. COPPER ALLOYS, 310 1 .050 650

WROUGHT 11-19 1 .030 700 M2, M7
145 332 360 482 20-48 1 .020 750
147 335 365 485 10%R 48 & Finer 1 .015 800
173 340 366 544 1o Annealed
187 342 367 623 70 RB
191 349 368 624 . .....
314 350 370 638 --
316 377 642 ..
330 356 385 782 1-2 1 060 650
3-10 1 .050 1 700
11-19 1 .030 750 M2. M7
20-48 1 .020 800
60 cold 48 & Finer 1 .015 850
100 R Drawn

For hobbing Class 9 (per AGMA 390 03) or oetter gears, itmay be See section 16 for Cutting Fluid Recommendations.
necessary to reduce speeds and feeds by 50% end/or take 2 cuts. -Feeds are based on the largest standard recommended hob diameter.
To meet finish requirements itmay be necessary to try both conven- When using a smaller hob diameter, the Feed must be reduced pro-
tional and climb cutting. portionally.

7-27

-I
7.1 Gear Hobbing
i j FEED' PER *
DIAMETRAI. REVOLUTION NOB HSS TOOL
HARD- PjrCH NUMBER OF SPEED MATERIAL
MATERIAL NESS CON1DITION OF WORKPIECE
: CUTS
ISOCU t z in fpm AISI
1-2 060 250g
1-2 I 060 250
34. COPPER ALLOYS,
3-10 1 050 300
WROUGHT (can) I11-19 1 .030 350 2. M7
190
226
425
435
466
467
667
675 10R
20-48
48&Fner
1
1
j .020
.015
400
450
230 442 613 687 to Anneaied
240 443 618 694 70 R. C 150-. <-- -

260 444 630 770 r-- 2152_tS ;__ v

268 445 632 -
270 464 651 F -t-. - ;6 a4
280 465 655 1-2 1 .060 300
3-10 1 .050 350
11-19 1 .030 400 M2. M7
20-48 1 .020 450
60 R8 Cold 48 & Finer 1 .015 500
to Drawn -- c-ir---c-
100ne gq

1-2 1 .060 100

101 125 185 614 3-10 1 .050 110
102 127 189 619 11-19 1 .030 130 M2.1M7
104 128 192 625 20-48 1 .020 135
105 129 194 674 10a 48 & Finer 1 015 150
107 130 195 688 to Annealed F --
109 142 210 706 70 Re
110 143 220 710- ,f - -5 t
111 150 411 715 - -

113 155 413 725 __ __.- _ .

___., _-_ _-_
114 162 505 745 1-2 1 .060 125
115 165 510 752 3-10 1 .050 150
116 170 511 754 11-19 o03 160 M2.47
119 172 521 757 20-48 1 .020 180
120 175 524 60 20l48 1 .020 10
121 182 608 to Cold 48& Finer 1 015 200
122 184 610 100 Drawn tVKWW

35. COPPER ALLOYS, CAST 121.6 0

3-1-I0 1 .050 700
834 855 934 953 11-19 1 .030 800 M2. M7
836 857 935 954 40 20-48 1 .020 900
838 858 937 956 to 48& Finer 1 .015 950

844 i.67 939 974 500kg __

848 879 943 976
852 928 944 978
854 932 945
1-2 1 .060 250
817 874 925 3-10 1 .050 300
821 875 926 11-19 1 .030 350 M2.M7
833 876 927 40 20-48 1 .020 400
853 878 947 to 48 & Finer 1 .015 450
861 903 948 175 As Cast
862 905 952 500kg
865 915 955
868 922 957
872 923 958

For hobbing Class 9 (per AGMA 390 03) or better gears. t may be See section 16 for
Cutting Fluid Recommendations.
necessary to reduce speeds and feeds by 50% and/or take 2 cuts -Feeds are based on the largest standard recommended hob diameter.
To meet finish requirements it may be necessary to try both convea- Whe, using a smaller bob diameter, the Feed must be reduced Pro
tional and climb cutting portionJy.

7-28
 Gear Hobbing 7.1

i TMERA IMT:" NUBE

FEDrPER
REVOLUJTION HOB HSS TOOL
MATERIAL HR- CONDITION OFHNUME OF jSPED MAEI.

NESSur WORKPIECE I 1m AS

8 8 15 1
80 1- 2 I 1 .060 100

tsU5 .20 902 962 401 11-19 I 030 1 301 W 1Z.17

C20-48 1 020 13
807 822 907 -- -3 to 48 &Fine, 1 .015 150
809 824 9090 964 200 As Cast -
811
813
814
825
826
827
91 0
911
913
966
99:
l500kg

'
[ --
-
1 7--
.

rt~

Fm .;I
j

For hobbing CUas9 (per AGIAA 390 03) or better gears. it ay be See sectioni 16 for Cutun Flud ev nmaons.
necessary to reduce speds and feeds by 50% andl/of take 2 cuts. *Feds are basfed on the larges standad recoaumended hob diarueWe.
To mee finish requireivents it may be necessary to try both coriwn- Whe using a iniusller hob dwwameter,h Feed must be reduced pro-
borst and climb cuttig portionaly.

7-29j
 EO~IG PACE BL"ka-NQP FILMh

Gear Cutting, Straight and Spiral Bevel 7.2

CUTTING SPEED - "HSSTOOL

CONDITION ROUGHING FINISHING MATERIAL
MATERIAL HARD-
NESS fpm tpm AISI

L Bhn _-____f tmid 5.S- : s-c,_

1. FREE MACHINING CARBON STEELS,
WROUGHT 100 Hot 125 250 M2. M7
Low Carbon Resulfurized to Rolled yo - -- - '
1116 1118 1211 150 or n"01rvMEN
1212 Annealed YEN
1117 1119

150 140 275 M2, M7

to Cold
200 Drawn

Low Carbon Resulfurized

100 Hot 140 275 M2. M7
1213
1215 to Rolled __ ____
150 or
Annealed

150 145 290 M2,M7

to Cold
200 Drawn

Low Carbon Resulfurized

Hot 110 225 M2. M7
1108 100
1109 to Rolled
1,0 150 or
1 Annealed

150 125 250 M2, M7

to Cold
200 Drawn I U

Medium Carbon Resulfurlzed Hot

1145 175 Rolled, 85 175 M2,M7
1132 1140
1137 1141 1146 to Normalized,
114
113 151225 Annealed

275 Quenched 70 140 '42,M7

toanI
325 Tempered - - -.-

325 Quenched 50 100 M3

375 Tempered

Low Carbon Leaded Hot

100 Rolled, 140 275 M2.M7
101-18
1 1L17 to Normalized,
150 Annealed

Hot
150 Rolled, 130 265 M2.M7
to Normalized,
200 Annmaled
or Cold
B
Drawr,

Cutting speed recommendations are for use with Alternate-Tooth

Milling Cutterr or Gea Generators.
For Planer-Type Generators use the recommended cutting speeds In
section 7 3 Gear Shaping.
See section 16 for Cutting Fluid Recommendations. 7-31

m . m =1 1 ...
: ... . . ... . ..- , .. ... ..
7.2 Gear Cutting, Straight and Spiral Bevel
CUTTING SPEED HSS TOOL
HARD- CONDITION ROUGHING FINISHING MATERIAL
MATERIAL fpm fpm AISI
NESS
_________________ Bhn __________ Th 1n m r 18soidNz

1. FREE MACHINING CARBON STEELS, Hot

WROUGHT (cont.) 200 Rolled. 110 220 M2.M7
Low Carbon Leaded (cont.) to Normalized,
250 Annealed m
(materials listed on preceding page)
or Cold uZ- ,
Drawn

Low Carbon Leaded Hot

100 Rolled, 145 290 M2. M7
12113
12L 14 to Normalized,
Annealed m-,_ -

1L5or Cold A.pr 4~Z

Drawn .NY S

Hot
150 Roiled, 145 290 M2,M7
to Normalized,
200 Annealed ,V5M
or Cold
Drawn y S41A.4

Hut
200 Rolled, 110 225 M2.M7
Normalized,
to
Annealed
orAMU 02aw -N 10
250

Medium Carbon Leaded Hot _.W

or Cold W; _R..
10145 125 Rolled, 110 225 M2,M7
10L50 to Normaized.
11 L37 175 Annealed e .A i~ .
11 L41 Drawn -A,

11L44 __________ .~~w,

Hot
175 or Cold
Rolled, 100 200 Ila_". M2,M7 "
to Normalized.
225 Annealed_.

Drawn 101-*
225 Annealed, _-
Hot Rolled.

IU
22 Normalized, 90 175 M2, M7
to Cold Drawn

275 Quenched -N '

225 Annealed, 9 7 2M
Tempered
Hot Rolled.
.. v.
Normalized, 80
325 or
to Cold Drawn
325 Quenched
and
Tempered -

to ~ Coldrw

2. CARBON STEELS, WROUGHT Hot

Rolled, 90 190 M2.M7
Low Carbon 85
1005 1012 1019 1026 to Normalized,
1&06 1013 1020 1029 125 Annealed

1008 1015 1021 1513n

1009 1016 1022 1518
1010 1017 1023 1522 Hot
1011 1018 1025 125 Rolled. 90 190 M2, M7
to Normalized.
175 Annealed
ol Il1

Culling speed recommendaions arc for use wih Alternate-Tooth

MillIng Cutters or Gear Generators
For 7,3Gear Generators
Planer-Type
sectIon Shaping. use the recommended cutting speeds In
See section 16 tor Cutting Fluid Recommendations 7-32

. w MCutters
.ling i, o r a
 Gear Cutting, Straight and Spiral Bevel 7.2
CUTTING SPEED HSSTOOL
HARD- ROUGHING FINISHING MATERIAL
MATERIAL CONDITION
NESS fpm fpm AISI
B,,, _ _ Mn ... ....
2. CARBON STEELS, WROUGHT (cont.) Hot
Low Carbon (cont.) 175 Rolled 80 165 M2,M7
(materials listed on preceding page) to Normaized.
225 Annealed F, j w- ?
Drawn
orCold M -1 '4 , - -"' - R
-

225 Annealed 70 145 M2. M7

tO Or
275 ColdV i v u wa
Drawn 1 O

Medium Carbon Hot

125 RnJ. 85 175 M2. M7
1030 1042 1053 1541
1033 1043 1055 1547 to Annealed
Normalized,
1548 175 onnold " _Q
1035 1044 1524
1037 1045 1525 1551 Drawn
1038 1046 1526 1552
1039 1049 1527 Hot
1040 1050 1536 175 Rolled. 75 155 M2, M7
to Normalized,
225 Annealed -10MR
or Cold ,-s
Drawn
Hot Rolled,
Normalized, 70 145 M2, M7
225 Annealed,
t3 Drawn
Cold or ' - -
275 Quenched
and
Tempered k- - ;Mt- -
Hot Rolled,
Normalized. 60 125 M2,M7
2/5 Annealed
to or
325 Quenched ~ ' , .. - .
and - -
Tempered I

50 100 M3
to Quenched
375 and
Tempered "

High Carbon Hot

175 Rolled, 70 145 2.M7
1060 1074 1085 1566
1075 1086 1572 to Normalized.
1064
1065 1078 1.. 225 Anae
or C2l
1069 1030 1095 Drawn
1070 Iced 1o6
Hot Rolled.
Normalized. 65 130 M2. M7
225 Annealed,
to Cold Drawn
275 Quenched
and
Tempered
Hot
Rolled. F^ M2,M7
275 Normalized.
to Annealed
325 Quenched
and
Tempered

325 Quenched
to and
375 Tempered 21

Cutting speed recommendations are for use with Alternate-Tooth

MillingCutters or Gear Generators.
For Planer-Type Generators use the recommended cutting speedt In
section 7.3Gear Shaping.
See section 16 forCutting Fluid Recommendations 733
7.2 Gear Cutting, Straight and Spiral Bevel

I - -CUTTING SPEED HSS TOOL

MAERA HAS ODTO ROUGHING FINISHING MATERIAL
MATERIAL fpODIINmp AISI

3. CARBON AND FERRITIC ALLOY STEELS

(HIGH TEMPERATURE SERVICE) 150 85 175 M2.M7
ASTM A369. Grades FPA, FPB, FPi. FP2. t0 As
FP12 200 Forged S4kS2,

ASTM A369 Grades Fi3b. FPi1V1 Annealed 75 150 M2M7

iLO of
to Normalized
200 and S <'S2
:?ti
Tempered_

ASTM A369. Grades FP5. FP7. FP9. FP2 1. Annealed 70 140 M2.M7
FP22 150 or
to Normalized
200 and
Tempered __ ~
4. FREE MACHINING ALLOY STEELS, Hot
WROUGHT 150 Rolled, 85 175 M2. M7
Medium Carbon Resulturized 1o Normalized,
Annealed
4140 4142Te 4147Te 200 or Cold :-4
4140Se 4145Se 4150 Drawn _

Hot
200 Rolled. 75 155 M2, M7
to Normalized.
250 or Cold __

_ _Drawn I_ _ _

275 Quenched 65 135 M2, M7

10 and
325 Tempered g_r

325 Quenched 4 5M
to and~--
75Tempered z~

Medium and High Carbon Leaded Hot

411-30 41L50 861-20 150 Rolled. 85 175 M2. M7
411-40 431-40 861-40 to Normalized.
41L45 5IL32 200 Annealed -
41L47
100or 2L Cold'
41-7 5LG rawn _ _ _ _ _ _

Hot
200 Rolled. 75 155 M2. M7
to Normalized.
250
250
Annealed ~
or Cold
Drawn

275 Quenched 65 135 M2, M7

325 Tempered

325 Quenched 4 0M
10 and
375 Tempered

Cutting speed recommendations are for use with Alternate-Tooth

Milling Cutters or Gear Generators.
For Planer-Type Generators use the recommended cutting speeds in
section 7,3 Gear Shaping.
See section 16 for Cutfng Fluid Recommendations. 7-34
 Gear Cutting, Straight and Spiral Bevel 7.2

CUTTING SPEED HSS TOOL

MATERIAL HARD- CONDITION ROUGHING FINISHING MATERIAL
NESS fpm fpmn AISI
Bhn m mSOK
S. ALLOY STEELS, WROUGHT Hot
Low Carbon 125 Rolled. 85 175 M2. M7
4012 4615 4817 8617 to Annealed -- _ ___

4023 4617 4820 8620 175 Corld

4024 4620 5015 8622 Drawn ii~ -,-
4118 4621 5115 8822 ______- ~ ______

4320 4718 5120 9310 Hot

4419 4720 6118 94B15 17Rotd 75 150 M2, M7
4422 4815 6115 94617 to Annealed
225 o
Cold
Drawn

Hot
25Rotted. 65 130 M2,M7
to Normalized. _______

25Annealed gp *-
or Cotd
Drawn 1z NNaMMN

No.,malized 60 120 M2 M7
275 or
to Quenched
325 and
Tempered W
35Normalized 50 100 M3
325 or
to Quenched
35and __

Tempered -

Medium Carbon Hot

1330 4145 5132 8640 175 Rolled. 65 135 M2. M7
1335 4147 5135 8642 to Annealed
1340 4150 5140 8645 225d orfi
1345 4161 5145 86845 Drawn
4027 4340 5147 8650 _____________ '-

4028 4427 5150 8655 Annealed

4032 4626 5155 8660 25Normalized. 60 125 M2. M7
4037 50840 5160 8740 Coo Drawn
4042 50844 51B60 8742 275 Quenched
4047 5046 6150 9254 and
4130 50846 81845 9255 ______Tempered______________ ______

4135 50850 8625 9260

4137 5060 8627 94830 25Normalized5510M.M
or7 5 1 M.M
4140 50860 8630
4142 5130 8637 to Quenched ;tA
325 and R
Tempered 0s__

Normalized 50 100 M3
325 or
to Quench~ed
35and
Tempered

High Carbon Hot

50100 175 Rolled,.015M.M
510to Annealed
52100 225 o
M-50Drw

Normalized.
225 Cold Drawn5010M,7

275 Quenched 5
and
Tempered
Cutting speed recommendations are for use with Alternate-Tooth
Milling Cutters or Gear Generators.
For Planer-Type Generators use the recommended cutting speeds In
section 7 3 Gear Shaping.
See section 16 for Cutting Fluid Recommendations 7-35
7.2 Gear Cutting, Straight and Spiral Bevel
CUTTING SPEED HSSTOOL
MATERIAL HARD-
NESCONDITION C IOUGHING fmfmAS FINISHING MATERIAL
NESS fpm I pm AISI
Bhn _0WAF 0__ I r
5. ALLOY STEELS, WROUGHT (cont.) Normalized 45 90 M2, M7
High Carbon (cont.) 275 or
(materia!s listed on preceding page) to Quenched
325 and K U
Tempered t _ -

325 Normalizeo 40 80
or M3
to Quenched i r -
375 and_
Tempered t4

6. HIGH STRENGTH STEELS, WROUGHT

300M 988V40 225 45 90 M2. M7
4330V 06ac to Annealed
4340' O 300 z.
4340 ~Hil~~*$ a
4340St H13 I -11 -- 'I,_
_______

300 40 80 M2. M7
to Normalized
350-

HP 9-4-20 40 80 M2. M7
HP 9-4-25 325
HP 9-4-30 to Annealed ,.

HP 9-4-45 375 -

7. MARAGING STEELS, WROUGHT

120 Grade 275 60 120 M2.M7
180 Grade to Annealed
325

ASTM A538- Grades A. B. C so 100 M2,M7

200 Grade 275
250 Grade to Annealed
300 Grade 325 SON
350 Grade
HY230

8. TOOL STEELS, WROUGHT

High Speed 200
M1 M10 T6 1o Annealed
M2 TI 250
M6 T2

High Speed
IM3-1 M33 M43 T5 225
M3-2 M34 M44 T8 to Annealed
M4 M36 M46 T15 275
M7 M41 M47
M30 M42 T4

I' R
Cutting speed recommendations are for use with Alternate-Tooth
Milling Cutters or Gear Generators

f-
For Planer-Type Generators use the recommended cutting speeds in
section 7.3 Gear Shaping.
See section 16 for Cutting Fluid Recommendations. 7-36
 Gear Cutting, Straight and Spiral Bevel 7.2

CUTTING SPEED HSS TOOL

MATERIAL M HARD-
NESCONDITIONfrnpmAS ROUGHING FINISHING MATERIAL
NESS fpM fpm AISI
Bhn - ______ CAW_________
Hot Work
150 80 160 M2.M7
H10 H19 H25
H1l H21 H26 to Annealed
H12 H22 H42 200 OEM-- --

H13 H23_____ L t-;A4Z _ _ -__, _-~

H14 H24 __-_'-_'-_- -

65 130 M2. M7
200
to Annealed .
250

325 Quenched 45 95 M3
to and -

375 Tempered WE -P

Cold Work
65 130 M2.M7
A2 A9 D7 200
A3 A10 01 to Annealed
A4 D2 02 250 K_
A6 D3 06 ____

A7 D4 07 __" .__
A8 D5

Shock Resisting 74"

S1 S6 175 70 145 M2,M7
$2 $7 to Annealed ~_____
$5 225 _ _/

Mold
P2 100 90 180 M2. M7
P4to Annealed -~=
P5 150 -_r -
P6 1

P20 150 80 165 M2.M7

P21 to Annealed -
200

Special Purpose
L2 150 70 145 M2.M7
L6 o Annealed --
L7 200 1

Special Purpose
200 65 135 M2.M7
F1
F2 to Annealed
250

Water Hardening
W1.W2.W5 150 90 180 M2.M7
SAE J438b. Types W108. W109. W110, to Annealed
Wi 12. W209. W210, W310 200

Cutting speed recommendations are for use with Alternate-Tooth

Milling Cutters or Gear Generators.
For Planer-Type Generators use the recommended cutting speeds In
section 7.3 Gear Shaping.
See section 16 for Cutting Fluid Recommendations. 7-37
7.2 Gear Cutting, Straight and Spiral Bevel
CUTTING SPEED HSS TOOL
HARD- ROUGHING FINISHING MATERIAL
MATERIAL NESS CONDITION fpm 1pm AISi
Bhn _ _ _ _ _ _ _ _ _ _ _

9. NITRIDING STEELS,'WROUGHT
200 65 130 M2.M7
Nitralloy 125
Nitralloy 135 to Annealed
Nitralloy 135 Mod 250 K
Niraloy 225 - #
Ntralloy 230
Ntralloy EZ Normalized 55 110 M2.M7
Notralloy N 300 of
Nitrex 1 'o Quenched ts -r-' Z .2 _,a
_.
350 and ______ ~

12. FREE MACHINING STAINLESS STEELS,

WROUGHT 135 85 175 M2 M7
Ferritic to Annealed
4301F 185
430F' Se- -

Austenilic
135 60 150 M2.M7
203EZ 303Pb
303 303 Plus X to Annealed
303MA 303Se 185 A- I_107M__&

65 135 M2.M7
225
to Cold

Martensitic
416 420F Se 135 85 175 M2.M7
416 Plus X 440F' 1o Annealed
416Se 440F Se 185
420F

185 Annealed 75 155 M2,M7

to or

Drawn
240 Cold2 M

275 Quenched
to and
325 Tempered

13. STAINLESS STEELS, WROUGHT

Ferritic 135 75 150 M2.M7
405 430 442 to Annealed - -

409 434 446 185

429 436

Austenitic
321 385 135 60 120 M2.M7
201 304
202 304L 347 to Ar.nealed
301 305 348 185
302 308 384

225
to Cold
275 Drawn

1 4
Cutting speed recommendations are foruse with Alternate-Tooth
Milling Cutters or Gear Generators.
For Planer-Type Generators use the recommended cutting spe .s In
section 7 3 Gear Shaping.
See section 16 for Cutting Fluid Recommendations 7-38
 Gear Cutting, Straight and Spiral Bevel 7.2

CUTTING SPEED HSS TOOL

MATERIAL HARD- CONDITION ROUGHING FINISHING MATERIAL
NESS fpm tpm AISI

AusteniticI
302B 310S 317 135 50 100 M2.M7
309 314 330 to Annealed -- RK.U i x
309S 316 185 M -M, -

225 45 90 M2, M7
to Cold
275 Drawn

Austenitic I_______________________________

Nitronic 32 Nalronic 50 210 4010)2 M7

Nitronic 33 Nitronic 60 to Annealed
Nitronic 40 250

Martenaitic
403 422 135 75 150 M2. M7
410 501 to Annealed
420 502 175

175 70 140 M2.M7

to Annealed ~~_______
225 I

275 Quenched 55 110 M2.M7

to and
Tempered

Martensitic
414 225 60 120 M2.M7
431 to Annealed
Greek Ascoloy 275 MI W- _P-

275 Quenched5510M.7
to and
325 Tempered

Martensitic
44A2555 115 M2. M7
4408 toAnnealed
440C 275 -

275 Quenched 5 5M.M

325 Tempered X

Cutting speed recommendations are for uae with Alternate-Tooth

Milling Cutters or Gear Generators
For Planer-Type Generators use the recommended cutting speeds In
section 7.3 Gear Shaping.
See section 16 for Cutting Fluid Recommendations 73
 ~~~~
-~ . ~~
MR::&z; , ,

7.2 Gear Cutting, Straight and Spiral Bevel

CUTTING SPEED
MATERIAL HARD- GSE - HSTO
NESS CONDITION ROUGHING FINISHING MATERIAL
Shn fpm fpm AISJ
14. PRECIPITATION HARDEING
STAINLESS STEELS, WROUGHT 50
15-5 PH to Solution
16-6 PH 200 Treated
17-4 PH-
17-7 PH
17-14 Cu Mo
AF.71
AFC-77 Ala 6 A-6)to 275 Solution
Treated 45 95 M2,M7
AlM-r360 -32 325 or --
AM-350
AM -355
n di tad
;.
. .1 ,Yr:r
1L
AM-363
Custom 450
Custom 455
325 Solution 40 85 M3
HNM tO Treated
PH 13-8 Mo 375 or - -
PH 14-8 Mo
Hardened... .
PH 15-7 Mo
Stainless W

15. CARBON S-TEEILS, CASTAn

e e , " --- --

Ca rboGrade-
Lo wA426-
ASTM n r f u i n Nr a ed
CP1 0oraie
1o 910S M2. M7

0i0 150 Normazed

1020 and
-TMedi,.um Carbon Tempered
Annealed.

I
ASTM A356 Grade to or
F-ud Rcommndaons7-4
1030
1040 175 Normastzed
and 16 fr Cutin
R -IR-0
10 50 T e mp e red
.
Annealed. 4

225 Normalized
and
Tempered
,

250 Ouenched 65 135 M2. M7

300 Tempered

16. ALLOY STEELS, IATAneld

Low Carbo n A0n
on a hled8 7 M .M
,ASTM A217 Grade WC9 150 Noraie
ASTM A326Grades LCP3P. C 510M.M
Pb CP11 anr
ASTM A4 2 Grades C 3,L 200 Normalized

CP 12. CP 15. CP2 1. CP22 Tempered

1320 2320 4120 8020 A n fa et
235
41 30 8620 200 Normalizedl 70 145 M2. M7

225 Norma~zed
and
Tempered

250 Ouenched J 65 130 M2. M7

300 Tempered

C ut t in g s e d r c m e d t o s a re fo r u se w ih A lt r a ? T oh
Milling Cutters or Gear Generators
For Plane-Type Generators use the recommended
cuttng speeds in
section 7 3 Gear Shaping.
See section 16 for Cutting Fluid Recommendations
7-40
 = - 7

Gear Cutting, Straight and Spiral Bevel 7.2

I CUTTING SPEED HSS TOOL

MAERA HARD- CNIONROUGHING FINISHING MATERIAL
NESS fpm fpm AISI
j Bhn __ _ _ _ _ __ _ _ Or
Medium Carbon Annealed,
ASTM A27- Grades Ni. N2. U-60-30. 60-30. 1751 Normalized. 70 145 M2. M7
65-35. 70-36, 70-40 to or
ASTM A148 Grades 80-40, 80-50. 90-60. 225 Normalized ~_
105-85. 120-95. 150-125. 175-145 and -. '
ASTM A2 16 Grades WCA. WCB. WC TepId-
ASTM A217 Grades WC 1. WC4. WC5. WC6 Normalized.
Grades
LC2-CC
1Normalized
1.LC2. 6 3 2M
ASTM A352-Gae C.L2L21 225 and6515M.7
ASTM A356. Grades 2. 5. 6,8. 9. 10 toTempered -

ASTM A389: Grades C23. 024 25ornce ~1~-

ASTM A486, Classes 70. 90. 120 and
ASTM A487. Classes IN, 2N. 4N, 6N. 8N. 9N. Tempered _____

ION. DN. 10. 20. 40 40A 60.,70.890.

90. 100 250 Quenched 65 130 M2. M7
1330 4130 80830 8640 1O and
1340 4140 8040 952530Teprd IW
2325 4330 8430 9530 Temere
2330 4340 840 9535 __________________

4125 8030 8630

300 Quenched 55 115 M2. M7
10 and
350 Tempered

350 Quenched 5010M4.3

10 and
400 Tempered

18. STAINLESS STEELS, CAST

Fairritic 1357510M.7
ASTM A217: Grades C5. C12 to Annealed - -
ASTM A296: Grades C13-30. CC-50. CE-30. 185 'W
CA6N. CA-6NM. 004 MCu
ASTM A297: Grade HC -

ASTM A487. Class CA6NM

ASTM A608- Grade 'I030

Austenitic
ASTM A296: Grades CF-16F. CN-7M. 140 Annealed70152.M
CN-7MS to0o
ASTM A35 1: Grade CN-7M 170 Normalized-

Austionitic: 010M.M
ASTM A296, Grades CF-3, CF-8, CF-8C. 135 Annealed
CF-20 to o
ASTM A351: Grades CF-3. CF-3A. CF-8. 185 Normalized-
CF-8A. CF-8C
ASTM A451i: Graaes CPF3. CPF3A. CPF8.
CPF8A. CPF8C. CPF8C (Ta Max)
ASTM A452: Grades TP 304H. TP 347H

Cutting speed recommendations are for use virlh Altemate-Tooth

Milling Cutters or Gear Generators.
For Planer-Type Generators use the recommended cutting speeds in
section 7.3 Gear Shaping.
See section 16 for Cutting Fluid Recommendations. 7-41
7.2 Gear Cutting, Straight and Spiral Bevel

CUTTING SPEED HSS TOOL

MATERIAL HARD-
NESS
CONDTION ROUGHING
1p
1FINISHING MATERIAL
1 fpm AISI
_____________________ hn min- ISOX

18. STAINLESS STEELS, CAST (cont.)

Austenitic 135 Anrnealed 50 00 M17
ASTM A296. Grades CF-3M. CF-8M. CG-8M.. to or
CG>12. CH-20. CK-20 185 Normal-zed153 42
ASTM A351* Grades OF-3M. CF-3MA.
CF-8M. CF- 10140. CH-8. CH- 10. CH-20. -_____________

CK-20. HK-30. HK-40. HT-30

ASTM A451 Grades CPF3M. CPF8M.
CPF 1OMC. CPH8. CPH 10. CPH20. CPK20
ASTM A452 Grade TP 316H

Austenitic
ASTM A297 Grades HD. HE. HF. HH. I. HK, 160 so 100 M2 ?A7
HL. HN. HP, HT. HU to As Cast -
ASTM A608 Grades HD5O. HE35. H-F3O. 210 ~ ~ ~
HH3O. HH33. H135. HK30. HK4O. HL-30. 1.
HL4O. HN4O. HT5O. HU50 ___________________

Mwitensitic
ASTMA2I7 GradeCA-15 135 70 145 M2. M47
ASTM A296. Grades CA- 15. CA- 15M4. CA-40 to Annealed
ASTM A426: Grades CP7. CP9. CPCA15 175 -~~

ASTM A487- Classes CA 15a. CA- 1514 ---- P- - 44- ~ - S2Y

Annealed
175 Normrazed 65 135 M2. 147
toor____

25Normalized
and
Tempered
~ =-=
~1 srz~
2550 Quenched 105 M2. 147
275
to and ---
325 Tempered - S__

19. PRECIITATION HARDENING

STAVNLSS; STEELS, CAST 325 3 5M
ASTM A35 1: Grade CD-4MCu to Solution
ACl Grade CB-7Cu 375 Trepled F _

ACI Grade CD-4MCu

WWI____
17-4 PH
AM-355

ZZV

21. GRAY CAST IRONS

Faritic 11090 185 M42.M7
ASTM A48: Class 20 to Anne:' ---:d
SAE J431c: Grade 61800 10O WS:

Peariti- Feretic
ASTM A48: Class 25 1 75 150 M2. M7
SAE J431c: Grade G2500 to As Cast
200

Cu'~zng epeed recommendations are for ube with Aternate-Tooth

M4.:ing Cutters or Gear Ganerators.
For Planer-Type Generators use the recommended cutting speeds in
section 7.3 Gear Shaping.
See section 16 for Cutting I-itad Recommendations, 7-42
 Gear Cutting, Straight and Spiral Bevel 7.2

ICUTTING SPEED HSS TOOL

MAERA HARD- CNIONROUGHING IFINISHING IMATERIAL
NESS fpm f pm AISI

Pearlitic - h mmn jI~i~i~

ASTMV A48 Classes 30. 35. 40 190 60 120 M2, M7
SAE J *3 Ic Grade G3000 toAs Cast 77-
220

Pearlitic ~-Free Carbides

ASTM A48 Classes 45. 50 220010 2M
SAE J431c Grades G3500. G4000 to As Cast
260

Pearlitic or Acicular + Free Carbides As Cas 40 80M

ASTLI A48 Classeb. 55. 60 250 Or 2 AI
t0 Quenched
320 and
Tempered .-.

Austenitic (NI-RESIST) 4 5M.M

ASIM A436 T~oes 1, 1b. 2 2b. 3. 4. 5. 6 100 4 5M I
to As Cast -- ~
250 ~~2 2

23. DUCTILE CAST IRONS

Ferritic 140 80 160 M42.M7
ASTLI A536 Grades 60-40-18. 65-45-12 to Annealed ___RM-74
SAE J434c Grades D4018.0D4512 190 ~~.~~
________________________: NA_______
T- ____

Ferritic- Pearlitic
ASTLI A536 Grade 80-55-06 190 70 140 M42.M7
SAE J434c. Grade D5506 toAs Cast
225

225 65 130 M7
M42.
to As Cast
260 R M.f P KW

Pearlitic- Martensitic
ASTI A536 Grade 100i-70-03 240 Normalized 60 125 M42. M7
SAE J434c. Grade 07003 to and
300 Tempered

111artensitic:
ASTM A536: Grade 120-90-02 270 Quenched 60 120 M42.1M7
SAE J434c G'2dje 0O&T to and
330 Tempered 1004 Ai _ az-

Austenitic (NI-RESIST Ductile)

ASTI A439. Types D-2. D-2C. D-3A. D-5 12C 3 5 2. 147
ASTI AS? 1. Type 0-2M4 to Anir-ealed
200 IB

Austenitic (NI-RESIST Ductile)

ASTLI A439 Types 0-28. D-3. D-4. 0-58 140 3 0M.M
10 Annealed
275

Culling speed recommendations are for use with Alternate-ooth

Milling Cutters or Gehir Generators
For Planer-Type Generators use the recommirendled cuttng speeds in
section 7 3 Gear Shaping.
See section 16 for Cutting Fluid Recommendations 7-43
7.2 Gear Cutting, Straight and Spiral Bevel

MATERIAL HR-CONDITION
NES
1 f ROUGHING
CUTTING SPEED
fpni
FINISHING
1pm- 4 "$STOOL
IMATERIAL
- AISI

SA A47SGradesP32510.308t aeahc

ASTM A220 Grades,40010. 45006. 45008. 10M~aizd7 :5LZM

50005 t6o and4
SA A602- Grade M4504. tA5D03 Tr0eae ;3Es2~
SAET A602 Grade!A4504. P5003 Treate

200 Maiteabizzed 70 145 I42. M"

to ad - -d

240 Heal
Treated __

Tempere Martenst
ASTMA A220 Grade 60004 200 PMateabtzed C5130 f.12. P7
ASIA A602 Grade 1.15503 to and_____
SAE J158- Grade M45503 255 Heal 1
Treated

Tempered Mairtewisite
ASIM A220. Grade 70003 220 Malleablized 60 125 V-2, M7
ASTMA A602 Grade M7002 toand___________
SAE J158* Grade M47002 260 Heal
Treated __-4S2 -

Temaered MAwtensite
ASTM A220. Grade 80002 240 )Aateablized 60 120 1A2MI7
ASTMA602 Grade P48501 to and
SAE J 158. Grade tA8501 280 Heat
Treated- 7 - s2

Tempered Martenithe
ASTM A220 Grade 90001 250 Mateablized 55 110 M 1.4P7
ASTM A602 Gradef.4&8501 and 1
SAE J 158- -rade MM50 320 Heal=~. ~=~-
Treatea TOP4'~

23. ALUMNUM ALLOVS, WROUGHT 3 4 9 4.M

EC 2218 5252 6255 to C4o20ld2P4
.060 2219 5254 6228Oran _ _
1100 2618 5.454 6463 SOicg .~ S- ~_
1145 3003 5456 6951 _

1175 3004 5457 7001

1235 3005 5652 7004 75Slto 4 275 M42. M74
2011 4032 5657 7005 to Treated
2014 5005 6053 7039 an .

20 5050 6061 7049 500kq

2018606 7050Aged__
552
2021 5056 6066 7075
2024 5083 6070 7079
2025 5086 6101 7175 _

2117 5154 6151 7178_ __

Cutting speed recommendlatio are for use wlti Allemal*-Tooth

M4t - Cutters or Gear Generators
Fo- -ner-Type Generators use the reconwrended cuttiN speeds in
section 7.3 Gear Shapin~g
Ste section 16 'or Cutting Fluid Recomendaticn-s. 74
 Gear Cutting, Straight and Spiral Bevel 7.2

CUTTING SPEED j HSS TOOL

MTRA'NESS
MATERIAL HARD. CONDITION ROUGHING FINISHING
p IJ MATERIAL
Ip AS
NESfpm fpm j AiSi
___________________ Bhn '%________ $TnnjIf&I4itO
L-ttit
Li so-

29. ALUMINUM ALLOYS, CAST

Sand dnd Permanent Mold 40 125 250 M2. M7
to
A140 3190 357 0 A712 0 100 As Cast
201 0 3280 3590 D712,0 500kg - ... .

2080 A332.0 B4430 7130

213.0 r332 0 514 C 771 0 j .. . _-_ . .-
2220 333.0 A514,0 8500
224.0 354.0 B514 0 A850 0 70 Solution 125 250 M2, M7
242 0 355 0 520.0 6850.0 to Treated
2950 C355.0 535.0 125 and - -
500kg
125and Aged 4 ~ K.. a~4l ik7&*
R_;:1- .-
4
B295 0 3560 7050
3080 A356 0 7070 _____ _-___-____ ____ -_ -;-
Hidumninium RR-350

~~~ -. ;QWe~2y

34. COPPER ALLOYS, WROUGHT

140 285 M2 M7
145 332 360 482 10 RD
147 335 365 485 to Annealed r . - -
173 340 366 544 70 R-1

187 342 367 623 __ ____ N____

191 349 368 624
314 350 370 638
377 642 60 R 155 310 M2,M7
316 353
330 q56 385 782 to Cotd 0 -M
100 R Drawn a -

190 425 466 667 M2.M Z4

115 230
226 435 467 675o
230 442 613 687 "o Annealed *

240 443 618 694 /0 R

260 444 630 770 i\.

268 445 632

270 464 651
465 655 60 R Cold 125 255 M2.*7
280
to Drawn_-- ..
100 RD .. ..... M

101 125 185 614 00 200 M2,M.

102 127 189 519 1
104 128 192 625 to Anneal~d_0
15 129 14 674 70 H
107 130
142
195
210
688
706
51M 04_______
109
110 143 220 710
60 A G 105 215 M2,M7
i1l 150 411 715
113 155 413 725 to Cold
114 162 505 745 100 Drawn g
115 165 510 752 S I
16 170 511 754 W
119 1/2 521 757
120 175 524
121 182 608 _
122 184 610 30 WINs

Cuttingspeed recn)mmendations are foruse withAlternate-Tooth

Mitting orGear Generators
Cutters
speeds In
Generators use therecommended cutting
For Plane:r-Type
7.3 Gear Shaping
section 74 -1- fg-<T IBM -
SSee section
18for
CuffingII
Fluid
Recommendations 4
7.2 Gear Cutting, Straight and Spiral Bevel

CUTTIN3 SPEED HSS TOOL

HARD- ROUGHING FINISHING MATERIAL
MATERIAL NESS CONDITIONIt fpm fpm AISI

35. COPPER ALLOYS, CAST 40 125 250 M2. M"7

834 855 934 953 to
336 857 935 954 150 As as
838 858 937 956 500kg
842 864 939 973
844 867 939 974
848 879 943 976
852 928 944 978
854 932 945 T

_-1 r
___-,__,
_m___
&N,

817 868 905 947 40 100 200 M2. M7

821 872 915 948 "o
833 874 ne2 952 175 As Cast w

853 875 923 955 500kg

861 876 925 957
862 878 926 958
865 903 927

801 815 828 916 40 85 175 M2,M7

803 818 863 917 to
805 820 902 962 200 As Cast
807 822 907 963 500kg
809 824 909 964
811 825 910 q66
813 826 911 993
814 827 913

Cutting speed recommendations are foruse with Alternate-Tooth

Milling Cuttersor Gear Generators.
For Planer-Type Generators use the recommended cutting speeds In
sect;on 7.3 Gear Shaping.
See section 16 for Cutting Fluid Recommendations. 7-46
 Gear Shaping 7.3
ROTARY FEED1
DIAMETRAL per cutter CUTTER HSS TOOL
hARD- NUMBER PITCH etroke SPEED MATERIAL
MATERIAL NESS CONDITION OF _(4"1 P.D. cutter)
CUTS in fpm AISI
Bhn mm n/ln IS
1. FREE MACHINING CARBON 25104 022
STEELS, WROUGHT 2 1 10 .016 85 M2M7
Low Carbon Resulturized Hot 2 20-49 .001
1116 1119 t. Rolled 2 24 0
1117 1211 15' or 4 --5
1118 122Annealed - 5-54

4 1-4 .022
P 5-10 .016 90 M2,tA7
1S0 2 11-19 O011
to Cold 2 20-481 0081
200 Drawn 2126-
-- 5 ..

Low Carbon Resulturized 41-4 .022

121 2-0 016 100 M2 M7
1215 100 Hot 29 11-19 .011
12o Rolled 2 20-48 .008
150 o
Annealed ~ ~ ~ 0 4S~

4 1-4 .022
2 5-10 .016 110 M2. M7
150 2 1-9.1
t0 Cold 2 20-48 _ 008
200 Drawn

Low Carbon Resulfurizod 414.2

1108 21 -9.1
1109 100Ho
1110 t0 Rolled220 4
115or MC
ils10 Annealed

4 1 -4 .2

150211Oi
to Cold 2 20-48 1 .008
200 Drawn - ~

Medium Carbon Reaulfurized 414.2

1132 1144Ho2510.180 M.7
1137 1145 175 Rolled, 2 I 11-19 .011
13 116Normalized. 2 20 -48 .008
1140 1151 225 Annealed M
1141 or Cold A1=1M111
Drawn 2
x~_;va qi.

275 Quenched 2 20-48 .008

to and
325 Tempered

For cutting gears otClass 9 (AGMVA 390.03) or better, the tI!ntary Feed
should be reduced and the number of cuts should be lncreasea.
See section 16 for Culling Fluid Recommendations

7-47
7.3 Gear Shaping

fDIAMETRAL
-f
ROTARY FEED
N per cutter CUTTER HSS TOOL
MATERIAL HARD-
HARD-IONOF i NUMBER PITCH
x" '.- .' stroke
(4D#P.D. cutter) SPEED MATERIAL
NESS CUTS ( P.D.-cutter)
KM
- in fpm AISI

4 1-4 .012
1. FREE MACHINING CARBON
STEELS, WROUGHT (cont.) 2 5-10 .010 40 M3,M42
2 11-19 008
Medium Carbon Resulfurized 325 Quenched 2 20-48 008
(cont.) to and -; . . -
(materials listed on preceding page) 375 Tempered ' 4. - - ;w . .

4 1-4 022
Low Carbon Leaded
10L18 Hot 2 5-10 .016 110 M2. M7
Rolled. 2 11-19 .011
11117 100
2 20-48 .008
to Normalized.
150 Annealed 4 . .... _ - "
or Cold ~ ~ t ~ :25 ~ ~ ~ tz-4-
Drawn.

4 1-4 .022
Hot 2 5-10 016 100 M2,M7
2 11-19 .011
150 Rolled.
2 20--48 .008
to Normalized,
200 Annealedt, ts 2 - -_
or Cold r X-4-~. .~_

Drawn t
4 1-4 .022

Hot 2 5-10 .016

2 11-19
20-48 .011
.008
200 Rolled.
to Normalized, 2 _.
-00 - __, _

Annealed _ - 85
250
Drawn
or Cold j-_

Low Carbon Leaded 4 1-4 .022

12L3 Hnt 2 5-10 .016 125
12L14 M2.M7
100 Rolled. 2 11-19 Oil
12 15 to Normalized,
150 Annealed a

Drawn -
4 1--4 .022 -

2 5-10 016
Hot .011
2 11-19
150 Rolled,
2 2041.0
to Normalized, 20-48 .008
200 Annealed . -

4 1--4 .022 A

Hot 2 5-10 .016 9M 7

2 11-19 .011
200 Rolled.
2 20-48 .008
to Normalized,
250 Annealed ,

or Cold A
Medium Carbon Leadd 4 1-4 022
10L45 Hot 2 5-10 .016 90 M2.M7
IOL50 125 Rolled.
to Normalized. 20--48 .008
11L37
11L41 175 Annealed :%-If
11L44 or Cold
Drawn

For cutting gears of Class 9 (AGMA 390 03) or better, the Rotary Feed
should be reduced and the number of cuts should be increased
See section 16 for Cutting Fluid Recommendations.

7-48
 Gear Shaping 7.3

DIAMETRAL ROTARY FEED

DUBMTRAL per cutter CUTTER HSS TOOL
HARDIANUMBER OF PITCH stroke
utr SPEED MATERIAL
MATERIAL HR- CONDITION
NESS NESS='_: CUTS : , - _ -("P
(4"1P.D.,cutter) po AS
U--O6ULE in 1pm AISI
Bhnr/rn IS
1. FREE MACHINING CARBON 4 1-4 .022
STEELS, WROUGHT (cont.) Hot 2 5-10 016 85 M2.M7
Mod:urn Carbon Leaded 175 Rolled. 2 11-19 .011
to Normalized, 2 20-48 .008
(cont.)
4
(materials listed on preceding page) 225 Annealed ::w_6 -5
or Cold --i2 f.- - 40-6
1
Drawn ,, 2-# , :: = 5-
. .
4 1-4 022
Hot Rolled. 2 5-10 016
Normalized. 75 M2.M7
2 11-19 008
225 Annealed.
to Cold Drawn 2 .

275 or %4~
Quenched -2 4 55.54.82!
and ~ ~ =

Tempered -at
Hot Rolled, 4 1-4 .018

Normalized. 2 51- 012 60 M2 M7

11- 9 010
Annealed. 2
275
2 20-48 008
to Cold Drawn
35or -45
Quenched - - - &5
and 4- ME-~
Tempered W#
4 1-4 .012
2 5-10 .010

2 20-48 .008
105u03eoNmlied,
1005

60
M 2M42
1119 .008 90
ar o f Classlled2 r ,t a
ForC
10 1016 1025 125 ~ aze,22--8.0
1017 1026 orCl '-- " i - -
1008
See
s o 16 FluidRecommer-nd-ations CCuttnlgd _
1009 18 109Drawn !
l10O lO1 1513 "
1011 1020 1518 4 1-4 018
1522 Hot 2 5-10 .01280M . 7
1012 1021 M,7W
125 Rolled, 2 11-19 .01080
1013 1022
to Normalized, 2 20-48 .008

n h ubro ctoudb inraed

shudbeue Drawn , ;,
4 1.-4 .018
Hot 2 ,5-10 012
2 11-19 .01070 M,7
175 Rolled,
to Normalized, 2- 20-48 .008
.. af.f,_
225 Annealed
or Cold _
Drawn ">

___ - f
-~~~ -
4 1-4 .016
2 5-10 .1
19 .010 60M2 M
225 Annealed 211-
to or 2 20-48 .008

For cutting gears of Class 9 (AGMA 390 03) or better, the Rotary Feed
should be reduced and the number of cuts should be increased.
See section 16 for Cutting
Fluid Recommendat ions
,
-4
 -- 7

7.3 Gear Shaping

ROTARY FEED
DIAMETRAL per cutter CUTTER HSS TOOL
HARD- NUMBER PITCH stroke SPEED MATERIAL
MATERIAL NESS CONDITION OF =: :3 (4" PD.incutter)
-- :("PO utr
CUTS AIsI

Bhn ~~~m- &mmn~ _____

2. CARBON STEELS, 4 1--4 .018

WROUGHT (cont.) Hot 2 5-10 .012 75 M2. M7
125 Rolled. 2 11-19 .010
Medium Carbon
Normalized. 2 20-48 .008
1030 1044 1526 0
1033 1045 1527 175 Annealed --- 4 5- -:
1035 1046 1536orod25-..3
1037 1049 15rw41 21 3 48
1038 1050 1547 _ 4
_ ___._-_, 15 . .0....
1039 1053 1548 1-04 .018
1040 1055 1551 Hot 2 5M10 0127
1524 1552 175 Rolled, 2 11-19 .010
1042
1043 1525 toNom he ,
Normalized. - " A2 -' 20-48-:-. _: .
.008 i:-'.- .
225 Annealed _1.44_ . , - .
or Cold =2<- - 55t5> crS S(
Drawn 2

4 1-4 .016
Hot Rolled.
Normalized. 2 5-10 .012 60 M2 M7
2 11-19 .010
225 Annealed.
to Cold Drawn 2 20-48 .008
V.
275 or
Quenched s"r" -& 3 '= ' - "' 'fl.- '-'
and Ali&~
Tempered . - ZAtr",-
4 1--4 .016
Hot Rolled. 2 5-10 .012
Normalized, 2 11-19 010 50 M2,M7
275 Annealed 2 20-48 .008

325 Quenched r ;> I i ;

andV 4
Tempered -_ -' A
4 1-4 .012
2 5-10 010 40 M3.M42
2 11-19 .008
325 Quenched 2 20-48 .008
to and k 2
375 Tempered -s 25

High Carbon 4 1--4 018

1060 1075 1090 Hot 2 5-10 .012 65 M2.M7
1095 175 Rolled. 2 11-19 .010
1064 1078
1065 1080 1561 to Normalized. 2 20-48 .008
1069 1084 1566 225 Annealed M 20_75k
1070 1085 1572 or Cold,
1074 1086 Drawn t t: 1 -
4 1--4
5-10 .016
.012
Hot Rolled, 2
Normalized, 2 1-19 .010 55 M2,M7
2 11-19 .010
225 Annealed,
2048 .008
to Cold Drawn -2

. -- --
2 75 or
Quenched p
Tempered t~ _r2-;si L 4 t&
Hot 4
2 I,41-4
5-10 .016
.012
Rolled. 45 M2.M7
2 11-19 .010
275 Normalized,
2 20-48 .008
to Annealed
325 or
Quenched
and
Tempered

For cutting gears of Class 9 (AGMA 390 03) or better, the Rotary Feed
should be reduced and the number ofcuts should be increased
See section 16 for Cutting Fluid Recommendations

7-50

- . -- ~- - - -- ~--3--r..
 Gear Shaping 7.3

jROTARY FEED
DIAMERAL
DAERL per cutter CUTTER HSS TOCI
HARD- NUMBER PITCH stroke SPEED MATERIAL
MATERIAL NES CONDIT;ON
NESCT OF --- (411
P.D. cutter)
MODULE' in fpn AISI

4 1-4 C)12
2. CARBON STEELS, 2m 5-10 01m0 S
WROUGHT (cont.) 2 11-19 008 35 M3,M42
High Carbon (cont.) 325 Quenched 2 20-48 .008
(materials listed on preceding page) to and 4 2 ~ ~ 3
35 Tempered2 -

4 14 .018 s~s-
3. CARBON AND FERRITIC 14 .018
ALLOY STEELS (HIGH 2 11-19 .010 60 M2. M7
TEMPERATURE SERVICE) 150 As2 2C-48 .008
ASTM A369. Grades FPA. FPB. to Asrge
FPi.FP2.FP12 200 Fogd ~2-6 5 I-
2- 5Z 32~18 $
52

ASMA6 rdsF~.4 1-4 .018

ASMA39Grds Pb 2 5-10 012
1501 Annealed 2 11-19 0105 M2. M7
2 20-48 .00
150 or .008
to Normalized
4~2 -- --
200 and 'f

Tempered ~ ~ '-5 0~~7 _S~

ASTM A369. Grades FP5. FP7. 2 5-10 012

FP9.FP21.FP22 Annealed 2 5101901020 M2M
2 20-48 .0105 2M
150 or
to Normalized 2 20-48 .008
200an-
Tempered - -- ''--i5

4. FREE MACHINING ALLOY 4 1-402

Ho. -00188022M
STEELS, WROUGHT
10 Rolled. 2 11-19 .011 0 M.M
Mdium Carbon Reulurized .008l
to50 Normalized. 2 20-48
4140 4145Se
4140Se 4147Te 200 Annealed 4,~~
5_ Q -
4142Te 4150 of Cold
Draw n

4 1-4 .2
2 5-10 .0187222M
Hot M.7
Rolled.211 1Oi75
200
to Normalized. 22 -8.0
250 Annealed ~k__
or Cold __
~
-k.
~
Drawn

2 11-19 010 50 M.M

275 Quenched
toand gg-
35 Tempered ~_

2 11-19 .008 3 3 4
325 Quenched
to and 2 204

3~5 Tempered ~

For culling gears of Class 9 (AGMA 390 03) or better, the Rotary Feed
should be reduced and the number 0f cuts should be increased
See section 16 for Cutting Fluid Recommendations

7-51
7.3 Gear Shaping
DIAMETRAL ROTARY FEED H

per cutler CUTTER HSS TOOL

HARD- NUMBER PITCH stroke SPEED MATERIAL
MATEHIAL NESS CONDITION OF . r (4"1 P.D. cutter)
NESS CUTS t tQ .
BhnZX~?9 4 ~ in fpm~ AISI

4. FREE MACHINING ALLOY 4 1-4

STEELS, WROUGHT (cont.) J Hot 2 5-10
022
.016 80 M2. M7
Medium and High Carbor. 150 Rolled, 2 11-19 .0
Leaded to Normalized. 2 20--48 008
41L30 41L47 51L32 86L40 200 Annealed rK "
41L40 41L50 52L100 o'Cold 24- 5-Q_., " ; -

41L45 43L40 86L20 Drawn -s- -2 4;1= 1;-_j1. .....

4 1-4 022
Hot 2 5-10 .016 75 M2.17
2 11-19 .011
200 Roled.
to Normalized. 2 20-48 .008
250 Annealed .--
or Cold 'Ss2~ 55ZrrS~A~~
D raw n ct ?5 2 - ' -_ - ,

4 1-4 018
2 5-10 .012 50 M2 M7
2 11-19 .010

to
275

325
and
Quenched

Tempered
2

- '
20-48 008

4 1-4 .012
2 5-10 .010 3 314
2 11-19 .008
325 Quenched 220-48 .008

sl bTempered

5. ALLOY STEELS, WROUGHT 2 51--- .012

Low Carbon Hot 2 1--19 .010 70 M2, M7
4012 4615 4817 8617 125 Rolled,21-19.0
4023 4617 4820 8620 to Aneld22-48.0

4320 4718 5120 9310 Dan -

4419 4720 6118 94B17 4 1- 4 .018

44241
15987Hot 2 5-10 .012 65 M2. M7
75 Rolled. 2 11-19 .010
175 Annealed 2 20-8
225 or .008

D~awn
4 1---4 .016
Hot 2 5-10 .01250 M,7
2 11-19 .01050 M,7
225 Rolled,
to Normahizod, 2 20-48 008
sectio
fooutnrFudRcmmnain
See01165 Annealed -
275

-- -. _ _ _ L ,-- ---' _
4 1-4 .012
2 5-10 ,010 45 M2. M7
Normalized 2 11-19 008
2 75 or 2 - - 20 - 4 8 .008-
to Quenched - -
325 and
Tempered

Fo,. cutting gears of Class 9 (AGMA 390 03) or belier. the Rotary Feed
should be reduced and the num~er of cuts should be Increased
See section 16 for Cutting Fluid Recommendations

7-52
 Gear Shaping 7.3
ROTARY FEED
DIAMETRAL
per cutter CUTTER HSS TOOL
HARD- NUMBER PITCH stroke SPEED MATERIAL
MATERIAL NESS CONDITION OF (4" P.D. cutter)
CUTS in fpm AISI
Bhn r-,n/un S
5. ALLOY STEELS, WROUGHT 4 1-4 012
(cnt.) 2 I 5-10 .010 40 M3M42
(Con Normalized 2 1 19 .008
Low Carbon (cont.) 325 or 2 20--48 008
(materials listed on preceding page) to Quenched_-
375 and .S.-2t 1
Tempered --- > 2 .

Medium Carbon 4 1-4 .018

1330 4427 81845 Hot 2 5-10 .012 60 M2.M7
175 Rolled. 2 11-19 .010
1335 4626 8625 20-48 008
1340 50840 8627 Annealed 2
1345 50844 8630 225 or _
$2
C old r-Z5, 2 .5 r- - 18 4* t-
4027 5046 863 7
4028 50846 8640 Drawn ~k~s-
4032
403 5085
50B50 862E~<iSt
8642
____

4037 5060 8645 Annealed. 2 1-4 01

4042 5B60 86B45 Normazed. 2 1 19 010 45 M2. M7
4047 5130 8650 225 Cold Drawn 2 20-48 .008
4130 5132 8655 to or
4135 5135 8660 275 Quenched-
-~ %
2 t - >-
'$.--

4137 5140 8740 and

4140 5145 8742 '-=
4142 5147 9254 Tmr 5 ----
--
---
4145 5150 9255 4 1-4 .016
4147 5155 9260 2 5-13 012
4150 5160 94830 275 Normalized 2 11-19 .010 40 M2,M7
4161 51B60 or 2 20-48 .008
to Quenched = "
4340 6150 325 and =.. &
Tempered

4 1-4 .012 -a

2 5-10 .010 35 M3,M42

325 or 20-4,
to Quenched f -7- - --
375 and - u n-- N_
Tempered

High Carbon 4 1-4 .018

t2 5 10 .012
175 Rolled, 2 11-19 .010
51100
to Annealed 2 20-48 008
52100
M-50 225 ord M -
Cold g

4 1-4 .01C ,
Normalized. 2 5-110 .012
2 11-19 .010
225
to Drawn
Cold Of 20-48 .008
275 Quenched -.-

Tempered

4 1.-.4 .016
2 5--10 .012
Normalized 2 11-19 .010 35 M2,M7
275 or 2 20-48 .008
to Queched
325 and
Tempered

For cutting gears of Class 9 (AGMA 390 03) or better, the Rotary Feed
should be reduced and the number of cuts should be increased
See section 16 for Cutting Fluid Recommendations.

7-53
7.3 Gear Shaping
DIMF A- ROTARY FEED
N IMT
E per cutter CUTTER HSS TOOL
NUMBER PITCH stroke SPEED MATERIAL
MATERIAL HARD CONDITION OF 717*- ' --- (4" P.D. cutter)
NESS CUTS
Ihn
_____-__________:_ in 1pm AISI

S.ALLOY STEELS, WROUGHT I 1 1-4 .012

Hcon
(cont.) c
High Carbon (cont.) ,325 Ii Normalized
or
22
2
5-10
11-19
20-48
.010
.008
.008
30 M3.MA42
(mrterials listed on preceding page) to j Quenched - -41-= _-_- -- t &.c0 - . = - --
375 and - ~ 5-. =-s 114
Tempered2 2 I-ti SO
*'~~~~~-~i 2gt<ti
Zg~' -Z Z=

6.HIGH STRENGT STEELS, 4 1-4 .016 M2.M7

WROU GTh 2 5-10 .012 45
2 11-19 .010
300M 98BV40 225 2 20-48 .008
4330V
4340
O6ac
iF1300("o~~z~-
to Annealed :2-N
4t=5zs-'
-~
4340Si m13 =: 1

4 1-4 .012
5-10 .010 40 M2.M7
300 2 11-19 .008
30 Nomlie 2 20-48 .008
to Normahzed _ Z' --

4 1-4 .012
HP 9-4-20 2 5-10 .010 45 M3.M42
HP 9-4-25 2 11-19 .008
HP 9-4-30 325 2 20-48 .008
HP 9-4-45 to Anneeed - -'-

,I - = - _~

7. MARAGING STEELS. 4 1-4 012

WROUGHT 1 2 5-10 M 45 M2.M7
120 Grade 10Gae252215 An11a19 20-48 .008
.008 I ,

180 Ga.-e to Annealed

4 1.-- .012
ASTM A538: Grades A B.C 2 5-10 .010
200 Grade 2 1119 .008 35 M2.M7
250 Grade 275 2 20-48 .008
300 Grade to Annealed ~ f. e" ,

350 Grade 325 cp

8. TOOL STEELS, WROUGHT 1 .012

High Speed 30 M2.M7 3
Ml T, 200 1
M2 T2 to Anneaed _-
M6 T6 250 = -

High Speed 4 1-4 012

M3-1 M34 M46 I 2 11-19 .01 20 M2,M7
M3-2 M36 M47 225J 2 20-48 [ 006
M4 M41 T4 to Annealed nn F
M7 M4? T5 275
M3.'0 M43 TS
M33 M44 T15 .J

For cutting gear, a! Cl-sS 9 (AGMA 390 03) or better, the Rotary reed
should be reduced and the number of cuts should be increased
See section 16 for Cutting Fluid Recommendations

7-54
 Gear Shaping 7.3

I I DAMETAL
DIMTRL
jROTARY FEED
per cutter CUTTER HSS TOOL
HARD- NUMBER PITCH I stroke SPEED MATERIAL
MATERIAL NESS CONDITION OF f (4" R.D. cutter)
Ho~o ~OUL~ in 1pm AS
Bhn ME _ _______ ____

5 2i 5-10 .015 50 M2. M7

H02 11-19 .010
K 102 20-48 .008
H12
H13
to
200
Annealed R5Mti0- W
L7: w'
H122 4 1-A .016
H123 2 5-10 .012 35 M2. M7
H4202 11-19 .010
H2 202 20-48 .008
H25 to Annealed ZA 3;~
H26 250 2 RE 2;~ r
H42 ZVI

__10ai ___-4i

4 1-4 .012
2 5-10 .010 25 M3,M42
325 Quenched 2 20-48 .006
to and - n-na M:;
375 Tempered -~r

Cold Work 414.1

A3 04 200 21-9.1
A4 05 to Annealed 2 2-8.0
A6 07 250
A7 01
A8 02
A9 06
A10 07
02

Shock Reatling

$2 175 2j048.0

$6 225
S7

P2 a

P4 ~~100 21-9.1
P5 to Annealed 22-8.0
P6 150

Mold 414.1
P202 -0.150 M.7
15021 -1 .1
P21

200

For cutting gears of Class 9 (AGMA 390 03) or better, the Rotary Feed
should be reduced and the number of cuts should be increased
See section 16 for Culling Fluid Recommendations.

7-55
7.3 Gear Shaping
DIAMETRAL pe utr "CUTTER HSS TOOL
MATERIAL HARD- CONDITION NUMBER
OF PITCH stroke
(4" P. cutter) SPEED MATERIAL

NESS CUTS in fpm A SI

Bhn 359 , -

. TOOL STEELS, WROUGHT 2 - 10 .014

(cont.) Purpose
Special 150 2 5-19 .015
2 20-49 .010
L2 to Annealed - -

SpeialPurose4 1-4 .016 ,

SeilProe2 5--10 012 35 M2, M7
F1 2 11-19 .010
F2 200 2 20-48 .008

250

W.
SAE W2. W5 Types W108.
J438b: 2 1-19 .010 M2, M7
150 2 112.-4819 .010
W109, W110, W1 12. W209. to Annealed
W210. W310 200

9. NTTRIDING STEELS,

Narllo
13o Anealed+. -
.01
01 M2--
WOGT2 5-10 .012 4
Nitralloy 125WRO T2 200 2 11-
20-48 .010M2
.00

Nitralloy 135 Mod. 250

Nttralloy 225
Ndtralloy 230
Ntralloy EZ 41-4 .012
N rallo y N 25 - 10 0 122 5M . 7
Nittx I Normahzed 211-19 .010 MM
300 or 2 20-8.008
to Quencheda

Tempered

STAW&IESS STEELS. 60-10,1 M2 M7

WRUGT 352 11-19 .010
WOGT152 20--48 .008

430F 185
430F Se--

4 020
.--
A us e t f 2 1 0.--15 M .M
203EZ 2 11-19 .010 M.M
303 135 2 20-04 .008

303Pb 186
303 Plus X
303Se

4 1-4 .020 2

225 S 2
2 5--0.015
11-1010MM
275 Drawn

For cutting gears of Class 9 (AGMA 390.03) or better. the Rotary Feed
should be reduced and the number of cuts should be increased.
See section 16 for Cutting Fluid Recommendations-

7-56
 Gear Shping 7.3

I DIAMETRL ROTARY FEED

I
IHARD
I BR Aper cutter CUTTER HSS TOOL
II
rNUMBE stroke SPEED
SPE MATERIAL
MATERIAL HR, CONDITION NFRUM'sroe
NESS CUS ~ ~ -(41 R.D. cutter)
MO4JEin fpm AISI
Bhn __ ~
4 1-4 .020
Martensitic
420F Se 2 5-10 015 102, M7
416
416 Plus X 440F i135 2 I1 19 .010
440F Se i to I Annealed 20-48 008
416Se
42F185 '~~~

5 4 1-4 020
S.-- j0 050 M2.M7
!2 2 11-19 ' .010
185 Annealed
to tO2402 or I 20-48 .008
Cold
. Drawn -o
I It' .o Z=2
1-19 .010
.- 25 M2.M7

275 Quenched 2 20-48 .008

to and ~sr __

325 Tempered SZi t m-v__

4 1-4 .020
WROUGHT STEELS,
13. STAINLESS 2 5-10 .015 40 M2.M7
Forfc135 2 11-19 .010
2 20-48 .008
--
405
409 434
436 185
to Annealed -
429 442
430 446

Awtenifti'

201 304L 348

2
4

2)oberteta0F30
5-10
1-4
.01
.020

M2,M7
202 305 384 35
bi nneaed 2 20-48 .008
301 308 385 to

4 1-4 .020
2 5-10 .01525 M.7
252 11-19 .010
to cold 2 20-48 .008

AvserIi 4 1-.4 .020

Au Mli ]2 5-10 .015
302B 314 1 2 11-19 .010 30 h12, M7
309 316 135 2 20-48 .008
309S 316L to Annealed [
310 317 185
310S 330 '

27-5
4 1-4 .020 0
2 ,5-10 .015
2 11-1q .01020 M M
225

For cutting gears of Class 9 (AGMVA 30-0 03) or better. the Rotary Feed
should be reduced and the number of cuts should2 be increased
See section 16 for Cutting Fluid Recommendavon's.

7-57
 - -- --

7.3 Gear Shaping

II N
I DIAMETRAL
ROTARY FEED ;
per cutter cL'rrER HSSTOOL
MATERIAL HADI
HARD CONDITION OF ("P.cterI
stroke'; SPEED MATERIAL
NESS j { CUTS - (4-P
,r J fpm A151
___________ hn -zjrrag

13. STAINLESS STEELS, 4 1-4 020 2 i

WROUGHT (conL) 1 2 5-10 015
Austnifc 210 2 11-19 11 .010 1
t c2 20-48 .008
Nitronic 32 Neronic 5C to Annealed - I -- - z _
Nitronic 33
Nitronic 40
Nitronic 60
I 250
I $n;_____
1 4 1-4 .020
j 2 5--10i .015 40 M2.M7
403 2 11-19 .010
I 135 2 20-48 .008
410
420 to Annealed- -
422 175 -

502

25--10 015 I
11 19 .010 135 M2.M7
152
175 Aneaed2 20-48 .008
225

4 1-4 .016
2 5-10 .012
2 11-19 .010
275 Qucnched 2 20-48 .008
Ito and W -- -
325 Tempered PODU__
-- ~"WO c

i s 4 1-4 .018 .
414 2 5--10 .012 30 M2 M7
431 2 1 19 .010
431 225 2 20-48 008
Greek Ascotoy to Annealed
275 ~~z'

4 1-4 .016
2 5-10 ! .012 20 2 M?
275 27 Q unhd2
ed08 11-19 i .010

Miir4 1,--4 .018

440A2 5- .012
44B 2 1119
2O-48 .010j22
.008
440B 225I2

275

A 1.--4 .016 .
2 5-10 .012 20 1 2.M

2 11-19 .00
275 Ouenched
7 7 04 08 -
tOand
45 Tempered

I4
For cuttn geas at Class 9 (AGMAA 390 03) a' better. the Ratary Feed
should be reduced and the number at cuts should be increased
See secton 16 forClming Fluid Recomnmendatto.

7-58

- - =
 Gear Shaping 7.3

fDIAMETRAL
ROTARY FEED
NUMER PICH per cutter CUTTER HSS TOOL
HARD- NUBR PTHstroke SPEED IMATERIAL
MATERIAL NES CONDITION OF ("PO utr
MOD LE-
-TS in fpm AISI
hr ~ iir/n n -
t4
____________ _________m_______

14. PRECIPITATION 1-4 .018

HARDENING STAINLESS 2 11-10 .010 35 M2, M7
STEELS, WROUGHT 150 21-9.1
15-5PH tO Solution 2 20-48 .008
16-6PH 200 Tead .,254 +
17-4PH 30 - 'A'5~
17-7PH 2~ 3 '25 Zfl
17-14 Cu Mo_______ds2 --

AF-71 4 1-4 018

AFC-77 2 5-10 .01225 M,7
Almar 362 (AM-362) 275 Solution 2 11-19 .01025 M.M
AM-350 to Treated 2 20-48 008
AM-355 35or 2-8 4
AM-363 Hardened -- ; 5-53
O.stom 450 ,;2- -2-' -~~25 ->-

Custom 455 ____w___ i-'.L: O

HNM 4 1-4 .016
PH 13-8 Mo 2 5-10 .0i
PH 14-3 Mo 32 ouin2 1-19 010 20 M3,M42
PH 15-7 Mo 2rae 20-48 .008
Stainless W to5 375Trae
or- --.'-
Hardened AVA - -1

-~
41-701
1.CARBON STEELS, VAST01
Low Carbon Annealed, 2 6-10 .012
100 Normalized 2 11-19 .010 80 M2, M7
ASTM A426. Grade CP1
1010 to Noraie 2 20-48 nn
1020 ~and S ;
Tempere
____WIN__ 1-0iz~_____ 2-- --

Medium Carbon 4 j 1-4 .018

ASTM A352. Grades LCA. LOB, Annealed. 2510 .01275 M.7
LCC 125 Normalized 2 11-19 010 7 2M
ASTM A356, Grade 1 to or 2 20-48 .008 ____

1030 175 Normalized A M. & _6

1040 and __ _0 j. 3 _

1050 Tempered
14 1-4 018
Annealed. 2 5-10 .012 70 M2, M7
175 Normal-zed 2 11-19 .010
2oo 20--48 .008
225 Normalized~~4
and ~-

4 1-4 .016
25-: ( 012 55 M2,.M7
2 11-19 .010
250 Quenched 2 20-48 008
to and
300 Timo~ered 7

For cutting go&.s .1Class 9 (AGMA 390 03) or better, the Rotary Feod
should be reduced and the number of cuts should be Increased
Iee section 16for Cutting Fluid Recommrendationis.

7-59
7.3 Gear Shaping
D R ROTARY FEED
NUMBR
NUMBER MPTH
PITCH per cutter
stroke CUTTER
SPEED HSS TOOL
MATERIAL
MATERIAL CONDITION OF (4" P.D. cutter)
NES CTS >MDU-Win 1pm AISI

16. ALLOY S'V'LS, CAST 4 1-4 018

Low Carbon Annealed. 2 5-0 .012 65 M2,M7
ASTM A217- Grade WC9 150 Normalized 2 11-19 010
ASTM A352' Grades LC3. LC4 to or 2 20-48 008
ASTM A426: Grades CP2, CP5, 200 Normalized, 4 25 - - 45
CP~b.OCP11, CP 12. CP 15. and 25-2 02 4S
0P21.0P22 Tempered 2' 2 55,- -
2315 4110 4320 8620 4 1-4 .018
Annealed, 2 5-10 012 M2,M7
200 Normalized 2 11-19 .010
to or 2 20-48 .008
22.5 Normalizedt2-
and 2m
:6t.2
'355
Tampered 215 ~54
4 1-4 .016
2 5-10 012
2 t119 .010 M2M7
250 Quenched 2 20-48 .008
to and v'-'-yn--
300 Tempered 4 . V2 EM-Asi

Medium Carbon 4 1-4 018

ASTM A27" Grades N1, N2. Annealed, 2 5-10 .012 55 M2,M7
U-60-30, 60-30. 65-35, 175 Normalized 2 11-19 .010
70-36, 70-40 to mali48
Nor 2 .008
ASTM A 148: Grades 80-40, 225 Normalized 2 -
80-50, 90-60, 105-85, and ,,-,4_-t Km
120-95, 150-125, 175-145 Tempered t& 4"'-
ASTM A216' Grades WCA, - - 4 t"b--- ..
WCB,WCC Normalized, 42 1-4
5-10
.016
.012
ASTM A217- Grades WC1, Normalized 2 1-19 .0145 M2,M7
WC4, WC5.WO6 225 and 2 11-19 .010
ASTM A352: Grades LC1. LC2. to Tempered 2 20-48 .008
LC2-1 250 or . . . - A.sV -
ASTM A356 Grades 2,5,6,8, Quenched NO|
. "=
9, 10 and -4,. -P , AX . = r -
ASTM A389 Grades C23, C24 Tenpered z fuY-$ --- o - -.. am
ASTM A486 Classes 70, 90. 4 1-4 .016
120 2 5-10 .012 M2 M7
ASTM A487: Classes 1N, 2N, 2 11-19 .010
4N,6N,8N, 9N. 10N, DN, 10. 250 Quenched 2 20-48 .008
20,40, 40A. 60,70, 8Q. to and
9Q. 100 300 Tempered '
1330 4130 80830 8640 r
1340 4140 8040 9525 _____ _01_____--___,-
2325 4330 8430 9530 4 1 4 014
2330 4340 8440 9535 2 5-10 .012
4125 8030 8630 2 11-19 010 -2
300 Quenched 2 20-48 .008 -
to
350 Tempered
and ~-
-

4 1,-4 .012
2 5-10 .010 30 M3 M42
2 11-19 .008
350 Quenched22--8.0
to and [. 2 20-4 .008

400 Tempered

For cuttinggears ofClass 9 (AGMA 390 03) or better, the Rotary Feed
should be reduced and the number ofcuts should be increased.
See section 16 for Cutting Fluid Recommendations

7-60
 Gear Shaping 7.3

DIAMETRAL ROTARY FEED

per cutter CUTTER HSSTOOL
NUMBER PITCH
OF stroke SPEED MATERIAL
MATERIAL HARD- CONDITION
NESS CUTS (411P.D. cutter)
in fpm AISI
Bhn
4 1-4 .020
1B. STAINLESS STEELS, CAST
Ferrific 2 5-10 .015 40 M2, M7
135 2 11-19 .010
ASTMA217: Grades C5,C12
ASTIVI A296: Grades CB-30, to Annealed 2 20-48 1 .008 --
CC-50, CE-30. CA6N. 185
CA-6NM, CD4MCu
ASTM A297: Grade HC
ASTM A487: Class CA6NM
ASTM A608: Grade HC30

4 1-4 .018
Austenitic
ASTM A296. Grades CF-16F. 2 5-10 .012 35 M2. M7
2 11-19 .010
CN-7M. CN-7MS 140 Annealed 2 20--48 .008
ASTMA351: Grade CN-7M to or W-H;
170 Normalized

4 1-4 .018
Austonitle
ASTM A296. Grades GF-3, 2 5-10 .012 30 M2. M7
2 11-19 .010
CF-8, CF-8C. CF-20 135 Anitealed 2 20-48 .008
ASTM A35 j: Grades CF-3, to or :7-
CF-3A, CF-8, CF-8A, CF-SC 185 Normalized
ASTM A451: Grades CPF3,
CPF3A. CPF8, CPF8A, 6 Z
CPF8C, CPF80 (Ta Max)
ASTM A452: Grades TP 304H,
TP 347H

--- - -- R
T -

1-4 .018
Austenific:
ASTM A296: Grades CF-3M, 5-10 .015 30 M2,M7
2 11-19 .010
CF-8M. CG-SM. CG-12. 135 Annealed 2 20-48 .008 A
CH-20, CK-20 to or M
ASTMA351: Grades CF-3M. 185 Normalized
CF-3MA, CF-8M. CF-10MC.
CH-8, CH-10. CH-20. CK-20.
HK-30, HK-40. HT-30
ASTM A451: Grades CPF3M,
CPF8M. CPF10MC, CPH8.
CPH10, CPH20. CPK20
ASTM A452- Grade TP 316H I I

For cutting gears of Class 9 (AGMA 390 03) or better. the Rotary Feed
should be reduced and the numberof cuts should be Increased.
See section 16 for Cutting Fluid Recommendations.

7-61
 S"'i ~rt Mqrl7'9 ~i Y Y~i2~inSt Y

7.3 Gear Shaping

DIAMTRAL ROTARY FEED
DIMTRL per cutter CUTTER HSSTOOL
HARD- NUMBER PITCH stroke SPEED MATERIAL
MATERIAL CONDITION
NESCUTS
OF ~ nt- -~("PO utr
A-I-SI
in~l 1pm AS
Bhn Susii
w- t -- ; rnM~n
19. STAINLESS STEELS, CAST 2 1-40 .012
(cont.)2 -0.130 M,7
Austenitic 160 2 20-48 010
ASTM A297: Grades HD, HE, to As Cast
HF, HH. HI, HK, HL. HN. HP, 210
HT. HU
ASIM A608: Grades HD5O, ~- 2152
I > _7' -
HE35, HF3O. HH3, HH33,
H135. HK3O, HK40. HL3O.
HL4O. HN4O. HTSO. HU50

Mrestc4 1-4 .020

ASTM A217 Grade CA-iS2510.1
ASTMA2S6- Grades CA-iS, 135 2 11-19 .010 40 M2, M7
CA-15M. CAAO0 to Annealed 2 204 .008c JN-N

ASTM A426- Grades 0P7. CP9, 175

CPCA15
ASTM A487 Classes CAl5a, _

CA-15M

19 PECPIATON4 1-4 .020

HARENIGaSAINES 2 5-10 .012
2 11-19 .010 3 2 M
LS
CASTal325
STE
Grade
ASTMo Aor u0oSouto 2 .D4M

ACI
CD - M0 G radeize
-.

174P 4 1-4 0
AM25 50 01

19. GRACATIRONS1 1-4 .08

A
ARDEIM 20
Cls TINES 1202
J4 51. Grade G1BOO~
STAE to Aounnled8.00
1I5W

shoul berdued and thTubra ut hudb n reaed

17-4 H -4Mu 7-62T U

-~~~~ -- W- Z.---~
 Gear Shaping 7.3

DIAMETRAL IROTARY FEED

NUBE ITH per cuter CUTTER HSS TOOL
MAEILHARD- NUMDITEO POTC stroke SPEED MATERIAL
MATEIALNESS CODUTOSO -7- P.D. cutter)
(411
I MODULE- in fpm AISt
Shn ______ Mm" -m/mn - ISO

Poarlitic- Ferritic f 4 1-4 018

ASTM A48, Class 25 251 1 5 MM
SAE J431c. Grade G2500 160 2 10-48 010
t0 As Cast 2 2048 0045
200 )2 5-5.0
-~~~ ~~ 2-15 I 2- 6 4S

2 5-0 02

ASTMV A48. Classes 30. 35. 40 2 5101 010 70 M2. M7

SAE J43 1c: Grade G3000 190 2 20-48 010
to As Cast 24 20-48 .008
220 ~54 0S42

Pearlitic + Free Carbides 2 1--10 .012

ASTM A48 Classes 45. 50 2 510 19010 60 M2.M7
SAE J431c. Grades G3500. 220 2 21-48 010
G4000 to As Cast - _

260 W, t; 256-4

Pearlitic or Acicular + Free 2 5-10 .010

Carbides sCs 2 11-19 .0104 M2
250 ACat2 20-18 .00840 M.7
A48: Classes 55, 60
ASTMV
to Quenched -3

320 and w 5
Tempered ~~~2 ~SS7
0-:115 Z-

Austenitic (NI-RESIST) 4 1--4 .018

,1b .2.2
ASMA3,Tps 5-10 012
.2.0 2 11-19 010 50 M2, M7
ASM.456 Tye .lb
3t.56o0 2 -20-48 .008
to As Cast Z___
_ LA -%~
250 M-2-~-ij~

23. DUCTILE CAST IRONS 4 1-4 .018

Frritic 2 5-10 .01210 M27
11-19 .010 10 MM
56.Grds
ASM 0-018 102
Gaes60411.24
6SM 5-45 654-2to 2 20-48 .008
Annealed - -, 0 Z
SAE J434c- Grades D4018. 190 O
045 12 ~~_

Ferritic- Pearlitic 4 1-4 .018

ASTM A536 Grade 80-55-06 2 5-10 .012
11-19 .010 80 M2, M7
SA 44:GaeD56 102
SAEJ44c:Grde0556
902 20--48 .008

225 @W,~

fff_2-- -- ___

4 1-4 .018
2 5-10 .012
2 11-19 .010 70 M2,M7
225
to A at2 20-48 .008

For cutting gears of Class 9 (AGMA 390,03) or better, the Rotary Feed
should be reducod andithe numt- *of cuts should be increased
See section 16 for Cutting Fluid Ri omrmendations

7-63

m
7.3 Gear Shaping
DIAMETRAL ROTARY FEED
NUMBER PTRAH
DUBR
PITCH per cutter
stroke CUTTER
SPEED HSS TOOL
MATERIAL
' ((4""D. cutteI
RD. cutter)
MATERIAL HARD- CONDITION
NESCUTS
OF ..... -
in fpm AISI

23. DUCTILE CAST IRONS 4 1- 4 .016

(cnt)2
(cont.) 2 11-19
5-10 ,010
.j2 6 M2, M7
Pearlitic- Martensitic 240 Normalized 2 20-48 _ 008
ASTM A536: Grade 100-70-03 to and -- : j t t? ''
- r '

SAE J434c' Grade D7003 300 Tempered

a5

Martensitic 4 1-4 .012

ASTM A536 Grade 120-90-02 2 5-10
11-19 .010
.008 45 M2. M7
SAE J434c: Grade DQ&T 270 Quenched 2 20-48 008
to and ___ -

330 Tempered ,

Austenitic (NI-RESIST 4 1-4 .012

Ductile) 2 5-10 .010 40 M2, M7
ASTM A439: Types D-2, D-2C, 120 2 11-19 008
D-3A, D-5 to Annealed -- 11
ASTM A571: Type D-2M 200

Austenitic (NI-RESIST 4 1-4 .012

Ductile) 2 5--10 .010 35 M2, M7
ASTM A439: Types 0-2B. D-3, 140 2 11-19 .008
D-4. D-5B to Annealed 20 8
275

24. MALLEABLE CAST IRONS 4 1-4 .018

Ferritic 22 5-10
11-19 012
.010 15 MM
ASTM A47. Grades 32510, 110
35018 to Malleablized -,-

ASTM A602. Grade M3210 160

SAE J158: Grade M3210

Pearlitic 4 1-4 .018

ASTM A220: Grades 40010. 2 5-10 .012 100 M2, M7
45006. 45008. 50005 160 Malleablhzed 2 11-19 .010
ASTM A602. Grade M404. to and 2 20-48 008
M5003 200 Heat
SAE J158: Grades M4504. Treated
M5003
4 1-4 018 9
2 5-10 .012 7 2 7- 411
2 11-19 .010
200
200an Malleablized 2 20-48 .008
toan
~~Treatedi 240 Heat

Tempered Martenalte
ASTM A220: Grade 60004 2 5-10 .012 65 M2. M7
ASTM A602: Grade M5503 200 Malleablized 2 11--9 .010
SAE J158: Grade M5503 to and 2 20--48 .008
255 Heat
Treated

For cutting gears of Class 9 (AGMA 390 03) or better, the Rotary Feed
should be reduced ano .he number of cuts should be increased
See
section 16 for Cutting Fluid Recommendations.4
e f n o
7-64
 Gear Shaping 7.3
ROTARY FEED

DIAMETRAL per cutter CUTTER HSS TOOL

HARD- NUMBER PITCH stroke SPEED MATERIAL
MATERIAL NESS CONDITION OF - (4" RD. cutter)
NESS ~~~CUTS 4++:++-+-
C -- ]Oj,: in fpm AISI

Olin JS
Tempered Martensite 4 1-4 018
ASTM A220" Grade 70003 2 5-10 012 60 M2,M7
ASTM A602: Grade M7002 220 Malleablized 2 11-19 010
SAE J158: Grade M7002 to and 2 20-48 .008
260 Heatr-
Treated ~h52- 3bc

Tempered Martensilte 4 1-4 016

ASTM A220: Grade 80002 2 5-10 012 50 M2.M7
ASTM A602: Grade M8501 240 Malleablized 2 11-19 .010
SAE J158- Grade M8501 to and 2 20-48 .008
280 Heat VF
WR. -' :
Treated KS65~

Tempered Martensite 4 1-4 .012

ASTM A220. Grade 90001 2 5-10 .010 45 M2,M7
ASTM A602 Grade M8501 250 Malleablized 2 11-19 .008
SAE J158: Grade M8501 to and 2 20-48 .008
320 Heat _ -44e
Treated " W t 2-4$'- - ___

28. ALUMINUM ALLOYS, 4 14 .028

2 5-10 .024 200 M2.M7
30 2 11-19 .015
EC 2218 5252 6253 to Cold 2 20-48 .008
1060 2219 5254 6262 80 Drawn -
1100 2618 5454 6463 500kg f 5'----
1145 3003 5456 6951 t- - W '- _

1175 3004 5457 7001

1235 3005 5652 7004 4 1-4 .028
2011 4032 5657 7005 2 5-10 .024
2014 5005 6053 7039 SolutionM2,M7
2017 5050 6061 7049 to Treated 2 20-48 .008
2021 5056 6066 7075 Ad
224 5083 6070 7079
2117 5154 6151 7178
2025 5086 6101 7175

825036075070 Solution 21-9.1

29. ALUMINUM ALLOYS, CAST 4 1-4 .028
500kg Aged
be
Shnd d Permanent Mold cuts180
40 2 11-19 .015 M2.M7
A140 319 0 357.0 A712.0 10 2 20-48 .008

208.0 A332.0 Ci
1443.0 dRs
713.0 765
213.0 F332.0 514.0 771.0
222.0 333.0 A514.0 850.0 -A -- ,-
224.0 354 0 8514.0 A850.0 I I
242.0 355 0 5200 880.0 2 10 .24
295.0 C355.0 535.0 2--1.04160 M2 M7
B295.0 356.0 705.0 70 Solution 2 11-19 .015
308.0 A356.0 707 0 to Treated 2 2G--48 .008
+
HidumniniumnRR-350 125 and - ' , -

For cutting gears of Class 9 (AGMA 390 03) or better. the Rotary Feed
should be reduced and the number of cuts should be increased
See section 16 for Cutting Fluid Recommendations. 76

7-65
 - -~ a..... 3' - -. . ,

7.3 Gear Shaping

MATE RIAL
1- 1DIAMETRAL
NUMBER PITCH
ROTARY FEED
per cutter
stroke u t r
CUTTER
SPEED
HSS TOOL
MATERIAL
NE SSDH CO NDIT IO N COF
F
USO -(
NESS II-'-,'--'- - .. (4"1P.D..Dcutter)

Bhn -- IS-C1--40
CUT 06 in - 1pm AISI
34. COPPER ALLOYS, 4 108
WROUGHT 2 5-10 012 100 M2.M7
2 11-19 .010 10 M.M
145 332 360 482 10 R 8 2 20-48 .008
147 335 ?35 485 to Annealed J--4
'

173 340 366 544 70% 2e 5.--'

187 342 367 623 -aa-s30 SS2-
191 349 368 624 t- - - - .2- ___-- -_ _. ___

314 350 370 638 4 1-4 018

316 353 377 642 2 5--10 .012
330 356 385 782 2 1119 .010 110 M2. M7
t0 Cold 2 20-48 .008

10 0 R Drawr42565

4 1-4 016
190 425 466 667 2 5-10 .01P 70 M2M7
226 435 467 675 2 11-19 .010
230 442 613 687 10 R% 2 20-48 008
240 443 618 694 to Annealed I-- ...- - _

260 444 630 770 70 Ri, .-

268 445 632 A T-
o1:4t5 -tr ty .p
270 464 651 _----e.W- 2
280 465 655 4 1-4 .016
2 5-10 012
2 11-19 .010
60 8 Cold 2 20-48 .008

to Drawn '-- rt=

100 Re R __

4 1-4 .012
101 125 185 614 2 5-10 .012
102 127 189 619 2 11-19 .010
104 128 192 625 10 Re 2 20-48 .008
105 129 194 674 to Annealed 'E--- - Sr
107 130 195 688 70 Re -1R-

109 142 210 706 p , 2"frt t 8

110 143 220 710 '.. ..
111 150 411 715 4 1-4 .012
113 155 413 725 2 5-10 .012
114 162 505 745 2 11-19 .010 40 M2. M7
115 165 510 752 60 Cl 2 20-48 008
116 170 511 754 to cold2 2--48 .008 -
119 172 521 757 100%R Drawn -~ 3 -4 - -

120 175 524 # t - S

121 182 608
122 184 610 2s z#-

For cutting gears of Class 9 (AGMA 390 03) or better, the Rotary Feed
should be reduced and the number of cuts should be increased
See section 16 for Cutting Fluid Recommendations

7-66
 . . . . -=.. i n=- W=,.- - _. *. -rw= -J. -._ _" -.

Gear Shaping 7.3

DIAMETRAL ROTARY FEE

NUMER I~c cute
pestroke CUTTER HSSTOOL
NUMBER PITI SPEED I MATERIAL
MATERIAL HARD- CONDITION
NESS OF (4"1 P.D. cutter)
NESS CUTS :.- _

~~i in fpm AIt'I

35. COPPER ALLOYS, CAST 4 1-4 018

25 2 5,-100.012 0!290 9 i M2, M7
834 855 934 953 1 40 .2 I 11-19 ! .010
836 857 935 954 to I 2 20-48 008
838 858 937 956 ,50 As Cast -. - . -'- j,
842 864 938 973 50CA 52 ss--zs 4'-.3g.>" - "
842 864 938 9734 0k
848 879 943 976 ~~__ t- 4 ~,
852 928 944 978
854 932 945

4 1-4 .016
817 868 905 947 2 5-10 .012
821 872 915 948 40 2 11-19 .010 60 M2 M7
833 874 922 952 to 2 20-48 .008
853 875 923 955 175 As Cast ___ -
861
862 876
878 925
926 957
958 500kg = --- -
865 903 927 _r A
4 1--4 .012

801 815 828 916 2 510 .012

803 818 863 917 40 2 11-19 .010
805 820 902 962 to 2 20-48 008
807 822 907 963 200 As Cast -r
809 824 909 964 500kg
811 825 910 966 -: tat
813 826 911 993 4 - _--__"

814 827 913

-i-

-I-- '~2~- -_____ ----

I - S
A -- -'~=~--=-i
--

For cutting gears of Class 9 (AGMA 390 03) 0' better, the Rotary Feed
should be reduced and the number of cuts should be increased
See section 16 for Cutting Fluid Recommendations.

7-67
 PfODA9~ BLAWL-1P F1-kZhD

Gear Shaving 7.4

CUTTER
DIAMETRAL FEED*t CUTTER
PITCHPITCH HSSTOOL
MATERIAL HARD- UNE MATERIAL
NESS CONDITION of g SPE
SPEED
MATRIL ES _9M_ in fpm AISI

ehn n-4: r m
&-- :E59
1. FREE MACHINING CARBON STEELS, 1-4 .012
WROUGHT 5-10 008 610 M2. M7
Low Carbon Resulfurized 100 Hot 11-19 .005
Rolled 20 & Finer .003 ,
1116 1119 to
1117 1211 150 or
1118 1212 Annealed

1--- .012
5-10 008 M2 M7

11-19 005
150
Cold 20 & Finer .003
to
200 Drawn

1-4 .012
Low Carbon Reaiulfurizod 1235-10 008 60 M2. M7
1213 1 9 .0
1215 100 Hot
to Rolled 20 & Finer .003
150 or MIN,
Annealed -R""""""" -

1---4 .012
5-10 .008 70 MM
150 1
Cold 20 & Finer .003
to Drawn
2GO

Low Carbon Resuflurized 1-4 .012

1108 10 .00 5 M2. M7
1109 100 Hot
to Rolled 20 & Finer .003
1110
150 o
Annealed -- Z"
1115

1.-4 .012
5--10 .008
.05 20 M2. M7
15011-9
50
Cold 20 & Finer .003
to
200Drw

Medium Carbon Rolturifzed .012

1132 1144 500 M2. M7

175 Rolled. 11-19 .005
1137 1145
to Normalized. 20 & Finer .003
1139 1146
'25 Annealed . .
1140 1151
111or Cold -
Drawn

11411
5-0 .008
5-190 00 350 M2. M7
275 Quenched 20 & Finer .003 2

325 Tempered -I

See section 16 for Cutting Fluid Recommendations

'Feed recommendations apply to CONVENTIONAL (axial-transverse)

gsar shaving.
tFeeds should be increased 100% for gears shaved by the DIAGONAL
(angular.transverse) method.
7-69
7.4 Gear Shaving
EED1 CUTTER
DIAMERAL
IMTHL peE . PITCH HSS TOOL
MATERPITCHAD ODTO fga LINE MATERIAL
CONETSO IRMOge SPEED

Bhn __________ jm mmr __

FEE MCHIING ARBO

1. STELS,1-4 .012
WOGT(ot)15-10 .008 275 M2. M7
1- 19 005
Medium Carbon Resulfurized (cont.) 325 Quetvhed 20 & Finer .003
(materials listed on preceding page) i t a-d .-- -- -

37 empered -M K101--

Low Carbon Leaded 1-4 .012

10118 Hot 5-10 .008 5 M27
100 Rolled, 11-19 005 65 2M
11117
to Normalized 20 & Fin~er .003
150 Annealed ~ ~~
or Cold

1- 012
Hot 5-10 .008 70 M.M
150 Rolled. 11-19 .005 70 M.M
10 Normalized. 20 & F tier .003
200 Annealed
or Cold - = ~
Drawn ~~~__
1-4 .012
Hot 5-10 .008 55 M.M
200 Rolled.119 05
to Normalized.20&Fnr .3
250 Annealed M~
or Cold _

Drawn

Low Carbon Leaded 14 .1

12113 Hot 51 08 70 M.M
100 Rolled.1-9 05
12114
12115 to Normalized. 20_&Fine_.00
150 Annealed RI
or Cold
Drawn

Hot -0 .8
150 Rolled.'1 19 .0
10 ormlizd.20 & Finer .003
200 Annealed Owl~
or Cold
Drawn -4 A2

Hot 10 .8
200 Rolled.119 05

to Normalized.2&Fie 03
250 Annealed
or Cold v
Drawn

Medium Carbon Leaded 14 .1

10145 Hot5-0 .8 60 2M
25 Rolled.119 05
10150
11L37 to Normalized. 20 & Finer ---- 003
11141 175 Annealed ~-
1Iol44 or Cold
Drawn

See section 16 for Cutting Fluid Recommendations

-Ffed recommfrendations apply 1oCONVENTIONAL (axisl-transverse)
gear shaving.
t Feeds should be increased 100% for gears shaved by the DIAGONAL
(angular-transverse) method
7-70

-~~~ ~ ~ ---- ~ 7;
 Gear Shaving 7.4

AMET
AL F EO~tCUTTER
IMTHL Perev. PITCH HSS TOOL
MAEILHARD, PONITCNH o erv LINE MATERIAL
M~ERALNESS CODTO _ogw SPEED
~3UG~t'~ in fpm AISI

1. FREE MACHINING CARBON STEELS, 14 .1

WROUGHT (cont.)
Medium Carbon Leaded (contt.) 175
Hot
Roled.
5-10
11-19 J005
.008 525 M2, M7

(materials listed on preceding page) to Normalizea. 20 & Finer .003

225 Annealed 2-6' 3
or Cold
Drawn

1-4 .012
Hot Rolled.5-0 '8
Normalized. 11-10 008 2 M.M
225 Annealed.111 05 42 2M
to Cod Drawn 20 & Finer .003
275 or 0922
Quenched
and 927
1empered
02
Hot Rolled.1-
Normalized. 51 08
.0 35 M.M
275 Annealed. 1-9
to Cold Drawn 20 & Finer .003
325 or
Quenched
Tempered

325 Quenched 20 & Finer 003

to and
375 TemperedJ

2. CARSON STEELS, WROUGHT 14 .1

Low Carbon Ht510 .0 2 2
1015 1023 85 Rotted. 11-19 .005 52 2*
1005 Normalized. 20 &Finer .003
1006 1016 1025 to
1008 1017 1026 125 Annealed -

1009 1018 1029 or Cotd .-

1010 1019 1513 Drawn _

1011 1020 1518 1 1 I--_-

1012 1021 1522 14 .1
1013 1022Ho510 .0 5W M.7
4a~rmalized. 20 & Finer .003
to
175 Annealed 1- .
MME
or Cold r
Drawn

175 Rotted. 11-19 .005

to Normalized. 20 & Fier .003
225 Annealed

275r Cold
Drawn

gea shavingier.00

tFeeds should be increaesed 10% for gears shaved by the DIAGONAL

(angutar-transvems) method
7-71
7.4 Gear Shaving
DIAMETRAL FEED~t CUTTER

P PITCH HSS TOOL

.AR*Li
MATERIAL
NES
A- S CONDITION o gea SPEE
INSPEED AS
in fpm AISI

1- .012
2. CARBON STEELS, WROUGHT (cont.)
Medium Carbon Hot -- 10 008 450 M2. M7
1030 1044 1526 125 Roi2ed. 19 003
1045 1527 to Normalized. 20 & Finer 003
1033
175 Annealed 2 ' ,
1035 1046 1536
1037 1049 154 or Cold
1038 1050 1547 Drawn
1039 1053 1548 1 -4 .012
1040 1055 1551 5-W .008
1042 1524 1552 H 11-19 05 400 M2. M7
1043 1525 175 Rolled. 2 & F9 005
to Normalized. 20 & Finer 003
225 Annealed
or Cold _ _
Drawn

1-4 .012
Hot Rolled. 5-10 .008
Normalized. 350 M2, M7
225 Annealed. 20 .003
to Cold Drawn 20 & Finer 003

275 o
Quenched
and
Tempered
Hot Roled. 5-10 .008
Normalized. 11-19 005
275 Annealed 20 & Finer .003
to of
325 Quenched __

and
Tempered
1-4 012
--- 617
11--19 008
005 275 olM3_ =
325 Ouenched
to ando, 20 & Finer .003
375 Tempered

Hbh C . .1-4 .012 '

1064 1078 lr*95 175 Rolled. 11-9 -" 05 35 7i
1060 1075 1090 275 nealet
n --
1561 to No trmalize , . 20 & F:"nr _03
0
1065 1080

1070
1074
1085
1086
1572
J or Coid
Drwn

1---4 .(0!2
8
I
Hot RClled. 5-
Norm3lized. 5 25 M2. M7
225 Annealed.
20 & Finer 003
to Cotd Drawn
275 of-

Tempered

I ! i~~--4 .1
ReL4ed.--0 .0 300 M2. M7
I-ot1-

20 Mnealed 20 & Fine .003

325 or
Ouenc."ed
and
t ! Tempeed
See section 16 for Cining Fluid Recommt ",itons.
*Feed r-commendal-ons apply to CONVENTIONAL (axial-lransvrse)
gear shaving.
tFeeds should be ;ncreased 100% for gears shaved by the DIAGONAL
(angular-transverse) method
7-72

-7-
 Gear Shaving 7.4

I PIAMETRAL FEEDt PITCH "SS TOOL

PITCH PerWev LINE MATERIAL
MATERIAL NES cowomw
CONDTIO SPEE
in fpm AS

2. CA0NSTEEL, WRUH (cont) NESS .012 ED AS

High Corbon (cont.) j5-10 008 250 M3

(materials listed on preceding page) 5 325 Quenched 11-0
& ie 0053
to I and .-
375 Trempered

3. CARBON AND FERRITIC ALLOY STEELS 14 .1

(HIGH TEMPERATURE SERVICE) 51 0 5 2 A
150 1-9 .0
ASTM A369. Grades FPA. FPS. FI'1. FP2.
to A ie
FP12

-
ASTM A369: Grades FP~'b. FP1'
Annealed 11-19 .005 0 2 -
150 o 0&Fr7 .0
toNomlzd-
200an

AS' LMA36C- Grades FPS- FP7. FP9. FP2i.1 5-0 .8

FP22 10Anae 11 05 30 M.M

200an
Ttmpered

4. FRAEE I&ACHNING ALLOY STEELS, 14 .012

WROUGom Hot 5-10 .008
MedQ, Czrbon Resufuadzsd 150 Rolled. V-9 .0
4140 4145Se to Normalized. 20 & Finer .003
4140Se 4147Te 2OAnae
4142Te 4150ofCl

200 Rolled. 11-i9 .005

t ofenaeizd. 20& Fier .003

25 Annealede

511 .08a2nM.dA

325 Temrpered

t~~~esds~~32
100% O h OAOA OuenJ18 20 &nr~e .003rs~ae
(antu~r~tans10e aetod
375 Tempe7
e
See ecton 1 fo CutingFlui Reonowato
*Feed_ _________________applyto__CONVE_____AL __________
go vism"________________i
7.4 Gear Shaving

FEEDt CUTTER
DIAMETRAL
PITCH PITH per rv.
pr rev. LINE
PITCH MATERIAL
HSS TOOL
HARD- CONDITION of gear
MATERIAL NESS SPFED

Ehn~int fpmn AISI

4. FREE MACHINING ALLOY STEELS, 1 4 012 I
WROUGHT (cont.) 510 .008 1Hot525 M2, M7
150 Rolled. 11-19 005
./) Medium and High Carbon Leaded Nomahed.20 & Finer .003
41L50 86L20 to Normalized.
41L30
41140 43140 86L40 200 Annealed -t'C - r tir
41L45 52L32 Drawn 4 t.._11,5j Y4--S
41L-47 52LI00
1-4 .012
Hot 5-10 .008 450 M2, M7

Rolled. 11t19 .005

200
to Normalized, 20 & Fier .003
250 Annealed =6 03R1
or Cold IM zi f~
Drawn -

1- -. 2
5- 10 ,08 350 M2, M7
275 Quenched 2011-19
& Finer 005
.003

325 Tempered

1--4 .012
5-10 .008 25 M
325 Quenched 2011-19
& Finer 005
003

3,5Tempered . ... a"

1-4
5. ALLOY STEELS, WROUGHT
Low Carbon Hot 5-10 .008 475 M2, M7
125 Rolled, 1119 005
4012 4615 4817 8617
4820 8620 to Annealed 20 & Finer .003
4023 4617
4024 4620 5015 8622 175 or
4118 4621 5115 8$22 o winn-"
4320 4713 5120 931C Draw,
4419 4720 6118 94B15 .
4422 4815 8115 94B17 1-4 .012
Hot 5_-10 .008 45 MM
175 Rolled, 1-1 005 45 iMM

003
to
t225 Annealed
or =...20 & Finer '

Cold
Drawi,, ,w it
1-4 012

Hot 5-i0 .008

350 M2, M7
225 Rolled, 11-19 .005

o Normalized, 20 Finer .003

2 75 Aonealed
or Coldgersag
Drawn *

1.,-4 .012
o b5-e10
Normalizd .008
to g 300
275 or 201119
& Finer .005
.0
to Quenched i,
325 and
Tempered

See section 16 for Cutting Fluid Recommendations.

*Feed recommendatins apply to CONVENTIONAL (-xl-transverse)
, ga
eeosshaving.
should be Increased 100% for gears shaved by the DIAGONAL
(angular-transverse) method.
71
 Gear Shaving 7.4

DIAMETRAL FEEDt CUTTER S TO

per rev. PITCH HSSTOOL
PITCH
HARD- LINE MATERIAL
MATERIAL CONDITION of gear
NESS _SPEED

30"
__M in fpm AISI
Shn T --S - _ . . ..
1 4 012
5. ALLOY STEELS, WROUGHT (cont.)
Normaized 10 .008 250 MS
Low Carbon (cont.) 20 & Finer 003 2
325 or
(materials listed on preceding page)
to Quenched 2- 6ZPt - . w -+

35and L t ~ ;
Tempered

1-4 012
Medium Carbon
1330 4145 5132 8640 Hot 5-10 .008 400 M2, M7
1335 4147 5135 8642 175 Rolled, 11-19 .005
to Annealed 20 & Finer 003
134U 4150 5140 8645
1345 4161 51,45 86B45 225 or .
407 4340 5147 8650 Cl
4028 4427 5150 8655 1 Drawn M.% . '*1Q ; a ....
S2=
4032 4626 5155 8660 n&'or2t.
1-4 N 012
4*N ;"' -st
4037 50B40 5160 8740 Annealed, 5-10 .008
4042 50544 51560 8742 Normalized, 11 -9 .005 325 M2, M7
4047 5046 6150 9254 225 Cold Drawn 20 & Finer 003
4130 50B46 81B45 9255 to or00
4135 50B50 8625 9260 275 Quenched aa,-
4137 5060 8627 94530 Querd t' 4r io4~& t
4140 50B60 8630 Tempered - 4 -

4142 ri3o 8637 Tmee

1-4 012
5-19 008
No'nalized 11-19 .005 275 M2. M7
25or 20 &Finer .003
to Qt,Inched r- - - -
3 , and R
Tmp.red -. .

1-4 .012
5-10 .008
Normalized 11-19 .005 225 M3
325 or 20 & Finer 003
to Quenched lp V
375 and ON
-
Tempered f7 . ZA

High Carbon 1-4 .012

50100 Hot 5-10 .008

Rolled. 11-19 .005
51100 175
Annealed 20 & Finer 00?
5210 to

Drawn + ... .. i

1.-4 .012
Normalzed, 5-10 .008 30
1 1-19 .00 5 C i F dM2ug i c e t7
2 25 Co ld D rawn
or 20 & Faer 003
to
275 AL QsodbicadndogashvbthDAN
Tempered

1-4 0;2 !
1 -10 .008 2 M2 'A,
275or Normalzed 20 & Finer .003
to Quenched -
(anguar-trnsvese) mthod

See section 16 for Cutting Fluid Recommendations

*Feed recommendations apply to CONVENTIONAL (axlaf-transverse)
gear shaving
tFeeds should be increased 100% 'or gears shaved by the DIAGONAL
(angular-transverse) method.
7-75
7.4 Gear Shaving
CUTTER
DIAMETRAL FEED*t PITCH HSS TOOL
PITCH per rev. INE MATIL
MAEIAARD- CNIONoger LINE MATERIAL
NESS Ot gear SPEED

n fpm AISI

1-4 012
5. ALLOY STEELS, WROUGHT (cont.)
High Carbon (cont.) Normalized 11-19 .005 200 M3
(materials listed on preceding page) 325 or 20 & Finer .003
tO Quenched A " _

35and Q..~- Q,~~.r-

6. HIGH STRENGTH STEELS, WROUGHT 1-4 .012

5-10 5-1 .008
.08 300 M2, M7
300M 98BV40 11-19 .005
4330V D6ac 225 20 & Finer .003
4340 Hl to Annealed
4340S, H13 300

1-4 .012

5-10 .008 25 M
11-19 .005 25 M
300 20 & Finer .003
to Normalized - 7r
350

1-4 .012
HP 9-4-20 5-10 .008
HP 9-4-25 11-19 .005
HP 9-4-30 325 20 & Finer 003
HP 9-4-45 to Annealed
375

7. MARAG:NG STEELS, WROUGHT 1-4 012

5-10 .008
120 Grade 11-19 005 350 M2. M7
180 Grade 275 20 & Finer .003
to Annealed 5

1-4 .012
ASTM A538: Grades A. B, C 5-10 .008
200 Grade 300 M2. M7
250 Grade 275 20 & Finer .003
300 Grade to Annealed
350 Grade 325
HY230

8. TOOL STEELS, WROUGHT 1-4 .012

High Speed 5-10 .008 225 M2,M7
M1 TI 200 20 & Finer .003
M42 T2 to Annealed
M6 T6 250

1,-4 .012
High Speed 5-10 .008
*43-1 M34 M46 200 M2,M7
M3-2 M36 M47 225 20 .003
M44 M441 14 to Annealed
M7M42 T5 2754
M30 M443 T ,--xsIM
M433 I
M444 RONS
See section 16 for Cutting Fluid Recommendations.
*Feed recommendations apply to CONVENTIONAL (axial-transverse)
gear shtlrg.
tFeeds should be Increased100% for ge a shaved by the DIAGONAL
(angular-transverse) method.
7-76
 Gear Shaving 7.4
CUTTER
PITCH HSS TOOL
DIAMETRAL FEEDf
per rev. I NE MATE I L
PITC H
HARD- CONDITION of gear E MATERIAL
MATERIAL NESS O N- f SPEED
4ZZ ....jj(W in fpm AISI

Hot Work 1-4 .012

1-10 H22 5109 0 325 M2. M7
H1O H23 150 20& Fner 00 3
to A n nea led 20. . .... 00
H 12 H 24
H13
H14 H25
H26 200 4t .t.Ss .
_'.,

H19 H42
1121 1-4 012
5- 10
1-19 .008
.005 300 M2,M7
2011-19 005
200 20 & Finer 003
to Annealed -: -- 'V _-'-
250 W k-tt -

1-4 012
5-10 .008
11-19 .005 250 M3
325 Quenched 20 & Finer .003
to and
375 1empered MN
.4 - RO
4
~-~-
Cold Work 1-4 012

A2
A3 D3
D430 5- 10
11-19 .005
.008 300 M2, M7
A3 DA 200 20 & Finer .003
A4 D5 to Annealed . - w e
A6 D7 250 W IT - - -

A7 01
A8 02
A9 06
A1O 07
D2

1-4 .012
Shock Resisting
S1 ~5-10 11- 11
.008
005
35
3 5M
MM
,M
S 217
$2 175 20 & Finer 003
$5 to Annealed
$6 225 A.2
$7 W0_

1-4 .012

P2 5-10 .008 500 M2,M7

P4 100 20& Finer 003

P6
P5 0to Annealed 2-ir 0

ISO
Mold1-4 .012
5-110 .00-10450 1 M2, M7
P20 11-19 .005
P21 1F 20 & Finer .003
to Annealed
200

See section 16 for Cutting Fluid Recommendations.

*Feed recommendations apply to CONVENTIONAL (axlal-liansverse)
gear shaving
tFeeds should be Increa-.ed 100% for gears shaved by the DIAGONAL
(angular-transverse) method.
7-77
 LJ .

7.4 Gear Shaving

DIAMETRAL FEED~t CUTCHTSE TO

HD-PITCH per rev. INEH MASTIL
MATERIAL NESS- CONDITION of gear SPED TEIA

Bhn~-IOUL'~ in fpm AISI

Bhn__ ______ _ -Mitt: iik,_____
8. TOOL STEELS, WROUGHT (cont.) 1-4 .012
Special Purpose 5- 191C 425 M2. M7
12 150 20 & Finer .003
16 to Annealed2-S3 4
17 200

Special Purpose 1-4 .012 1

Ft1 510 .008 37 M2.M7
F2 0011-19 .005

Wate
Hadein0 20& inr~ .003
to Annealed ,4

Wae Hreig14 012

Wi1, W2. W5 I 5-10 008 400 M2. M7
SAE J438b: Types W 108. ,v109. WI110. 150 & nr
20-1 003
Wi 12. W209, W210. W310 to Annealed - 0&Fnr 0
200 5 2 .s

9. NITRIDING STEELS, WROUGHT 1-4 012

Nirloy155-10 .008 375 M2.M7
Nitralloy 135 200 20 & Finer 003
Nitralloy 135 Mod. to Annealed -X - , .-
Nitrattoy 225 250 -- 6zi2 - "- " I
Nitratloy 230 ~ ~ Z
Nitraltoy EZ
Nitratloy N ____ 4 El ; - ~-5
Nitrex 1 1 4.1
Normalized 5-10 008 275 M3
11-19 .005
300 of 20 & Finer 003
to Quenched
350an
Tempered :a4fp
1-401
-10 .008 M
12. FREE MACHINING STAINLESS STEELS,
WROUGHT 1 19 05 300 M2.M7
Ferritic 135 201&Fin9 003
430F to Annale
430F Se 183 _ - - i

II

Austenitic .1
203EZ 15-19 008 250 M2, M7
303 135 20 & Fine~r .003
303MA to Annealed ____4 -
303Pb 185 gK
303 Plus X
303Se fu -
1-4 .012
5-10 .008 225 M2. M7
2511-19 005
to Cold 20 & Finer .003
275 Drawn

See section 16 ior Citling Fluid Recommlendatio~ns

'Feed recommendations apply to CON VENTIO)NAL (axial-transverse)
gew shaving
t Feeds shiould be increased too% lcorgears shav3d by the DIAGONAL
(angular-transverse) method
77
 Gear Shaving 7.4

DIAMETRAL FEEDS I CUTTER

ICH prrv PITCH HSS TOOL
HAD MTRA
MATERIAL HD.CONDITION of gear IE
NESS SPEED
MDL- in fpm I AISI
416Bhn ______ mm. m6imii, ISO.
Martensiic 15 1
4012 0
46 42OF Se 11j 00 0 M2. M7
416 PlusX 440F 135 201&Fin9 0053 0
416Se 440F Se to Anr'ealed 2 ie 0
420F 185 2-
.2 1 12 482

I1-4 012
5-10 .008 27 2M
185 Annealed 11-19 .005 27 M27
to or20 & Finer 003
240 Cold 25m-6 3
Drawn -2
2- 15-- 12 8 -_ 4
1-4 .012
5-10 .008 225 M2, M7
11-19 05
275 Quenched 20 & Finer 003
to and ~ SP
325 Tempered 2S42
12

13. STAINLESS STEELS, WROUGHT 1-40 .008 2522

Ferritic 5101 005 7 M.M
405 434 135 11& ine 003
409 436 to Annealed
429 442 185
430 446 2j 1

Austenitic 1-40 008 2522M

201 304L 348 5101 005 2 MM
305 384 135 1-9 .0
202
30 38 85t~Annealed 20 & Finer .00
302 321 185 - DOE

14 012
5-10 .008 20 M.M
225 11-19 005 20 MM
to Cold 20 & Finer .003
275 Drawn
___
___ ___
___ ___ _ ~ ~ t~1 gI~ -

Austenitic 1-4 .012

3028 314 51 08 20 M.M
309 316 135 1
110Fier 003
309S 316L to Anneaied N;x-
310 317 185 at 3 -. - - !
310S 330 S

1-9 .0
225
toCold 20 & Finer .003
275 Drawn___

See section 16 'or Culling Fluid Recommendations

*Feed recommendations aPPly to CONVENTIONAL (nxlal-transverse)
gear shaving
tFeeds should be increased 100% for gears shaved by the DIAGONAL
(angular-transverse) method
7-79

________________ 7_ ___________________________=
7.4 Gear Shaving

DIMTHL ,ee. ITC HSS TOOL

MATERIAL HARD- PONITCNH per
o LINE MATERIAL
oNEgeS SPEED
Ajin fpmn AISI
__ __ __ _ __ _ _ Bhn ___ ___ ___ _

13. STAINLESS STEELS, WROUGHT (cont.) I-A .012

Austenitic 5-10 008 M.M
11-19 .005 17 M27
Nitronic 32 210 20 & Finer 003
Nitronic 33 to Annealed
Nitronic 40 250
Nitronic 50
Nilronic 60

Martensitic 1-4 .012

403 5-10 008 275 M2. M7
410 135 11-19 005
20 & Finer 003
420 to Annealed
422 175
501
502 __

1-4 012

1520 & Finer .003

to Annealed
225

275 Quenched20&Fnr .3
to and
325 Tempered Ws-

Martensitic1-A .2
414 1 -9 .
431 225 11-1ie 10053 2 2M
Greek Ascotoy to Annealed
2750

275 Quenched 200&MFner 00

325 Tempered

Martensitic
440A111 .05 25 M.17
440B2220&Fnr .3
440CtoAnae -- I-1
275 --

275 uenc~hed 20 & Finer .003

325 Tempered

See section 16 for Cutting FRuid

Recommendations
*Feed recommendations apply to CONVENTIONAL (axal-transverse)
gear shavingI
tFeeds should be increased 100% for gears shaved by the DIAGONAL
(angular-transverse) method 78

7-80~--~
 Gear Shaving 7.4

DIAMETRAL FEED*t CUTTER I

PITCH jHSS TOOL
HR-PITCH per rev. LINE MERIAL
MAARD- ES CONDITION of ea SPEED MT

J.
_ ___
___ ______I ___ ___ ~in fpm I AISI

14. PRECIPITATION HARDENING I A0 .081,2'

STAINLESS STEELS, WROUGHT I 51-10 .005 225 M2.M7
15-5 PH 150 S11ut19 0&Fnr .003
16-6 PH to Souto 20&Fne 0
17-4 PH 200 Treated-2-6 -

17-7 PH
17-14 Cu Mo
AF-71
J~--- i...- 4S2i-
-Z't~-

'FC-77 -40I
Almar 362 (AM-362) 5_10 I.008 20 M.M

AM-350 25Solution 1 -9 005 20 M2M

AI35to Treated 20 & Finer .003
AM-363 325 o
Custom 450 Hardened S2
Custom 455
HNM
~'- _________ ~ ON___
I&ioZ.O7
-
PH 13-8 Mo 1-4 .012
PH 14-8 Mo 5-10 .008 175 M3
PH 15-7 Mo 325 Solution 11 0
Stainless W to Treated 20 &riner .003
375 or
Hardened ES--
01

15. CARBON STEELS, CAST 14 .1

Low Carbon Annealed. -0 .0 50 M.M
ASTM A426 Grade CPI 100 Normalized 1-9 .0

1010 to or 20 &Finer : .003

1020 150 Normalize(, , .

Tempered

Medium Carbon 14 .1
ASTIA A352 Grades LCA. LCR LCC Annealed. 51 08 45 M.M
ASTM A356- Grad-r 1 125 Normalized 1-9 .0
t0 or 20 & ier .0
1030
1040175 Normalized
1050 and 2 3Q9
~
-4O -
A
Tempered

Annealed. 1-10 .005 7 MM

175
to ior
Normalized 1-10
20 & Finer
.0085
.003 j 7 2M

225Nomlzdssc

300 Tempered

gear
sarng20&.inr 00

mto.78
(angulrcmedtosapyt OVNINL(xa-transverse)

gear____ _________________________________

tF~~~~~~~ds~~~ shul
yteDAO inrese
A 10%ltgasSae -e
7.4 Gear Shaving
T DIAMETRAL FEEDt ICUTTER f TO
PH perev PITCH HSSTO
MAERA HARD- CODITOC pear
o LINE MATERIAL
MAERALINESS CODTO 1w SPEED
I MOWAE in fpm AISI
Bhn 4-M
_________ _____Mj /mh,- -ISO
16. ALLOY STEELS. CAST 1-4 012 r
Low Carbon Anneale 5-l0 008 425 M2. M7
ASTMIA217 Grade WC9 10Normalized 11-19 005
ASTM A352 Grades LC3. LC4 15oo 20 & Finer 003
ASTM A426 Grades CP2. CP5. CP5b. OPI 1. 200 i Normalized 2-6 -

CP12, CPI5.CP21. CP22 and f --

1320 2320 4120 800Tempered 213V12S4S
2315 4110 4320 8620 -_______________ &mr________
1-4 012
Annealed. 008 3-10
200 Normazed 11-19 .005 M M
to of &Fnr 003
225 Normalized ~ - .3-- -

and 5 32 > 2
Tempered 15 1_2-

1-4 .012
5_10 I.008 32
.1-19 005 35 M .M4
250 Quenched 20 & Finer .003
to and .-.
300 Tempered __ yN-- -

Medium Carbon 14 .1
ASTM A27 Grades Ni1, N2. U-60-30 60-30. Anae.10 .008 352ZM
65-35. 70-36 70-40 175 Normalized. 11-19 .005 37 2.7
ASTM A148. Grades 80-40. 80-50. 90-60. to or 20 &Finer .003
105-85 120-95. 150-125. 175-145 225 Normalized ~ o--
ASTM A216- Grades WCA. wCB. WCC: and _

ASTM A217: Grades WC1 WC-4 WC5 WOS I ___:

ASTM A352. Grades LCl. LC2. LC2-1 ____________ ~ _

ASTM A356 Grades 2. 5. 6.8. 9. 10 Nomlzd1-4 .012

ASTM A389. Grades 023. C24 Normalized' 11-19 08 35 M.M
ASTM A486 Classes 70. 90. 120 2251 and
ASI M A487. Classes IN. 2N, 4N. 6N. EN. 9N. Teprd20 & Finer .003
10N. DN 10. 20,40. 40A. 60,70.80. 20or-
250
90. 100 Quenched
1330 4130 80830 8640 and ~ ~ ~ -

1340 4140 8040 9525 ______ Tempered ~ ;b

2325 4330 8430 9530 1-4 012
2330 4340 8440 9535 5-10 .008 30 M.M
4125 8030 8630 2501 Qunhd20.Fnr 003

300 Quenched 20 & Finer 003

to and

400 Tempered

gearsunceavinginr
00
(anula-trnsvrse
metho
35 7..-82
Tmpre .. W

- -:-_wL in
 Gear Shaving 7.4
AL EFtECCUTTER
DIAMETR AL PITCH HSS TOOL
MATERIAL HARD- PITCH pejrv LINE MATERIAL
NESCONDITION SPEED
in fpm AISI
______________ hn :~. is~f/ll
h________ S
1- 012' 1
18. STAINLESS STEELS, CAST5-0 08' II
Ferritic f 0 250 M2.0M7
ASTM A217 G.ades Cs. 012 235 1-119 05 20 MM
20 & Filler 003
ASTM A296 Grades C8-30. CC-50. CE-30. j to -neae
6
ASTM A487 Class CA6NM
ASTM A608 Grade HC3 I -
-.

Austenitic 1-4 012

ASTM A296 G~z 'esCF- 16F. CN-7M 5-10 .008 200 M2. M7
CN-7MS 140 Annealed

I.0
20 & Fmner .003I
ASTM A351 Grade CN-7M to or
70 ormaized

CF'O135
Austnitc

ASTM A296 Grades CF-3 CF-8, CF-8C

ASTM A351 Grades CF-3 CF-3A. CF-8. to
I1-4
Iutni
Annealed
or
5-0
20 & Finer
.0
003
00
012

175 M2.M7

CF8.CF-8C 185 Normalized

ASTM A451 Grades CPF3. CPF3A. CPF8. ~ ~
UP-AP8.CPF8C (Ta Max)~
ASTM A452 Grades TP 304H. TP 347H _____________

Austerniic r1-4 012

ASTM A296 Grades CF-3M. CF-8M. CG-81'1. 5-10 boa 175 M2. M7
CG-12 CH-20. CK-20 135 Annealed 20 & Ftner .003
ASTM A351. Grades CF-3M. CF-3MA. to or ____I
CF-8M, CF-1OMC. CH-8. CH-10. CH-20. 185 Normal~zed
CK-20. HK-30. HK-40. HT-30I
ASTM A45 1: Grades CPF3M. CPF8M.
CPFIOMC. CP.L8. PH10. CPH2>O. CPK2O
I -40

____I_________

ASTM A452 Grade TP 316H

Austenitic 14 .1
ASTM A297- Grades HD. HE. HF. HH. HI. HK. 51 08 15 M.M
HL. HN. HP. HT. HU 160 I20 & Finer .003
ASTM A608: Grades H050. HE35. HF3O. t0 As Cast
HH3O. HH33, H135. HK3O. HK4O. HL3O. 210

HL4O. HN4O. HT5O. HUSO

See section 16 for Cutting Fluid Recomrnendations

*Feed fecommrenlaons apply !o CONVENTIONAL (axialImtrnsverse)
gear shaving
tFeeds shonuld be increased 100% lor gears shaved by the OIAGG. AL
(angular-transverse) miethod
7-83
7.4 Gear Shaving
I CUTTER
DIAMETRAL FEEOI PTC SSOL
PHTHRD-' LINE MATERIAL
MATERIAL CONDITION of gem SPE
NESSSPE
Ma~AS n forn AISI

18. STAINLESS STEELS. CAST (cont.) 0h124{m~~[ ~S~

Itartonsitic 05 250 !V2. M7
ASrMAA217 Grace CA-' Is 0 r ~ 0
ASTMA A296 Grades CA-'5 CA-ISM. 0-A-4C 20 Finerd 003
ASTIM A426 Grades CD7. CP9, CPCA15
ASTIA AA87 Classes CAI 5a, CA- 15M
75 F
V _

Annealed 5_10 00812.M

15Normalized - - I 0
or6 20& -11Fier 1 003
225I Normalize
and
Temper'ed C
5. W,-'-:

2-1lt=---1
2
69 8S2.-
_______~~~~~ 12i~~
7-
0_______

1oo00 200 M2.M7

27 Qunce
275 Ounche 20 & Fine., 003

325 Tempered

19. PRECIPITATION HARDENING I I01

STAINLESS STEELS, CAST
325
I 5-at
1 I
008
005
15
17
M.M
M27
ASTM A351 Grade CD-4MCu 0

I20 &~F-II- 003

AC ACIGrdeCB-CutoSolution
Gad C1-CIt T'eat C
ACI Grade CO-4fUCu j 375
17-4 PH I_
AM-35-n ___ .=

21. GRAY CAST IRONS 14 01

lFerrific Cls 0!I9 05135 M.M
ASTM A48 Cls 2 20
SAE J43Ic. Grade G1800 to Annealed

Peartitic- Ferritic 1- 1
ASTM A48* Class251 19 05 30 2M
SAE J43 Ic Grade G25-30 20&Fie0.0
to As Cast -

Pearitic 1-
ASTM A48 0lasses, 30. 35 40 5- 0010 230 W M7
SAE J431c Grade G3000 l10 & ie
20-1 003
to As Cast - ~
220 .

Psuelitic + Firee Carblides51 08

ASTM A48- Classes 45. 50 20 2I
StE J431c Grades G3500. G-006 2201-9
to As Cast ___

se section 16 for Cutting Flid Recomrinendatioins

.Fee recommendations aply to COt4VENTKONAI. (axial-transverse)
gear shaving,
tFeesSl e incesd 100% for gears shaved by the DIAGONAL
(angular-trartsverse) method
7-84
 Gear Shaving 7.4

IuDIAMETRAL FEED t
' ;
CUTTER
PITCH i HSSTOOL

MATERIAL
HARD-
NESS
j CONDITION
ODTO gea
LINE
SPEED
MATERIAL

__________________________in Bh _______pm I AISI

Bh 1- -ZWzs

Peadiic or Acicular + Free Carbides 1-4 s012

ASTM A48 Classes 55. 0 1As , AS Cast1t-19
Cast 1--1 005i 100 M2.M7
250 or 20 & Finer 003

to0 Quenched
30and t~ ~ ~ ~ __
Temperedi--

Austenilic (NI-RESIST) 5-10 008

ASTM A436. Types 1. lb. 2. 2b. 3.4. 5. 6 j 150 M2. M7
10 20& Finer 003
250 -;-' _

I to As Cast jj - ' -r4

23. DUCTILE CAST IRONS

IFerrific

ASTM A536. Grades 60-40-18. 65-45-12 140

{ -10
5-10

2 &1Fine
.005
W8
.003
400
4 M2. M7

SAE J434c: Grades D4018. D4512 to Annealed

* 190

Ferdtic- Peatiiic 1-4 .012

ASTM A536- Grade 80-55-06 5_10
II11-19 .008
.005 350 M2. M7
SAE J434c. Grade D55C6 190 . 20 & Finer C03
to As Cast

I 1-4 .012 I
5---10 .008 30 M.M

22511--19 22520 &Finer .003

I t As Cast

Marhmlti 1-4 .012-_

Pndfific afunl
ASTM A536" Grade 100-70-03 11-19
5-10 .005
.008 20
2. M.M T
SAE J434c: Grade D7003 240 Normalized 20 & Fnner .003
to and
300 Tempered

..... 1,-4 012

ASTM A536: Grade 120-90-02 5-10 .005 175 M2. M7

SAE J434c: Grade DO&T 270 Quenched 20 & Finer .003
to and

Aust (MIRE.ST Ductif) 1-4 .01

ASTM A439: Types D-2. D-2C. D-3A. D-5 125 M2. M7
ASTM AS7 1: Type 0-2M 20 201F
10 Annealed
200

See section 16 for Cutting Fluid Recommendations

'Feed roccmnmendatbons apply to CONVENTIONAL (axialtransvee)
gear liMg. Z
tFeedls shOuld be increased 100% for gears shaved by the DIAGONAL
(rSg%V-trainsvere) method
7-85
4
7.4 Gear Shaving
I 1 CUTTER
*DIAMETRAL FEED t PITCH HSS TOOL
i AD PITCH per rev. LINE IMATERIAL
MATERIAL NES CONDITIONofga
NESS SPEED
uowi in fpm AISI
Bhn [jmrn [3 iii S
!23. DUCTILE CAST IRONS (conit.)
* -4
T- 012
Austenfliic (NI-RESIST Ductile) a 00 M2 1.17
ASTM A439 T.'oes 0-28 D-3. 0-4. 0-58 .0 r 00'
cAnnea'e I 2.c
275 Z_

24. MALLEABLE CAST IRONS 02

Ferritic 08j 1 00
51 1,2, M7
ASTMA47 Grades32510O35Oi8 I 10'
ASTM A602 Grade IM3210
SAE JI58 Grade M3210
10a20eabtzeo
I160 F 003
12I
4- 150 - 4

pearlifi
ASTM A220 Grades 40010. 450G6. 45008.40
0!2
W.17
500105 1 60Mleabtzed g IOO 40 I M '
ASTM A602. Grade M4504. IA5003 and 20 rifler .003
SAEjt58 Grades M4504. M5003 20re0e I

14 012
5_0 008 M2.1I'?
200 MalleabtrzzedC~ie 003
to and 2C&InI0
240 Heat
I j Treated

Tempeired Mansite I -- 4 012

A~STIA A-720 Grnde 60004 5_10 008 32 M2 W
ASTM AW32- Grade M.5503 Mat~eabizec I 11 I00
to and 20&Fier 003_ _ _ _

255 IHeats W:z;SzZ-g

I Treated

Tempered Mortensite tI1-A .1

ASTM A220. Grade 700035-to .0

22 ?a'ea~ied11-19 .005#
SAE -J158. Grade t,7002 toald '0&me 03 - V= =

TemperedMTreated

Teprd I~ 1-4 012

ASTV A220- Grade 8"02 !15-19 005 25IA.M
ASTM A602. Grade 1USSO 1 240 250 M2. 1.47
SAE J158- Grade V.8501 I aid 20 & ie 003
280
20Treated
Heat --- - ~
---

Tempered Martnite5
ASTIA A220, Grade 90001 .0 0 2
AS -MA602 Grade M8501 250 Mlebzd1-9 .3
SAE J158: Grade 1.48501 and 20 & Fie .0

ITreated fY R

See SetOn 16 fxr Cuiting Fluid Recormendatiori

*Feed recofrnendlatio. ap*l to CONVENTIOUAL (axka-tansyerse)
gear sti~ng
t Feeds should .e increased 100% for gears shaved by t"e DIAGONAL.
(angutar-transverse) inethod
7-86
 Gear Shaving 74
FEEO. C*rlTTER
DIAMETRAL FEEO-t PITCH HSS TOOL

HARD- PITCH '. LINE MATERIAL

MATERIAL I CONDITION of gear
I NESS C-- - I SPEED
1 1i n fp"n A,SI
8'~n _______ -mmfm...: ISO_
02 0. M
28. ALUMINUM ALLOYS, WROUGHT
EC 2218 5252 6253 30 ""-'9 C 0
060 2219 5254 6262 :o & 0e ,3120
100 2618 5454 6463 1 8;; -e .
1145
1175
3003
3004
5-456
5457
6951
7001
1500:,C-1
I 2-1 12
3
1235 3005 5652 7004 0 2
201 4032 5651 7005 -4 02-
0__,--_
2014 5005 6053 7039
2017 5050 6061 7049 M7 M7-,'
2018 5052 60633 7050 . : A !
5056 6066 7075 .;3 eae-2 & - 3
Z021
2024 50P-3 6070' 7079 10 Ianda
2025 5086 6101 7175 _ _ _

29. ALUMINUM ALLOYS. CAST -012 1 i

Sand woPeent Mold 0 -10 .0 -i0 M2. M7
40 ' 00
A',40 319-0 3570 A712 0 1 0 . ,
20i 0 328.0 359.0 D7120 100 As Cast '
208 0 A32
2130
0 8"3
F332-0 5140
0 713 0
7710
50 I 0F,
--
-

- 0,-
-
28 A3330 A5430 70
2220 3330 A5140 8500 , - -
2240 354 B514 0 Ad50.0 0 12
3550 520.0 B8500 I i.
2420
250 0C355-0 5350 0 i --
0,o
C05 I iP 42. M7
705 C 70 !1-
8295 0 3560
3080 A356.0 707 0 tO Tea:eoJ 2&-f... 0 i
HIduminium RR-359 125 and

500kc o--d 1
___ ___ ,
r,.
34. COPPER ALLOYS, WROUGHT
145
147
332
335
360
365
482
485 to
1 I
I
I w
2'
-
5 -10
.
1 008I
012
oos i
.003
-2.,7

=
173
187
340
342 366
367 5440
2370 Pe Anrneatedf - i ;-
191 349 368 624-
17 342 367 62340 ~~
314 350 370 638 k i :
316 353 377 642
385 782 I 5-10 012
330 351
35i3-
78,51 0081 127
6A Re I -0D !M t .
6 % 1'- Qt
1o CC' 20 & F-,a'e .003

4 1-4

190 425 466 667 15---!0 012

226 435 467 675 I 5- i 0 6001 M2. M7
230 442 613 687 10Re 20 & r 1d003"
240 443 618 6SI to I An,,'0a0ed3_-
260 444 630 77G 70 Re
28 445 632 I
270 464 651 ~~t~= --
280 465 655 i
1- 012
to Dr'awn 5-.0 000 700 M2.M7
11-19 -0

See section 16 for Cuttn Flud RecomeTons-3

Feed recomendtons ap;4 to CONVENTIONAL (axi-transmrm)
gear s"avng
Weeds Uoutd be increased 100% for gews shavWd by the DIAGONAL
(an r-transe,',) mehod
7-87
7.4 Gear Shaving

DIAMETRAL FEEDI- CUTTER

PITH errv.PITCH HSS TOOL
MAPITCHHRD CODIIO rev.a LINE MATERIAL.
MAERALNESS 00%f ea SPEED
in fpm ..ISI
Bhn Fy~~
34. COPPER ALLOYS. WROUGHT (cont.) 1-4 .012
101 125 185 614 51 0 5 2M
102 127 189 619 10R 8 10&i19 .003
104 128 192 625 10 Annealed
105 1219 194 674 70 Re
107 130 195 688.......
109 142 210 706
110 143 220 710 14 .1
Ill 150 411 715 10 . 8
113 155 413 725 11 05 40 M.7
114 162 505 745 60 R5ol 20 &Finer .003

116 65 to50 75 -

70R11 74raw
116 10

Se1s1to 12 f Cutn7FudReomndtos
2r
1e2d reomedtin a524oCOVNINL altrnvre
gear s 1a2ng.
t122d s 1oul 6ecesd100%frgassae yteDAOA

(5.nguPaR-tAnsveS ethod.4
7-88M.M
 Gear Grinding, Form 7.5

DIAMETRAL WHEEL
IDENTIFI- INFEED WHEEL TRAVERSE
AR-PITCH
MATERIAL HARD- CONDITION TIF SPEED RATE
NESS CATION
MOULE , ANSI in/pass Ipm 1pm

1. FREE MACHINING CARBON 1 to14 A6OKV .0315 5500

STEELS, WROUGHT 5 to 8 A60KV .0012 to 20-30
Low Carbon Reaulfurized Over Carburized 10 to 16 A80KV .0005 6500 0
Ovr and/or 186&
finer IAIOOLV .0005
1108 1115 1118 1212 48Rc Quenched and
1109 ! 116 1119 1213 Tmee ...6t,:6 -. .

1110 1117 1211 1215

Medium Carbon Reaulfurized 1 _.- k>h-- &
1132 1140 1145
1137 1141 1146
1139 1144 1151 I
Low Carbon Leaded
10L18 121-13 121-15 - -- -.
, - - . . . .
11L-17 12-14
Medium Carbon Leaded
10L45 11L37 11L44 90 :.- .- _ . -__

1OL50 11L41

2. CARBON STEELS,WOGT5 I to
to48 AGOK%
A60KV .0015
.0012 to5003
w Carburized 10 to 16 A80KV .0005 6500
LowCarbon Over and/or 16 & finer A100LV .0005
1005 1012 1019 1026 48R Quenched and N _____Z
1006 1013 1020 1029 Tempered
1008 1015 1021 1513 Tmr _ t. =. 'v-
1009 1016 1022 1518
1010 1017 1023 1522
1011 1018 1025
Medium Carbon
1030 1042 1053 1541
1033 1043 1055 1547
1035 1044 1524 1548 t R A-Ai
1037 1045 1525 1551 I
1038 1046 1526 1552
1039 1049 1527
1040 1050 1536
High Carbon
1060 1074 1085 1566
1064 1075 1086 1572
1065 1078 1090 -32
1069 1080 1095
1070 1084 1561

*See section 16 forCutting Fluid Recommendations.

See section 20 for additional information

7-89
7.5 Gear Grinding, Form

T DIAMETRAL
PITCH WHEEL
IDENTIFI- IHEELINFEED WEL TRAVERSE
TAES
HARD- SPEED RATE
MATERIAL NESS CONDITION - - CAT ON

4. FREE MACHINING ALLOY 1 toi4 A60KV .0015

5 to 8 A60KV .0012 5500
STEELS, WROUGHT
Medium Carbon Resulfurized Carburized 10 to 16 A80KV .0005 to 20-30
and/or 16& finer A100LV 0005 6500
4140 4142Te 4147Te Over
4140Se 4145Se 4150 48Rc Quenched and s 2i.'t -
Medium and High Carbon Tempered .

41130 41147 51132 86140 - t5&'nt c- A1 - -0 --

41140 41150 521100
41L45 43140 86120

5. ALLOY STEELS, WROUGHT 1 to 4 A60KV .0015

5 to 8 A60KV .0012 5500
Low Carbon
Carburized 10 to 16 A80KV .0005 to 20-30
4012 4615 4817 8617 Over and/or 16 & finer A100LV .0005 6500
4023 4617 4820 8620 4
4024 4620 5015 8622 4 Quenched and - - _
4118 4621 5115 8822 Tempered z.. t

4320 4718 5120 9310

4419 4720 6118 94815 ________~t fn~'t~V
4422 4815 8115 94817
Medium Carbon
1330 4145 5132 8640
1335 4147 5135 8642
1340 4150 5140 8645 --
1345 4161 5145 86B45
4027 4340 5147 8650
8655
4427 550
4028
4032 4626 5155 8660
4037 50B40 5160 8740
4042 50844 51860 8742
4047 5046 6150 9254
4130 50846 81145 9255
4135 50B50 8625 9260
4137 5060 8627 94B30 . -

4140 50B60 8630

4142 5130 8637
High Carbon
50100 51100 52100 M-50

'See section 16 for Cutting Fluid Recommendations.

See section 20 for additional information.

7-90

- ---- n- _____________~'~ -
 Gear Grinding, Form 7.5
7
DIAMETRAL *HEEL { WEL TAES
HARD- PITCH IDENTII"I INFEED WHEEL TRAVERSE

MATERIAL NESS CONDITION - "r;-t"2- CATION j RATE

cr~MOPLE~:~ ANSI nps p p

6. HIGH STRENGTH STEELS, 1 to4 A6011V .0015

WROUGHT 5tO8 A60KV 0012 5500
300M 10 to 16 A8OKV 0005 to 20-30
30 Overnd 16 & finer A10LV .0005 6500
43048R C and .
Tempered ~ ~ 3

98BV40 Aw BOKp v7OS-$-

D6ac __ ~ t.&i ~~AOL~ ~M1 ~ t
Hil
H13
HP 9-4-20
HP 9-4-25
HP 9-4-30 ----- , t
?.-- _ ,
HP 9-4-45 s __

7. MARAGING STEELS, 1 to 4 A60KV .0015

5 to 8 A60KV .0012 5500
WROUGHT 10 to 16 A80KV .0005 to 20-30
ASTM A538: Grades A. B. C Over 16 & finer A100LV 0005 6500
48R Maraged 16& e ... -
120 Grade
180 Grade &
200 Grade
250 Grade
300 Grade ________ AiootV~
350 Grade
HY230

8. TOOL STEELS, WROUGHT

Gop15 1 to 8
4 A80JV
A80KV .0012
.0015 5500
50
Group I i0to 16 A100KV .0005 to 20-30
A2 H13 L6 P20 Over Quenched 16 & finer A120KV .0005 6500
A3 A66H19~
H114 01L7
A4 01
SSP21 48Rc
SiTempered
111
and R;g- No -

A6 H121 02 82 ~~~-- L-9s

AB H122 06 S5
A9 H23 07 S6 1 ,rt
A10 H24 P2 S7
H10 H25 P4 Wi
H11 H26 P5 W2
H12 L2 P6 W5
SAE 143ftt. Types W108. W109. '

WiG0. Wi 12. W209. W210.

W310 .- -
Group 11 1 to4 A80JV .0315
5to8 A80KV .0012 5500
D2 F2 M10 T4 0 A100KV to
6500 20-30
Over Quenched 16 &finer A120KV .0005
D3 H42 M30 T8
48R and 1 &f
D4 M1 M42
05 142 Ti48r C Tempered --
F1 M3-1 T2 A tots -t

*See section 16 for Cutting Fluid Recommendations.

See section 20 for addition3l information.

79
7-91

. - ........ -...
_ _ _ _ _ _ _ _ _ __
..... -. ~
-- :! ~
_ _
-:- . - -
_
: = -
_ _ I1
...- -.=,
. ,--
7.5 Gear Grinding, Form

DIAMETRAL 1IDNIi
WDEELM
WHEEL TRAVERSE
MATERIAL HARD- CONDITION
PITCH
CATION jSPEED
INFEED
RATE
NS ANSI isn/pass fpm fpm
Bhn _____ ~S ' ~ a ~ f ~ 7~~
S. 'TOOL STEELS, WROUGHT
(cn.
I I
58
A8JV
A8K
.00 15
0012
5500
Group. Ove Quenche 1I A100KV .0005 to 20-30
Gru IIOer Qenhd 16 & finer A12OKV 0005
A7 M7 M41 M47 458R and AN-WTiL 502-'--
07 M433 M43 TS Tempered ~~~-
M46 1436 1446 ~t'se~A2Kj t1O~~~~ ~~
GrupI 1 to 4 A8OJV .0015 50
Grop I I5 to B ABOKV .0012 60
M44 10 to 16 A100KV .0005 to 20430
115 Over Quenchied 16 & finer IA120KV 0005 60
48Rfi and c---
Tempered&

17. TOOL STEELS, CAST 1t4 A0V .05 50

ASTM A597- Grades CA-2. 00-2. j 0toa1 A 0KV .0015to 203
00~.01~2.1113001. Over Qunhe 16 & finer A1'20KV .0005
CS-s 48%FI and i~-fu-
Tempered - -M_' L

'So. section 16 for Cutting Fluid Recommendations.

See section 20 for additional information,

7-92
 SECTION 8
GRINDING OPERATIONS

8.1 Surface Grinding-Horizontal Spindle, Reciprocating Table .................................. 8-3

8.2 Surface Grinding-Horizontal Spindle, Reciprocating Table-
Cubic Boron Nitride Wheels.............. ........................................ ............ 8-29
8.3 Surface Grinding-Horizontal Spindle, Reciprocating Table-
Diamond Wheels.................................................................. ................. 8-39
8.4 Surface Grinding-Vertical Spindle, Rotary Table ............... ................................. 8-43
8.5 Cylindrical Grinding ................................................................................. 8-61
8.6 Cylindrical Grinding-Cubic Boron Nitride Wheels ......... ................................. 8-93
8.7 Cylindrical Grinding-Diamond Wheels ......................................................... 8-97
8.8 Internal Grinding................................................................................... 8-101
8.9 Internal Internal Grinding-Cubic Boron Nitride Whees ...... .... .......................... . 8-133
8.10 Internal Grinding-Diamond Wheels..................................................... .. 8-139
8.11 Centerless Grinding............................................................................. 8-143
8.12 Centerless Grinding-Work Traverse Rates...................................................._.. 8-175
8.13 Abrasive Belt Grinding ............................................,.....................8-177
............
8.14 Thread Grinding ...... ................... ............
. .... .................................... 8-179

8-1
 PECED11iO PAGE~ BLANIC-NOr FILLAED

L Surface Grinding-Horizontal Spindle, Reciprocating Table 8.1

MATERIAL ICONDITION
NESS
HARD-
WHEEL
SPEED
TABLE
SPEED
I1HEL
OOWNFEED
I
CROSSFEED J IDENTIFI-
CATION
Ipm fpm inpassJ n/pass ANSI
Shn __________/-/sasms~4 - 111- iso/p-
5500 50 Rough: .003 050-.500
1. FREE MACHINI!JG CARBON
STEELS, WROUGHT
Lo CronReufnzd
Hot Rolled. Normalized.
50 Rc Annealed. Cold Drawn
eto
6500
to
100
Finih
j001 max,
(Max: 1/4 of
WheelWidth)
i A46JV

11 ma8115x11or Quenched L-ARog 77 12~

1109 1116 1119 1213 and Tempered to __IFInis (Max>t4.oA4r3
110 1115 1211 1212
Medium Carbon Resulfurized DOW'0 50 Rough 002 025- 250
15Carburized
11214 t0 to j Finish (Max: 1/10 of A461V
1132 1140 1145 Over and/or 6500 100 0005 max Wheel Width)
1137 1141 114641

Low Carbon Loaded Teprd -- o - b- -ins- -jiiOf A4V

iOl_1B 121_13 121_15 _ _ _ _ _ _ _ 3- 30 O ma.
11L17 12114
Mdium Carbon Leaded
10L45 11137 11L44"

lOL50 111_41 -
s- *

2. CARBON STEELS, 5500 50 Rough:.003 .050-.500

WOGTHot Rolled. Normalized. t0 to Finish (Max: 1/4 of A46JV
Low Carbon 50 Rc Annealed. Cold Drawn 6500 100 001 max. Wheel Width)
WROUGHTmax. or Quenched Lo
g-z7-
1005 1012
1013
1019
1020
1026
102ziadTmee
and-Tempered~
~ ~ ~-
-M.-4< A4J
1006 i~is'
1008 1015 1021 1513 - ________ ___ ______ ______

1009 1016 1022 1518 5500 50 Rough..002 .025-.250

1010 1017 1023 1522 Carburized to to Finish (Max: 110 of A461v
1011 1018 1025 Over and/or 6500 100 .0005 max. Wheel Width)
Medium Carbon 50 RC Quenched and "_
Z;15 MOIRO5O<_
1030 1042 1053 1541 Tempered ~~- ~ Ui-
1033 1043 1055 1547 - _______ -O3neLZ Wid,)
1035 1044 1524 1548
1037 1045 1525 1551

1039 1049 1527 ;=

1040 1050 1536 ___ ___ ______

High Carbon ______ ___ ____

1060 1074 1085 1566

1064 1075 1086 1572 I
1065 1078 1090 I. ~ *-~.
1070 1084 1561

3. CARBON AND FIERRITIC 5500 5o Rough: .003 .050-,500

ALLOY STEELS (HIGH IS0 As Forged. to to Finish (Max: 1/40of A46JV
TEMPERATURE SERVICE) to Annealed 6500 100 .001 max. Wheel Width)
ASTM A369. Grades FPA. FPB, 200 o omlzd~i~o4 ~ .52~
FP1. FP2. PP3b. FP5. FP7. and Tempered ~~- ~ ~ ~ ~ ~ MI~
FP9. FP 1. FP12, FP21. FP22 - _______ I WiVdti

__________________ wi E ~

See section 16 for Cutting Fluid Recommrendations.

'Wheel recommnendatIons are for wet gnnding. For DRY grinding-use
a softer grade wheel. Also see secton 20.2. Grinding Guidelines

8-3
 8.1 Surface Grinding-Horizontal Spindle, Reciprocating Table
HARD- WHEEL TABLE WHEEL
MATERIAL CONDITION DOWNFEED CROSSFEED IDENTIFI-
NESS SPEED SPEED CATION
fpm fpm in/pass in/pass ANSI
Bhn MWA7J Ml i - m p 0/
_ _

5500 50 Rough .003 .050-.500

4. FREE MACHINING ALLOY
Hot Rolled. Normalized, to to Finish (Max: 114 of A46JV
STEELS, WROUGHT
50 Rc Annealed, Cold Drawn 6500 100 001 max. Wheel Width)
Medium Carbon Rolslfurizod
4140 4142Te 4147Te moruc
4140Se 41455e 4150 and Tempered

Medium and High Carbon -

Leaded 5b u 50 Rcugh: .002 .025-.250
Catburized to to Finish (Max: 1/10 of A461V
41L30 41L47 51L32 86L40 Over and/or 6500 100 .0005max. WheelWidth)
41L40 41L50 52L100 50Rc Quenched and - Sr r eI-
41L45 43L40 86L20 Tempered M

5. ALLOY STEELS, WROUGHT 5500 50 Rough: 003 .050-.500

Hot Rolled. Normalized, to to Finish (Max: 1/4 of A46JV
Low Carbon
50 Rc Annealed. Cold Drawn 6500 100 .0005 max. Wheel Width)
- -
4023 4617 4820 8620 max. or Quenched
4024 4620 5015 8622 and Tempered
4118 4621 5115 8822 - -

4718 5120 93!0 3000 50 Rough:.002 .025-.250

4320
4419 4720 6118 94B15 Carburized to to Finish (Max: 1/10o A461V
4815 8115 94B17 Over and/or 4000 100 .0005 max. Wheel Width)
4422
Medium Carbon 50 Rc Quenched and N 2 =

5132 8640 Tempered

1330 4145
1335 4147 5135 8642 1
1340 4150 5140 8645
1345 4161 5145 86845
4027 4340 5147 8650
4028 4427 5150 8655
4032 4626 5155 8660
4037 50840 5160 8740
4042 50844 51B60 8742
4047 5046 6150 925A
4130 50B46 81B45 9255
4135 50850 8625 9260
4137 5060 8627 94B30
4140 50B60 8630
4142 5130 8637
High Carbon
50100 51100 52100 M-50

6. G STRENTH STEELS4000 50 Rough: .002 .050-.250

Annealed. to to Finish (Max: 1/4 of A46JV
WROUGHT
300M 50 Re Normalized 6000 100 .0005 max. Wheel Width)
4330V max- or Quenched-
4340 and Tempered ,- "
43405i=
4340Si
98BV40 50 .025-.250
1o to Finish (Max: 1/10 of A60HV
Hllc Over Quenched 4000 100 .0005 max. I Wheel Width)
HI -- Tempered
H1350Ran
HP 9-4-20
HP 9-4-25
HP 9-_-30
HP 9-4-45

See section 16 for Cutting Fluid Recommendations

'Wheel recommendations are for wet grinding. For DRY gnnding-use
a softer grade wheel. Also see section 20.2. Grinding Guidelines.

8-4

... - r - - ....-- - - -- -_- w

 Surface Grinding-Horizontal Spindle, Reciprocating Table 8.1

HARD WHEELTAL HE
MATERIAL HR- CONDITION WEL TBE DOWNFEED CROSSFE ED jIDENTIFI-
NESS SPEED SPEED CTO
fpmn fpm in/paSS in/pass ANSI
________________Bhn ______ /m m i 1l 6 X
7.MAINSTES MARAINGSTELSto 4000 50o Rough. .003 050-.500
Finish (Max: 114 of 6V
WROUGHT 50 RC Annealed 6000 '00 I.001 max Wheel Width)
ASTM A538, Grades A. B. C max.O I R_ - -_ - -
120 Grade oare 1_';~ 5. ~ ~ 1i~
180 Grade -

200 Grade-.
250 Grade 3000 50 Rough: 002 025-250
300 Grade to to Finish (Max, / 10 of A60HV
350 Grade Over 4000 100 .0005 max. Wheel Width)
HY23050 Rc Maraged ZM1I :OO_"

S. TOOL STEELS, WROUGHT

Group I
A2
~1
H14
6
L6
P0
P210
Ito
50 SIC
ax
Annealed
or Quenched
5500

6500
50
to
100
n
Rough. .003
Finiish
.0005 max.
.050-.500
(Max: 1/5 of
Wheel Width)
A46JV

A H1
L7 P1and Tempered ~.dm-T i
A4 H-19 01 Si
A6 H21 02 S2 - _______ c- ~1i- _____

A8 H22 06 S5 3000 50 Rough: .002 .025-.250

A9 H23 07 S6 to to Finish (Max. 1/100of A461V
A10 H24 P2 S7 Over Quenched 4000 100 .0005 max. Wheel Width)
Hi -26P 2 C Tempered AV -
H12 L2 P6 W5 IN__I_____
SAE J438b: Types W 108. Wi109.
WI 1. W1 12. W209. W210.
W310

Group aU 0
02 F2 MIO T4 0R Anae
03 H42 M30 T8 0c Anae 6500 100 .0005 max. Wheel Width)
max. or Quenched
D4 Ml M42 and Tempered
05 M2 Ti 1n-
F1 M3-1 T2 1 _______ _

3000 50 RoughO.0l .025-250

50to to Finish (Max. 1/100 A61V
Over 0cnea 4000 100 005mx Wheel Wiidth

4000 50 Rough:.002 .025-250

G p*to to Finish (Max: 1/80o A6HV
A7 M M1MA OvrC Quneaed 40oo 100 .0005 max. WelWdh)

A6 M36 M416 4 0R Anae

D7 M33 S mxC uenchd

o Q4 6000 150 .0005 max. Wheel Width)

See2
secio 16 for Cutnd
4 Flud Rcomenains
M6ee Leomenaton arM46 e ridn.FrDR dn-s
Alosescin2..Vndn
a00 so5e grade.00 udln
wheel.5

50 PICuen8.5
toFinsh
t Max:1/1
of 601
to 1and10
f400 MaX. Wheel-Wdth
_ _ _~~0
_ _ _ __ _ __ _ _
 8.1 Surface Grinding-Horizontal Spindle, Reciprocating Table

MATERIAL HARD- CONDITION WHEEL TABLE RSFED WHNED

IEELFI
NESS SPEED SPEED DONCDARSFED IETIFI-
fpm 1pm in/pass in/pass ANSI
Bhn L:Wn/df/mlin . mpa _mmps----

8. TOOL STEELS. WROUGHT 3000 75 Rough .001 .020- 200

(cont.) II to to Finish I (Mar* 1/ 12 of J A60HV
Over Quenched 4000 I150 0003 max., Wheel Width)
Group III (cont.) 58 FI- ail.-- ~ -~-
(materials listed on preceding page) 58eRceand Aj- 2- Rob 05tU O.O'

GrouplIV 4000 50IRuh02 020- 200 I

M4 s Aneldto to Finish (Max. 1/10 of A46HV
TO15 Aneae 6000 I100 .0005 max, Wheel Width)
TIS max. ~~or
Quenched ir 15 04.0O CO5Ouz
and Tempered z trM
300 7 Ruh .01 .00.0

to to Finish (Max: 1/12 of j A6H

5500 75 Rough. .002 .050-.500

to to Finish (Max: 1/12 of I A60GV
n 650 0I
0 0005 max. Wheel Width)

WRUM20 Ana-. to to Finish (.Max: 1/4 of A46JV

0MAlo
125 275 Norlzdawn 10 .4) gil. W e l
With

See secton165 for Cutin Fluidhe

Reomnain
WheeI~~~~~~~n
a ferade w1eel AMod
areaa
foIe
reeomeertien
ndn.Fo R rnn-
sesc-n202 rnig udlns

Nitraloy826

-irlo -3 r -og:.0 55 so- .025-.2501......

 Surface Grinding-Horizontal Spi idle, Reciprocating Table 8.1

HARD- WHEEL' TABU. WHIEDECTLO

MATERIAL NES CONDITION 'SPEED SPEE ) *DOWNFEED CROSSFEE IDENTIFI-

fpm inps ANSI

_____________ Bhn ______ __5
1pm
~.__
&iiw~i
W
npass
_ -- V IS
Martensitic j 150
5500 toFinish 'lough .002 I 050.500
(Max- 1/4 of A461V
416 420F Se 125 Annealed to0 100 00 Wheel Width)
416 Plus X 440 F to or - ,12-557
5;1;> -
416Se ~
}5500
44OF Se 240 Cold Drawn 7-
420F I _______ 3 'i~O3i ~We~f1
_

-. 50 Rough: A0 1 .025-.250
to to Finish I(Max: 1/l0ot A46HV
IOver Quenched 650 100 .0005 max. Wheel Width)
275 and i
Tempered _

13 SAILSSSTEL,5500 53 Rough:.002 .050-.500

1.SANESSELto to Finish (Max: 1/4 of A461V
WROUGHT 135 6500 100 .0005 n-ax. Wheel Width
Fordtic to Annealed -ir-
405 429 434 442 185 ~~v
409 430 436 446

AutntcIto to Finish (Max: 1/4 of j C46J

201 304L 310S 330 135 Annealed 6500 100 I005ma. Wheel Width)
202 305 314 347 to or
301 308 316 348 275 Cold Drawn A-,V u~~. i1~-
302 309 316L 384 ~- ~ _

3028 309S 317 385 -

304 310 321

Austenitfic 50 o Ruh.0 00.0

Nitronic 32 210 t5o 100 Finsh Width)J
(Max 11ee
Nitronic 33 to Annealed 60 0 0( 1. Wel-t
Nitronic 40 250
Nitonic 50_nM0
Niitonc60 -5500 so Rough:.001 .025-.250 0? G

325 to to Finish (Mx10o C4H

to Cold Drawn
375

403 422 440C :o toF3is (Max: 114 of A461V

410 431 501 to Annealed 60 0 00 a. Wel-Wdh
414 440A 502 275
420 4408
Greek~ Ascotoy
to to Fiih (Max: 1/10 of A46IfV
Over Quefi~hed 6500 100 003ax WheWdt

See section 16 for Cutting Fluid RecomMendations

-Wh"e recommendations awefor wet gnindinig For DRY gnnding-zse
a softer grade wtiat Also see section 20 2. Gnnding Guidities.

8-7
 81Surface Grinding-Horizontal Spindle, Reciprocating Table
~ WHEELcotrno,
HARD.I TABL
MATERIAL HARSS CODTO SPEELD AL DOWNIFEED ICROSSFEED * IDENTIP-
I I CATION
f pm fo1m *in -pass : in/pass ;S

14. PRECIPITATION 5500 1 50 1Rough: 002 050.500

HARDENING STAINLESS .50 j1C iih (a.141A~
STES
RUH
STESWOGH 06500
oISoiuton Treaed -~
1100
t
i .000:5 rmax.
It7D
Wheel Jdtdth)
-i
15-5 PH 200II ~
_____mw '1m1~b--
I_.14'd
U

17-4 PH L... __________ ___ O~ae ___________

17-7P . j55M0j . Rough*.001 025-250
17-74 CPH o F-i (ax1 0 41I
AF- 127 *Sotbo Teaed 6500 100 0I 0 rnsax. I Wheel Width)
AFC-77 4 i V-1end-
Almar 362 (AM-362) O 1 - h 4 110o AdH
AM-350 1 fI~ -~3' 1 a.~ 11d)
AM-355
AM-363 I
Custom 4550_
HNM
PH 13-8 Mo
I_ .-- ~-- F:2________ __

t
_
PH 14-8 Mo I
PH 15-7 Mo
Stamnless W/~~ _

5500 so Rough:.003 .0550-.500

15. CARBON STEELS, CAST Anineaed Norma~zed. to to I Fiih (Mx: 114 of A46JV
Low Carbon 100 Notrnalized and 6500 100 __.01_axWhel ___th

ASTIA A426. Grade CPI to Terpered. - 1~2.&

1020 and Tempered ~I icT&~.-
Mediumn Carbon
ASIM A352: Grade-, LCA. LCD. 5500 so Rough: .002 025-.250
LCC Ca-burized to to Fnzsii (Max.- 1/10 of A461V
ASTM A356: Grade I Ovr aridor 6500 10 .0005 max, Wheel Width)
50%R Ouenct'ed and =-=~
1030 1040 1050 T-~~--- ~---
5500 50 Rough: .003 .050-.500
16. ALLOY STEELS, CAST Annealed. Normnalized. to to Finish (Max: 1/4 of A46NV
LwCbn10
ASIM A217: Grade WC9 to
Normalized and
Tempered.
6500 100 I.0005 max. Wheel Widfth)
--
ASTM A352: Grades LC3. LC4 400 or Ouenched -- - Z
ASTM A426: Grades CP2. CP5. and Tempered
_
~ 214
CP~b. CP11. CP12. CP15. - _ ____- -
CP21. CP22 300 50A&*:.0 .2 .5
1320 2320 4120 8020 Carbuized to to Fih (Max: 1Of A4T
2315 4110 4320 8620 jOve anld/or
X0ra 0 0 teW~h
11di1m Carbon 0R unbdadP
ASTM A27: Grades N1. N2. Tempered
U-60-30. 60-30.65-35. j
70-36. 70 40
ASTM A 148: Grades 80-40.
80-50.90-60.105-85.1
*20-95. 150-125. 175-145!2pr
ASTMVA216: Grades WCA.

WC4e. WC5. WC6

PSTM A352: Grades LC1. LrC2.
LC2- 1
(materials continued
on next page)
See section 16 for Cut"n Fluid RecmenaIons
*WheeI recoridathons are for wet gnim4 For DRY grindig-use
a softer grade wheel, Also see section 20.2. Griding Guidelies.

8-8
 Surface Grinding-Horizontal Spindle, Reciprocating Table 8.1

HARD- WHEEL TABLE WHEEL

MATERIAL CONDITION DOWNFEED CROSSFEED IDENTIFI-
NESS SPEED SPEED CATION
fpm fpm in/pass in/pass ANSI

16. ALLOY STEELS, CAST

(cont.)
Medium Carbon (cont.)
(materials continued from M EM V IN , 0 N O
preceding page) , - -,,w I' 1.
ASTM A356 Grades 2, 5, 6, 8, -.. ___ _ --
__

9. 10
ASTM A389: Grades C23. C24
ASTM A486. Classes 70, 90,
120 T-W l
ASTM A487 Classes iN, 2N.
4N, 6N, 8N, 9N, 10N, DN, 10,
42Q
,
4Q,0A. 60,70, 80,
90. 100
1330 4130 80B30 8640
1340 4140 8040 9526
2325 4330 8430 9530
2330 4340 8440 9535 Fm, , M..
4125 8030 8630

17. TOOL STEELS, CAST 5500 50 Rough:.003 .050-.500

to to Finish (Max: 1/5 of A46JV
A 48Tu
50 Re Annealed 600 100 .0005 max. Wheel Width)
Se secon 16GradeCuin Fluidor Quenched
CH-12 CH-13, CO-1 s so2. Grid and Tempered

to to Folish (Max: 1/10 of A461V

50 Re Quenched 4000 100 0005 max. WelWdh
to and
58 Rc Tempered

3000 50 Rough: .001 .025-.250 "

to to Finish (Max: 1/10 of A601V

c Tempered .. i

50 IRough:. 003 .05 0-.500

Group 115
ASTM A597: Grades CD-2. 200 to .00Fiis I (Max: /ax I A46JVh
Whee W i AJ

i
t tO- Finismax.
.0005
CD-5 to Annealed -
250 , -

3000 50 Rough: .002 .0.'5-.;.50

to to Finish (Max: I1/10 of A461V
48 R c Quenched 4 0 10 .0005 max. Wheel Width)
to and . .
_ r--, .
56 Rc Tempered 1

I 300 50 Rough: .001 .025-.250

tto to Finish (Max: 1/ 10 of A6HV

Ove Qenhed 400 oo .0005 max. Wheel Width)II
5Rc Tempered

See section 16 for Cutting FluilJ Recommendations.

'Wheel recommendations are for wet gridng. For DRY grinding-use
a softer grade wheel Also see section 20 2, Grinding Guidelines.8-

,8-9
 Surface Grinding-Horizontal Sp!ndle,. Reciprocating Table

I.HARD W E T E WHEEL*
MATERIAL HARD CONDITION WHEEL TABE DOWNFEED CROSSFEED IDENTIFI-
NESS SPEED SPEED CATION
fpm fpm in/pass in/pass ANSI
Bhn k'Af/ _3Lni/mln -- n _IIZ
L'M j5i
18. STAINLESS STEELS, CAST 5500 50 Rough: .002 .050- 500
F 1o to Finish (Max. 1// of A461V
Ferritic 135 6500 100 .0005 max Wheel Width)
ASTM A217- Grades CS, C12 to Annealed -,
C C -50. C E-30, C A 6N .
, .. - -
,,A-6NM, CO4UCu.
4, =.. . _ ) 't|a/l' },-,
ASTM A487
ASWe A297: Class
Grade CA6NMV
HC w g .r ri -

ASTM A6dwh8.Grade HC30 20.2. Grinding Guidelines

Ausenitic 5500 50 Rough 002 .050-.500

ASTM A296 Grades CF-3, 135 Annealed, to to Finish (Max. 1/4 of C46JV
CF-3, CF-, CF-S10. CF-M, to Normalized 6500 100 .0005 max Wheel Widt
CF-1 6F, CF-20, CG-8M, 20or ; " O ",, . . . ' IMM'"P
C G -1 2, C H-20, C K-20, As C ast
CI7,CN-71IMSP " tO C .
-
ASTMVA297" Grades HD, HE,
HF, HH, H;, HK, HL, HN, HP,
HT, HU
M W
CF-3A, CF-3M, CF-3 MVA,
_ .

CF-1O1VC,
CH20 cH-, CH-10,
20
,CN7,
HK-30, HK-40, HT-30
ASTM A451: Grades CPF8A,
' NIN
. f,
CPF3, CPF3A, CPF3M, CPF8.
CPF8C, CPF8C (Ta Max.), .-
CPF8M, CPF1OMC, CPH8,W I
CPH1 0, CPH20, CPK20
ASTMVA452: Grades TP 304H,
See eI'A216 foraeCuting
Fli1Rcmmnatos
, ASTM A608: Grades HDS0,
HE35, HF30. HH30, HH33,
H 135 , H K 3 0 , H K 4 0 , H L3 0 ,,
. .. --

M te iicAnnealed, 5500 50 Rough: .002 .050-.500

A SG M
'dAe C
2 7 -1 1 5 No rm a liz e d to -10~l to 0 F in ish (Ma x : 1 / 4 of A 4 6 1V
AS M A296: Grades CA- 15, to or 6 50 10 . 05m x

ASTMV A426: Grades CP, IPS. ed

anem
CPCA15 Tmee
ASTM A487 Classes CAt5;a, 5500 50 Rough: .001 .025-.250
CA-15MI to to Finish (Max: 1/10 of A46HV
Over Quenchedprdn 6500 100 ._0005 Max. Wheel Width)

See sect. ri 16 for Cutting Fluid Recommendations.

* Wheel recommendations are for wet grinding. For DRY grinding-use
a softer grade wheel. Also see section 20.2, Grinding Guidelines.

8-10
 Surface Grinding-Horizontal Spindle, Reciprocating Table 8.1

WHEELS
MATERIAL HARD- CONDITION WHEEL TABLE DOWNFEED CROSSFEED IDENTIFI-
NESS CSPEED SPEED CATION

fpm fpm in/pass in/pass ANSI

19. PRECIPITATION 5500 50 Rough- .001 .025-250

325 Solution Treated to to Finish (Max: 1/10 of A46HV
HARDENING STAINLESS
STEELS,CAST to or 6500 100 .0005 max Wheel Width)

ASTM A351 Grade CD-4MCu 450 Solution Treated 11 4._-.1S(4t, . '

ACI Grade CB-7Cu a g_ ,_

ACI Grade CD-4MCu
17-4 PH
AM-355

21. GRAY CAST IRONS 5500 50 Rough: .003 .050-.500 C36JV

As Cast. to to Finish (Max: 1/3 of or
Ferritic
ASTM A48: Class 20 4 Annealed 6500 100 .001 max Wheel Width) A46JV
SAE J431c: GradeGSOO
G 1800 max orQuenched - -
Pearlitic- Ferritic and Tempered t -.
ASTM A48: Class 25 ,
SAE J431c: Grade G2500 5500 50 Rough: .002 .050-.500 C361V
Pesrlitic 45 R c As Cast, to to Finish (Max: 1/5 of or
ASTM A48: Classes 30, 35, 40 to G Annealed 6500 100 .0005 mnax. Wheel Width) A461V
SAE J431c: Grade G3000 52 R c or Quenched o

Peerlitic
ASTM A48: Classes Carbidec
+ Free 45, 50__MI and Tempered
SAE J431c. Grades G3500. 5500 50 Rough: .002 .025-.250 C46HV
G4000 to to Finish (Max: 1/10 of or
Peirlitic or Acicular + Free 48R c R Flame 6500 100 .0005 max. Wheel Width) A46HV

ASTM A48: Classes 55, 60 60 c Inducion Hardened

Austenitic (NI-RESIST) 5500 50 Rough* .005 .050-.500 Rough: A46HV

b ,2,
ASMA3.Tps1 10to to Finish (Max: 1/3 of Finish
3,M 456.Type 2, 0 As Cast 6500 100 .001 max. Wheel Width) A80GV

22 RAHIE5500
CMPCTD 50 Rough: .003 .050-.500 C36JV
CATIOSto to Finish (Max: 1/3 of or
6500 100 .001 max, Wheel Width) A461V

5500 50 Rough: .003 .050-.500 C361V

23. DUCTILE CAST IRONS Annealed, As Cast, to to Finish (Max: 113 of or
F rritic 5 S N o rma lize d a n d6 5 0 1 0. 1 ma . W e l I A4 V
ASTM A536: Grades 60-40-18, 52 Tempered01 a. helWdt) A41
-45-12 max. Tmee
65 or Quenched
SAE J434c: Grades D4018, and Tempered
D4512 -..
Farrii- Pedlitic 5500 50 Rough: .002 .025-.250 C46HV
ASMA3:Gae8-50 3RFaeto to Finish (Max: 1 /10 of or
SAET A3: Grade 05506 toRc Form 6500 100 .0005 max. Wheel Width) A46HV
-~~ -p-
90
Marteneit
P'earlitic- 60RFc Induction Hardened -
ASTM A536: Grade =00-70-03
SAE J434c' Grade D7003 i
Martenaltic
ASTM A536: Grade 120-90-02
SAE J434c: Grade DQ&T

t See section 16 for Cutting Fluid Recommendations.

*Wheel recommendlations are for wet grinding, For DRY grinding-use

; a sifter grade wheel. Also see section 20.2, Grinding Guidelines

8-11
8.1 Surface Grinding-Horizontal Spindle, Reciprocating Table
HARD- ODTO WHEEL TABLE WHDENELD*
MATERIAL NESS CNION SPEED SPEED RSFED CANED
IETIN-

forn fpm in/pass in/pass I ANSI

Blin M___W#0_ Mi ffiiidiWI
-___
23. DUCTILE CAST IRONS 5500 50 Rough .005 .050-.500 Rough: A46HV
(cn)101to to Finish (Max. 1/3 of Finish
(ot)106500 100 001 max. Whee; Width) A80GV
Austeflitic (NI-RESIST to Annealed k. WE
Ductile) 275 N RAA
ASTM A439. "'pes D-2. D-28, & -0kh-ft'
D-2C, D-3, u-3A. D-4. D-5, --

0-58
ASTM A571: Type D-2MM
- 72 4 .

5500 50 Rough: 003 .050-.500 C361V

24. MALLEABLE CAST IRONS Malleablized to to Finish (Max: 1/3 of or
Feritic 5 r60 0 0 a. Weli 41
ASTM A47: Grades 32510, 52AC 50 10 .0 a. WelWdh 41
35018max.~ Malleablized
ASTM A602: Grade M3210 andt
reate
SAE J158: Grade M321 0 - Ha rae
Peatlltic 50 50 Ruh.02 .025,.250 C46HV
ASTM A220: Grades 40010, to to Finish (Max: 1/10 of or
45006,~~~ 450.nosOvrOC Q .0005 miax. Wheel Width) A46HV
ASTM A602: Grade M4504, 52 Rc or0
M5003 ~~induction Hardened -- .-

SAE J 158: Grades M4504. _____5____

M5003
Temered Martonalt.
ASTM A220: Grades 60004,
70003, 80002, 90001
ASTM A602: Grades M5503,
PA7002, M8501
SA1E J158: Grades M5503,
M7002, M8501

25. WHITE CAST IRONS 00 5 Rog:.2 .2-20

(ABRASION RESISTANT) 60A As Cast, to to Finish (Max: 1/ 10 of C361V
ASTM A532: 6 c Ann6aled 6500 100 .0005 max. Wheel Width)
Class 1,Types A, B, C. D max. o
Class 11,Types A, 8, C. D. E Hardened

26. HIGH SILICON CAST IRONS 5500 50 Rough: .002 .025-.250

t o Fns Mx 0o
Duriron Welidh
10 05ma.
Duriclor52R60
ASTM A5' 8

27. CHROMIUM-NICKEL ALLOY 5500 50 Rough: .001 .025,.260

CATIGS27 600 100 .0005 max. Wheel Nldth)
ASTIM A560: Grades 5OCr-SONi, to As Cast
6OCr-4ONi 375

See section 16 for Cutting Fluid Recommendations.

'Wheel recommendations are for wet grinding. For DRY grinding-use
a softer grade wheel. Also see section 20.2, Grinding Guidelines.

8-12
 Surface Grinding-Horizonitai Spindle, Reciprocating Table 8.1

HAD HE AL WHEEL*
MATERIAL HARDS CONDITION SPEEL TABE DOWNFEED LROSSFEED IDENTIFl-
NES PED SPE CATION
fpm fpm in/pass in/pass ANSI
___________ hn AM_____ ~7 ~ ~ .-M-011

28. ALUMINUM ALLOYS, 4000 50 Rough- 003 .050-.500

WROUGHT 30 Cold Drawn to t0 Finish (Max: 1/3 of C46JVt
to or 5000 100 .001 Max Wheel Width)
EC 2218 5252 6253 150 Solution Treated
1060 2219 5254 6262 500kg andAgdl
1100 2618 5454 6463 _ _

1145 3003 5456 6951 - _ __' '

1175 3004 5457 7001

1235 3005 5652 7004
2011 4032 5657 7005 _

2014 5005 6053 7039 WE 0_

2017 5050 6061 7049 _0~
2018 5052 6063 7050 _______- ~ ~ ______

2021 5056 6066 7075

2024 5083 6070 7079
2025 5086 6101 7175
2117 514 6151 7178 ' o

29. ALUMINUM ALLOYS, CAST400 5 Rog:.3 .5-50

Sand and Permanent Molds 40 As Cast to to Finish (Max: 1/3 of G46JVt
to or 5000 100 .001 max. Wheel Width)
A140 295.0 51 ..u A712.0 125 Solution Treated -
201.0 B2qr A514.0 D712.0 500kg and Aged ---
Pn.: 308.0 8514.0 713.0
213.0 319.0 520.0 771.0 -

222.0 3550 5350 850.0

224.0 C355.0 705.0 A850.0
242.0 8443.0 707.0 B850.0
Hidluminiumn RR-350
Die Castings
C443.0 518.0

Prann
Ml 4000n 50 Rough: .003 .050-.500
Sadan
emaet od 40 As Cast to to Finish (Max: 1/3 of A461V
328.0 333.0 A356.0 to or 500 100 .001 max. Wheel Width)
A3320
35.0 37.0 125 Solution Treated
F332.0 356.0 359.0 500Okg adAe
360.0 A380.0 3900 A413.0 -

A360.0 383.0 392.0

380.0 A384 0 413.0

550 50 Rough: .003 .050-.500 046K

30 MGESUMALO0 Annealed, to to Finish (Max: 1/3 of or
WROUGKT$* to Cold Drawn 650 100 .001 max. Wheel Width) A46KVI
AZ21A AZ61A HM21A ZK60A 90 or
AZ31B AZ80A HM31A 500kg Solution Treated
AZ31C HK31A ZK40A and Aged

See sect ion 16 fcr Cutting Fluid Recommendations. twax tilled

*Wheel recommendations are for wet grinding For DRY grinie- i-use ttCAUTION: Potential Fire Hazard. Exercise caution In grinding and
a softer grade wheel. Also see sect ion 20.2. Grinding Guldel. . disposing of swaf. Do NOT use water or water-miscible cutting
fluids for magnesium alloys.

8-13
8.1 Surface Grinding-Horizontal Spindle, Reciprocating Table
HARD- WHEEL TABLE WHEELO
MATERIAL CONDITION DOWNFEED CROSSFEED IDENTIFI-
NESS SPEED SPEED CATION
fpm fpm in/pass in/pass ANSI
Bhn 9-MR17QU WN5IesAc%6YSOa5
As Cast. 5500 50 Rough: .003 .050-.500 C46KV
31. MAGNESIUM ALLOYS,
CAST# 50 tc to Finish (Max: 1/3 of or
to Annealed 6500 100 .001 max. Wheel Width) A46KV
AM60A AZ91 C ZE41 A 90 or
AMlOOA AZ92A ZE63A 500kg Solution Treated NEW-
AS41A EZ33A ZH62A and Aged - NO4 sik }ta-
AZ63A HK31A ZK51A
AZ81A HZ32A ZK61A
AZ91A KiA
AZ91 B 0E22A --. " - _-

32. TITANIUM ALLOYS, 3000 Rough: .001 .025- 95O

of C54.'V*
WROUGItpi 110 60
to 003.0005 FinA:l
max. Wheel 1/10
(Max: Width)
Commercially Pure to Annealed 1 .0005 m Whee-WitQ,
99.5 99.0 275 .
99.2 98.9
Ti-0.2Pd
TiCODE-12

3000 Rough: .001 .025-.250

Alpha and Alpha-Deta Alloys
60 Finish (Max: 1/ 10 of C54JV$
to
4000 .0005 max. Wheel Width)
Ti- 1AI-aV-5Fe to Atb(n)ioi e
Ti-2AI-1 Sn-5Zr-8Mo 380
Ti-3AI-2.5V
Ti-5AI-2Sn-2Zr-4Mo-4Cr (Ti- 17) WI
Ti-5AI-2.5Sn 3000 Rough: .001 .025-.250
Ti-5AI-2.5Sn ELI 320 to 60 Finish (Max: 1/10 of C54JVt:
Ti-5AI-6Sn-2Zr-lMo to Solution Treated 4000 .0005 max. Whe Wid

Ti-6AI-6V-2Sn
T,-6AI-2Sn-4Zr-2Mo
Ti-6AI-2Sn-4Zr-2Mo-.25Si

Bea lly=3000 Rough: .001 .025-.250

to 60 Finish (Max: 1/10 of C54JV*t
Ti-3AI-SV-6Cr-4Mo-4Zr 275 Annealed 4000 .0005 max. Wheel Width
T,-8Mo-8V-2Fe-3A1 to or : _-
Ti- 11.5Mo-6Zr-4.5$n 350 Solution Treated
Ti- 10V-2Fe-3AI
Ti- 13V- 11Cr-3AI
3000Rough: .001 .025-.250
350 60 Finish (Max: 1/10 of C54JV*
to Solution Treated 40 .0005 max. _Wheel Width)
440 and Aged i : i

See section, 16 for Cutting Fluid Recomandations tise tral (gengi)siio abd

*Wheel recommendations are for wet grinding. For DRY grinding-use #I CAUTION: Potential Fire Hazard Exercise caution in grinding and
a softer grade wheel. Also see section 20.2. Gridng Guidelines disposing of swarf. Do NOT use water or water-miscible cutting
fluids for magnesium alloys

8-14
 Surface Grinding-Horizontal Spindle, Reciprocating Table 8.1
MATERIAL HARD-
NESS CONDITION WHEEL
EE TABLE
E DOWNFEED HE
ICROSSFEED IDENTIFI-
HARDN SPEED SPEED CATION

fpm fpm in/pass in/pass ANSI

33. TITANIUM ALLOYS. 3000 Rough: .001 .025-.250

33.As Cast to 60 Finish (Max: 1/10 of C54JV*
or 4000 .0005 max. Wheel Width)
Commercially Pure to _zi 4''_5i ; -_Zm ,r
T-0.2Pd 990250 Cast
andAsAnnealed Iv Z.j
18 - 0_1& -025 r'-
f' r _R _S i
ASTM B367- Grades C-1, C-2. i---e-'
C-3, C-4. C-7A, C-78. C-SA,.
C-8B

Alpha and Alpha-Soto Alloys ACat3000 Rough: .001 .025-.250V

2105A32 368 460Ato 60 Finish (Max 1/3of C54JVt

3506A-i~-Z--
As CaP' -
ASTM 8367: Grades C-5. C-6 ,Ae= 07)

34. COPPER ALLOYS, 5500 50 Rough: .003 .050-.500

WROUGHT 10 Re to
6500 to
100 Finish
.0005 max, (Max: 1/3
Wheel of
Width) C36iVf

101 116 143 182 to Annealed

104 120 147 185A

107 122 155 1897 5500 50 Rough: .003 .050-.500

to to Finish (Max: 1/3

Wheel of
Width) C361Vt
10a 12 16 19 R
00 R1 6500 100 .0005 max.
111 128 162t 1920

113 129 172tt 194 W

114 130 173tt 195. ..
115 142 175tt

34,7 6 o Anae
226
210
220

230
332
335

342
368
370

385
464
465

467
O
10R

70 RS
5500
to .
60
50
to
100
Roug
Finish
.0005 max.
.050-.500
(Max: 1/3 of
.Wheel Width._._
C361Vt
__

240 349 411 482

260 350 413 111ATIO1Poental7ireHazrd.Execis0catio
855500 50 Rough: .003 .050-.500 ingridin an
268 353 425 667 to to Finish (Max: 1/3 of C361Vt;
270 356 435 687 60 Re 6500 100 .0005 max. Whee idh

314 365 443 694 100 Re

316 366 444
330 367 445
8-15. 1

See section 16 for Cutting Fluid Recorrim-ia'los tWax filled.

*W'heel recoinmendations are for wet grinding. For DRY grinding-use :tUse friable (green grit) silion carbide.
a softer grade wheel Also see section 20.2, Grinding Guidelines. I t CAUTION: Toxic Material, refer to National Institute for Occupational
Safety and Health (NIOSH) for Precautions
#:CAUTION, Potential Fire Hazard. Exercise caution in grinding and
disposing of swart.

8-15
8.1 Surface Grinding-Horizontal Spindle, Reciprocating Table

HARD,-I WHEEL TABLE WHEEL

MATERIAL HARD CONDITION WHEEL TABE DOWNFEED CROSSFEED IDENTIFI-
NESS SPEED SPEED CATION
fpm fpm in/pass in/pass ANSI
Bhn RMO Q-mpZ -_F~it __
34. COPPER ALLOYS, 5500 50 Rough..003 .050-.500
to to Finish (Max, 1/3 of C361Vt
WROUGHT (col.) 10 Re 6500 100 .0005 max. Wheel Width)
505 608 623 642 to Annealed .
510 610 624 651 70 R
511 613 625 655 011ucIdt-1~~O3l
-__
521
524
614
618
630
632
674
675 5500 50 -
Rough: .003 .050-.500
524 618 632 675 to to Finish (Max 1/3 of C361V
54 4 61 9 63 8 60 R e 5 0 1 0 . 00 a .e
to Cold Drawn 650 10 .000 mx Whe Wdth
100 R e _ . .. '' ' '-

5500 50 Rough: .003 .050-.500

706 752 to to Finish (Max: 1/3 of C36IVf
710
7 15 573
7754 to B A n ae -;6500 100- .0005 max Wheel Width-

S e 1 r 6Re6500
t lto to
100 Fnish
.0005 max. (Max: 1i3
Wheel o
Width) C36Vt

100 Re

3.CPEALOSCAT5500 50 Rough: .003 .050-.500

'WhC m
801 e B1t AtOs f
616ft A825tt 40
to As Cast to to Finish (Max: 1/3 of C361Vt
6500 100 .0005 max. Wheel- Wid

805 814 821tt 827tt 50kg Heat Treated

807 815 822tt 828tt
809 617tt 824t-t 5500 50 Rough: .003 .050-.500

1/3 of
(Max: Width) A46JV
a 4R
s C
to Heat Treated
t6500
to 100
to
Z
Finish
.0005
-
max. Wheel

45 Rc

5500 50 Rough: .003 .050-.500

833 852 862 874 35 6 5to0 0 - Lto Finish (Max: 1/3 of C361Vt -
834 853 863 875 to 100 .0005 max. Wheel Width)

838 855 865 878 500kg -

842 857 867 879
844 858 868
848 861 872

5.0 50 WRough: 003 .050-.500

902 916 934 948 40 to to Finish (Max: 1/3 of C361Vt
903 917 935 952 to 650 100 .0005 max Whe Wdh

907 923 938 954 500kg

909 925 939 95 r_-_ --
910 926 943 956 550 Rough: .003 .050-.500
91 9 77 4 o to Finish (Max: 1/3 of A46JV
913 928 945 958 Over As Cast 100 .0005 max. lWheel
Width)
915 932 947 100 or

See section 16 for Cutting Fluid Recommendat ions. tWax filled.

*Wheel recommendations are for wet grinding. For DRY grinding-use ttCAUTION: Toxic Material. refer to National institute for Occupational
a softer grade wheel. Also see section 20.2. Grinding Guidelines. Safety and Health (NIOSH) for Precautions

8-161 2
 Surface Grinding-Horizontal Spindle, Reciprocating Table 8.1

MATERIAL AD.
IR CONDIT.ON WHEEL TABLE OOWNFEED CROSSFEED
WHEEL*
IOENTIFI-
INESS
1 ________
SPEED
ftpm J j
SPEED
pM
_____ICATION

in/pass in/pass ANSI

- ~
-5500 50 IRough: .03 .050-.500
962 974 50 to to Finish (Max: 1/31of 0361 Vt
963 976 to 6500 100 .0005 max. Wheel Width)
964 978 100 As Casts- .
966tt
973
993 500kg ~_-~_____ -

5500 50 Rough: 003 .050-.500

to to Finish (Max: 1/3 of A46JV
Oer As Case 6500 100 .0005 max. Wheel Width)
500kg Heat Treated

36. NICKEL ALLOYS, 4500 50 Rough: .001 .040-.400

WR'UKTAD
AS 8 nnaldto t0 Finish (Max. 116 of A461V
WRUH NDCS 0 neld5500 100 .0005 max IWheel Width) _____
Nickel 200 to or ______

Nickel 201 170 Cold Drawn

Nickel 205 _ _ _ _ _

NICKei 2 I
Nickel 220
Nickel 230

MONELAllo 4005500 50 Ruh01 .040-.400

MONEL Alloy 40101 Annealed, to to Fiih (Max: 1/6 of A461V
MONEL Alloy 404 to Cold Drawn 6500 100 05ma. Wheel Width)
MONEL Alloy R405 240 or-
ASTMAP296: Grades CZ-100.
M-35
ASTMAP494: Grades CZ-100.
M-35

DURANICKEL Alloy 301 o toFinish (Max: 1/6 of A601V

MONEL Alloy 502 150 6500O 100 00 a. WelWdh
MONEL Alloy K600 to Solution Treated .00 ma.IWelWdh
NI-SPAN-C Alloy 902 320
PERMANICKEL Alloy 300

33 o to Finish (Max: 1/601f A601V

6500 100 .0005 max. Wheel Width)
360

37. BERYLLtIM NICKEL 500 Rough .=6 o0f-461V

ALLOYS, WROUGHT AND 200 As Cast 60 00 a.
CAST# oo 00 D5mx wWel'dh
elWdh
Berylco 4.40 250 Solution Treated4
Berylco 410
Berylco 420C00Ruh .0 00.0
Beryfco 430
00
Brush Alloy 2000 283 Hardened 6o30in00Ma:160 4H
Brush Alloy 2200 to or
Brush Alloy 2600 425 Aged

See section 16 for Cutting Fluid Recomrmendations tWax tilled.

Wheel recommendations are for wet grinding. For DRY grinding-use t tCAUTION: Toxic Material, refer to National Institute for Occupational
a softer grade wheel Also see section 20.2. Grinding Guidelines. Safety and Health (NIOSH) for Precautions.

8-17
8.1 Surface Grinding-Horizontal Spindle, Reciprocating Table

HAD.
MATRIA CONITIN HEE TALE DOWNFEED CROSSFEED IDENTIFI-
MAEILNESS CNION SPEED SPEED CATO
tpm fpm in/pass in/pass ANSI

NCKEL
37. INIRYLUUU11111 5000 Rough:.001 .040-.400

ALOYS WROUT) A) 4 RC Hree 6000 .0005 max, Wheel Width)__

(materials listed on preceding pag)SR Aged - i ~ ~ ~ ~ ~ ~ i~~ -~~

tRough:.002 .025-.250
38. HITINOL ALLOYS,
WROUGHT
Nitonr
210
t.0005
to
K5i4TWogt5000
Wrought
40 Finish
max.
(Max: 1/l10of
Wheel Width)
556:S~
C601V

r
Nitinol 56Ni-44Ti 340 Annealed ~' '
Nitir'ol 6ONj-4OTi , 4 .hdIti~

SRough:.002 .025-.250
48 RC 500 4 Finish (Max: 1/10 ot C601V
to Quenched _
~0005 . max. Wheel Width)
52 R0 _

39. HIGH TEMPEA[UR 3000 50 Rough:.001 .020-.200 -

ALOS NRUH eld3to to Fi:h (Max: 1/ 12 of I A46HV
ALOSWOUH AD 200 Annae 3500 100 .0005 max. Wheei Width)
CAST to or ~---
Nickl 1111",Wintought 390 Souto Treated
AF2-1DA Souin rae
Astroloy - "NN R~
Haynes Alloy 263 3000 50 Rough: 001 .020-.200
IN-102 3003 to to Finish (Max: 1/ 12 of A46HV
Incoloy Aboy 901 to Solution Treated 3500 100 .0005 max. Wheel Width)
Incoloy Alloy 903 45 adAe
'nconel Alloy 617
--nel Alloy q 5________
700
/02
706
lnconei ovioy 718
Inconetl Alloy 721 9
Inconel Alloy 722
Inconel Alloy X-750
Inconel Alloy 751
M252
Nimonic 75
Ngrnic 80
Nirnionto 90
Nimonic 95
Rene 41
Rene 6.3
Rene 77
Rene 95
Udimet S00
Udimet 700
Udiniet 710
Unitemp 1753
Waspaloy

See section 16 for Culling Fluid Recommendations. ttCAUTION, Toxic Material, refer to National Institute for occupational
Wheel recommnendations &tefor wet grinding. For DRY gninding-use Safety and Health (NIOSH) for Precautions.
a softer grade wheel Also &e section 20.2. Grinding Guidelines.

8-18
 Surface Grinding-Horizontal Spindle, Reciprocating Table8.

WHEEL TABLE I WHEEL'

MAERALHARD-
MAERA NSS
OD~~O
CNDTIN SPFED SPEED IDOWNPEED CROSSFEED IDENTIFI-
lpr'~i fpmCATION
Bh { rnmi rn/nu ln/pas -S irn/pass ASI

Nickel Bae, Wrought 3000 50 Rough: 001 .025,.250

Hastelloy Alloy
I to to Finish 1 (Max: 1/10 of A46HV
B 140 Annealed 4000 100 .0005 max,_ Wheel Width)
H-asteltoy Alloy 8-2 to 15k~t
Hastelloy Alloy C 220 Solution Treated IJ I- __ V -~ -=66:---&S
Hastelloy Alloy C-216 jD4' nf~- ~M~,i~t 41I
Hastelloy Alloy GS1 3000 50 Rough:.001 .025-.250
Hastelloy Alloy S 4 odDan 40 100 0005 max Wheel Width)
Inc ol oy A ll oy 8 04 to r 4o
Incooy llo i s_
15 RAodh. 025f
IncloyAloy
25310
lnconel Alloy 6010________1
Inconel Alloy 6001
Aged
~-...-
0 ~msi3 1 (ailo'i. __J
4H~

Refractaloy 26
Udimef 630

Nike as, rugt5500 50 Rough: .002 .050-.500

TO-ickelt 180,Wouh to to Finish (Max 1/4 of Ilet
TD-Ni-crtt to18ole 6500 100 I .0Ofl --- ~ vneel Width)
200 NO -W_15

Nickel Base, Cost 3000 50 Rough. .001 .020-.200

to to Finish (Max: 1/ 12 of A46HV
B-1900 200 As Cast 3500 100 .0005 max. Wheel Width) __
GMR-235 to Of- -- _-
GMR-2350 425 Cast and Aged _;jlfg
H-astelloy Alloy B
Hasteroy Alloy C -~S 3 ~~0~.~ ~eIW)
Hastelloy Alloy D
IN- 100 (Rene 100)
IN-738

Inconel Alloy 71308~

M252
MAR-M200
MAR-M246
MAR-M421 7--- MIM-'MPUMM-
MAR-M432
Rene 80 -

Rene 125
SEL
SEL15
TRW VI A
j e ~~Udimet
500W~-~*
Udimet 700
XSTf. AP2,b Grades CW-12M. - ______ __

N-12M. CY-40
ASTM A297: Grades HW. HX
AST M A494: Grades'N- 12M- 1. -

N-12M-2. CY-40. CW-12M-1. _ _

ASTMI A6O8: Grades HW5O. -_ _ _ _ _ _ ~ ~-

See section 16 f or Cutting Fluid Recommendations. ttCAUTION* Toxic Material, refer to Naticnal Institute for Occupational
*Wheel recommendations are for wet grinJing. For DRY gninding.-use Safelty and Health (NIOSH) for Precautions,
a softer grade whieel. Also see section 20.2. Grinding Guidelines.

8-19

7c =~---~
 81 Surface Grinding-Horizontal Spindle, Reciprocating Table
HARD-WHEEL TABLEWHEEL'
MATERIAL NAED- CONDITION WHEEL TABE DOWNFEED CROSSFEED IDENTIFI-
NESS PEED PEEDCATION
fpm fpm in/pass in/pass ANSI
8M
hn M~~j m
39. HIGH TEPRTR 3000 50 Rough: 001 020-.200

to to Finish (Max: 1/ 12 of A46HV

WROUesT toLYS 4N80300 400 .05 max. Wheel Width)

CAS Soterial. CAUxiON: Toxi retere

toNaioalIntiut fr ccpaio

J-1570 270 todios Fin s of Mx /1 A46rH.

MR-M9 to Solutio Trae 350 100 .0005 max Wheel-.-.-.----.

Width)
 Surface Grinding-Horizontal Spindle, Reciprocating Table8.

MAERALHARD)-
MAEILNESS
CNl
CNION
WHEEL
SPEED
ITABLE
SPEED
I DOWNFEED -
CROSSFEED
HIETFI
IDCATIN-
fpm fpm inipass; in/pass I ANSI
___________ Bhn __________ -_a-- 5t

Tantalum"
0
2000 jRough: 001 .020- 200
ASTAR 81 IC 200 10 40 Finish j(Max- 1/12 of A46JV
T- 111 10 Stress 4000 I.0005 max. IWheel Width)
T-222 250 Relieved 'AN
Ta-lOW k - ,

Ta-Hf ________ ~ IWO~b.~

0 Rough .001 .020200 A46NV

Tuigstens 140
85% density 180 Pressed and Sintered. 2000 to Finish~ (Max: 1/ 120of or
93% dest to 60red 0005 max. Wheel Width) C36JV
96% dest 320 or~
100% density Arc Cast - 'A'~~j

t2(=
~40
Tunle-2Tod
hra lmd ..
1Rough:.COl
rnisf tra;".
.020,.200
:!2 rif C6OJV
260 Prssd 60 .0005 max. Wheel Width)
to andI -
320 Sintered

TijmgiAloys 40 Rough: .001 .020-.200

GE28202000 to Finish (Max: 1/ 12 of C6OJV
G-18 260s as 60 .0005 max. Wheel Widt)
W5e320 _

W-25Re-30Mo ______

40 Rough: .001
40.020-.200
2yromet (Max: 1/ 12 of C6OJV
Mallory 2000 t n
W-1OAg 320 Sintered
W-7Ni-4Cu

7193h A~oa40 Rough: .001 .020,200 f

4000 to Finish (Max: 1/ 12 of C6OjV
Anviloy 110029Prse
Anvitoy 1150toad-1 6 _05ax WheWi)
Anviloy 1200 30 Snee

~ WOI BhI~4
44 URAIUM, 300 50 Rough: .005 .0520
56,RAIIKWOGKI to to Finish (Max: 1/1001f C46GV

58 RA

See section 16 for Cutting Fluid Recommendations Due to the brittleness of refrtory alloys, cracking. chipping, flaking
.Wheei recomnmendations are for wet grinding. For DRY grinding-use and breakout tend to occur. partcularly on the edges of the ma-
a softer grade wheel. Also see section 20.2. Grinding Guidelines. chined surfaces
tCAUTION: Toxic Material, refer to National institute for Occupational
Safety anid Health (NIOSH) for Precautions
$.'CAUTION. Potential Fire Hazard. Exercise caution in gninding and
disposing of sv art.

8-211

_0 ..... .......-Z
8.1 Surface Grinding-Horizontal Spindle, Reciprocating Table
R E T WHEEL'
MAENA
MATERIAL HEESS ONTON
CONDITION SPEED
WHEEL SPEED
TABLE DOWNFEED CROSSFEED IJ CTO
IDENTIF-
I CATION

o I Ro-gh
P . M, -.00
45. ZIRCONIUM ALLOYS,
WRO040 Rolled. , ish
Fn140 (Max: 1/6 of C46.JV
rOHI.del i 140 ERudled i i .0005 max. Wheel Width)
Zr-0.001%HI (Grade 21) I280 or orgd 5 1 I
Zircaloy 2 (Grade 32) ____I___ O3a. -1/ d._______
Zrcaioy 4 (Grade 34) i

47. POWDER METLi 5s10 50 .050-.5mI 1ough:.oo3

ALLOYS" TLto 50 RE to Finish f (Max: 1/3 of C36
* 0 6 100 0005 max. Wheel Wt)
Copper to As Sintered .
70 R17~5 c4:.0%~15

Bae 5500 50 I Rough: .003 .050-.500

to to Finish (Max. 1/3 of C36IVt"
CZP-0218-T 350 6500 100
H .000 max. Wheel Width)
CZP-0218-W 81 RH 75_HoZ _ - _-
90Cu- lOZn -i-_
90Cu-1Ufn-u.:ru _ _
70Cu-3OZn I
68.5Cu-30Zn- 1 5Pb

lot 5500 50 Rough: .003 .050-.500

CT-0010tN 30 R1 o to Finish (Max: 1/3 of C361Vt
CT-0010-N 30 A Se6500 100 .0005 max. W
07-00 10-S 75 RF
9.SCu-5AI W
77Cu-15Pb-7Sn-1Fe-1C _ _ _

Copr-NickeAiop * , 5500 50 Rough: .003 .050-500

CZ-
22Tto to Finish (Max: 1/3 of C36IVf
CZN-1818-T RH 0005 ma Wheel Wth)
CZN-1818-U to As Sintered 650 100 .00 ax W h)
CZN- 1818-W 100 RH_
CZNP-1618-U _:llI--

90Cu-10Nt
62Cu- 18Ni- 18Zn-2Sn

...,i, 14500 50 Rough: .001 .040-.400

to 10 FwniSh (Max: 1/F of A6oV
5500 -00 .0D05max. Whe W tt)

See section 16 for Cutting Fluid Recomnndations. t Wax filed

Weel recommendatins are for wet griaig. For DRY grindirng e G-:ndng of Iow-dens parts isnot reconteided ecause
a softer grade wheel AlSo see section 20-2. Grinding Gwdeuxes porosity w-lbe reduced or los.
IS CAUTIONd. Potentia Fire Hawad Exercise cauition in grinding and
disposing of swan.

8-22
 Surface Grinding-Horizontal Spindle, Reciprocating Table 8.1

HARD WHEL TBLEWHEEL

MATERIAL HARD- CONDITION WHEEL TABE DOWNFEED CROSSFEED IDENTIFI-
NES SPED PEE CATION
1pm 1pm in/pass rn/pass ANSI

Nickel Alloys" 5500 50 Rough. 001 .040-.400

to to Finish (Max* 1/6 of A461V
67'Ji-300u-3Fe 34R6500 100 .0005 max. Wheel Width)
to As Sintered V jTW
.4- -:4~a

Reratoy etl as"50 Rough .001 .020-.200

Refra3ctr Meal0a1 2000 to Finish (Max: 1/ 12 of C60JV
87-lC 11100 .0005 max. Wheel Width)
BSW-iSAg to As Sintered :- _,1
74W-260u 260
72.5W-27 SAg figtk Sy~
tXo#'g
k4KAI
t F -.
t4ffa ~tWA~d&
i
~~xIiqck~'6gVt
~
*

65W-3SAg
56W + C-440u
SSW-45Cu
51W-49Ag _

5OW + C-5OAg ;7,p ~ -~

Refractory Metal ease** 40 Rough: 001 .020-.200

6lMo-39Ag 75R4000 to Finish (max: 1/ 12 Of A46KV

F-0000-P 101 AsSnord 600 100 .0005 max. Wheel Width) A41

w-esedatsI o ecm eddbcas ufc

00- 16 foSulniFudRcm enainntenrgol
Seesecio
F-000eeo
- mndios r orwtgrnig Fo4R rnigus ooiywl b rdcdo ot

soha grad whee Alsos

a00 sec1o 20.2 GrndngGudeins
seax

FC-028823
8.1 Surface Grinding-Horizontal Spindle, Reciprocating Table
WHEEL TABLEWHEEL$
MATERIAL HR- CONDITION WHEEL SA8E DOWNFEED CROSSFEED IDENTIFI-
NESS PEED PEEDCATION
1pm 1pm in/pass in/pass ANSI
Bhn WM____
*222y mc
________M2jMMW-rWC-7

47. POWDER METAL 4000 50 Rough: .003 .050,.500

ALLOYS" (cont.) 5RHto to Finish (Max 1/3 ot C46JVt
Aluminum Alloys" to Solution Treated 500 100 .01max. Wheel Width)
90SA-~n4C 8 H and Aged I
88A1-SSn-4Pb-3Cu H -s r1 R WEMR
Al-lMcl-0.6Si-0.25CuIt
Al-I) 6g-0.4$i1
Ai-4.4Cu-0 8Si-0 4Mg

48. MACHINABLE CARBIDES 5500 50 Rough: .002 .010-060 Rough:A46FV

Fer-i 0to to Finish (Max. 1/ 12 t j Finish
FroTc4RC6500 S0 01 max. Wheet Width) AOGV
to Annea:9d tr 111-7k-M - .%

5500 50 Rough: .002 .010,060 C46FV

to to Finish (Max: 1/ 12 of or
68 Ac Hardened 6500 60 .0005 max. Wheel Width) A80GV

70 Rc Tempered

49. CARBIDES 00 3 og:01 .3,6 RuhC0G

Tiaim
abdeAiR 6000 50 0005 max. Wheel Width) C100 v
Tungsten Carbide
4to T
9 RAW

50. FREE MACHINING55D 5 og:03 .0,0

MAGNEIC ALLOYS 185 650 100 max.:
Fi001 Whee Width6J
Magnetic Core Iron-FM (up to to Wrought 650 10 .1ma. Welidh
2.5% Si) 240

Hi Perm 49-FM550Ruh.2 .0,0

185 6500 100 .0005 max. Wheel Width)

240

51. MAGNETIC ALLOYS s 00.0

I0
Magnetic Core Iron (up to 4% Si) 185 650 100 max. WheoWdh
(M00:
to Wrought 60 0
240

HyMu 80 185 650 100x .000 max Whel Wdth

_ __ to Wrought

See section 16 for Cutting Fluid Recommendations. axled

*Wheel recommeridations are for wet grinding. For DRY grinding-use tOiamono wheel ispreferable, see section 8 3.
a softer grade wheel. Also see section 20.2. Grinding Guidelines. Gfrinding of low-deilsily parts isnot recommended because surface
porosity will be reduced or lost

8-24
 Surf ace Grinding-Horizontal Spindle, Reciprocating Table 8.1

HARD WEEL I ABLEWHEEL*

MATERIAL NAEDS CONDITION WPEEL TABE DOWNFEEO CROSSFEEO IDENTIFI-
NESS PEED PEEDCATION
fpm fpm in/pass in/pass ANSI

Aiio15500 Rough: .002 .015

to 30 Finish (Max: 11/10 of A54GV

Alio1 5O6500 60 .0035 max. Wheel Width) 6V

Alnic A Cas IIIto

!v.Q%_"
-ft
Alnico
Alnico
4000c

V-
20 Rough .03 .2- 0

Alnico XI
ColumaxI rfealsescin8
Seeluse co16frCtigFudRcomnain.-7l oonntiewelI

- ~ ALY
2
to
neld40
8ONROL51
or________-p
00 a.
~
WelWdh
~-..
jX
8.1 Surface Grinding-Horizontal Spindle, Reciprocating Table

MATERIAL
HARD-
NESS CONDITION
WHEEL
SPEED
TABLE
SPEED DOWNFEED CROSSFEED
I HEEL*
IDENTIFI-

fpm fpm in/pass in/pass ANSI

55. GLASSES & CERAMICS 5000 j 50 Rough 002 025- 250 1Rough: C461Vt
(cont.) iver to to Finish (Max 1/l0ot Finish
Ceramics 800 Fired 5500 100 .0005 max. -Wheel Width) C6OIVt
Alumina (Aluminum Oxide) Knoop 1 R~~5
u5. ~ .565 RuhC6V
Alumina-Mullite tor,~1SW a
Aluminum Silicate 03fii E-M _ki)
Beryllia (Beryllium Oxide)ft O mx. Wi Ih)= ... c0 t
Magnesia (Magnesium Oxide)
Mullite ___

Siticon Carbide A
Silicon Nitride*-. - 4
Thoria (Thorium Oxide)tt
Titania (Titanw'n Oxide)
Titanium Diborideti
Zircon (Zirconium Siticale)
Zirconia (Zirconium Oxide) 4

56. PLASTICS 5500 Rough .005 .050,500

Thiermoplastics Cast. Molded, to 40 Finish (Max* 1/3 of C54JV
-Extruded. 6500 .0005 max. Wheel Width)
or t2 'V-
Filled and Molded W O

Thormosettlrng Plastics 5500 Rough: .005 .050,.500

to 40 Finish (Max: 1/3 of A54GV
Cast. Molded 6500 .0005 max. Wheel Width)
- or 3W--
Laminated '0 1 e-sw
a 4 WiW eL*w,..3
Gil. FLPAE (THERMAL) 00 3 og:01 .0,0
SPRAYED MATERIALS t oFns Mx /1 f C0V
Sprayed Carbides 6500 50 max.
.00USJ Wheel WIt)
Chromium Carbide SWR~ 426
Chromium Carbide-Cobalt Blend
Columbium Carbide 7
0
Tantalumn Carbide
Titanium Carbide
Tungsten Carbide
Tungsten________Carbide-Cobalt__________
Tungsten Carbide-Cbl
(Cobalt)-Nickel Alloy BlendIs
Inorganic Coating Mateiials 5500 35 Rough:.001 .010,030
Alumina (Pure) to tIiih (a:1 2o 10V
Alumina. Nickel-Atuminide _ 15 1
Blenda
Barium Titanate
Borontt
Calcium Titanate
Calcium Zirconate
Chromium Disilicidett
Chromium Oxideft
Cobalt (40%), Z;rconia Blend
Columbium (Niobium)tt
Glass (Kovar sealing)tt
Hexaboron Siticideft
Magn:.,sia A!umina Spinet
(materials continued 1
on neAt page) _____

See aection 10 for Cutting Fluid Recommendations. t Diamond wheel ispreferable. see section 8.3
*Wheel recommendations are for wet grinding. For DRY grinding-use Diamond wheel is preferable for flame sprayed carbides and ceram-
a softer grade wheel. Also see sertIon 20.2. Grinding Guidelines. ics, see section 8 3.
ttCAUTION. Toxic Material, reter to National Institute for Occupational
Safety and Health (NIOSH) for Precautions
4

8-26
 Surface Grinding-Horizontal Spindle, Reciprocating Table81

HARDWHEL TBLEWHEELV
MATERIAL HARD- CONDITION WHEEL TAPE DOWNFEED CROSSFEEO IDENTIFI-
NESSSPEE SPED ICATION
fpm fpm in/pass in/pass ANSI
____________ StiBr, 'yi/i fiAl'7.rm/!i ~ S~
58. FLAME (THERMAL)
SPRAYED MATERIALS

Inorganic Coating Materials ~~. -

(cont.) s
(materials continued from__________ *- - -------

preceding page)
Magnesium Zirconate
Molybdenum Disilicide -

Mullite N I
Nickel (40%). Alumina Blend
Nickel Oxide 01_____6110 __1__11

Rare Earth Oxides

Tantalum
Titania (50%), Alumina Blend
Tolnium Oxide - : __ Big- am n 77
Tungsten
Yttrium Zirconate
Zircnr (Lime Stabilized)
Zirconia, Nickel-Aluminide
Blends
Zirconium Oxide (Hafnia Free. - ~ ~ r-.
Lime Stabilized)
Zirconium Silicate gm~

Sprayed Metals (Group 1) 5500 35 Rough: .001 .0 10-. 100

Co-Cr-B Alloy (Self Fluxing) to to Finish (Max, 1/10 of C46HV
Ni-Cr-B Alloy (Self Fluxing) -6500u /b .0005 max. Wheel Width)
Nickel Chrome Steel (Special) t- --. . - M
Stainless Steel .Q4

Sprayed Metals (Group 11) 5500 40 Rough: .001 .0 15-.120

Bronze to to Finish (Max: 1/10 of C60JV
Chromium -6500 100 .0005 max Wheel Width) _______

Cobalt
Nickel - -.

Molybdenum
Monet

Sprayed Metals (Group 111) 5500 40 Rough: 001 .015-.120

Carbon Steel t oFns Mx 0o 4J
Iron650 10 .05mx Whe i )
Precipitation Hardening Steel
I

59. PLATED MATERIALS 3000 Rough: 001 .025-.250

Chromium Plate t 0 Fns Mx /0o 6H

Nicl Plate to 40 Finish (Max: 1/6 of C60HV

See section 16 for Cutting Fluid Recommendations.

*Wheel reicommendations are for wet grinding. For DRY grining-use
a softer grade wheel. Also see section 20.2. Grinding Guidelines

8-27
8.1 Surface Grinding-Horizontal Spindle, Reciprocating Table

MATERIAL HARD-
NESS
CONDITION WHEEL
SPEED
ITABLE IDOWNFEED
SPEED ICATION
CROSSFEED IPNII

Ipm fpm in/pass in/pass ANSI

Bhn ______ flI 7 1 ____ __ _ _

61. RUBBER 5500 50 Rough. .003 .050- 500

to to Finish lVjx. 1/4 of C24NB
Soft -6500 100 .
001 ma..x Wheel Width)

5500 50 Ruh.03 050,500

to to Finish (Max, 1/4 of C24LB
Had6500 100 001 max, Wheel Width)
Hard R ~

See section 16 for Cutting Fluid Recommendations

Wheel recomme-idations are for wet grinding For DRY grinding-use
a softer grade wiooet Atso see section 20.2. CrInding Guidelines.Z

8-28
 Surface Grinding-Horizontal Spindle, Reciprocating Table 8.2
Cubic Boron Nitride Wheels
WHEELWHE
SPEEDWEL
MATERIAL HARD- CONDITION DRY WET* TABLE DOWNFEED CROSSFEED IDENTIFI.
NESS SPEED CATION
fpm fpm fpm in/pass in/pass ANSI
Bhn __ __ _ _

1. FREE MACHINING CARBON Rough: .25-1.00

STEELS, WROUGHT 5500 50 001-.002
Low Carbon Resulfurized 400 t oBl00T756
10118Carburized800 15 Fns. (a-/2o
1109 1119 Over and/or 0005 max. Wheel Width)
110 1119 5OFIC Quenched .-.

1212
1115 andTempered -
1116 1213
1117 1215
Medium Carbon Rosulfurized-
1132 1140 1145
1137 1141 1146
1131 1144 1151
Low Carbon Leaded
10L18 121-13 121-15
1IL17 121-14
Medium Carbon Leaded
I0L45 11L37 11L44
lOL50 111L41
2. CARBON STEELS,500 02 .- 10
WROUGHT400 t tolOTB
1005 101a 119o02 Carburized 8000 125 Finish: (Max: 1/2 of
1006 1013 1020 1029 Over and/or .0005 max. Wheel Width)
1008 1015 1021 1513 50OFc Quenched
1009 1016 1022 1518 and Tempered
1010 1017 1023 1522
1011 1018 1025
Mediumn Carbon
1030 1042 1053 1541
1033 1043 1055 1547 -

1035 1044 1524 1548

1037 1045 1525 1551
1038 1046 1526 1552
1039 1049 1527
1040 1050 1536
High Carbon
1060 1074 1085 1566
1064 1075 1086 1572 -

1065 1078 1090

1069 1080 1095
1070 1084 1561

*See section 16 for Culling Fluid Recommendations.

See section 20 for additional information.

8-29
8.2 Surface Grinding-Horizontal Spindle, Reciprocating Table
Cubic Boron Nitride Wheels
WHEEL
SPEED WHEEL
MATERIAL HARD- CONDITION DRY WET* TABLE DOWNFEED CROSSFEED IDENTIFI-
NESS SPEED CATION
fpm fpm fpm in/pass in/pass ANSI
Bhn tZa' K,

4. FREE MACHINING ALLOY Rough: .25--l.00

5500 50 001-0002
STEELS, WROUGHT
4000 t0 to Bl00T75B
Medium Carbon Resulfurized
8000 125 Finish- (Max: 1/2 of
4140 Carburized
and/or 0005 max. Wheel Width)
4140Se Over
4142Te 5ORC Quenched
and Tempered
i
,?tA
~ i
4p,&Cr - Ro ; _

4145Se _.

4147Te " Us e"'

AA R1-M
4150
Medium and High Carbon
Leaded
41130 41L47 51L32 86140
41140 41150 521100
41145 43L40 86120

5. ALLOY STEELS, WROUGHT Rough: .25--1.00

Low Carbono to T75B
4012 4615 4817 8617 Carburized 8000 125 Finish. (Max: 1/2 of
4023
4024 4617
4620 4820
5015 8620
8622 5Overc Qece
and/or - -- max
.0005 ,''-' Wheel Width)

4118 4621 5115 8822 Qenched

and
4320 4718 5120 9310 1 and Tempered -_ ---
4419 4720 6118 94615 IN
4422 4815 8115 94617
Medium Carbon .
1330 4145 5132 8640
1335 4147 5135 8642
1340 4150 5140 8645
1345 4161 5145 86B45
4027 4340 5147 8650
4028 4427 5150 8655
4032 4626 5155 8660
4037 50B40 5160 8740
4042 50844 5160 8742
4047 5046 6150 9254
4130 50B46 81645 9255
4135 50650 8625 9260
4137 5060 8627 94B30
4140 50660 8630
4142 5130 8637
High Carbon
50100 51100 52100 M.50 f

*See section 16 forCutting

FluidRecommendations
See section 20 for information.
additional

8-30
 Surface Grinding-Horizontal Spindle, Reciprocating Table 8.2
Cubic Boron Nitride Wheels
WHEEL
SPEED WHEEL
MAEILHARD- CNION DR~Y WET TABLE DOWNFEED CROSSFEED IDENTIFI-
CONDTIO SPEED CATION
fpm fpm fpm in/pass in/pass ANSI
_____________Bhn ________ i~~Eii Voi ~ ~ ~
6. HIGH STRENGTH STEELS, Rough: .25-1.00
WROUGHT 5500 50 .001-.002
300M H11 4000 to t0 B100T75B
4330V H13 Quenched 8000 125 Finish: (Max 1/2 of
430 P -420 Over ad.0005 max Wheel Width)
4340Si HP9-4-25 50~ Tempered -.
98BV40 HP 9-43 3- O 6
D6ac HP9-4-45 _ _ ~~ ~ ~UJi

7. MARAGING STEELS,Rog. 2510

WROUGHT 50 0 .0-0
120OGrade 300 Grade800 15 Fns: (a:/2o
180OGrade 350OGrade Over.05ma. Welidh
200 Grade HY230 50ORC age
250 Grade 7
ASTM A538: Grades A, B. C I

8. TOOL STEELS, WROUGHT r~n 5 05.05 1-.

Group I 00 t oBOT5
A2 H13 L6 P20 8000 125 Finish: (Max: 1/2 of
A3 H4 L7 P21.0005 max. Wheel Width)
A4 H19 01 Si Over and
A6 H21 02 S2 50ORc Tempered
AB H22 06 S5
A9 H23 07 S6
A10 H24 P2 S7
H10 H25 P4 Wi
H1i H26 P5 W2
H12 L2 P6 W5
SAE J438b. Types W108, W109.
W1 10.Wii12. W209. W210,
W310

*Seesection 16 for Cutting Fluid Recommendations.

See section 20 for additional information

8-31
8.2 Surface Grinding-Horizontal Spindle, Reciprocating Table
Cubic Boron Nitride Wheeis
WHEEL
SPEED WHEEL
0
MATERIAL HARDS CONDITION DRY WET* AL DOWNFEEED CROSSFEED CAETIN-
NESS SPEED CTO
fpmn fpm fpm in/pass in/pass ANSI
Bhn 94!_____ _____

S. TOOL STEELS, WROU'3HT 550 Rough- .12-1.00

(cant.) 50 50 0005--.0015
Group 11 4000 to to Bl00T758
02 H2 M2 O~ Quenched 8000 125 Finish- (Max* 1/2 o1
D3 H42 Ti Oe and Max.
.____0005 Wheel Width)
D4 M2 T2 5Oc Tempered 0 l
05 M3-1 T4
F1 M10 T82
F2 M30

Group IIIRog: 1 .0
A7 M41400 t toBOT5
D7 M43800 15 Fns: (a:12o
M3-2 M44 Quenched005mx Welidh
M6 M46 Over an.00ma. Welidh
M7 M47 50 Rc Tempered
M33 T5
M34 T6

Group IV Rough- 0610

Grou IV5500 50 .0005-.0010 06 0
M44000 to to Sl00T758
T15Qunce 8000 125 Finish: (Max: 1/2 of
Over aunchd .0002 max. Wheel Width)
50 RC Tempered

9. NITIRIDING STEELS,Rog: .5 0
WROUGHT
Nitralloy 125800 15 Fns: (a:/2o
Kitratloy 135 60ORc .05mx WelWdh
Nitralloy 135 Mod. j to Nitrided
Nitralloy 225 I 6n
Nitralloy 230
Nitralloy EZ
Nitrattoy N
Nitrex 1

8-32

- -- -- ,~ -_ - ~ ~::-~ AA
 Surface Grinding-Horizontal Spindle, Reciprocating Table 8.2
Cubic Boron Nitride Wheels

WHEEL I WHEEL
H SPEED I IWEEL
MATERIAL CONDITION DRY WET* TABLE j DOWNFEED CROSSFEED IDENTIFI-
NESS SPEED CATION
fpm fpm fpm in/pass in/pass . ANSI

___

13. STAINLESS STEELS. Bhn5

_ _ I Rough.
0o.
10A 25- _ 1
_ww
25-1.00
iR1
5050 001-0G02 B
WROUGHT
Martensitic
Quenched 8000 125 Fnish: (Max 1/2 ofi
403 440A
and .0005 Max Wheel Width)
410 4408 Over
414 440C Sc Tempered -
420 501
422 502
431 Greek Ascoloy
I - _-_____,__
15. CARBON STEELS, CAST I .25-1.00
Low Carbon 50 001.002
Grade CP1
ASTM A426*AST0 49 oB075
Carbunzed 8000 125 Finish: (Max: 1/2 of
1010Oaune
.0005 max Wheel Width)
1020 Over and/or
50Rc Quenched - I _ _Z
Medium Carbon
ASTM A352: Grades LCA. LOB. anNepee
LCC
ASTM A356: Grade 1
1030 1040 1050

16. ALLOY STEELS, CAST 5500 50 Rough-

.001-.002 .25-1.00
Low Cabon
ASTM A217: Grade WC9 4000 to to Bl00T75B
ASTM A352: Grades LC3. L04 Carburized 8000 125 Finish: (Max: 1/2 of
Over and/or .0005 max. Wheel Width)
ASTM A426: Grades CP2. CP5.
0P12. CP15.
CP5b. CP 11. 50Rc Quenched
CP21. CP22 and Tempered
1320 2320 4120 8020
2315 4110 4320 8620
Medium Carbon -

ASTM A27: Grades NI. N2.

U-60-30. 60-30. 65-35.
7.'-36, 70-40
ASTM A148: Grades 80-40.
80-50,90-60. 105-85.
120-95, 150-125. 175- 145
ASTM A216: Grades WCA.
WCB.WCC
ASTM A217: Grades WC1.
WC4.WG5,WC6
ASTM A352. Grades LCl. L02.
L02-1
ASTM A356: Grades 2. 5. 6. 8.
9. 10
ASTM A389: Grades C23,C24
ASTM A486: Classes 70. 90.
120
(materials continued
on next page)

'See section 16 for Cutting Fluid Recommendations

See section 20 for additional Informatinn

8-33
8.2 Surface Grinding-Horizontal Spindle, Reciprocating Table
Cubic Boron Nitride Wheels
WHEEL
I SPEED IWHEEL
MATERIAL HARD- CONDITION DA~Y WET* TLE DOWNFEED CROSSFEED IDEI4TIFI-
NESS SPEED (CATION
1pm 1pm fpm in/pass in/pass ANSI
Bhn __________ ___ ; _
15. ALLOY STEELS, CAST
(cont.)
Medium Carbon (cont.)
(materials continued
from preceding page) __

ASTM A487- Classes i N. 2N. j~~

4N. 6N. 8N, 9N. ION. DN. 10.
20.40. 40A. 60.70U.8d
90. 1001
1330 4130 80B30 8640
1340 4140 8040 9525
2325 4330 8430 9530
2330 4340 8440 9535
4125 8030 8630

17. TOOL STEELS, CAST Rog:12-10

0 .0102
ASTM A597: Grades CA-2.500
CO-2. CD-5. CH- 12. CH-i13.800 15 Fns: (a:/2o
CO-i. CS-S Over Quenched .0005 max. Wheel Width)
50 Rc Tempered

21. GRAY CAST IRONSRog- .510

FewriticAsCs400 0 toBOT5
ASTM A48: Class 20 Anrealed.
SAE J43ic: Grade G1800 45 Rc Quenched 8000 125 Finish: (Max: 112 of
Peaditic- Ferritic to and Tempered .0005 max. IWheel Width)
60 Rc or Flame P1BW
ASTM A48: Class 25
SAE J43i1c: Grade G2500 j or Induction

ASTM A-18- Classes 30.35.40

SAE J431c: Grade G3000
Pearitc + Free Carbidee
ASTM A48: Classes 45. 50
SAE J431c: Grades G3500.
G4000
Pwlitic or Acicular +i Free

ASTM A48: Classes 55. 60

*See section 16 for Cutting Fluid Recommendations

See section 20 for additional information.

8-34
 Surface Grinding-Horizontal Spindle, Reciprocating Table 8.2
Cubic Boron Nitride Wheels
Ii
ISPEED
WHEEL
WHEEL
MATERIAL jHR. CONDITION DRY WET* TABLE DO1! sCOS)DIEtJTIFI-
NESS SPEED ICATION
hnI fprtA f pm fpm in /pass in pass ANSI

23. DUCTILE CAST IRONS I jRough: 25I0

Ferritic 400 to to
50 GlW175B
ASTM A536: Grades 60.40.18. I o t 8075
I I I 000 i 125 Fin'ish (Max 1/2 o'
65-4512 1Over Flm rI0005
Induction Sbg
nilax I Viheel 'Width)
SAE J434c: Grades D4018. 5 I
D4512 PrltcI Hardened ~1
ASTMV A536, Grade 80-55-06 41 0 lm.~ Ux12 ~---
SAE J434c. Grade D5506 1O~a. WeIi.-
Pearlitic- Martensitic
ASTM A536- Grade 100-70-03
SAE J434c- Grade D7003 II
I I I
Martens itic I

ASTM A536Grade 120l-90400t-0210.5

SAETA602: Grade D 1 oug

24. MALLEABLE CAST IRONS I 50. 0 25--1.0

35018 i l 50 125 Fish (Mx /o

SAE J 158: Grade M32 10 5 Hadeed -- ~'~-~ 05~-
ASTM A220. Grades 40010. - -- -

45006.45008.50005 -1 3. (M-i2v
ASTMVA602: Grade M4504. ~- - mt~. ie~dl Ii
M5003 II
SAE J 158: Grades M4504.I
M45003
Tempered MairtensiteI
ASTM A220: Grades 60004.,
70003.80002.90W01 P~-~-'I
A602- Grades M45503.--
ASTMV -

M47002.1M8501 101~
SAE J158 Grades M45503. - -- - -- ~
Rough.
25. Wi4ITE CAST IRONS 550 5 05.00 06-1.00
(ABRASION RESISTANT) to
5000 to 081000758
Cass Type A53. B .DA~s. 2 Finish: (Max. 1/20of
Clas I1.Types A. B.0C. As CaE 800 12 W02 mnax. Wheel Width)
. .C D E
Clas I.Typs Over Annealed ~=-~
Class Ill. T'.pe A 45Rc or Hardened zV W.' 0. - ____

'See section 16 for Culling Fluid Recommendations

See section 20 for additional iformation
8.2 Surface Grinding-Horizonta! Spindle, Reciprocating Table
Cubic Boron Nitvide Wheels

-, WHEEL
HARD
D-j
CON DITION
I SPEED
1,DRY IWET.
iWHEEL
I TABOLE= ONED! RSFE IDENTIFI-
.. A~P.LNESS a ISPEED 'CATION
fPni fpm I tprr ANISns
An/as
_
__ _ _ _ IBhn T-,V INiI - R Pas
39. IGHTEMPRATRE Rough I
39 IHTMEAUESeel 5500 II r- D 25-100
ALLOYS, WROUGHT AND NttIt
CAST
Nickel Base, Wrought SouinTetd8000 .25 Finish (Max, 1/2 of
3010 Soui nTetdIWelWdh
i or 00OOO-nax MetWdh
AF2- IDA tI Solution Treated ';7_MrWM
Aslolo 475
Haynes Alloy 263
and Aged C2CSF
1R. ~ -
or
IN- 102 ------

Incoloy Alloy 903 _____ ~~-= ~~- 1imi~~~

Inconel Alloy 617
Inconel Alloy 625
Inconel Alloy 700
Inconel Alloy 702
Inconel Alloy 7061
finconel Alloy 718
lncone: Alloy 721
Incorel Alloy 722
1 *__
-s~

- -~~-

Inconel Alloy X-750

Inconel Alloy 751
M252
1-
I
.-

Nirnonic 75
Ninionic 0
Nimonic 90
Nimonic 95
Rene 41
Rene 63
Rene 77
Rene 95
Udimnel 500
Udimel 700
Udirnet 710
Untrrmp 1753
Waspaloy

Nickel BSeo, WroughtRog:1.5-.0

Hastelloy Alloy 8 See 5500 50 Oi-.002 6107
Itastelloy Alloy 6-2 I Noe to t IT5
Halelo~loy, I8000 125 Finish: (Max. 1/2 of
Hastelloy Alloy C-276 240 Cold Drawn 005 ax. WheelWdth)
H-aselloy Alloy G I to or Aged
Hastelloy Alloy S -310
Hastelloy Alloy X
Incotoy ~~~ _________ ~ ~
AloN0O ~ 9
Incoloy Alloy 825-
Inconl Alloy 825j
Incone. Alloy 6010
Relractaloy 26
Udimel 630W

-See section 16 for Cuttin; Fluid Recommendations flNot recommiended.

See section 20 for addithonal information3

8-36
 Surface Grinding-Horizontal Spindle, Reciprocating Table 8.2
Cubic Boron Nitride Wheels
WHEEL1
SPEED WHEEL
MAERALHARD- CODTO DR -E TABLE DONED COSED IDENTIFI-
MAEILNESS CODTO R E*SPEED DONED COSED CATION
1pm 1pm fpm in/pass in/pass ANSI
___________Bhn ___ ilwoo*m ~ ~ A4~t
Nickel Base, Cast Rough: 25- 1OO0
B-1900 MAR-M200 See 5500 50 001-.002
GMR-235 MAR-M246 Notef to to(ax0/2o B 00T758
-M235D MAR-M421 200 As Cast 8000 125 Finish (Maxd/2ho
Hasteiloy Alloy B MAR-M432 t0 Or R- 05ma1helWdh
Hastelloy Alloy C Rene 80 425 CatadAed3--
Haslelloy Alloy 0 125 Cene Age X .-- 1r. ; - ~
IN-100 (Rene 100) SEL It~ 8 QZB

t_
IN-738 SEmlS X' n ? .

IN-792 TRW_VIA - '7 4 f

Inconel Alloy 7 13C jdimet 500
Inconel Alloy 718 Udimet 700
ASTM A296. Grades CW-12M,
N-12M. CY-40
ASTM A297: Grades HW, 1--X
ASTM A494: Grades N-12Mn-1,
N- 12M-2. CY-40, CW- 12M-l1,
CW-12M-2
ASIM A5O8: Grades HW5O, o om.MsAm
HX50

Cobalt Base, WroughtRog: .510

AiResist 213 Se 50 o 01.0
Haynes Alloy 25 (1605) toBl775B 8100to
Haynes Alloy 188 2700 Soltio Treateda: /
$-1570 to ouinTetd005mx he it)A
MAR-M05 32 and Aged-
MAR-M918
S-8 16
V-36

*Seesection 16 to ',utting Fluid Recommendations JNot Reco mmnnded.

See section 20 foi 0 dditional information.

8-37
8.2 Surface Grinding-Horizontal Spindle, Reciprocating Table
Cubic Boron Nitride Wheels

WHEEL
SPEED WHEEL
o
MATERIAL HARD- CONDITION DRY WET TABLE DOWNFEED CROSSFEED IDENTIFI-
NESS SPEED CATION
fpm fpm fpm in/pass ri/pass ANSI

39. HIGH TEMPERATURE Rough- .25-1.00

See 5500 50 001- 002
ALLOYS, WROUGHT AND
Notet to to Bl00T75B
CAST (cont.)
8000 125 Finish: (Max: 1/2 of
Cobalt Bate, Cast
AiResis e Ast 290 As Cast 5 max. Wheel Width)
AiResist 215 MAR-M322 to or w'9,
5
< -2t% ,1it J' 'r3
425 Cast and Aged
FSX-414 MAR-M509
HS-6 NASA Co-W-Re w ~tt~
ji IV,2 -- ~t . T i'~
HS-31 (X-40) X-45 %',n> 4v4: t;&Omx WheNd
HOWMET #3

51. MAGNETIC ALLOYS Rough- 020

Alnico t Alnico V-7 5500 50 .010 .2
- to to B100T75B
Alnico It Alnico XII
Alnico III
Alico III Alm XllRc8000
Columax-5 45 c 125 002 max.
Finish- (Max: W
Wheel 1/4dth)
of

Alnico IV Hyflux Alnico V-7 to As Cast . 0 mt

Aln:co V58RC

_______ - a '_ w a 4'vw

*See section 16 for Cutting Fluid Recommendations fNot recommended.

See section 20 for addilional information

8-38
 Surface Grinding-Horizontal Spindle, Reciprocating Table 8.3
Diamond Wheels
WHEEL

SPEED TABLE DOWNFEED CROSSFEED WHEEL

MATERIAL HARD-
NESS CONDITION DRY WET* SPEED IDENTIFICATION
fpm fpm fpm in/pass in/pass ANSI
Bhn woffovng-wom
5. ALLOY STEELS, WROUGHT 40 Rough 080 080-N100-B-1/8i
5000 003
High Carbon to
50100 Carburized Finish. (Max 1/4 of
51100 50 ic and/or 5 0005 max Wheel Width) D100-NIOO-B-1/8t
52100 to Quenched % 'f o grr r;-r I'Z-

M-50 65 Rc and Tempered X - --- 8

8. TOOL STEELS, WROUGHT 40 Rough 060 D60-N100-B,1/8t

1 001
Group II to
D2 D5 H42 M3-1 M42 T4 6000 Finish (Max" 1/4 of
D3 Fl Ml M1O Ti T8 Over Quenched 50 0005 max Wheel Width) D70-N100-8-1/8t
04 F2 M2 M30 T2 58SRC and Tempered--
Group IIIj - #f-4OO OW0
A7 M6 M34 M43 M47 _ .7~~
07 M7 M36 M44 T5
M-2 M33 M41M416,,-:oaaii T dh _ /E

Group IV 30 Rough 050 D80-N100-M-1/8

M4 5000 .00"5
to
T15 6000 Finish (Max 1/4 of
Over Quenched 40 0005 max Wheel Width) 0100-N100-M-118
58 Rc and Temnpered Ell~~~r r.

13. STAINLESS STEELS, 50 Rough 040 D80-N IO0-M-1/8

WROUGHT 50to 0015
Austenitic 6000 Finish, (Max 1/4 01
201 304L 310S 330 135 Annealed 0 .0005 max Wheel Width) D100-N1O0-M-1/8"

301 308 316 348 275 Cold Drawn 3i .

302 309 316L 384
302B 309S 317 385 ..
304 310 321

21. GRAY CAST IRONS

Ferrtic5000 60 Rough*
002 .060 DS0-N1O0-M-1/8
Ferritic to
ASTM A48" Class 20
SAEJ431c GradeG1800 48Rc6 Flame600 5 Fish (x/o
Pearlitic- Ferritic to or 0005 max. Wheel Width)
ASTM A48: Class 25 60 Rc 1.iduction - ' - -. M
SAE J431c Gade G2500 Hardened S
Pearlitic
ASTM A48. Classes 30, 35. 40
SAE J431c" Grade G3000 ..
Pearlitic + Free Carbide.
ASTM A48 Classes 45. 50
SAE J43 1c. Gades G3500,
G400C
Pearlitic or Acicular + Free
Carbide*
ASTM A48' Classes 55, 60 a

*See section 16 forCutting Fluid Recommendations tMetal-coated diamond

See :ection 20 foradditional information

8
8-39

_______________________
 L
- ---- -

8.3 Surface Grinding-Horizontal Spindle, Reciprocating Table

Diamond Wheels

MAEILHARD. CODTO TABLE DONEDCOSED WHEEL

MAERALNESS CNTINSPEED DONEDCOSED IDENTIFICATION
fpm fpm in/pass in/pass ANSI___

48. MACHINABLE CARBIDES 20 Ruh .030 D100-L-100-B-1/8

Ferro-Tic 10 0

68 Rc Hardened 1500 30 Finish (Max 1/4 o 101-1--/

to and 0005 max. Wheel Width) 50L0-i/
72 HC Tempered

49. CARBIDES 4 og: .5 D5-10B1

Titanium Carbide 50 0
Tungsten Carbide t

35R
00 5 Finish. (Max- 1/8 of D220-R75-B 1/8

40 Rough .050 D00-N500-M-1/

160 secio
Cutting Recommendations-1
8e9 6o (luid

Saeeetion 20CoraIiona iformation

2404

___ _____-
 Surface Grinding-Horizontal Spindle, Reciprocating Table 8.3
Diamond Wheels

WHEEL
SPEED
* TA B L E
MATERIAL HARD- CONDITION DRY WET DOWNFEED CROSSFEED WHEEL
NESS SPEED IDENTIFICATION
fpm fpm fpm in/pass in/pass ANSI

Graphite 30 Rough 050 D60-N50-M-1/8

5500 003
to
6500 Finish (Max 1/4 of
001 max Wheel Width)

55. GLASSES & CERAMICS 650.01005

6 Rough 050 D00N0--/
D100-N100-M-1/8
Machinable Glass-Ceramic to 0
(MACOR) 250 7500 8 Fnish
02mx (Max
Welit) 1/6 of D220-N 100-M- 1/8
Knoop Cast 0 m Wheel Wdth)

PYROC AV 650 30 Rough .050 D60-N100-M-1/8

80 8500 0 Finish (Max 1/8 of

bogto .001 max
to0
1o0g
Knoop
Nr
M 40
3500
- Wheel Width) D220-N100-M-1/8

Gas20 Rough .030 D60-N 100-M- 1/8

Glas j 5500 003

480 to
48o 6500 30 Finish. (Max 1/8 of 20N0M-/
530 3 .0005 max Wheel Width)D2 -NO--8

50g

Ceramics 50 Rough: .080 D2-N100-M-1/8

4500 .002
Alumina (Aluminum Oxide)
to
Alumma-Mullite
Aluminum Silicate Over 5500 .0005 max.
Finish Wheel Wdth)
(Max 1/4 D220-N100-M-1/8
Beryllia
(Beryi,,n Oxide)tt 800 Fired - AN
Magnesia (Magnesium Oxide) Knoop
Mullite
SiliconCarbide M
SiliconNitride
Thoria (Thorium Oxide)tt .
Titania(Titanium Oxide)
Titanium Diboridett
Zircon (Zirconium Silicate)
Zi.conia (Zirconium Oxide)

*See section 16 for Cutting Fluid Recommendations. ttCAUTION. Toxic Material. refer to National Institute forOccupa-
See section 20 for additional information tional Safety and Health (NIOSH) for Precautions.

8-41 -
8.3 Surface Grinding-Horizontal Spindle, Reciprocating Table
Diamond Wheels
WHEEL
SPEED
HARD- CONDITION DRY WET* TABLE DOWNFEED CROSSFEED WHEEL
MATERIAL
NESS SPEED IDENTIFICATION
fpm fpm fpm in/pass in/pass ANSI
Bhn iioi3 a~> t ~~'-
51. COMPOSITES 5 Rough .030 D180-R100-M-1/8
5500 003
Kevlar 49 to -
Graphite Epoxy 6500 Finish (Max 1/8 of
Fiberglass Epoxy 6 .001 max Wheel Width) D220-N100-M-1/8
(E) Glass - - 5?
(S) Glass - iffa075;-3
Boron Epoxy_ - I ThA

357 Rog 3 D22O-N1OO-M-t/8~

58. FLAME (THERMAL) 5500 5 Rough 030 12N100-B-1/8

SPRAYED MATERIALS 5500 002
Sprayed Carbides to to
Chromium Carbide 6500 6500 50 hFinish, (Max. i/8 of
Chromium Carbide-Cobalt Blend - 0005 max Wheel Width) 0320-R75-B-1/8
Columbium Carbide 1i "i4 h 410120.-. J/8T*
Tantalum Carbide &8g.2;5~
Titanium Carbide '"_ FUME
Tungsten Carbide myW MOW$.f
Tungsten Carbide-Cobalt2 OI1r*X: Ir fue. 't~l
Tungsten Carbide
(Cobalt)-Nicke Alloy Blend

Inorganic Coating Materials Rough: 030 D120-N100-M-1/8

Alumina (Pure) 5500 5 003
Alumina (Grey) containing Titania to to
Alumina. Nickel-Aluminide 6500 6500 50 Finish: (Max: 1/8 of D220-N75-M-1/8
Blends Mulle -001 max. Wheel Width)
Barium Titanate Tantalum rR p
Boront Tungsten
Calcium Titanate ~-'.
Calcium Zirconate .s
Chromium DisilicideTt
Chromium Oxidet
Cobalt (40%). Zirconia Blend
-~~t~~

I
Columbum (Niobium)Tt
Glass (Kovar sealing)tt
Hexaboron Silicidet T
Magnesia Alumina Spinel - EN 5
Magnesium Zirconate ....
Molybdenum Disilicide
Nickel (40%), Alumina Blend
Nickel Oxide _________

Rare Earth Oxides

Titania (50%). Alumina Blend
Titanium Oxide
Yttnum Zirconate
Zirconia (Lime Stabilized)
Zirconia. Nickel-Atuminide
Blends ffivT7
Zirconium Oxide (Hafnia Free, M -ROME
Lime Stabilized) X-v
Zirconium Silicate .. .
*See section 16 for Cutting Fluid Recommendations ttCAUTION Toxic Material. refer to National Institute for Occupa-
See section 20 for additional Information. tional Safety and Health (NIOSH) for Precautions

8-42
 Surface Grinding-Vertical Spindle, Rotary Table 8.4
WHEEL

WHEEL TABLE* DOWNFEED IDENTIFICATION

SPEED (WORK) per rev. OPERATION NARROW BROAD
HARD-
MATERIAL CONDITION SPEED of table WORK WORK
NESS AREA AREA
fpm fpm in ANSI ANSI
Bhn _____ iiiah SY 4S2r
1. FREE MACHINING CARBON Hot Rolled, 3500
to 80
to .001
to Roughing A301V A30HV
STEELS, WROUGHT orahed to 10
Low Carbon ReNulfurized 50 Rc 6000 200 005 Finishing A801B A80HB
Annealed, Cold Drawn . - _-'tt . _ ... .
1108 1115 1118 1212 max. or Quenched
1109 1116 1119 1213 and Tempered u
1110 1117 1211 1215 -
Medium Carbon Resulfurized 3500 100 .0005 Roughing A46GV A46FV
1140 1145 Carburized to to to
1132
1137 1141 1146 Over and/or 6000 250 .001 Finishing A80GB A8OFB
1139 1144 1151 50Rc Quenched and 2721f
t
Low Carbon Leaded Tempered M40
__-_____ . G J
IOL18 12L13 12L15 - O_ _

11L17 12L14
Medium Carbon Leaded
10L45 111-37 111-44 WMF R;W
1OL50 11L41

2. CARBON STEELS, Hot Rolled, 3500 80 .001 Roughing A301V A30HV

WROUGHT Normalized, to to to
Low Carbon 50 Rc Annealed. Cold Drawn 6000 200 .005 Finishing A801B A80HB

1005 1012 1019 1026 or Quenched - _

-
1006 1013 1020 1029 and Tempered 496RfOn 2
____ _____
1008 1015 1021 1513
1009 1016 1022 1518 3500 100 .0005 Roughing A46GV A46FV
1010 1017 1023 1522 Carburized to to to
1011 1018 1025 Over and/or 6000 250 .001 Finishing A80GB A80FB
Medium Carbon 50 Rc Quenched and "2-3 Rf __

1030 1042 1053 1541 Tempered

1033 1043 1055 1547 'O
. .... O-S 4_' tF fGS .... .
1035 1044 1524 1548
1037 1045 1525 1551
1038 1046 1526 1552
1039 1049 1527 2F II5 -

1040 1050 1536 E-mo E

High Carbon ______ ~ s ___ ir<
1060 1074 1085 1566
1064 1075 1086 1572
1065 1078 1090
1069 1080 1095 w__g
1070 1084 1561

3. CARBON AND FERRITIC 3500 80 .001 Roughing A301V A30HV

ALLOY STEELS (HIGH 150 As Forged, to to to
TEMPERATURE SERVICE) to Annealed 6000 200 .005 Finishing A801B A8OHB
ASTM A369. Grades FPA. FPB. 200 or
andNormalized
Tempered 0: 93
'%.,
FP1FP2FP3b. FP5,FP7.
FP9. FPFP12.FP21. FP22

See section 16 for Cutting Fluid Recommendations

*See section 20 4 for calculation of Table rpm and Downfeed in 'pm

8-43
8.4 Surface Grinding-Vertical Spindle, Rotary Table
WHEEL
WHEEL TABLE* DOWNFEED IDENTIFICATION
HR-SED (WORK) per rev. OPERATION NARROW BROAD
MATERIAL HARDS CONDITION SED SPEED of table WORK WORK
NESSAREA AREA
fpm fpm in ANSI ANSI
___________ ~Bhn _ _ _ _ ~ ~ I ~ ~ ~ ~ ~ ~ o
4. FREE MACHINING ALLOY Hot Rolled. 3500 80 .001 Roughing A301V A30HV
STESoOUH to to
W ROsUTu
STeELSCabo 50 RC Normalized. 6000 200 .005 Finishing A801B A80HB
Medium
Crbon Reulfmax. Annealed. Cold Drawn - .~,.-
4140Se 4145Se 4150 and Tempered '

Medium and High Carbon -"E --- I

Leaded 3500 100 0005 Roughing A46GV A46FV
4130414751328640Carb~urized to to to
411-30 41L47 51-2L 861-4 Over and/or 6000 250 .001 Finishing A80GB A80FB
411-4 521100
411-0 5 FIC Quenched and
41L45 43140 861-20 5% Tmee ?,,- fl4ARR -Z

S. ALLOY STEELS, WROUGHT I Hot Rolled. 3500 80 .001 Roughing A301V A30HV
Low Carbon
401 465
41 67 5Rc
j Annealed.
Normalized,
Cold Drawn
to
6000
to
200 r" .005
to
Finishing A801B A8OHB
402417 4820 8620 mxj or Quenched
4024 4620 5015 8622 and TemperedI IA6
A118 4621 5115 8822
4320 4716 5120 9310 3500 100 .0005 Roughing A46GV A46FV
4419 4720 6118 94815 Carburized to 10 10
4422 4815 8115 94817 Over and/or 4500 250 .001 Finishing A 80131 A80FB
Medium Carbon 50 R.. Quenched and
1330 4145 5132 8640 Tempered_
1335 4147 5135 8642 - ____ ___ _____

1340 4150 5140 8645

1345 4161 5145 868345
4027 4340 5147 8650
4028 4427 5150 8655
4032 4626 5155 8660 -
4037 504 10 8740 __ _ ______ .A

4042 50844 51860 8742

4047 5046 6150 9254
4130 50846 81845 9255
4135 50850 8625 9260
4137 5060 8627 94830
4140 50860 8630 _____O N___
4142 5130 8637
High Carbon
50100 51100 52100 M-50

6. HIGH STRENGTH STEELS, 3500 80 .001 Roughing A30HV A30GV

WROUGHT Annealed, to to to
50 RIc Normalized 6000 200 .003 Finishing A8OHB3 A80GB
300M max or Quenched
4330V
4340 and Tempered -

4340Si _1 - ik

QHac Over Quenched 4500 250 .001 Finishing A100GB A100FB

H13 50OR, and
HP 9-4-20 Tempered
HP 9-4-25 ________

HP 9-4-30
HP 9-4-45

See section 16 for Cutting Fluid Recommendations

'See section 20 4 for calculation of Table rpm and Downteed in ipm
4

8-44
 Surface Grinding-Vertical Spindle, Rotary Table 8.4

1I WHEEL
WHEEL TABLE' DOWNFEED I IDENTIFICATION
SPEED (WORK) per rev. OPERATION NARROW BROAD
HARD-
MATERIAL CONDITION SPEED of table WORK WORK
NESS AREA AREA
fpm fpm in ANSI ANSI
Bhn ________ ZiV R 5,f
7. MARAGING STEELS, 3500 80 .001 Roughing A301V A30HV
WROUGHT to to to
WROUG50 BC Annealed 6000 200 .005 Finishing A801B A80HB
ASTM A538" Grades A. B C max. or -, z 'r . ..
120 Grade Maraged "
180 Grade moo
200 Grade _A
250 Grade 3500 100 .0005 Roughing A46GV A46FV
300 Grade to to to
350 Grade Over 6000 250 .001 Finishing A8CGB A80FB
HY230 50 R Maraged N

8. TOOL STEELS, WROUGHT 3500 80

to .001
to Roughing A301V AJ0HV
GopIto
Group I 0RO Annealed 6000 200 .003 Finishing A801B A80HB
A2 H13 L6 P20 max. or Quenched
A3 H14 L7 P21 and Tempered 5-
A4 H19 01 Si
A6 H21 02 S2 ,.3 . %A fB
AS H22 06 S5 3500 100 .0005 Roughing A46HV AI6GV

A9 H23 07 S6 to to to
S7 and Finishing A100HB A100GB
A10 H24 P2 $7 Over Quenched 4500 250 .001
H10 H25 P4 WI 50 a
Tempered
Hl1 H26 P5 W2 _

H12 L2 P6 W5 -

SAE J438b: Types W108. W109.

W110. W112. W209. W210.
W310

Group II 3500 80 .001 Roughing A30HV A30GV

to to to
D2 F2 M10 T4 50 R Annealed 6000 200 .003 Finishing A80HB A80GB
D3
442 M30 78 max. or Quenched
D4 M1 M42 and Tempered
D5 M2 TI
3500 100 .0005 Roughing A46GV A46FV
to to to
sO RC Quenched 4500 250 .001 Finishing Ai00GB A100FB

58 RC Tempered

3500 100 0005 Roughing A46GV A46FV

to to to
"
Over
58 R Quenched
and 4500 i250 .001 Finishing A100GB A100FB
Tempered

3500
to to .001
to Roughing A30HV A30GV _
Group Il
A7 M7 M41 M47 50 R Annealed 6000 200 .003 Finishing A80HB A80GB
D7 M33 M43 T5 max0- or Quenched
M3-2 M34 M44 T6 and Tempered
M6 M36 M46

3500 100 .0005 Roughing A46GV A46FV

50 Bc Quenched 4500 250 .001 Finishing A100GB A100FB

58 B0 1empered

See set.Jon 16 for Cutting Fluid Recommendations

*See section 20.4 for calculation of Table rpm and Downfeed in ipm

8-45
8.4 Surface Grinding-Vertical Spindle, Rotary Table

MATERIAL AR-
NESS
IAD CONDITION
WHEEL
PE
SED
fpm Ifpm
TABLE'
(WORK)
SPEED
DOWNFEED
per rev.
of table
in
OPERATION NARROW
WORK
AREA
ANSI
WHEEL
IDENTIFICATION
BROAD
WORK
AREA
ANSI

8. TOOL STEELS, iOUGHT 3500 100 0005 Roughing A46GV A46FV

Grop Intcot) Over Qunhd 4500 250 001 Finishing A100GB A10FB
Grou II
(cnt. SRc and j 3d 0 s
,'materials listed on preceding page) C Tempered

Group IV 3500 80 .001 Roughing A30HV A30GV

to to to
M4 50 R Annealed 6000 200 .003 Finishing A80HB A80GB
T15 maxC or Quenched PI =24_ - -
and Tempered _ _ .__

3500 100 0005 Roughing A46GV A46FV

to to to
50 RC Quenched 4500 250 .001 Finishing A100GB A100FB
58 RIC Tempered ~11

3500 100 0005 Roughing A46GV A46FV

Over Quenched 4500 250 001 Finishing A100GB AIOOF8

58 R, and
Tempered

9. NITRIDING STEELS, 3500 80 .001 Roughing A30HV A30GV

WROUGHT 200 Annealed, to to to
Nitralloy 125 to~ Normalized 6000 200 .005 Finishing A80HB A80GB
Nitralloy 135 350 or Quenched B.#
Nitralloy 135 Mod, and Tempered
Nsitrailoy 230
Niraloy EZ300R 3500 100 .0005 Roughing A46GV A46FV
Nitralloy N to Nitrided 4500 250 .001 Finishing A100GB A100FB
Nitrex 1 65 Rc OM R E7

10. ARMOR PLATE, SHIP 3500 80 .001 Roughing A30HV A30GV

PLATE, AIRCRAFT PLATE, Aneae to to
WROUGHT 45 RC ornQenced 6000 200 .003 Finishing A80HB A80GB
max. or Qunce 91
HY80126 and Tempered 315 A

HY100 ~~ 6 ~ ~ _ _ _

MIL-S- 16216
HY180

11. STRUCTURAL STEELS, Hot0Roiled.uhng A21V A2H

WROUGHT* 48 R Normalized. 6000 200 005 Finishing A801B A80HB
30 50 90 150 max. StesRlvd
35 65 100 160 or~uenched
42 70 110 165 and Tempered -- A-
45 75 135 185 3500 100 .0005 Roughing A301V A30HV
50 80 140 210 t ot
55 85 145 Over Quenched 6000 250 .001 Finishing A80G8 A80FB
46 Pic and Tempered -

See section 16 for Culling Fluid Recommendations -In this handbook, Structural Steels are designated by yield strength
*See section 20 4 for calculation of Table rpm and Downfeed in ipm in units of 1000 psi. For example. 50 mans a steel with 50.000 psi
yield strength. Similarly. 140 means 140.000 psi yield strength.
Therefore, in order to select lIte appropniate block of machining
data, itlls necessary to know the yield strength or Bhn.

8-46
 Surface Grinding-Vertical Spindle, Rotary Table 8.4

7HE NESAREA
(WORK)
WAD-SEEL
SPEED
SPEEDLCODIIO
TABLE DOWNFEED
per rev.
of table
OPERATION
I
jNARROW
WORK
WHEEL
IDENTIFICATION
T ROAD
WORK
AREA

fpm fpmj in ANSI IANSI

____________ I_____ ~~ Zi~ ___ __: _AO__I
12 REMCIIG13500 100 .001 Roughing A461V A46GV
STAINLESS STEELS, 135 to to to
WROUGHT to Annealed 6000 5 003 Finishing A80HB A80GO
Feirritic 185 -__ ----~ - -
430F 430F Se AOH 578G
Austenitic 3500 100 .00 1 Roughing CA4618 CA46GB
to to
03Z 23Z
33b15to
33bAnnealed 6000 350 .003 Finishing CA801B CA80GB
303 303 Plus X to or z~zi t3Q - - CASB_-M68
303MA 303Se 25 Cold Drawn -~~.-
3 o~

Martensitic 350 10 .001 Roughing A461V A46GV

to to to
416 420F Se 135 Annealed 6000 350 .003 Finishing A80HB A8OGB
416 Plus X 440F to or &;- 3 IMw-06GB
416Se 44OF Se 20 Cold Drawn to. --- I -

3500 100 001 Roughing A46GV A46F

to to to
over Quenched 6000 350 003 Finishing A80GB A80FB
275 and T25r8 - -= , - -
Tempered to___

13. STAINLESS STEELS, 3500 100 001 Roughing A461V A46GV

WROUGHT 135 to to to
Fenitic tAneld 6000 350 .003 Finishing A80HB A80GB
405 429 434 442 185 ~&
409 430 436 446 :r ~-z
Auatnitic 3500 100 001 Roughing CA4610 CA46GB
201 304L 310S 330 135 Annealed 6000 350 .003 Finishing CA801B CARCGB
202 305 314 347 to or I,, ..I_ -.- TI ' _ - --- _
301 308 316 348 275 Cold Drawn
302 309 316L 384 POI
3028 309S 317 385-
304 310 321

Austuiiiit 3500 100 .001 Roughing ICA461B CA46GB

Ni-onic 32 Nitronic 50 210 Annealed 600 350 t0oibig CAOB C8G
Nitronic 33 Nfironic 60 to or 600 30 _ 03 Fiihng__IB CBG
Nitronic 40 375 Cold Drawn ~ -

Martensitic t ot
403 422 440C 135 6000 350 .003 Finshino A80HB A8OGB-
410 431 501 to Annealed -

414 440A 502 275 1 7

420 440B
Greek Ascoloy

Over Quenched 6000 350 .003 Finishing A80GB A8OFB

See section 16 for Cutting Fluid Recommendations

*See section 20 4 for calcuiation of Table rpm and Downteed in spmn

8-47
8.4 surface Grinding-Vertical Spindle, Rotary Table
I WHEEL

IWHEEL "ABLE' DOWNFEED I IDENTIFICATION

HR-I I SPEED (WORK) per rev. OPERAT ION NARROW ROAD
HARD-IA CONDITION SPEED of table WORK WORK

fpm ~fpmi 1 in AN4SI ANSI

_ __ _ _ _ _ Bhn _ _ ~_ ~_ W__

14 RCPIAIN350X; tVa .001 Pough ng A461V A46GV

HARGENING STAINLESS 150 t
STEELS, WROUGHT to Solution Treated 6000 350 .003 Finishing A80HB A8008
15PHor Hardene:d kd U~~'
16-6 PH Il -
17-4 PH-
17-7 PH
17-14 Cu M
AF-71
AFC-77
Alnar 362 (AM-362)
AM-350________
AM-355
AM-363t
Custom 450
Custom 455
PH 13-8 Mo
PH- 14-8 1.o
PH 16-7 Mo
Stainless W

15. CARBON STEELS, CAST

Low Carbon 100o
j .

10Normalized. Normalized
Annealed,.50
600
8
200
t
0
005
oghn
Finishing
31
A8018
3H
A80HB
ASTMA A426: Grade CP1I10 and-Tempered.,.s.
1010 300 or Quenched
1020) and Tempereo
Medium Carbon-300 10 .05 Ruhn A4G A4F
00 .05 Ruhn A4G A6V
ASTMA A352. Grades LCA. LCB.350
LCC Carburized to to to
ASTM A356: Grade I Over and/or 6000 250 .001 Finishing A8GGB A8OFB
1030 10501040 SRC Quenched and ~

16 LOAT3500
TES 80 .001 Roughing A301V/ A30HV/
LOW Curbon 150 Norinahized. Norma!Lzed 6000 200 .005 IFihng A801B A80HB
ASTM A217: Grace WC9 FoianiTemired
ASTMAA352: Graces LC3. LC4 400 or~uenched ~
ASTM A426: Grades CP2. CP5. and Tempered - 7-- 1

CP5b. CPI 1. CP12. CP15. -

CP2I. CP22 3500 100 .0005 Roughing A46GV A46FV

1320 2320 4120 8020 Carburtzed to to to
2315 4110 4320 8620 Over and/or 600 250 .002 Finishing A8OGS A80F8
Modketn Cwbo 50 FC Quenched and
ASTM A27: Grades Ni.N2, epee
U-60-30. 60-30. 65-35. -_

70-36. 70-40 0
ASTM A148- Grades 80-40.1
80-50. 90-60.,105-85. A
120-95. 150-125. 175-1453_q
ASTM A2' 6: Grades WCA._
WCB. WCC
ASTMA217. Grades WCI,
W04. WC5. WC610
ASTM A352 Grades LIA C2.
LC2-1
(materials continued on next page)

See secton 16 for Cutting Fluid Recommendations

*See section 20 4 for calculation of Table rpm and Dcwnfeed inipm

8-48 __
 Surface Grinding-Vertical Spindle, Rotary Table 8.4
I WHEEL
WHFEL TABLE' DOWNFFED IDENTIFICATION
HARD- T I SPEED (WORK) per rev. OPERATION NARROW j BROAD
MATERIAL CONDITION SPEED of table WORK WORK
NESS I AREA AREA
fpmIfpmfpm i n ANSI I ANSI

16. ALLOY STEELS, CAST i I-

(cot.) i
Medium Carbon (cont.) j_ 1 -t"
r----. j -_
(matenals continued from =- ..-- '-"

preceding page) II .~~-~

ASTM A356- Grades 2 5 6 8. -
9.10 -
ASTM A389- Grades C23. C24 i I
ASTM A486: Classes 70. 90. 120
ASTM A487:
4N. 6N. 8N,Classes 2N,1.
9N, 10N1N.DN. t ; _5
_tQ"-"- -

20.40.40A. 60.70.80. I1 __._ r' - ;t-, --'--

90.100
1330 4130 80B30 8640
1340 4140 8040 9525 I
2325 4330 8430 9530 , - __~r- __

2330 4340 8440 9535 _ % . -- W R-r

4125 8030 8830 ~~___
17. TOOL STEELS, CAST 3500 80 .001 Roughing A301V A30HV
Group I !to to to
GrouA I Annealed 6000 200 003 Finishing A801B A80HB
ASM A597. Grades CA-2 max.
5OCH-0-
R or Quenched l' I.- - - -
CH-12. CH-13. CO- 1, C5-5 and Tempered
0 r _ 4''"V o'

3500 100 0005 Roughing A46HV A46GV

to to to
50 R Quenched 4500 250 .002
to and - 2 4 ~~ T
Finishing
W ~
A100H8
W~:~
A100GB

58 RC Tempered -

3500 100 0005 Roughing AC6GV A46FV

to to to
Over Quenched 4500 250 001 Finishing A100GB A100FB
58 Ac and-a r ~- r r r.
D Tempared

3500 80 .001 Roughing A1V A30HV

ASTM A597: Grades CD-2.
CD-8
I200
to
i Aneaed 600
o
200
tot
003 Finishing A801B A80HB
to to 10_-

1o Anald
3500 100 .0005 Roughing A46HV A46GV
to to to
48C Quenched 4500 250 .002 Finishig A10HB A100GB
toR an %:q4 -

3500 100nj .0005 Roughing A46GY A46FV

to to t
"SeeQuenched 4500o 25 .001 Finishing AIOOGB A100FB

~ ~ ~
See1Tfemumed~i seRio ~
eomedain
5
568R and4
Tempered _ f jM

0 M.

See section 16 for Cutting Fluid Recommendations

*See section 20 4 for calculation of Table rpm and Downfeed in ipm

8-49

_w"W
8.4 Surface Grinding-Vertical Spindle, Rotary Table
1 1 WHEEL
SWHEEL TABLE' DOWNFEED I IDENT'FICATION
HARD-i HAW.EED SPEED (WE
(WORK)j ftal
per rev. OPERATION i NPO
A BROAD
MATERIAL NES. CONDITION SPEED of table I WORK I WORK
NESS AREA AREA
pm r pm in ANSI ANSI
{Bhr Sl '--- _ ____ __
50 I 1 00 00; Roughrio i AS01V 1A30HV
19. STAINLESS STEELS, CAST 1 100li 00____ Roghn A1V A3H
Fernitic j135 toj
to 600 350 1 to
a,),; Fin-sh-rT A801B A80H8
ASTM A217 Grades C5. C12 t0ona~ 0-0 30Fnsirc BI BH
ASTM A296: Grades CB-0 1851 8 30 25 * Rubgj
CC-SO. CE-30. CA6N.
CA-6NM. CD4MCu_ _15
I_
ASTM A297 Grade NC
ASTM A487 Class CASNM ,

k++
ASTM A6C8. Grade HC30 i ,

CF-6F.cF-20 .
Aulltenilic
Auelfc3500
ie , I100
30 +_+ .001 RcL~hinQ i
-
A301V
+A+H
A30rHV
ASTM A296 Grades
CF-8, CF-3.
CF-BC. CF-6M. 1.5
to Annealed.
Normalized T0
6000 to
350 to
003 Finishi n A&OIB IA8HB
CF-3M.
CF-16F. CF-20. CG-8M 210 or __5 q02-
V

ASTM A297 Urades HD. HE. J i

HF. IiH. HI, HK. HL. HN. HP. II
HT. HU
ASTM A351: Grades CF-3. j _
CF-3A. CF-3M. CF-3MA.
CF-10MC.CH-8.CH-10. - .. .

CH-20, CK-20. CN-7M. III

HK-30 HK-40. HT-30
ASTM A45 1: Grades CPF8A.
CPF3. CPF3A. CPF3M. CPF8.
-_ _ - -

CPF8C CPF8C (Ta M~x.

CPH1O. CPH20. CPK20
ASTM A452. Grades TP 304H.
TP 316H. TP 347H 77
ASTM A608: Grades hDSO. . .
HE35. HF30. HH30. HH33.
Hv35. HK30, HK40 HL30.
HL40. HN40. HTS0. HUS0 I I
-

Annealed 3.50-3 100 00i RcoughirNgIAOV AO4

STAeaadC- to to to
.STMA217: Grade CA-15 135 N rmalized 6000 350 003 Fmish m-g A8OIB A80H
ASTM A296:CA-40
CA-15M. Grades CA-15. to
225 or Nermalized
andTempered K e--biti1 i0W-~MK~ ,-
++

ASTV' A426: Grades CP7. CP9.

CPCA15 ______

ASTM A487: Classes CA15a. 5 100 .0005 Roughing A46GV ,4FV

Over Otenched 6000 35G 002 F mhing 80GB A80FB

C1 - .. _ _ ., -
275 andTemperd _

I ______________

-ee secrior 16 for Cuttlng Fluid Recomrriendatuns

'See sectWin 2. 4 for calculation of Table rpm and Downfeed in ipro
_____-__

8-50
 r

Surface Grinding-Vertical Spindle, Rotary Table 8.4

MATERIAL HARiD-
I .IWHEEL
__________________ fWHEEL
____________

CONDITION
NESAREA
I
SPEED
.

TABLE'
(WORK)
SPEED
DOWNFEED
per rev.
of table
OPERAT;ON
IDENTIFICATION
NARROW I 8BROAD
WORK jWORK
AREA

19. PRECIPITATION N I 80 001 Roughing A301V A30HV

SELATto
STEL, AS 25 Souto Tebed
or Solution Treated
I6000 200
-~-
.003 Finishing A801B A80HB

ACt Grade CB-7Cu 40 adAe

PH CD-4MCu
Gad I f _ _ _

AM-355

21. GRAY CAST IRONS 3500 100 003 Roughing ASOIV A3OHV
Ferritic As Ca: to to0t
ASTM A48. Class 20 5211c Annealed 6000 350 .008 Finishing C801B 00B
SAE J43 1c*Grade G1800 or #42 q RunheN
Pearlitic- Ferritic and Tempered
ASTM A48: Class 25 X4______ VV~
SAE J431c, Grade G2500
Pearlitic
ASTM A48, Classes 30. 35. 40
SAE J431c: Grade G3000
Pearlitic + Free Carbides
ASTM A48 Classes 45. 50=1
SAE J431c Grades G3500.
G4000
Pearlitic or Aclcular - Free
Carbides
ASTM A48: Classes 55, 60

Austenitic (NI-RESIST) 3500 100 001 Roughing A30HV A30GV

ASTM A436: Types 1. lb. 2. 2b, 100 600 350 00tiisigo0M BG
3.4.5,6 t sCs
250

22. COMPACTEID GRAPHITE 3500 100 0G1 Roughing A301V A30HV

CATIOS156000 350 .005 Finishing C801B C80HB

225

23. DUCTILE CAST IRONS Annealed, As Cast, 350 100 I0 ogig 2H G

Ferritlc 52R. Normalized52R600 30 MFishn A8H A0G
ASTM A536 Grades 60-40-18., ' and Tempered 60 5 0 iihn 8H 8G
65-45-12 ma. or~uenched
SAE j 134c: Grades D40 18, and Tempered
D4512 _ 3
Ferritic- Pearlitic
ASTM A536: Grade 80-55-06
SAE J4,S4c: Grade D550o
Pearlitic- Martensltlc
ASTM A536: Grade 100-715-03
SAE J434c: Grade D7003
Martanhtic
ASTM A536: Grade 120-90-02
SAE J434c- Grade DQ&T

S ~e sec~ion 16 tor Cutting Fluid Recommendationa,

Seesection 20 4 tor calculation of Table rpm and Dowrnteed in ipm.

8-51
8.4 Surface Grinding-Vertical Spindle, Rotary Table
WHEEL
TABLE* DOWNFEED IDENTIFICATION
WHEEL
(WORK) per rev. OPERATION NARROW BROAD
HARD- SPEED
WORK WORK
MATERIAL
N'S';
CONDITION
j SPEED of table
AREA AREA
fpm fpm in ANSI ANSI
I- .
23. DUCTILE CAI" IRO'eS
Bhn
3500 100 001
W-s9-'-Q ~st
Roughing A30HV
i IS
A30GV
(cont.) 120 to to to
to Annealed 6000 350 005 shng A80HB A80G
Austenitic (NI-RESIST
Ductile) 275g
ASTM A439 Types D-2, D-21.
0-20, 0-3, D-3A, D-4, D-5, IS 7
D-5B
ASTM A571 Type D-2M

ROS
24 MLLABECAT ale~hzd 3500 100 .001 Roughing A30HV A30GV
24. MALLEABLE CAST IRONS ~MaI lzdt ot
Ferritic5 ora000.e to to to
ASTM A47, Grades 32510, 52 o 6000 350 .005 Finishing ABOH A80GE
35013 and
ASTM A602. Grade M3210 Heat Treated
SAE J158 Grade M3210
Peariltic
ASTMA220 Grades 40010
45006, 45008, 50005
ASTM A602. Grade M4504.
M5003 R.
SAE .1158 Grade M4504,
M5003
Tempered Martenuite
ASTM A220' Grades 60004.
70003,80002. 90001
ASTM A602: Grades M5503,
M7002, M8501
SAE J158' Grades M5503,
M7002, M850i

001 Roughing C241:V C24GV -

.5. WHITE CAST IRONS 3500
to 100
to 1 0oA
(ABRASION RESISTANT) As Cast. 6000 350 .005 Finishing C80HB C80G9
ASTM A532: Annealed or
Class I, Types
Types A,
A,B,
8,C, L E
C,D, max Hardened i " ..
ClassI1,
Class 111,Type A -"A .-P-_-

28. ALUMINUM ALLOYS, 3500 100 .001 Roughing CA461B CA46GB

WROUGHT 30 to to to
Cold Drawn or 6000 250 .004 Finishing CA601B CA60GB
tor
EC 2218 5252 6253 150 Solution Treated
1060 2219 5254 6262 500k andAged-
1100 2618 5454 6453
1145 3003 5456 6951
1175 3004 5457 7001
1235 3005 5652 7004
2011 4032 5657 7005
2014 5005 6053 7039
(materials continued on next page)

See section 16 for Cutting Fluid Recommendations

*See se i;on 20 4 1or ccculat=,n o. Table rpm and Downieed in pm

8-52
 -- _ z_7 - -

Surface Grinding-Vertical Spindle, Rotary Table 8.4

WHEEL
WHEEL TABLE' DOWNFEED IDENTIFICATION
HR-SED (WORK) per rev. OPERATION NARROW BROAD
MATERIAL HR- CONDITION SED SPEED of table WORK WORK
NESS AREA AREA
1pm -in ANSI ANSI
Snfpm

28. ALUMINUM ALLOYS,

WROUGHT (cant.)
(materials continued from
oreceding page)M
,!017 5050 6061 7049 .. ____ ____ ___ ___
2018 5052 6063 7050 - ________. .______ __________

2021 5056 6066 7075

2024 5083 6070 7079
2025 5086 6101 7175
2117 5154 6151 71768*

29. ALUMINUM ALLOYS, CAST 3500 100 .001 Roughing 0A461B CA46GB
Sand and Permanent Mold 40 As Cast to to to
A0
25. 54. 720 to or 6000 250 .004 Finishing 0A601B CA60GS
2010
2Y38.0
B295.0 A514.0
308.0 B514.0 713.0
D712.0 125 I Solution Treated
IN SadAgdd
Offil" ..

213 t, 3190 5200 771C0 aEm

222.0 3,550 5350 8500
2240 C356 0 7050 A850 0
2420 B443.0 707 C 8850.0
Hiduminium RP-350
Vie Castings
C44.0 5180 -

Sad
PrmnntMod
n 40 As Cast to to to
328 0 333.0 A356.0 to or 6000 250 004 Finishing CA601B CA60GB
A332.0 354.0 357 0 125 so~ition Treated
F332 0 356.0 359.0 500kg adAe
DWe Castings g
360.0 A380.0 390.0 A413.0 -1 R1.
A360 0 383.0 392.0
380.0 A384.0 413.0

30. MAGNESIUM ALLOYS, 50 Annealed, to to t

toUH* Cl rw 6000 250 .004 Finishing CA6018 CA60GB
AZ21A AZ61A HM21A ZK60A 90 or C-,
AZ31B AZ80A HM31A 500kg Solution Treatedk
AZ31C HK31A ZK40A and Aged

31. MAGNESIUM ALLOYS, 5sCat 3500 1030 .001 Roughing CA461B CA46GB
CAT4to 6000 250 .004 Finishing CA601B CA60GB
AM60A AZ91A HK31A ZE63A 90 0ouio1ete
AM100A AZ91B HZ32A ZH62A 00g and Aged
AS41 A AZ91C KIA ZK51A
AZ63A AZ92A QE22A ZK61A -

AZ81A EZ33A ZE41A

See secion 16 for Cutting Fluid Recommendations #CAUTION Potential Fire Hazard. Exercise caution in grinding and
'See section 20.4 for calculation of Table rpm and Downfeed in 1pm. disposing of swarf. Do NOT use waler or water-miscible cutting
fluids tor magnesium alloys.

8-53
8.4 Surface Grinding-Vertical Spindle, Rotary Table
WHEEL
TABLE* DOWNFEED IDENTIFICATION
WHEEL
(WORK) per rev. OPERATION NARROW BROAD
HARD- SPEED
MATERIAL CONDITION SPEED of table WORK WORK
NESS AREA AREA
fpm fpm in ANSI ANSI

32. TITANIUM ALLOYS, 3500 50 .0005 Roughing C36HV C36GV

WRUH#10to to to
WROUGHT** 110 6000 100 .001 Finishing C01V C60HV
Commercially Pure to Annealed
99.5 99.0 275 )
99 2 98.9
Ti-0 2Pd
TiCODE- 12

3500 50 .0005 Roughing C36HV C36GV

Alpha and Alpha-Beta Alloys to to to
Ti-SMn 300 Annealed or 6000 100 .001 Finishing C601V C60HV
Ti-1AI-BV-5Fe to Solution Treated

Ti-3AI-2.SV ll~ =,uw C0"V

Ti-5AI-2Sn-2Zr-4Mo-4Cr (Tv-17) MEM R-
_.2 ._
Tj-SAf-2.5Sn
T3-5AI-2 5Sn ELI
Ti-5AI-6Sn-2Zr- 1Mo
TI-6AI-2Cb-1Ta-0.SMo " .1_ 20 ff-

Ti-6AI-4V ELI WL
# - , 4,.
Ti-6AI-6V-2Sn
Tv-6AI-2Sn-4Zr-2Mo
Tj-6AI-2Sn-4Zr-2Mo- 25Si

T -37l8VC-4Mo -4r25 Anae, t t

Ti-6Mo-1V foSndaions TreCAUTI6000-oten0i1 Fi hing and

250 As-4asI WE-

Beta
TIAUAlloy S, 3500 50 .0005 Roughing C36HV C36GV
CTi-I8V6r4 Z 2750 Aneaed to to to

Ti-8Mo-8V-2Fe-3AIto n ' -
TI-O2Pdand Agnaed
ATM G-2e-adeC-1, C-,

Slee section 6000 100 0ca1 Foashing C601V C60HV

8-54
 Surface Grinding-Vertical Spindle, Rotary Table 8.4
T WHEEL

WHEEL TABLE* DOWNFEED IDENTIFICATION

HARD- SPEED (WORK) per rev. OPERATION NARROW BROAD
MATERIAL CONDITION SPEED of table WORK WORK
NESS AREA AREA
fpm fpm In ANSI ANSI
Shn n-s s______
sjThi~~-/mn:
z__

Alpha and Alpha-Beta Alloys 3500 50 0005 Roughing C36HV C36GV

Ti-5AI-2 5Sn 300 As Cast t0 to to
Ti-63AI-4V to or 6000 100 .001 Finishing C601V C60HV
Ti-6AI-2Sn-4Zr-2Mo 350 As Cast .
Ti-8A-Ilvo-IV and Annealed ~~3~
ASTM 8367 Grades C-5, C-6 _ _ 00W COV

-M N_0

34. COPPER ALLOYS, 13500 100 .001 Roughing CA461B CA46GB

WOGTR 8 Annealedor 6000 250 .004 Finishing CA6018 A60GB
101 116 143 182 to
1021511 84 10R 8 Cold Drawn -V
104 120 147 185 loos wt-e:5 !Ao4
RgCMI CAO
105 121 150 187 ____

107 122 155 189

109 125 162 190
110 127 165 191 ri _M'20 M _____
111128 170ff 192
113 129 172ff 194
114 130 17In95 -.--. _____

115 142 175ff

3500 100 001 Roughing CA461B CA46GB

210 332 368 464 1 et ot
220 335 370 465 1 6 Annealed or 6000 250 .004 Finishing CA6018 CA60GB
226 340 377 466 to 3' _
230 342 385 467 loose Cold Drawn
240 349 411 482 ~7~ -A O Cn~-
260 350 413 485 -

268 353 425 667

270 356 435 687
290 360 442 688 __=
314 365 443 694
316 366 4441-10O
330 367 445- -______ --- -

3500 100 .001 Roughing CA46IB CA46G81

505 608 623 642 t ot
510 610 624 651 10R8 Annealed or 6000 250 .004 Finishing CA6I CA60GB
511 613 625 655 to
521 614 630 674 loose Cl~rw ~ ~-~~5-.~~
524 618 632 675
544 619 638-

See section 16 for Cutting Fluid Recommendations itCAUTION. Toxic Material, refer to National Institute tor Occupa-
*Seesection 20 4 for calculation of Table rpm and Downfeed In Ipm. tional Safety and Health (NIOSH) for Precajtions

8-55
8.4 Surface Grinding-Vertical Spindle, Rotary Table
WHEEL
0
WHEEL TABLE DOWNFEED IDENTIFICATION
SPEED (WORK) per rev. OPERATION NARROW BROAD
HARD-
MATERIAL CONDITION SPEED of table WORK WORK
NESS AREA AREA

fpm fpm in ANSI ANSI

34. COPPER ALLOYS, 3500 100 .001 Roughing CA461B CA46GB

to to to
WROUGHT (cont.) 10 R1 6000 250
706 725 754 782 toAn e edo .004 Finishing CA601B CA60GB
710 745 757 100RS
715 752 770 z,

35. COPPER ALLOYS, CAST 3500 100 .001 Roughing CA461B CA4CGB
88t85t 40 ACatto to to
01
11
963 976
8to AsCast 6000 250 004 Finishing CA601B CA60GB
805 814 821tt 827tf 500kg Heat Treated, _
807 815 822ff 828tt .1
809 817tt 824tt

3500 100 .001 Roughing CA461 CA46GB

833 852 862 874 35 to to to
834 853 863 875 to 6000 250 .004 Finishing CA601B CA60GB
838 855 865 878 500kg ii - 4me
844 858 868
848 861 872

3500 100 001 Roughing CA461B CA46GB

902 91t6 934 948 40 to to to
903 91t7 935 952 to As Cast or 6000 250 .004 Finishing CA601B CA60GB
905 922 937 953 100 Heat Treated
907 923 938 954 50k
909 925 939 955
910 926 943 956
911 927 944 957
913 928 945 958
915 932 947

3500 100 .001 Roughing CA461B CA46GB-

962 974 50 to to to
963 976 to As Cast or 6000 250 .004 Finishing CA601B CA60GBA
964 978 100 Heat Treated J mj
966tt 993 500kg
973
36
IKLALY,3500 100 .0005 Roughing A36HV A36GV
ROGtto to to d
WOGTAND CAST 80 Annealed 4500 200 .001 Finishing A60HV A60GV
Nickel 200 to or ii
Nickei 201 170 Cold Drawn
Nickel 205
Nickel 211A
Nickel 220
Nickel 230

Se: section 16 for Cutting Fluid RecommeiJations #tCAUTION. Toxic Matrial. refer to National institute !or Occupa-
See section 20.4 for calulaton of Table pm and Downfeed in pm tional Safety and Health (NIOSH) for Precautons. M

8-56
 Surface Grinding-Vertical Spindle, Rotary Table 8.4

WHEEL TABLE' I DOWNFEED [IDENTIFICATION

MATERIAL NS CONDITION SPEED
SPE WR) of table OPRTN WORK WORK
NESAREA AREA
I1pm 1pmn in ANSI ANSI
___________Bhn ________ K-1, witvi R-rzi 1O I___~$O

MNLAly403500 100 0005 Roughing A36HV A36GV

MONEL Alloy 401 115 Annealed, to to to
MOELAloy40d Drawn 4500 200 .001 Finishing A60HV A60GV
MONEL Alloy R405 240 or - -- AtV'

ASTMA296. Grades CZ- 100.

M-35

DURAICKE Aloy31 50 0 .0005 Roughing A36HV A36GV

MORNIEL Alloy 0 15 to to to
MNLAly52104500 200 001 Finishing A60HV A60GV
MONEL Alloy K500 to Solution Treated 4EMl.
NI-SPAN-C Alloy 902 320
PERMANICKEL Alloy 300 __ _______' ____ 0 ___

3500 100 .0005 Roughing A36GV A36FV

330 to to to
Aged 4500
40 200 001 Finishing A60GV A60FV
to
360

37. BERYLLIUM NICKEL 30 0 G5 Ruhn 3H 3G

ALYWOGTAD 200 As Cast 350 250 .001 Finishing A80HV A8OGV
CASTtttoo
Berylco 440 250 Solution Treated .

Berylco 41 C

Berylco 43C 00 10 005 Ruhn A3G A6F

Brs
0C23 lo Hardened 3500 250 001 Finishing A80GV A80FV
Brush Alloy 220Ctor
Brush Alloy 260C 425 Aged -
I4w

3000 100 .0005 Roughing A36FV A36EV

47 RC Hardened 3500 250 .00, Finishing A80FV A80EV

See
1 fo CutingFlui R
ecton oasn orCUIN oi aeil ee t ainlIsiuefrOcp

See section 206for Caultion Fu Tblemndon ee inNpm.i andeealth

MinlSa reSfr PeautionistuefoOcpa

8-57

- - . ~ -- 6
8.4 Surface Grinding-Vertical Spindle, Rotary Table

WHEEL
WHEEL TABLE' DOWNFEED IDENTIFICATION

HR-SED (WORK) per rev. OPERATION NARROW BROAD

MATERIAL HARD- CONDITION SPEED SPEED of table WORK WORK
NESS AREA AREA
fpm fpm in ANSI ANSI

39. HIGH TEMPERATURE

HIHTMEAUEto 3500 100
to .0005
to Roughing A36GV A36FV
ALLOYS, WROUGHT AND 200 Annealed 4500 200 .001 Finishing A60GV A60FV
CAST to or
Nickel Ba. ,W rought 390 Solution Treated 9$_X115
AF2-1DA ~4 S~~$~-~-
Astroloy .. ..
Haynes Alloy 263 3500 100 0005 Roughing A36GV A36FV
IN-102 300 to to to
Incoloy Alloy 901 to Solution Treated 4500 200 .001 Finishing A60GV A60FV
Incoloy Alloy 903 475 and Aged St3- -A' O3% 1R
9.. ;
Inconel Alloy 617 -'A ."
Inconel Alloy 625
Inconel Alloy 700
Inconel Alloy 702
Inconel Alloy 706
Inconel Alloy 718 t$4 - '
Inconel Alloy 721 30 1
Inconel Alloy 722 ' rr - -
Inconel Alloy X-750
Inconel Alloy 7C 1
M252

Nimonic 80 ' - -
Nimonic 90 To .;1sz&-
Nimonic 95 E_- , - _ -_ _ __'

Rene 41
Rene 63
Rene 77
Rene 95 16 -5 WE~
Udirme 500 -OOM

L"dimret 700 C -_ RM__

Udimet 710
Unitemp 1753
Waspaloy

Nickel Base, Wrought

NiklBeWogt3500 30 100 0005 Roughing 36
A36GV A36FV
to to to
Hastelloy Alloy B 140 Annealed 4500 200 .001 Finishing A60GV A60FV
Hastelloy Alloy B-2 to or
Hastelloy Alloy C 220 SoltioETeatd=
Hastelloy Alloy C-276
o
Hastelloy Alloy G MQEV.. z
Hastelloy Alloy S 3500 100 .0005 Roughing A36GV A36FV
Hasteloy Alloy X 2to to to
Incoloy240
Incoloy Alloy 804 Cold or
Drawn 4500 200 .001 Finishing
to A60GV A60FV
Incoloy
Inconel Alloy
Alloy 825
60 310 Aged ;M 4 .r-S nt
Inconel Alloy 600

Refractaloy 26
Udirmet 630

-~ -_ag. - S -Z101_____

See section 16 for Cutting Fluid Recommendations

*See section 20 4 for calculation of Table rpm and Downfeed in

8-58
 Surface Grinding-Vertical Spindle, Rotary Table 8.4
1 WHEEL
TABLE' DOWNFEED i IDENTIFICATION
WHEEL
per rev, OPERATION NARROW BROAD
WHEED (WORK)
MATERIAL HARD CONDITION SPEED of table WORK WORK
NESS AREA AREA

fpm fpm in ANSI ANSI

___________ Bhn lfi it ~jrW45 h5MfitJ tjmX '-.o is~iSO
Nickel Bate, Cast 3500 100 0005 Roughing AS6GV A36FV
B-1900 to to to
200 As Cast 4500 200 001 Finishing A60GV A60FV
GMR-235 to or ir O - N-4-i - - 4 g
GMR-235D 425 Castand Aged . - tr ,j%.@j _w .-; -. C-
Hastelloy Alloy B
Hastelloy Alloy C - _ _ _ 5 lnhi A6OQV" r ,MORVt
Hastelloy Alloy D
IN-100 (Rene 100)
IN-738
IN-792 4 t:Z i -

Inconel Alloy 713C ms =NR.-?&. t AA

Inconel Alloy 718 '--
M-'
M252
MAR-M200
MAR-M246
MAR-M4321 I -
Rene 80
Rene 125
SEL
S EL 15

TRW VI A

,
ASTIJ A296 Grades CW-12M, * - o ...
N- 12M. CY-40
ASTM A297 Grades HW. HX
ASTM A494: Grades N-12M-1.-
N-1Z2M-2. CY-40, CW-12M-t.1

ASTM A608 Grades HW50.. I _ ... .... - i -- .. .

HX5C

Cobalt Base, Wrought 3000 100 .0005 Roughing A30GV A30FV

AiRest 213 A e~t23104000 180 to to
200 to
001 Finishing A60GV A60FV
Haynes Alloy 25 (L605) to Solution Treated 40 2 0
Haynes Alloy 188 230 - 1_00 !r'OW ---- TOW -

MAR-M905 -_ ---- M0-C

MAR-M918 3000 100 .0005 Roughing A30GV A30FV
S-816 270 to to to
V-36 to Solution Treated 4000 200 001 Finishing A60GV A60FV
320 and Aged - K ON W W-AaF-

~~!

See section 16 for Cutting Flid Recommendations

*See section 20 4 for calkwation of Table rpm and Downfeed in ipn:

8-59
8.4 Surface Grinding-Vertical Spindle, Rotary Table

WHEEL
WHEEL I TABLE DOWNFEED IDENTIFICATION
HARD- SPEED (WORK) per rev. OPERATION NARROW BROAD
MATERIAL I NESS CONDITION SPEED of table WORK WORK
AREA AREA
fpm fpm in ANSI ANSI

39. HIGH TEMPERATURE I3000 100 0005 Roughing A30GV A30FV

Sto to
ALLOYS, WROUGHT AND 220 As Cast to
4000 200 001 Finishing A60GV A60FV
CAST (Cont.) to or o13& ,9y2
Cobalt Bose, Cast 2A9
AiResist 13
AiResist 215
atan gd ' Z
.-
_
1%__0 .
FSX-414 3000 100 0005 Roughing A30GV A30FV
HS-6 to to tO
HS-290 As Cast 4000 200 .001 Finishing A60GV A60FV

x-45
MAR-M32509 1425 _%

5 .0005 Roughing A36GV A36FV

NA-5 5 50.01F9hn totoo ! 6G
A-286 180 I 6F
Oictyt ouinTetd 450 20 .001 Finishing A60GV A60FV
Incotoy Atkoy 800 230 . - "" - -'

Incotoy Alloy 800OH _.

Incoioy A;oy 802 2 100 A36FV

V-57 to Solution Treated 4500 200 .001 Finishing A60GV A60FV

W545 320 and Aged -- A
19.9Dlo A___0___ ?5 10
_02 005 Roghng A3GV A36FV

_ _ _
_ _ __ _ _ __ _~_
!
_ _ _ _ W_ _. ,~_
0- _ __
,
- - - - - . -

W-545___ -__-_______ % -.

I _ __9D

"C:.?~32r a.Khno al p n ond ac~n2

Age ifpm t

-. -A -~

8-60

See section 16 f~i GCu'!tng Fluid Recommendations

',iction 20 4 f~r caik..j;ation of Table rpmnand Oownleed in ipm

8-60
 Cylindrical Grinding 8.5
TRAVERSE
WHEEL WORK INFEED Wihe WDETL
SPEED SPEED on dia. wit DNII
MATERIAL HARD- CONDITION per rev. CATION*
NESS of work
fpm fpm in/pass ANSI
___________________ Is-__ k'1SOl

1. FREE MACHINING CARBON STEELS, 10 Rough 112 A6L

WROUGHT 5500 70 002
Low Carbon Reaulturizedto oA6V
Hot Rolled, Normalized 6500 100 Finish 1/6
1108 111O50PC Annealed, Cold Drawn 0005 maix.
1109 1119 max o~ece
1110 1211-
1115 1212 and Tempered 2 2 00
1116 213FA60LV~
1116 1215 I

Medium Carbon Reaulfurized

112 14 145Rough: 1/4
112 14 1455500 70 .002
1137 1141 1146 to to A60KV
Low9Ca Leade
144 Carburized 6500 100 Finish: 1/6
LwCroLeddOver and/or .0005 max.
lOL18 121.13 12015 50OPI Quenched and ~ ~ '- j~
111_17 121_14 Tmee
5'*diumn Carbon Leaded Tmee

2. CARBON STEELS, WROUGHT Rough: 1/2

Lo Crbn5500 70 .002
Lo abnto to A60LV
1006 1013 1020 10296 Hot Rolled. Normalized. 6500 100 Finish: 1/6
1008 1015 1021 1513 so RC Annealed. Cold Drawn .0005 max.
1009 1016 1022 1518 max orWece _

1010 1017 1023 1522anemed =B-21 __

1011 1018 1025

1030 1042 1053 1541 Rough:~L
1043R055 15h 1/4
.033 103 15 575500 70 .002
1035 1044 1524 1548 to to A60KV
1037 1045 1595 1551 60 0 iih
103 126
106 552Carburized 60 10 Fnsh 1/8
03 106 12 152Over and/or .0005 max.
1039 1049 1527 5 I unhdadNW
1040 1050 1536 5 cQece n 9---t
High Carbon Tempered -2
1060 1074 '085 1566 =

1065 1078 1090 57

1069 1080 1095
1070 1084 1561

3. CARBON AND FERRITIC ALLOY STEELS Ruh 1

(HIGH TEMPERATURE SERVICE) 50 0 0
ASTM A369, Grades FPA. FPB. FP1. FP2. 65o 100 Fin0h
FP3b. FP5. FP7. FP9. FP 11.FP 12. FP2l1.

___________________________
150
to2
200
]Normalized
IC
As Fc:ged.
Annealed
ano Tempered
6M

ZIOP-
10 Fns'max._ /

See section 16 for Cutting Fluid Recommendations

'Wheel recoMmendations are for wet grinding of 2- to 4-inch [50 to
100 minI d'ameler work For DRY grinding-use a softer grade wheel
For LARGER diameter work-use a softer and/or coarser grit wheel
For SMALLER diameter work-use a harder grade wheel Wheel rec-
ornmendatiofls also apply to plunge grinding applications Also see
section 20 2 Grinding Guidelines

8-61
8.5 Cylindrical Grinding
TRAVERSE
Wheel WHEEL
SPEED SPEED on dia. width IDENTIFI-
HARD- CATION*
MATERIAL CONDITION per rev.
NESS of work
fpm fpm n/pass ANSI
Bhn _m /smlmin :mm/lli- .. ISO_:
4. FREE MACHINING ALLOY STEELS, Rough 112
500 70 002
WROUGHT
to to A60LV
Medium C3rbon Resulfurized
4140 Hot Rolled. Normalized, 6500 100 Finish 1/6
4140Se 50 R c Annealed. Cold Drawn .0005 max.
414emax.
4142Te orQuenched '1-_'] -Rou--
.05_ : 1_/2i-
41456e andTempered 2 21 050
4147Te to tO- A60LVI.
415o i.o-6
Medium and High Carbon Leaded Rou03
41130 41L47 51L32 86140 Roughuu 1/4 I
to to A6KV
41140 41L50 52L100
41145 43140 861-20to oA6K
Carburzed 6500 100 Finish 1/8
Over and/or .0005 max
-
50 Rc Odenched and Rog.
Tempered 28 -2 050

5. ALLOY STEELS, WROUGHT Rough. 12

Low Carbon 5500 70 .002
to to A60LV
4012
4023
4615
4617
4817
4820
8617
8620 Hot Rolled. Normalized. 6500 100 Finish I/6
4023 4617 4820 8620 50 RC Annealed, Cold Drawn 0005 max
4024 4620 5015 8622 max or Quenched s - . "--i_
4118 4621 5115 8822 !1 X1 2?k=-
4320 4718 5120 9310 and Tem pered 28 -: O5 .- -- 3'-X2f
4419 4720 6118 94815 O .

4422 4815 8115 94817 ' Zi

Medium Carbon Rougi
1330 4145 5132 8640 4000 70 002 :4
1335 4147 5135 8642 to to A60KV
1340 4150 5140 8645 Carburized 6000 100 Finish: 1/8
1345 4161 5145 86845 Over and/or .0004 max.
4027 4340 5147 86^50 50 Rc Cuenched and PM -.--- ___e.

4028 4427 5150 8655 jI= _

4626 5155 8660 Tempered 2 2=

4032
4037 50840 5160 8740 - - - " -.
4042 50844 51860 8742 '

4047 5046 6150 9254 -_'---____

4130 50846 811345 9255 I
4135 50B50 8625 9260 I
4137
4140
4142
5060
50860
5130
8627
8630
8637
94830
j
I

High Carbon =9~

50100 51100 52100 M-50 9-

Seesection 16 for Cut.- Fluid Recommendations

' Wheel recommendations are for wet grinding of 2- !o 4-mnch [,50 to
100 m] diameter work For DRY grnng-use a rotter grade wheel
For LARGER niamete, work-is'e a softer and/or coarser grit wheel
For SMALLER diameter work-use a harder grade wheel Wheel rec-
ornmendations also apply to plunge grnng applications Also se3
section20 2. Grnung GuidReones

8-62
 Cylindrical Grinding 8.5

WHEELI WORK INFEED Wihe WEETL

MAEILHARD- SP15EDj SPEED on dia. it EOII
MAESSA CONDITION Iper ev. CATION*
N E Sf m 1pm in p a ss o w rk ANSI
Bhn rn0mmk mp- S
6. HIGH STRENG H STEELS. W R:OUGHT
40 70 02 1 2
300M to to IA60KV
4330V Annealed 5500 100 FniSh- 1/6
4340 50 RcNormalized 0005 max.
4340St I mrax or Quenched Run 1
988V40 ~andTempered -2 21 .0
D6ac - j3
Hi 1 28 30 '-
. E Ir
HP 9-4-20 Rough 1/
HP 9-4-25 4000 70 .002 14
HP 9-4-30 to to A801V
HP 9-4-45 OeQunhd5500 100 Finish- 1/8
OveAuenchd 0004 max
STempered -14
-_P5

Rou,
7. MARAGING STEELS, WROUGHT 55ugh 70 02?
ASTM A538. Grades A. B. C Ito to A'60KV
120 Grade 650 10 Finish: I
180 Grade 50 P Annealed 650mx 1/6 1
200 Grade max.C or .05mx
250 Grade Maraged 12JIO
:
300 Grade ~~- _
350 Grade -3- 3 Thih
HY230 O3a
Rough: 114
4000 70 00?2

50 100 Finish: .8 A81

Over .0005 max
50 R ~ Maraged 0

Rough 112
8. TOOL STEELS, WROUGH4T 60/2 Rough0
Group I to40 to 0
P2 H13 L6 P20 6500 !00 Finish-
A3 H14 L7 P21 50 R Annealed 0005max 1w6
A4 H19 01 SI max.C or Oi-enched7
A6 H21 02 S2 and Tempered I~~--
AB H22 06 S5 ~-=~-
A9 H23 07 SG
A10 H24 P2 S7
Hi0 H25 F14 Wi1
Hi1 H26 P5 W2 Ruh 1
H12 L2 P6 V15400160 .0
SAE j43Ab* Types W108, W109. WilD0. Wi 12.to oA0K
W209. V1210. W310 Over I uenchrA6D 10 Fnih /

50R ~ and 004mx

c ~Tempered 5R

See section 16for Cutting Fluid Recommendations

'Wheel recommnendations are 1o-wet grinding of 2. to 4-inch 150 to
1040mini ciarneter work For CRY grinding-use a softer grade wheel
For LARGER diameter *,irk-use a softer and/or coarser grit whfevl
For SM%.LLER diaireter work-use a harder grade wheel Wheel rec-
o'Omendatio'is also apply to plunge gninding applicqtions Also see
section 20 2. Glinding Guidelines

8-63
 65Cylindrical Grinding
[ I TRAVERSel
Wheel 11WHEEL
WHEEL WORK IINFEED 'ONII
1width IETF-
HARD- SPEED1 SPEEDi on dia.
COI:DITION per rev. CTO
MAT~rNESS
NESS~o j Iowork
tp'P fpm I n pass *ANSI

8. TOOL STEELS, WROUGHT (c;ont.) 112

Group 11 0 02
!)2 H42 ./42 iIASK
03 VAi TI 50 An-nealed 1,6
0Rcr uned0005 mnay
D4 M2 T2
Max -og
035 M3-1 T4 and Tempered 2 1
Fl MID T800
=2 M30 tjt

Ij Rogh

to% Ouencnied O0 max

fl' ~
tO and
58 RC Tempered 6
-R18

40u0GW 002( "

t0 to jA 80V

Over Ovr-h .00 a, ___

-8Rand
CTempered _ 14_

GroupIN aRough-

A7 fM4
Grup1 40 1 0 060 I
D7 M4360001 Finish-
M3-2 M44 RAnnealed
i00
o. e..
MS 1n4 ax or ouenched 7- - 7-

M7 M47 and Tempered Rf0 C J12__

M33 T5 8 39 2
M34 T6 ~.~D---DK

Ro-,gh :A8J

50H in~5500 100 Fh s 1

10 and
58 Rc Tempered ~ ~ ~ ~ ~ = --- _

h400 60 Rough-
.001 .14 1 Sk
to IA81
Ove Onced 5500 100 Fiish:
Ov8r and -- ODD3mnax
5CTempeed _ _

See section 16 fr Ctiffing Fluid ReCommendations-

Wiheel recorrnmeodslrc-ns are for wet grinding *12- to 4-mo. 150 to
100 mzJ diameter work For DRY gnviding-use a softer graoe2 wheel
For LARGER diameter worc-ise a softer anld/or roamser gri. wheel
For SMALLER diameter work-use a harder grad- eieei Wheel rtc-
orifnlendtin5 also apply to plunge gr.nding; applications Also te
section 20 2. Grinding Guideltines

8-64
 Cylindrical Grinding 8.5

TRAVERSE
Wheel WHEEL
INFEED WIdth IDENTIFI-
WHEEL WORK
SPEED SPEED on dia.
HARD- CATION*
MATERIAL N -SS CONDITION per rev.
NI of work
fpm fpm in/pass ANSI
Bhn /tii n/nr nt/n~- $tzS
Gru VRough: 1/2
Group IV 4000 60 001

to to A60JV
T1
100 .0004 max.
Finish: 6
50 maA uneaed
c Queced 5500
ari T)empered tM Al

Rough: 1/
0 60 001
400
to to A8OKV
soa 135 Aunled5500 100 Finish 116
0 totraeno.0003 h ~and ; . max3u
58 RC Tempered -

Rough /
400 60 .001
to to A80HV
"3 100 0003 max.
Finish ,
60Ruenchd
58e Ac 5000
Tempered Z'u! - "gg
_,.
2-.N.,_

9. NITRIDING STEELS, WROUGHT 5500 Rough: 1/2

1t;, to A60KV
Nitralloy 135

Nitralloy 135 Annealed, 6500 !00 Finish:

or .0003 max.
Nralloy 25 MNormahzed
350 Quenched,-'
Nitralloy 230
Nitralloy EZ and Tempered _ "

Pough
4000 ,90 .001 1/

1 tC A01V

60 Rc 5500 100 Fdosh: 1/8-

max
tcti n 2 . ' G0003
65 Rc

10. ARMOR PLATE, SHIP PLATE, AIRCRAFT 50 0 Rough: 1/2N

PLATE, WROUGHT 550 .O 00? I'
to A60JV
HY0to 100 Finish:
HY06500
MIL-S-12560 45 Rc Annealed .00 a. 1/6
HY100max. or Quenched

MIL-S-16216 and Tempered "

HY180

See section 16 for Cutting Fluid Recomrnendal,cnis.

*Wheel rec;ommendations are for wet grinditi of 2. to 4-inch (50 to
100 m] diameter work. For DRY grinding-use a softer grade wheel
For LAPGER diameter work-,use a -ofter and/or coarser grit wheel.
For SMALLER dis meter work-use ., hurder grade wheel Wheel rec-
omelendation. .? apply to plunge grinding applications Also see
5echlon 20.2. 0 1Guidelines

8-65
8.5 Cylindrical Grinding

TRAVERSE
Wheel WHEEL
INFEED Whdth WDEF
WHEEL WORK
SPEED SPEED on dia.
HARD- per rev. CATION*
MATERIAL CONDITION
NESS of work
fpm fpm in/pass ANSI

12. FREE MACHINING STAINLESS STEELS, 5500 50 002

WROUGHT
to to A60JV
Ferritic
430F 135 6500 100 Finish
.0005 max 1/6
430F Se to Annealed --

AutntcRough:. 1/ 2
Austenitic 5500 50 .002
203EZ to to C54JV
303 6500 100 Finish,
303MA 135 Annealed 0005 max
303Pb to or .-
303 Plus,' 275 Cold Drawn 5

303Se

Martensitic 5500 1/4

416 to to A60JV
416 Plus X 6500 100 Finish.
416Se 135 Annealed .0005 max /8
420F to or
240 Cold Drawn WI - mg
420F Se
440F
440F Se

Rough 114
5500 50 002
to to A601V

Quenched 6500 100 Finish 118

Over and .0005 max
275
TemperedW-

13. STAINLESS STEELS, WROUGHT Rough- 1/2

Ferritic 5500 50 002
to to A60JV
405 434 6500 100 Finsh
409 436 135 .0005max 1/6
429 442 to Annealed
430 446 185

AutrilcRough. 1/
Austentlc5500 50 .002
201 308 317 to to C54JV
202 309 321 6500 1,0 Fnsh
301 309S 330 135 Annealed 0005 max.
302 310 347tor
3028 310S 348 275 Cold Drawn
304 314 384
304L 316 385
305 316L

See section 16 for Cutting Fluid Recommendations

'Wheel recommendations are for wet grinding o 2- to 4-inch (50 to
10 mm] diameter work For DRY grinding-use a softer grade wheel
For LARGER dameter work-use a softer and/or coarser grit wheel
For SMALLER diameter work-use a harder grade wheel Wheel rec-
ommendations ilso apply to plunge grinding applications Also see
section 20 2.Grinding Guidelines

8-66
 Cylindrical Grinding 8.5

TRAVERSE
INFEED Wheel
Width WHEEL
WDEF
WHEEL WORK
SPEED SPEED on dia.
HARD- per rev. CATION*
MATERIAL CONDITION
NESS of work
fpm fpm in/pass ANSI
Bhn 'Tii~~/nv1mm/ t tWcj.<> Io
Austenific Rough 1t2
5500 50 002
Nitronic 32 to to C54JV
Nitronic 33 6500 100 Finsh
Nitronic 40 210 .0005 max 1/6
Nitronic 50 to Annealed
Nitronic 60 250 . R.:

Rough 1/4
5500 50 002
to to C541V

325 6500 100 Finish 1/8

to Cold Drawn 0005 max.
375 " C

Msrtsnsitic Rough 1/4

5500 50 002
403 440A to to A60JV
410 440B 6500 100 Finish:
414 440C 135 .0005 max 1/8
420 501 to Annealed -'-- _' t-,.r
422 502 275 5i _ _W1%
431 Greek Ascoloy

Rough. 1/4
5500 50 .002
to to A601V
Ouencned 6500 100 Finish:
Over .0005 max.
275 and
Tempered Z : =

14. PRECIPITATION HARDENING Rough- 114

STAINLESS STEELS, WROUGHT 5500
to 70
to .002 A60JV
lb-5 PH 6500 100 Finish
16-6 PH 150 .0005 max 1/8
17-4 PH to Solution Treated - - - --
17-7 PH 200 rz
17-14 Cu Mo geRam
AF-71
AFC-77
Almar 362 (AM-362)
At-350 Rough
AM-355 5500 70 002
AM-363to to A601V
Custom 450 275 Soluton Treated 6500 10.Finish:
Custom 455 toor0 m
HNM 440 Hardened
PH 13-8 Mo
PH 14-8 Mo
PH 15-7 Mo
Stainless W
See section 16 for Cutting Fluid Recommendationc
*Wheel recommendations are for wet grinding of 2- to 4-Inch (50 to
100 mm] diameter work For DRY grinding-use a softer grade wheel
For LAHGER diameter wcrk-use a softer and/or coarser grit wheel
For SMALLER diameter work-use a harder grade wheel, Wheel rec-
ommendations also apply to plunge grinding applications Also see
section 20.2, Gnnding Guidelines.

8-67
8.5 Cylindrical Grinding
WHEE
WOK INEED TRAVERSE

WHEL
WRK INFED Wheel WHEEL
HARD- SPEED SPEED on dia. wit DNII
MATERIAL NESCONDITION per rev. CATION*
NESS of work
fpm fpm in/pass ANSI
Bhn M mmi pi2 ~ iO
15. CARBON STEELS, CAST 50 70 Rough 1/2
Low Carbon
ASTM A426. Grade P1
1010
Inrmaled,
100
60

50 1
0

00
.0

0 mais-x
1/6t
/
A60LV

Medum 1020 to Normalized and Tempered,~/~

MeimCarbon or0Quenched
ASTMV32 Grades LCA. LOB. ICC and Tempered -- ~ -- ~-
ASTM A356- Grade 1 97j - _
1030 1040 1050L oai1 iii
Rough- 1/4
5500 70 002
to to A60KV
Carburized 6500 100 Finish 1/
Over and/or .0005 max
5OC Quenched and ~'Rih
Tempered ~ ~ 1~~eu

16. ALLOY STEELS, CAST Rough 1/2

Low Carbon 5500 70 .002
ASTM A217. Grade WC9 to to A60LV
Annealed. 6500 100 Finish- 1/
ASTM A352 Grades LO3. L04 50Normalized, .0005 max. 1/
ASTM A426- Grades 0P2. OP5. CP5b. CPi 1., to Normalized and Tempered, V1__ - .- ---
GP12 0P15. CP21, CP22 400 or Quenched _

1320 4110 8020 and Tempered ~ ~ ~ ~ I

2320 4320 A -

Medium Carbon MA
ASTM A27: Grades N1 . N2. U-60-30, 60-30, Rough: 114
65-35. 70-36. 70-40 4000 70 002
ASTM A148. Grades 80-40. 80-50. 90-60. to to A60KV
105-85. 120-95. 150-125.,175-145 Carburized 6000 100 Finish 1/8
ASTM A216 Grades WOA. WOB. WOO Over and/or .0005 max
AM'TMv A217: Grades WC1. WC4, wos. W06 50 Rc Quenched and __
_Z I
ASTM A352, Grajs 101. L02. L02-1 Tempered ft-2
ASTM A356 Grades 2, 5,6. 8. 9, 10 ~~-
ASTM A389: Grades 023. 024
ASTM A486, Classes 70. 90. 120
ASTM A487 Classes 1N. 2N. 4N. 6N. 8N. 9N.
1ON, DN, 10. 20. 40, 40A. 60. 70, 80.
90. 100
1330 4130 80B30 8640
1340 4140 8040 9525
2325 4330 8430 95307
2330 4340 8440 9535
4125 8030 8630

W
See section 16for Cutting Fluid Recommendations.
*Wheel recommendation- are for wet grinding of 2- to 4-inch 150toI
100 Mmndiameter work For DRY grinding-use a softer grade wheel.
For LARGER diameter work-use a softer and/or coarser grit wheel.
For SMALLER diameter work-use a harder grade wheel. Wheel rec-
ommendations also apply to plunge grinding applications Also see
section 20 2. Grinding Guidelines

8-68
 Cylindrical Grinding 8.5

TRAVERSE
Wheel WHEEL
WHEEL WORK INFEED Width iDE i
on dia.
SPEED SPEED
MATERIAL HARD- CONDITION per rev. CATION*
NESS of work
fpm fpm in/pass ANSI
Bhn j s;

17. TOOL STEELS, CAST Rough*

.002 I/2
4000 60
Group 1
t0 to A60LV
ASTM A597. Grades CA-2. CH-12. CH-13,
CO-1. CS-5 50 R Annealed .0005 max. 1/6
max or Quenchea tI
and Tempered 5-gM _

Rough; 1/3
4000 60 .002
to to A60KV

50so Quenched 5500 100 Finish-

to and 04 m

58 RCTempered -to -t. .

Over Quenched .0004 max

"
Tempered - " - -

ASTC-5to
A57:Graes D-, to A60JV

Rough: 1/4
4000 60 .002

SQuenched00 100 Finish 1/

t000 and

Gru 1Rough: 1/2

to to A60KV
6000 100 Finish: 1/8

564000 60 .002
ZRNMR
R Quenchedmax.
to andle

Rough: 1/43_
4000 60 .002
to to A60KV_
4A5500 100 Finish: 1/8
Ove Quenched .0004 max.

100~~~ ~ afergae~
56 FIc

~
he ra00 ~
Tempered

~ ~ ~ 50
NAI,
FimtrnoisFrDh:rnin-s
Fo AREdaetrwok-ue ote ndo O tver 0003ema
Cutting Fluid Recommendations.
See section 161cor
"Wheel recommendations are Ior wet gnnding ot 2- to 4-inch [50 to
100 SmAmLEdiameter work- R gdn-use a grade wheelelrc
softer

ommendatrons also apply to plunge grinding application Also see

section 20 2, Gnnding Guidelines

8-69
8.5 Cylindrical Grinding

WHEEL WORK INFEED Wit WHIEELFI

HARD- SPEED SPEED on dia. it DNII
MATERIAL CONDITION per rev. CATION*
NESS of work
fpm fpm in/pass ANSI
Bhn rn/s_ Im I mm/pass -_ISO-
18. STAINLESS STEELS, CAST 50 5 Rough: 1/2
5500 50 002
ASTM A217 Grades C5, 012 tO0 to0 Finish
ASTM A296- Grades CB-30, CC-SO, CE-30, 135 650 10 Fns: 1/6
CA6N, CA-6NM, CD4MCu to Annealed 000 msx
ASTM A297 Grade HC 185 ogh 12

ASTM A608- Grade HC30 Finish-A.0J

Ol3max. 1/
Austeflitic Rough: 1/2
ASTM A296 Grades CF-3. CF-3M. CF-8. 5500~ 50 002
CF-BC. CF-8M. CF-16F. CF-20. CG-BM. 650 100 inis
CG-1 2. CH-20, CK-20. CN-7M, 135 Annealed,.50 10 Fns 1/6
CN-7MS to Normalized .0005 max
ASTM A297- Grades HID, HE. HF, HH, HI, HK, 210 or . Rog
HL, HN, HP, HT, HU AsCstP8 - -5~0
ASTM A351 Grades CF-3, CF-3A. CF-3M,
CF-3MA. CF-B, CF-BA. CF-BC. CF-8M, .

CF-1 OMC. CH-B, CH-1 0, CH-20. CK-20, _____ R__________

CN-7M. HK-30. HK-40, HT-30
ASTM A451, Grades CPFBA. CPF3, CPF3A.
CPF3M, CPF8. CPFBC. CPFBC (Ta Max).
CPFBM. CPF1 OMC. CPH8,.CPH1O0,
CPH2O. CPK20
ASTM A452 Grades TP 304H. TP 316H, TI'P
347H
ASTM A608 Grades HD5O. HE35, HF3O, ~~~~- -~~~~-

HH3O. HH33. H135. HK3O, HK4O. HL3O. jZ:; .-

HL40. HN4O. HT5O. HU50 ____________ SE .

Martensitic Rough: 1/4

ASTM A217- Grade CA-i to o
t50 002J
ASTM A296: Grades CA-i15. CA- 15M. CA-40to oA6J
ASTM A426. Grades CP7. CP9. CPCA15 135 Annealed. 6500 100 Finish-' /
ASTM A487. Classes CAi5a. CA-15M toNomlzd00ma 1/

225 or Normalized
an Tempered Ww;,

550 50 Rough. 1/4

to to A601V
Qunced6500 100 Finish:' /
Over ad-0 005 max.
Tempered

A00
See section 16 for Cutting Fluid Recommendations
-Wheei recommendations are for wet grinding of 2- to 4-inch (50 to
100 min] diameter work For DRY grinding-use a softer grade wheel
For LARGER diameter work-use a softer and/or coarser grit wheel
For SMALLER diameter work-use a harder grade wheel Wheel rec-#
ommendations also apply to plun ,j grinding applications. Also see
section 20 2. Gnnding
Guidelines
8 7
 Cylindrical Grinding 8.5

MATERIAL
____________________________
_______

HARD.
CONDITION
SPEED SPEED
-TRAVERSE

WHEEWOK IFE on dia.

T
Iper
Wheel
wit
rev.
WHEEL
DNII
CATION*
NES pm fpm in/pas owr ANSI
Bhn -_ -- _ISO_-
-mniip-~rn/rni --Ps
19. PRECIPITATION HARDENING Rough 1/4
STAINLESS STEELS, CAST 5500 70 002
ATA31GaeC-Muto to I A601V
A32A51Gae
D4~ Solution Treated 6500 100 Finish 1/
ACI Grade CB-7Cu 325 0005 max 1/
ACt Grade CD-4MCu to o
17-4 PH 450 botution Treated -oug
and Aged28 2 5- 14
AM-355 o o 2 - Ae i
-33 - 3-~~~h

21. GRAY CAST IRONS Rough 1/2

Ferritic Cas5500 70 .002
ASTM A48 Cas20 to to C46KV
SAEJ431c Grade G1800 As Cast, 6500 100 Finish: 1/6
Pearlitic- Ferritic 45SRC Annealed .001 max
ASTM A48- Class 25 max or Qunce -6Jh
---
SAE J431c Grade G2500anTeprd-3Z
Pearlitic ---- -

ASTM A48. Classes 30, 35. 4033 30. cFih

SAE J431c. Grade G3000_______ ___ 02i P-
Pearlitic + Free Carbides Rough- 1/3
ASTM A48 Classes 45. 50 5500 70 002
SAE J431ic Grades G3500, G4000 to to C54JV
Pearlitic or Acicular + Free Carbides 45 R0 As Cast. 6500 100 Finish: 1/6
ASTM A48 Classes 55. 60 to CAnnealed 0005 miax
52 R0 or Quenched N7.ugh
Cand Tempered 3-62- .0-O51r0

Rough: 1/4
5500 70 002
to to C601%/
48R Flame 6500 100 Finish. 1/8
H0 0005 max
to or - -
60 PIC Induction Hardened R" -

_______~ o ~ ~ AI# -

Austenific (NI-RESIST) 40 Rough 1/2

ASTM A436 Types 1, lb. 2. 2b, 3. 4. 5. 6 5500 40 002
to to A6OKV
1006500 65 Finish. 1i
10000 .05mx m1
to As Cast
250 if

22. COMPACTED GRAPHITE CAST IRONSRog 1/

185 6500 100 Finish 1/

225

See section 16 for Cutting Ftuid Recommendations

*Wheel recommendations are for wet grinding of 2- to 4-inch (50 to
100 min] diameter work For DRY grinding-use a softer grade wheet
For LARGER diameter work-use a softer and/or coarser grit wheet
For SMALLER diameter work-use a harder grade wheet Wheel rec- 4
ommendations a!so appty to ptunge grinding applications Also see
section 20 2 Gninding Guidelines

8-71
8.5 Cylindrical Grinding
TRAVERSE
Wheel
W idth WHEELF
WDEN
W HELL W ORK INFEED
SPEED SPEED on dia.IDENTIFI-
HARD- per rev. CATION*
MATERIAL CONDITION
NESS of work

fpm fpm in/pass ANSI

Bhn /!tImhtmpn
!g_______
- ~ ~ s m;5ao-
23. DUCTILE CAST IRONS 5 Rough: 1/4
5500 70 .002
Ferritic
to to C54JV
ASTM A536 Grades 60-40-18.65 . 12
SAE J434c- Grades 04018, D4512 Annealed. As Cast 6500 100 Finish: 1/8
Ferritic- Pearlitic 52 Rc Normalized and Tempered .0005 max
ASTM A536- Grade 80-55-06 max or Quenched
SAE J434c. Grade D5506 and Tempered 5
Pearlitic- Martensitic g
ASTM A536: Grade 100-70-03
SAE J434c- Grade 07003 _________ W1nX tz#S z&~
Martensitic Rough: 1/4
ASTM A536 Grade 120-90-02 5500 70 002
SAE J434c Grade DO&T to to C501V
6500 100 Finish:
53 Ac Flame .0005 max
to or
60 AIc Induction Hardened -~

Austenitic (NI-RESIST Ductile) Rough: 1/2

5500 40 002
ASTM A439. Types D-2. D-2B.D-2C. D-3.
to to / An0:
D-3A. D-4. D-5. D-58
ASTM A571: Type D-2M 120 6500 65 Finish:
to ~~Annealed.05ma
275 0:7i ,

24. MALLEABLE CAST IRONS Rough: 1/3

5500 70 .002
Ferritic
Malleablized 6500 100 Fiish:
ASIM A47. Grades 32510. 35018
ASTM A602: Grade M3210 52 or1/6
52 of .0005max.
SAE J158: Grade M3210 c
Pearlitic max Malleabized
ASTM A220. Grades 40010. 45006. 45008, Heal Treated
50005
ASTM A602: Grade M4504. M5003
SAE J 158: Grades M4504. M5003 -
Tempered Martenaite Rough:
ASTM A220 Grades 60004. 70003. 80002. 5500 70 .002 1
90001 to to C601V

52OverPCor
ASTM A602: Grades M5503, M7002. M8501 6500 100 Finish.
Flame 0005 max. 1/8
SAE J158 Grades M5503, M7002. M8501
5Ac Induction Hardened

Rough:
25. WHITE CAST IRONS (ABRASION P0ugh: 1/4
RESISTANT) REISAN)to 50 to0 .0 C601%
ASTM A532:
6500 100 Finish:
Class I. Types A. B, C. 0 60 R, As Cast. .0005max. 1/8
Class II. Types A. 8. C. D. E
Class III.Type A
max Annealed
or Hardened - A

See section 16 for Cutting Fluid Recommendations

*Wheel recommendations are for wet grinding of 2- to 4-inch 150 to
100 mmj diameter work For DRY grinding-use a softer grade wheel
For LARGER diameter work-use a softer and/or coarser git wheel
For SMALLER diameter work-use a harder grade wheel. Wheel rec-
ommendations also apply to plunge gnnding applications Also see
section 20 2.Grinding Guidelines

8-72
 Cylindrical Grinding 8.5

I 1
TRAVERSE~
WHEEL WORK INFEED Wheel WHEEL
HAD SPEED1 SPEED j on dia. width IOIENTIFI-
MATERIAL HR-CONDITION I jperrev. .CATION'
NESS I Iof wark
fpm fpm In'pass IANSI
Bhn rn)Imrnn On/-

26. HIGH SILICON CAST IRONS Rough 14 Rough

Duiriclor 1t00
to 10 I Fns ,vh
160 101Fii 1/8 Fin-
ASTM A518
52%
R As Cast j _ ---- hf

I 5E0 0

275-I 10i 02 ..

1000F maxj
to Is Cast -- I
376~1 1

to 30 -1 5i4tiV'
-

10360 2219 5254 6262

6463
30
to
I Drawn
Co.1d
orSdutior
t-500 1150 Finish.
.005 max 1/6
1100 2618 5454
1145 3003 5456 6951 150 1npited -

1175 3004 5457 7001 500kg "'id Aged ~ ~ --

1235 3335 5652 7004 I~-
2011 4032 f 657 7005 i*- ~ _

2014 5005 6053 7039 -oa~

2017 5050 6061 7049
2018 5052 6063

I_
7050
2021 5056 6066 7075 1
2024 5083 6070 7079
2025 5086 6101 7175
2117 5154 6151 7178

IQ _

29. ALUMINUM ALLOYS, CAST so c Rouh. 1/3

Sand end Pormaniint Mold102
A140 2950 5140 A712.0 6500 150 Finish-
2010 B250 A1 72040 As Cast16
2080 308.0 B514 0 7130 t0 of_.005_max

319.0 520.0 771.0 .25 Solution Treated - tMNITughIE -

2130
2220 3550 535.0 850.0 50gadAe
7050 A850.0 95Q
2240 C355 0
2420 8443 0 707.0 Bq50,0O.. ~7j
0
Hiduminiurn RR-3O
Die Castings
(A430 518.0

See section 16 for Culling Fluid Recommendations t Wax tilled

'Wheel recommendations; are for wet grinding of 2- to 4-inch 150 to
100 min) diameter work- For DRY grinding-ese a softer grade wheal
For LARGER diameter work-use a softer and/or coarser grit wheel
For SMALLER diameter Work-use a harder grade wheel. Wheel rec-
omnmenidations also apply to plunge grirding applications Also see
section 20 2. Gninding Guidelines

8-73
8.5 Cylindrical Grinding
TRAVERSE

F MAEILCONDITION
HWH
WRK
WHEL INFED
SEEL WOEEK InFEED
Wheel
width
Iper rev.
WHEEL
IDENTIFI.
CATION'
NESS of work
Ipm fpm u-/pass ANSI
Bhn -rnJ i:nhtriijinn s _-

29. ALUMINUM ALLOYS, CAST (cont.) Rough. 1/

Sand and Permanent Mold 5500 50 002
to to A541V
328 0 3560 40 As Cast 6500 150 Finish 1/
A30 A360to or 0005 max
F332 0 3570 125 Soltion TreatedRog 13
333.0 3590 500kg and Aged28 1 05
354.0to t 5I-
Die Castings33 4 ms.
3600 A380.0 3900 A413 0 N 013n,mI
A360 0 383 0 39200-
3800 A384 0 4130

30. MAGNESIUM ALLOYS, WROUGHT#* Rough- 1/3

5500 70 .002
AZ21A HK31A *0 to C60KV
AZ31B HM21A 50 Annealed. 6500 150 Finlish: 116
AZ31C HM31A to Cold Drawn .0005 max
AZ61A ZK40A 90 or E-2 * S91ZO- --- I
A-780A ZK60A I 500kg Solution Treated and Aged r4_= 2m O 0

31. MAGNESIUM ALLOYS, CAST#z Ftough, 1/3

15500 70 002
A-,s6OA AZ91C ZE41A to to C60KV
AM100A AZ92A ZE63A 50 As Cast. 6500 150 Finish: 1/6
AS4 IA EZ33A ZH62A to Annealed ___ 005 max.
AZ63A HK31A ZI( 51 A 90 or -
AZ81 A HZ324 ZK61A 500kg Solution Treated and Aged Q528w! 92f .050
4
AZ91B 0E22A =00%~ 6
S- ~; R01M-

32. TITANIUM ALLOYS, "ROUGHT#* Rough 1/5

Commercially Pure 30 50 .001
995t C601vt
954000 100 Finish-
99.2 110 300 0 005 a 11
S90 to Annealed I -t
98 9 275 -=~
Ti-0 2Pd Zi=r
TiCODE- 12 7y~r

See section 16 tor Cutting Fluid Recommendations iuse -riate (g'een grit) silicor. arbidie
*Wheel recommentdations are for wet grinding of 2- to 4-inch 150 t0 11 CAUTION Potential F.re Hazard Exercise cautin in grinding and
100 mi diameter morlr For DRY grinding-use a softer grade wheel disposiiig ot Swarl Do NOT use water or waler i'vscible cutting
For LARGER "maieter work-use a softer and/or coarser grit wheel fluids for magnesium alloys
For SMALLER diameter work-use a harder grade whee: Wheel rc-
ommerdatiOns also apply to plunge grinding applications Also see
sec.ion 20 2. Gninding Guidelines

8-74
 Cylindrical Grinding 8.5

MATERIAL HARD-
NESS I
fWHEEL
CONDITION
WORK
SPEED SPEED
INFEED
on dla.
TRAVERSE

Wheel
wit
per rev.
of workc
WEELFI
DNII
CATION*

I pm fpm in/pass ANSi

Alpha and Alpha-Beta Alloys 30 50 Rough: 1/5

Ti-8Mn 30 50 .001
Ti- 1AI-8V-5Fe to' to C6OJVt
Ti-2AI-1-lSn-5Zr- IMO 300 4000 100 Finish, 1/10
0005 max.
Ti-5A-2Sn-2Zr-4Mo-4Cr (Ti- 17) 380 -/~
Ti-5A-2.5Sn j1 5 coy
Ti-5Al-2 5Sn ELI I1 0 A

Ti6A-2Cb- lTa-0 8Mo __________ - - O3ImC

Ti-ISA1-4V Rough. 1/5
I i-6AI-4V ELI 3000 50 .001
Ti-6AI-6V-2Sri I( to C60JV*
Ti-6AI-2Sn-4Zr-2Mo 320 4000 100 Finish: 1/10
Ti-6A-2Sn-4Zr-2Mo- 25Si toSolution Treated .0005 max.
Tt-6AI-2Sn-4Zr-6Mo 440 and Aged -5 ---

Ti-8A1- illo- o &K_25-CO

Beta Alloys Ruh /

Ti-3At-8V-6Cr-4Mo>-4Zr 30 0 .0
Ti-8Mo-8V-2Fe-3AI10v o t
Tt.1 1 5Mo-6Zr-4.5Sn 275 Annealed400 10 Fns: /0
Ti-!OV-2Fe-3Al to or .005_ax
Ti-13V-llCr-3Ai 350 Solution
Treated

3500 So0 .ln

to Treated
440and Age

33. TITANIUM ALLOYS, CASTft1/

99Comeial Pre 150 As Cast 4000 100 Finish 11

ASTM 3367 Grades C-i1. C-2. C-3. C-4. to O
C-7A. C-7B3. C-BA. C-88 250 AsAnnalet5

Alpha and Alplit-Beta Alloys Ruh /

30 0 .0
Ti-5A-2.5Sn
Ti-15AI-4VV0 t ~v
T;-6A!-2Sn-4Zr-2Mo 300) As Cast D 10 Fns: 10
Ti-8A-lMo-IV to
ASTM B367: Grades C-5. C-6 350 As Cast ~ ~ ~--
and Anneale

See section 16 for Cutting Fiuid Recommendations tUse triabie (green gal) siiicon carbide
*Wheei recommendations are for wet grindirr2 o. 2- rI 4-inch 150 to J$CAUTIOJ Potential Fire Hazard. Exercise caution in grinding and
100 m] diameter work For DRY grinding-use a softer gradt whieal disposing of swart
For LARGER diamneter worl-ise a softer and/or cov-ser gra wheel
For SMALLER diameter work-use a harder gride wheel Wheel rec-
ommnendations also apply to plunge grinding applications Aiso spa
section 20 2. Giding Guidelines

8-75
8.5 Cylindrical Grinding
TRAVERSE
Wheel IWHEEL
INFEED Wdth HIDENTIF-
WORK
WHEEL SPEELU
HARD- ~SPEED on dia. wit DNI-

MATERIAL HARD CONDITION per reSo.d CATION*

NESS of work I
Ipm Ipm in/pass ANSI
Bhn n ,riT7~iuipm ;; *IS 2

34. COPPER ALLOYS, WROUGHT 5500 70 g 1/3

101 116 143 182 to to C46JV

102 119 145 184 6500 100 Finish
104 120 147 185 10 0005 ma 1/6
105 121 150 187 to Annealed I .- .--
107
109 122
125 155
162 189
190'_ 70B i
N- -/
-
110 127 165 191 :.._
.-. __ -
111 128 170tt 192 -- 'm- _ *U
113 129 172fl 194 Rough:
114 130 173tt 195 5500 70 .002 1/3
115 142 175#t to to C46JV

60 Re 6500 100 Finish: 1/6

.0005 max
to Cold Drawn
100%R AWE

Rough, 1/3
210 332 368 464 5500 70 002
220 335 370 465 to to C46KV
226 340 377 466 10 R 6500 100 Finish 1/6
230 342 385 467 to .0005 max
240 349 411 482 Annealed -

260 350 413 485 70%R

268 353 425 667 -

270 356 435 687

280 360 442 688 , -

314
316 365
366 44?
444 6941
9 Rough: 1/3
316 366 44 5500 70 .002
330 367 445 to to C46KV

60 Re 6500 100 Finish: 1/6

to.0005 max
100 AB

Rough: 13
505 613 632 5500 70 .002
510 614 638 to to C46KV
511 618 642 6500 100 Finqh:
521 619 651 10 Re .00,_5 max.
524 623 655 to Annealed -

544 624 674 70 Re

608 625 675
610 630

Rough: 13-
5500 70 .002 1/
to to C46KV
60 Re 6500 100 Finish: 4

to Cold Drawn
100 Rb,

See section 16 for Cutting Fluid Recommendations t t CAUTION Toxic Material, refer toNational InVclute for Cccupational
-Wheel recommendations are for wet grinding of 2- to 4-mc!# [50 to Safety and Health (NIOSH) for Precautions,
100 min diameter work For DRY grinding-use a softer grade wheel.
For LARGER diameter work-use a softer and/or coarser gnt wheel.
For SMALLER diameter work-use a harder grade wheel Wheel rec-
ommendations also apply to plunge gnnding applications Also see
section 20 2. Grnng Guidelines

8-76

_
___ _ _ ____ I-=1
 Cylindrical Grinding 8.5

I TRAVERSE
WHEIWORK INFEED Wheel IWHEEL
HR-SEDSPEED onda width IDENTIFI-
MATERIAL HR-CONDITION I t t per rev. CATION*
NESS ot work
1p
pm in/pass ANSI
__ __
_ _ _ _ __ _ _ Bhn __ __ _ __ _ 1*7417S ~J~

71075 5500 70 .002

70754 to to C45KV
715 757 I50 10 Fns
725 770 10 H8 650.00 0
Finish1
745 782 t0 Annealed
70 a

6OA8 6500 100 Finish. /

to Cold Drawn - .05mx

100R

35. COPPER ALLOYS, CAST Ruh 1

801 814 ~824ttt o44J
803815825t' 4065 10 Fish /
805 87t 826t11 to As Cast .05mx
807 818tt 827tt 200orF K
809 820tt 8281t 500kg Heal Treated
I ~ 821tt
813 622tt

5500 -0 .00

34 % 6500 10 Finish:
to Treated
IHeal -.

45RA

833 854 86755 70 .2

34 855 868to o 4K
836 857 872 35 z 10 Fish 1/
838 858 874 to .05mx
842 861 875 200 As Cast
844 862 876 500kgNO 1
848 863 878 FVA1
852 864 879
853 865

902 916 934 948 550 7 .0 /

903 917 935 952 totI4K
905 922 937 953 40 60 0 iih /
907 923 938 954 to .05mx
909 925 939 955 100 As Cast
956 500kg J
910 926 943
911 927 944 957
913 928 94-5 958
915 932 947N
See section 16 for Cutting Fluid Recommendations. +t CAUTtON Toxic Material. refer to National Institute for Occuparal
-Wheel recommendations are for wet gilning of 2- to 4-inch (SOto Safety end Health (NIOSH) torPrecautions.
100 mm] cliameter work For DRY grinding-use a softer grade wheelA
For LARGER diameter aork-use a softer and/or coarser grit whe--!
For SMALLER diameter work-usae a harder gradle %Nheel.Wl'ee rec-
ommendations also apply to plunge grinding applical, Mo
I see
section 20 2. Gninding Guidelines

8-77a

_____________________
8.5 Cylindrical Grinding
I WhAVEqS E

WHEEL WORK INFEED Whet j WHEEL

SPEED SPEED ondia. idth IDENTIFI

MATERIAL NESS
HARD- CODTC rv AIN
lof workl
fpn- fpm in pass ANSI
.h m/ni,- -mmps, ts
5500Ro7 gh
.02
35. COPPER ALLGYS, CAST (cont.)
(materials hised on precedng page) I 02o A54LV

Over ,As Cast 6500 1000 irnh

005axis6
1oo~~oo max.__
500kg Heal Teaec j Ropgh. _ - 3 --

36o /6V

962555i 7 02
964 s 6500 100 1 F ih 1/6

9661 to I 00I5 ma i
973 100 As Cast w8>f21 --
974 -5-- -i/3-

976 50gA~
978 - - I
993
993 ____ ________ -I-
5500 70
Rough.~
.002 13
k i I * I

j
-L

over 6500 10Ii-s

I to o A54LV
500kg Heat Teatec

N~ke 20 AND CAST

36. NICKEL ALLOYS, WROUGHT I II5500 - .31 Ro-ugh:
002 1/5 ,
ickel 200 to to
Nickel 201 6500 100 Finish.
Nickel 205 80 Annealed .0005 max I/10
Nckel 21A to f-
Nickel 220 170 Cold ~~g
PROW~
Nickel 230 1i ~ ~ ~ ~ c~

MONEL Alloy 400 I 50 i0h

MONEL Abov 401 t 0 02C6j
MONEL Alloy 404 115 A'veaed. 6500 !00 Finish. /10
MONEL Alloy R405 115 Col 005mx. 11
ASTM A296: Grades CZ- 100. M-35 :o Colr 0a-'- _0 max.
ASTM A494. Grade CZ- 100. M-35 240 p -_
Cast -~__

I 5
JRough-
. 1/
DURANICKEL Alloy 301 5500
MONEL Alloy 5021 to to C60
MONEL Atloy K500 , 6500 100 F inish
NI-SPAN-C All / 902 150 i 0005 max. 1/10
PERMANICKEL Aloy 300 to Soulion Treated ,
320

See section 16 for Cutting Fluid Recommendations i t CAUTION Toxic Mateial refer to National Inst-ute for Oc.u.at.ojal
*Wheel recommendations are for wet grinding ol 2. to 4.inch .50 to Safety and Health (NIOSH) for Precaut.ons
100 mm.n]diameter work For DRY grimdmg-use a softer gra etieel
For LARGER mareler work-use a sontor and or coarser gri wheel
Fa- SMALLER damnele w.k-use a harder grade wheel Whertl rec-
omendations also ap. j ti piune gn ing appacations Also se7a
secwi n 20 2. Gnndirg Gupde-i-es

8-78
 Cylindrical Grinding 8.5
TRAVERSE

W14EEL WORK INFEED Wihe WEEL

HARD- SPEED SPEED, ondla. wit DNII
MATERIAL NESCONDITI')N per rev. CATION*
NESS of work
fpm fpm in/pass ANSI
Bhn I m/s- 'rn/mmn iiipass-., ,4SO'-J
36. NICKEL ALLOYS, WROUGHT AND CAST 550 50 Rough 1/5
(cont.) to0 to 002OJ
(material,; listed on preceding page) 306500 100 Finish 11
330.0005 max
to Aged - - ;;' g
36028 >5'

tW *.,
';-013mii __

37. BERYLLIUM NICKEL ALLOYS, Rough, 1/5

WROUGHT AND CASTtt 5500 50 .002
to to A60KV
Berylco 440 6500 100 Finish:
Berylco 410C 200 As Cast .0005 max.
Berylco 420 to or .

Berylco 430 250 Solution Treoted ~ ~ qg~

8rush Atloy 2000 V15
g28 -
Brush Alloy 2200C AP8
Brush Alloy 260C
Rough '1
5500 50 002
to to A60JV
283 H~ardened 6500 100 Finish. 1/10
.0005 max.
425 Aged

Rougn: 1/
5500 50 .002
to to A601V
47 RCHardened 6500 100 Finish 1/10
to or005mx
52RP Aged

38. N4tTlNOL ALLOYS, WROUGHT Ruh /

Nilinol 55Ni-45Ti 500 to 0
Nitincit -464l44Ti.0 Fnsh
Nitinoil 60Ni-40Ti 210 Wrought 0005 max. 11
to orNM
340 Annealed

500 50 .002
to0 oC61

52oR Quenched * .005mx

&.eesection~ Cuttng Fluid Re~commendations tfCAUTION Toxic Material, refer to National Institute for Occupational
-Whe-V recommendtations are Vw,eat ndng of 2- to 4-inch (Oto Safety and Hoalth (NIOSH) lor Precautions
100 rmn dineter 'NOMFo' or y g'ineing-use a softer grade wheel
Foi i.At 3ER diarnater work-tsg a softer and/or Coarser grit wheel
'r 5W.A LER d-ar'eter worX,e a harder grade wheel Wheel rec-
on1i eno,.oinx a-so apply to plunge grinding appticalioi~s Also see
secliI ' 21 ?. Grinding Guidelines.

8-79
8.5 Cylindrical Grinding
I TRAVERSE
Wheel WHEEL
I
ARD-PEED
S D oNFEd width IDENTIFI-
MATERIAL HARD-
NESSI CONDITION SPEED SEED on dIa. perrev.
of work CATION*

fpm Jfpm in/pass ANSI

__ _ _ _ _ _ _ _ _ Bhn __ __ _ __ _ 1tm hiIRough 1/
39. H!GH TEMPERATURE ALLOYS, 3o 15
WROUGHT AND CAST 3000 5 01
Nickel Base, Wrought to to A6OjV
A F2-DA AF21D 20
200 Annealed 300 00 Finish
0002 max 1/10
-ps,*'W3j
Astrn'oy
Haynes Alloy 263
IN- 102
to
390
or
Solution Treated r I ',. . F
A

Incoloy Alloy 901 rv

1OOOy Alloy 903
Inconel Alloy 67 W.Oi .... ''
Inconel Alloy 625 Rough 1
Inconel Alloy 700 3000 50 001
Inconel Ailoy 702 to to A60JV
Inconel Alloy 706 300 3500 100 Finish 1/10
Inconel Alloy 718 to Solution Treated .0002 max.
Inconel Alloy 721 475 and Age' 4NIu q.-
Incor'e!Ahoy 722 -
;nconel Alloy X-750 t

Inconel Alloy 751 -w

M.252 -

Nimonic 75
Nirnonic 80
Nimonic 90
Nimonic 95
Rere 41
Rene 63

L
Rene 77
Pane95
Udimet 500 W
"1 W1
RE
Udimet 700
Udimet 7 10
Un-temp 1753
Waspatoy

Nickel Base, Wrought j3000 50 00i

R/--
Hasteltoy Alloy 8-2to
A6toV
Hasteloy Alloy C 140 Annaled i 002 x
Hasteiloy Alloy C-276 to or
Hastelloy, ,N-yG 220 Solution Treated
Haslelloy Alloy S -
Hastelloy Alloy X
Incoloy Ai;oy 804
Incoloy Alloy 825 ___. A
Inconel Alloy 600 Rough,
3000 50 .001
Inconel Alloy 601
Refracta ay 26 to to

Udimet 630 243 Cold or

Drawn
to .000 max
310 Aged !

See section 16 for Cutting Fluid Recommendations.

'Wheel recommendations are for wet grinding of 2- to 4-Inch (50 to
100 mn! diameter wc ror DRY grinding-use a softer grade wheel
For LARGER diameter wori- use a softer and/or coarser grit wheel
4
For SMALLER diameter wors-use a harder grade wheel Wheel rec-
ommendations also apply to plunge grinding aoplicatlois Also see Ina
section 20 2. Grndiog Guidelines

8-80
 Cylindrical Grinding 8.5

TRAVERSE
WHEEL WORK INFEED Wihe WEEL
HARD- SPEED SPEED on dia. wit DNFI
MATERIAL NESCONDITION per rev. CATION'
NESS af work
fpm fpm in/pass ANSI

Nickel Bass, Wrought IRough 1/2

TD-Nicke'ft 5500 50 .002
TD-Ni-Crtt1 to to A60JV
180 6500 100 Finish /
0005 max
to As Rolled
2u0 c .112 W
F- A

Nickel Base, Cast 3000 510 Rough 1/

B-230 to to A60JV
GM-253500 100 Finmsh
G.MR-235D 200 As Cast002mx 10
Hastelloy Alloy B oo V
Hastelloy Alloy C 45Cast and Aged _
Hastelloy Alloy 0 2
IN- 100 (Rene 100)
IN-738
IN-792
Inconel Alloy 713C
Incoriel Alloy 718
M252
MAR-M200
MAR-M246
MAR-M42 1
MAR-M432
Rene 80

SEL 15
TRW VI A
Udirnet 500
Udimet 700
ASTLI A296 Grades CW- 12M, N-12M, CY-40
ASTM A297 Grades HW. HX
ASTM A494 Grades N-12,M- I. N-12M-2,
CY-40. CW- 12MV1, CW- 12M-2
ASTM A608 3raaes HW.5O dY"Q

Cobalt Bae, Wrought 3000 50 .001 1/4

AiResist 213 to to A6J
Haynes A'.y 25 (L605)
Haynes Alloy 188 180 350 100 Finish, 10A

S-816
V-36

3000 50 .0014

I 203500 100 Fin'sh: 4

to Solution Treated _
and Aged -:a
320

See seclior IF or Cutting Eluid Recommendations ttCAUTiON Taxi .ial. refer toNational nstitute f Occuipational
*Wheel recommendations are for wet griiiding of 2- to 4-inch (50) to Safety ard He- *0ICS) for Precautions
100 mmj dlamster work For DRY grinding-use a softer grade wheel
For LARGER diameter work-use a softer aiid/or coarser grit wheel
For SMALLER diametar work-Jse a harder grade wheel Wheei roc-
ommendmtions also apply to piunge grinding applciceions Also see
section 20 2. Grinding Guidelires
8.5 Cylindrical Grindin;

WHEEL WORK TIIon

NFEED TTRAeRel WHEEL

MATERIAL
HARD-
NESCONDITION
NESS
SPEED SPEED
Iper
dia.
jof
width
rev.
workI
IDENTIFI.
CATION*

fpm -fpm In iripas ANSI

Bhn rn/s Amlm -mrn/Ps IS 'I

39. HIGH TEMPERATURE ALLOYS, 30 50 Rough t

WROUGHT AND CAST (cont.) to0 to 001J
Cobalt Base, Cast 350 1t0 FinihJV

Aiessl13220 As C. 3 0002 max 0

AiResist 215 to or > otigh 11
FSX14 90Cast and Aged _t
HS-6
HS-31 (X--40)A60
HOWMET j3 ________ ~O~a.~
MAR-M302 Rough: 1/
MAR-M322 3000 50 001
MAR-M509 to to A60JV
NASA Co-W-Re 290 ACat3500 100 Finish- 1/10
WI-52 As Cas .0002 -max
X-45 425Cast and Aged

Iron Base, Wrought Rough: 1/5

A-286 3000 50 .001
Discaloy to to A6OJV
lflco'oy Alloy 800 180 40,30 100 Finish:, 1/10
Incooy Aloy 00H0002 max
Inclo Alo 80Hto So;ution Treated -X ren~
Incoloy Alloy 801 230 -

incoloy Alloy 802

N-155

______ tA
V_______ x
16-25-6 Rough-
19-9DL 3000 50 001
to to A60JV
250 4000 100 Finish: 1/10
to Solution Treated 0002 max.
320 and Aged

4C. REFRACTORY ALLOYS, WROUGHT, 1/Rug.

CAST, P/M** 1 10 001
Coumiun~ft4000 to A60KV

C 103 170 10/Fi1s

to Stress .0003 max. 11
C1 29Y
CD- lZr 225 Relieved A~.j'
Cb-752
FS-85
WC-3015______ ___

Fea section 16 for Cutting Fluid Recommendations Due to the brittleness of relrictoiy atloyq. cracking. chipping, flaking
'Wheei recommondalionib are for wet grinding of 2- to 4-inch [50 to and breakout tend to occur, pa licularly on tlip edges of the ma-
100 hm) diameter work For DRY grinding-use a softer grade whee! chined surfaces
For LARGER diameter work--,,- 3i softer cnd/or coarser grit w#heel t tCAUTION Toxic Maloeirefer to NationatlInstitute for Occupaional
For SMALLER diameter work-use a harder grade wheel Wheel rec- Safety and Heciih (N'iOSH) for Pre~:autions
ormmendations also apply to plunge grinding applications Also see ttCJTION FtAential Fiie Hazard Exorcise caution in grirnding and
section 20 2. Grinding Gudelnes d'3posrrg of Swart

8-82
 Cylindrical Grinding 8.5
--r - TRAERSEW
WHEEL WORK INFEED Wihe WEEL
HARD- ISPEED
~SPEED on dla. wit
perrey.
DNII
CATION*
MATERIAL HAEDS CONDITION

fpm fpm :n pass owrk ANSI

Bhn tws m/in I 1pm- ______

Molybdenum" 5 Rough 1/
220 10 Finis
Mo 4000 to A60LV
TZCJ T to Stress 0003 max I 11
ZM 290 Relieved - - Rog:-

N.01-l 1 AnIshr -
z:- - A %ON/.10

Tantalum o Rough - ,
ASTAR 81 1C 4000 50 001A6K
T- 111 to0 Finih.V
T-222 200 00 Fns. 1/10
Ta- ioW to Stress .0003 max
Ta-Hf 250 Relieved - RuIi i j

Tungsten Rough /
85%denty50 001
85% density 2000 to C60KV
96% density 180 Pressed and Sintered. 100 Finish- 1/10
100 desit toForged. .0003 max.
Arc Cast

IRough /
Tungsten -2 Thoria** tT gh
0/5
2000 to C60KV
260 Pressed 100 Finish- 11
.0003 max
320 Sintered J ,_ *

Tungsten Alloys" Rodgh: 1/5

GE-218 200 00o 60KV
xV-15mo10
Fish
W-5Re 260 10 Fns: 1/10
W-5. .0003 max.
W-25Re-3~ to As Cast )- - -0

0-,

Tunosten Alloys,- Rough: 1/

Marcr"-:20 2000 to C60KV
Mallor 200'i100 Finish 11
W. 10Ay 290 Pressed .0003 max 11

30Sintered
____________to

I an

: * seci,-ri 16 for Cutting Fluid Recornrendations *Due to the brittieress of refract ry alloys. cracking. chir~ping. flaking
'Wheeel reconmnindatione nre for *at grinding o' 2- to 4,incii (50 to arid breakout tend to occur. *jaflicularly on the edges of the ma-
100. thin diarmeter Yvork
Fc' 011Y .3rnding-use a softer grade wheel ctlined surfa'es
For L.,RGER d~aiteler .3rk-.s'. a softer and/or coarser grit wheel t YCAUTION, Toxic Mater-at. refer loNational inatituo for Occuptional
For SMALLEP diameter work-use a harder vrade wheel Wheel rec- Safety and Health (NIOSrI) for Pre~autions
ornrminoations also apply to i'lunge ;rnrding appicatir. is A so see
section 20 2. Onrnomng Guidelines

8-83
8.5 Cylindrical Grinding

ITRAVERSE
WHEEL WORK INFEED vheeI WHEEL
HARD SE width IDENTIFI
MATERIAL HARD CONDITION SPEED SPEED o perrev. CATION*
SNESSI of work I
tpm fp ~ asJtANSI

40. REFRACTORY ALLOYS, WROUGHT, Rough

CAST, P/M** (cont.) 50 001

Tungsten Alloys" 2000 "o C60KV
I 100 Finish
An29oy 1100 290 Pressed 0003 i Iax
Anviloy 1150 to and 0003 max
Anviloy 1200 320 i5

44. URANIUM, WROUGHTf -ij 3000 . Rough V

3000AO 002
to to GS46HV
56 RA 5000 60 Frisn
Annealed 0005 max 1Ii0
to

~5 g - Rogh

45. ZIRCONIUM ALLOYS, WROUGHTit R001 /K

Zr-2%Hf (Grade 11) 3000 to or
Zr-0 001%Hf (Grade 21) Finish CA60PS
Zircaloy 2 (Grade 32) 140 Rolled. 0005 max 1/12
Zircazoy 4 (Grade 34) to Extruded
280 or Forged

47 POWDER METAL ALLOYS Rough,

Copper 5500 70 002
+ to to C46JV

50 RF 6500 100 F;nish 1/6

maxASe
to.0005
70 R

BrsesRough. 1/3
Brasses 5500 70 002

to to C46KV
CZP-0218-T
CZP-02180
mn d
C028-Wz o r an to AsSitee c
6500 100 0005 max.
Finish 16

o0Cu-30Zn to A eN n F a c u i n
68 5Cu-30Zn- I 5b

Bronzes6 5500 70 001/

CT-0tf,-N C46KV
CT 0010-R to to
CT-0O010-S 30 RF 6500 100 Finish 1/6 :
95Cu-SAi oA Snee 0005 max
77Cu-tS5Pb-TSn- IFe- 1C 75 RF ' .

112

See section 16 for Cutting Fluid Recommendations "Due to :ne orittlet.m of refractory alloys. cracking, chippfng, flaking
Wheel recommendations are ;'rwet gnndmng of 2. to 4.inch 150 to and breakout tend :o occur. particularly on the edges of the mea- f
100 mini diameter work For DRY grinding-use a softer grade wheel chined surfaces
Fo' LARGER diameter work-use a softer and/or coarser grit wheel ttCAUTION Toxic Material refer to National institute for Occupat, onai
Fol SMALLER diameter work-t se a harder grade wheel Wheel rec- Safety and Health (NIOSH) for Pr, %utons
ornmendations also apply to plunge grnng apphicatlons Alo see t;:.CAUTION Potential Fire Hazar .xercise caution in grnng and
section 20 2. Grnng Guidelines disposing of swarf
Grinding of low-density parts is not recommended be";aus surface
porosity will be reduced or los:
8-84-l
 Cylindrical Grinding 8.5

WORK IFEED TRAVERSEI

Wheel IWHEEL
width
1WEL IDENTIFI-
MAHILiARD. 1SPEEDI SPEEDI on dia.
MAESSA CONDITION Iper rev. CATION-
of work
fp- fom ;)ass A~NSI

Copper-Nickel AlloysP Pough

CZN 808- 7I00
CZ-8-8U600 100 002 C4,
GzN-18i18'W 22 R,~ 1 1/6
CZNP-61,841 :0 1 1As-. max1re
CZNP-1,618-W lOOP As r4/3 I Rouh
9OCu-lONi
62Cu- l8Ni 18Zn-2Sn
- _

Nickel:~0 0 P hIA6V

4; As Sintered I005-a 0
160001100 maxiih

Nicke Allos Rough- 5

Nike Aly55 00 150 002
67Ni-30Cu-3Fe Ito to C601V

34 R 6500 100 Finish 1/10

tO As Sinteard 0005 max _ :
50 R We to

Refractory Metal Base I Rough~

8'i~i1 001
87W- 3Cu.~000 to Goto~
85W- ISAg 200 50o C0KV
74W-260u l0 100iiOs
72.5W-27 5Ag 10o A.; Sintered 00 a
65W-35Ag
56W -
55W-45cu
C-4,40u
260
I
I
I5A
"v
I

0W*C-50Aq .j _ _ _-I-9g J 1 O 4

I -13

Rough:
Refractory Metal Base 1I0 00 1
61Mo-39A9 4000 t0 A60LV
SO~oSOI j oo0 Finish
75 RE 0003 max 11

82 RB

See section 16 for Cutting Fluid Recommendations ~Grinding of low-density parts is not recommended because surface
'Wheel recommendations are for wet grinding of 2- to 4-inch ISO0 orosity will be reduced or lost
100 minI diameter work For DRY grinding-use a softer grade wheei l
For LARGER diameter wvork-use a softer and/or coarser grit wheel
For SMALLER diameter work-use a harder grade wheel Wheei rec-
cmimendations also apply to plunge grinding aoplications Also see
sedc..n 20 2 Grinding Guidelines

8-85
8.5 Cylindrical Grinding
TRAVERSE
WHEEL WORK INFEED Wheel IWHEEL
HAR- SEEDSPEDI n da. width IDENTIFI.
MATERIAL HAED. CONDITION SPE PE 1 o i. per rev. CATION'
NfEwoS
f pm -fpm in pass ANSI
tShn rn/is m/mtih rn/pas -- ISO I

47. POWDER METAL ALLOYS(cont.) Rough. 1/2 I

Irons 5500 70 002
F-00Nto to 046KV
F-0000-N 50 6500 100 F i 13i1si/
F-0000-R to 00 1 max
P0000-R 67 As Sintered og: 12
F 000 S500kg '50-
02
-- Ito , . I1 -n _-G:--f46WV

Steels6 Rouo' 1/2

P.0008-P' 5500 70 002
F-0008-S to to jA60MV
F.0005*S 101, As Sintered 6500 100 Finish 1/6
FC-020-S to 0005 max.
FC-0208-S to6 'e~Ruh
P0-0208-P 426 ~Heat
Treated ~ N1 .a~-
F0-0208-S .

FC-0908-P
FC- 1000-N /
FN-0205-S i O3nx
FN-0205-T
FN-0405-R
FN-0405-S
FN-0405-T
PX- 1005-T
FX-2008-T -___

-t --

Stainless Steels Rough- 1/2

SS-303-R 5500 50 002
SS-304-R to to C54jV
SS-3'6-R 0 sSnee 6500 100 Finish 16
As Sintere .0005 max 11
SS-410-Rto or~
285 Heat Treated --- 'i

Aluminum Alloys Rouoh- 1/2

90 5A-6Sn-40u 5500 50 002
88A-5Sri.4Pb-301u 10 to C54JVI
Al- IlMg-0.6Si-0 250u 55R, 6500 150 Finish 1/6
AI-0 6Mg-0 4Si t Solution Treated .0005 max.
Al 4 4Cu-O MS-0 4Mg 98I and Aged__

41. MACHINABLE CARBIDES Pough 1/6

Ferro-Tic 40 -0 .0
to to A60HV
40ORC 6000 60 Finish. 1/12
.0003 max

See section 16 for Cutting Fluid Recommendations I Wax filled

'Wheet recommendations are for wet grinding of 2- to 4-inch 150 to Grinding of110w-density parts is not recommended . cause surface
100 minI diameter work For DRY grinding-use a softer grade wheel porosity will Ite reduced or lost
For LARGER diameter work-use a softer andior coarser grit wheel
For SMALLER diameter work-use a harder grade wheel Wheel rec- 4
omnmencations also apply to plunge grinding applications Also see
section 20 2. Crinoing
Guittelines
8 8
 Cylindrical Grinding 8.5

I !TRAVERSEI
HARD-WHEEL WORK INFEED I DNF-
1 HR-SPEED! SPEED Ion dia. Idt
MATERIAL NESCONDITION

jANSI
ofrk A~N

fpmn fpm in pass

hn I SO
T
__ ____ __ __ __ 1mi/s. mii4inrm/pass
48. MACHINABLE CARBIDES (coat.) 140r00 Rough
001 i
1/
j'naterials Isted on oreceding page)

68 R, Hardened 00 A0V
to- and I 0003 max
I 70 Temnperedc~h /

49~~F I00 .9h. i Rough

49CARIDES 50 00 1o 1o15i C60JV
Ttanium Caroide
-ugtn
a;de
9o-650 t
6500
OFii l
89R 0 0003 ma C120Iiz

50 FREE MACHINING MAGNETIC ALLOYS Rough 112~

to to IA46KV
Mane~cCoe
ro-F (p o toSi Wrought o mw
-- -ikw-~g
240 46;j

H Pemr49-FM 5500 50 002o

to to C54KV
185 6500 100 Finish- I
0005 max
to Wrought
240-

51. MAGNETIC~ ALLOYS 5507I0 /

Magnetic Core iron (up to 4%Si) to t 4K
1851/
to24 Wrought -

Hi Penn 49 Rough: /
HyMu 80 to1 to C54KV
I I6500
85 100 Finish
to Wicught
240

See section 16 'of Cun-rig Fluid Recommendiations Diamond wheel ispreteraDle. see section S 7
' Wheel recommendations are for wet grinding ct 2- to 4-inch f50 to
10OmmJicrmeter worki For DRY grinding-use a sotter grad~e wheel
For LARGER dian'eter work-use a softer and -or coarser grit wheel
For SMALLER diameter work-use a harder grace wheel Wheel rec-
orimendations also apply to plunge grndirng applications Also see
section 20 2 Girinding Guidelines

8-87
8.5 Cylindrical Grinding
T 1 TRAVERSE!
IWheel WHEEL
!EEL, WORK INFEED
iW width IDENTIFI-
HARD- ;SPEED; SPEED: on dia. I
MATERIIAL AR-CONDITION per rev. 'CATION'
NESS Iof work
1pmr fP17, zass ANS'

151. MAGNETIC ALLOYS (cont.) 11 Z<Ocr 1;_0 1f~g

002 1'
A;%o -7 I I~

Columax5 P

1 12 Annale 0005ma

Aloc X1 I6

MACHNIN
CONTOLLE 220 1je ~Roughr
53.
CNRLEW ALLOYS
ASON 550 50 002o-.

125o 5a0 10 i Finish

I i2 Annealed iax 0600 /10
t0 o1r __ t_ - -
250 Coc
idrawnr.~

~C54KV~
54.
N S
C A R2O 1500 AnneAaleT 1 RoughF/2ish

't Mod.0005 max

&_RP11TE
CABN S4

Beru Gradeso o~r 1

1811 Ioto I C36L V
40Molded 650 75 Fw/6
to jOOO5nax

Shore Et ie _ R_
- W= 7M - -
_ _ __ __ __ _ 4r

Fou r ad CLERdamro are raewee helrc Rough

seto Gunideline62020

8-8
-n5n

0001ua
 Cylindrical Grinding 8.5

fT7 TRAVERSE

IWHEEL'
NESS
WORK INFE]ED Wheel JWHEEL

of work
Ifpm fpm in pass I ANSI

GraphiteRog 11 Ruh
1 5s000 50 002 3j
I,16500 75 Fiwsh 16 iFns
axIC360JV
0005
2- Rough

0005
a~ IC6OJVf

5.GLASSES & CERAMICS 5S0 ough Rough

Glass 550 70 301 IC80GV
406500 100 '0, Fns
1 0005 CT x A18OKV
ig~
530 ..

lOog 2~-

Roughf
Porcelain Enamel j 55001 70 Do1
1/
1/50K
6500 100 Finish 11
0005 max

Ceramics Rough 1/5 R~ough:

Alumina (Alumi~num Oxide) so
t 70 00o46V
Aiumna-Mulie 16500 100 Finish- Finishi
Aluminum Silicate I 0002 max 1/1 C8/iD
Berylia (Berylliumn Oxide)f &00 Fired
Magnesia (Magnesium Oxide) Knoop -W T_-F- t
Mullite O O a
Slicon Carbide___
Silicon Nitride ~~~
Thoria (Thorium Oxide)', ~ . NO_______ ~ SSV
Titania (Titanium Oxide)
Titanium Dibonideit
Zircon (Zirconium Silicate)I
Zarconia (Zirconium Oxide) I
MRough

56. PLASTICSI .005

Thermoplastics 5500 1, 70
to to 060KV
Cas. M~.dd. 6500 10 Finish /
Extruded. .0005nmax
PiidadMolded

See section 16 for Cutting ciuid Recommendations Diamond wheel is Preferable, see section 8 7,
'Wheel recommendations are for- wet grnoing of 2- to 4- ich 1S0 to ft CAUTION Toxic Material, refer to National Inst tute for Occupational
100 mmJ diameter work For DRY grinding-use a softer grade w"eel
For LARGER diamele' work-use a softer and 'or coarser grit wheel
For SMAALLER diameter work-use a h~arder grade wheel Wheel rec-
ommiendationS also apply to Plunge gninding applications Also see
section 20 2. Grind~rng Gr..delines
Safety and Health (NIOSH) tor Precautionsl

i
8-89
8.5 Cylindrical Grinding

MATERIAL
I
HAR~~~
HR-CONDITION
I I
~ ~WHEEL;
WOKIIFE
ITAVERSEI
SPEED SPE'onda
SEI SPE!o
heel
ia per rev.
WHEEL
DENTflFI-
CATION'
NESS itot work
Ip pm urC, : ps ANSI

56. PLASTICS (cont.) Sr. j j PougtvI

Thermosetting Plastics to0- C470SIV0

I I BoCO0 L 0 riis
- Cast

T Rough-

00~O 70' 005'

IIto tojC6K
- Moded io6500 - Finish

lnaed

58.
SRAYEFAME ThERAL) r -

SprayedaCarbide
Chromiume-Ug
ln Ca0d-obl

Tantlu Carbides oC0V

Chroanum. CarbideI/1216

Tungsten Carbide
Tungsten Carbide-Coball
Tunasten Caroide (Cobatt)-Nicke Alloy Blend2

See section 16for Cutting Fluid Recommendations Diamond whieel is preferable for flame spraired carbides and cerarn-
*Wheel recommendatins are for wet grinding of 2-,to 4-Inch (50 to ts see section 8 7
100 mm) diameter work For DRY grinding-use a so.ter grade wheel
For LARGER diameter wvork-use a softer and'or coarser grit wheel
Pa' SMALLER diamneter work-use a harder grade wheel Wheel ret- 4
ommendators also apply t0 pluNge grinding applications Also see
section 20 2 Grnding Guidelines

8-90
 Cylindrica! Grinding 8.5

WHEEL WR FE Wheel WHEEL

HAR. SEEDSPED n da. width IDENTIFI.

MATERIAL HARDS CONDITION SPE 1 PED odl. rev. CATION"

Ifpmj _pm in pass owrk ANSI

iogai Coating Materials I 50

55j00
5 ough
W*1
114-112
Alumina (Pire,
Aium~na (Grey) containing Titania i Ito :o 1iis Ct00GVS
Aiurmnra Nir kel-Atnmide Blends I6500 10 riooshmx
000 max
1/12-1/6
Barium TIana*e
Boronrt11411
Calcium Titanale J5 "02-5
Calium Zirconate -1- 1OV
Chr.omium Disilicidett'3-3 klf
Chromium Oxide', _________ 03m1 1 I
Cobalt (40%) Zirconia BlendI
Columbiumn (Nobium)-l
Glass IKovar seaiing)t
Hexaboron SiticideT tI
Magnesia Alumina Spinet
Magnesium ZirconateI
M.olybdenum Disilicide ~-jy
Mullite
INickel Oxide[______J___________
Rare Earth Oxidesr
I
Tantalum
Tdtania (50%). Aiumina E!lend
T*taniujm OxJe
* urgsten
Yttriumn Zirconate 1 j-
Zirconta (Lime Stabdtized) 2: Ri ZCS
Zirconia. tockel-Aluminide Blends
Zirconium Oxide (Halnia Free. Lime Slatilied)__

Sprayed Metals (Group 1) j5()3 70 gh 1/4-1/2

Co-Cr-B Alloy (Self Fluxing) to 70 I CO1
t . JW
Ni-C--B Alloy (Self Fluxing)
S:~:ntess Ste-l - 0005 max

Sprayed Metals (Group 11) Rogh li14 1'2

0morize to to 0 1 C6OJV

Coat6500 100 Finish- 1/12-1/6

.0005 max
Molybdenum
rn 4

Monet

Sprayed Metals (Group 111) 5500401/00

Paon Stel0 10 Finish-06K
Precizitation Harde.ng Steel I 50 10 0005 max 1/12-116

See seciror. 16 fo, Cutting Fluid Recommendations Diamond .tsee! is preferable for flame spayed carbK"- znd ceram-
*Wheel recommrendations are for wet gninding of 2- t0 4-inCh [50 10 ics. see section 8 7
100 mmj~ndiameter work For DRY grinding-use a softer grade wheel t tCAUTION, Toxic Material. refer to National Institute fos(ccupational
For LARGER diameter work-use a softer andior coarser grit wheel Safety and Health (NIOSH) for Precautions
For SMALLER diameter wa-k-use a harder grade wheel Wheel rec-
om'menda:id1ns also apply to plunge grinding applications Also see
section 20 2.Grinding Guidelines

8-91
8.5 Cylindrical Grinding

WHEEL WORK INrEED Wh DElTWFE-

MATERIAL NESCONDITh3N SPE PE ni.per rev. CATION*

of work
fptn in pass ANSI
Bnfpm
59. PLATED MATERIALS Bough- 1/4
Chromium Plate 1 3000 70 01 80v
to 't12!V
4000 100 Finsh I l AI20V
1.0004raxl

Sive Plt 50 0 C)

SooI to

Fnish 00
6500 1,1

I-lard -x

See ecton 1 fo CutingF~ndRecmmedatins.t~orcom ercil fnis

60.hIMI o U metonre forgh

we1rn/go5- o4ic 5 o P ihfns

100 ~~~ ~ ~ ~ ~ ~ ~~
dimtrioknFrDYirnin-ssasfergae:he o log

For~ ~~~~~~~~~~~_
~~ LAGRdaeeMokueasftradoWore
u he

For~~~ ~ ~
rd welWelrc SMALEdimtrwr-seahre ~ ~~ 50
ontrend..os 110Aloaplyto
pung grndin apliction seto
section~t 20. rndngGidlie

659W nh / a5
- -S0 -- 1 -. max-

Rcuo3
 Cylindrical Grinding 8.6
Cubic Boron Nitride Wheels
TRAVERSE
Wheel WHEEL
WORK INFEED width IDENTIFI-
WHEEL
SPEED SPEED on dIa.
HARD- per rev. CATION
MATERIAL CONDITION
NESSof work
fpm fpm in/pass ANSI
Bhn /t -t r$m
i-!hlssI- 4: Anslzs;

1. FREE MACHINING CARBON Rougn 1/4

5000 50 001B
STEELS, WROUGHT to to B 100T 100B
Low Carbon Resulfurized
1108 1118 Carburized 7500 100 Finish 1/8
1109 1119 Over and/or 0002 max 1/
1109 1119 50RC Quenched - *i4 ,Roug Th
1110 1211 4
1M
1115
1212 ~~and
Tempered fSr . I

1116 1213 i
.,
1 s * , hrt9:4
r 8,,s
1117 1215 <.

Medium Carbon Resullurized

1132 1140 1145
1137 1141 1146
1139 144 1151
Low Carbon Leaded
10L18 12113 12L15

Medium Carbon Leaded k i4

10L45 11L37 11L44 . ____

10L50 11L41
Rough 114
2. CARBON STEELS,
WROUGHT 5000 50 001
to to BlOOT100B
Low Carbon
Carburized 7500 100 Finish. 1/8
1005 1012 1019 1026 Over and/or 0002 max.
1006 1013 1020 1029 50 Rc O,,enched " r 5
t i -i
1008 1015 1021 1513 and Tempered
1009 1016 1022 1518 IG~t ~ 4~
1010 1017 1023 1522 -M4 ,3v - -
1011 1018 1025 M-
i--0jmi +
Medium Carbon
1030 1042 1053 1541
1033 1043 1055 1547 A
1035 1044 1524 1548
1037 1045 1525 1551
1038 1046 1526 1552
1R A -02
1039 1049 1527 M
(,"51_+_
1040 1050 1536 -tfE

High Carbon " t

1060 1074 1085 1566 '-
1064 1075 1086 1572
1065 1078 1090
1069 1080 1095
1070 1084 1561

NN~N
t "
See section 16 for Cutting Fluid Recommendations
See section 20.1 for additional information.

~8-93
8.6 Cylindrical Grinding
Cubic Boron Nitride Wheels

HARD.
IWHEEL
SPEED
WORK
SPEED
INFEED1
on dia.
TRAVERSE
Wheel
width
WHEEL
IDEI4TIFI.
]

MATERIAL NES CONDITION I per rev. CATION

fpm fpm in/pass I______ ANSI

4. FREE MACHINING ALLOY 5000u0h- 114

STEELS, WROUGHT 00 so .001
Medium Carbon Resulfurized t0 to B lOOT 1008
44Ovr Carburized 7500 100 Finlish- /
414 Oer and/or .0002 max
4140Se 501% Ou,.nched R gh * 14 '
41 42TeA 4
414,'iSe and Tempered 255 ~Q 5
4147Te 3.~~to~ to
3
1
-, 5ii~ ~ - ooa~-
4150 " _ _ __ _ __ _
Medium and High Carbon
Leaded
41130 411L47 51132 86140
41140 41150 52LI00
41145 43140 861-20

5. ALLOY STEELS, WROUGHT R00ou000 1/4

Low Carbon 50 0 .0
to to BlOOTlOOB
4012 4615 4817 8617750 10 Fns
4023 4617 4820 8320 Carburized 70 10 Fnih1/8
4024 4620 5015 8622 Over and/or .0002 max
4118 4621 5115 882^2 50 Rc Quenched _ KE.jrV
4320 4718 5120 9310 and Tempered O2 .
4419 4720 6118 94B15 4-_
4422 4815 8115 94B!7
Medium Carbon - ________ ~ ~ -

1330 4145 5132 8640

1335 4147 5135 8642
1340 4150 5140 8645
1345 4161 5145 86845
4027 4340 5147 8650 s- --
4028 4427 5150 8655
4032 4626 5155 8660
4037 50840 5160 8740 V
4042 50844 516 8742'
4047 5046 6150 9254 -'

4130 50846 81845 9255

4135 508350 8625 9260
4137 5060 8627 94830
4140 50860 8630

High Carbon 7FEW

50100 51100 52100 M-50

6. HIGH STRE4GTH STEES, Rough- /

WROUGHT I5000 50 .001
300M Hl I 10 t0 8100TIO08
4330V H13 7500 100 Finish: 1
4340 HP 9-4-20 Ovr Quenched 0002 max
4340SI HP 9-4-25 50 Ri and Tempered
988V40 HP 9-4-30
D)6ac HP9-4-45

Lsee section 16 for Cutting Fluid Recommendations

See section 20.1 for additional information

8-94
 Cylindrical Grinding 8.6
Cubic Boron Nitride Wheels
TRAVERSE

j
Wheel WHEEL
WDEN -
WHEEL WORK INFEED Wheeh
SPEED SPEED on dia.IDENTIFI-
MATERIAL NESS
NESS CONDITION perwork
of rev. CATION

fpm fpm in/pass ANSI

7. MARAGING STEELS, Rough: 1/4

5000 50 001
WROUGHT
to to BIOOT1OOB
120 Grade 300 Grade 7500 100 Finish
180 Grade 350 Grade Over 0002 max 1/8
200 Grade HY230 50 Rc Mdraged . . . -
250 Grade & -i
ASTM A538 Grades A, B C -;3O - rm-b.::
0ough" 3114.-

8. TOOL STEELS, WROUGHT Rough- 1/4

5000 50 .001
A2 H14 M10 P20 to to BI00T100B
A3 H19 M30 P21 Quenched 7500 100 Finish 1/8
A4 H21 M33 Si Over and 0002 max.
A6 H22 M34 Tempered
A7 H23 M36 S5 MEN10t.
A8 H24 M41 S6
A9 H25 M42 87
A10 H26 M43 Ti ~
D2 H42 M44 T2 -

03 L2 M46 T4
04 L6 M47 T5
D5 L7 01 T6
07 Ml 02 T8
Ff M2 06 T15~4Z
F2 M3-1 07 Wi RR O
HlO1 M3-2 P2 W2 - ;j7'f ZZ
HiJ M4 P4 W5<4 # 5 ___

H13 M7 P6 - M
SAE J438b. Types W108. W109.
W1 10, W1 12, W209. W210,
W310

9 . NI R D I G T E L ,R ough 1/ 4
9. NITRIDING
WROUGHT STEELS, 5000 50 Rough50
.001 1/4
125 Nirato to BlOTlOOB
Nitralfoy 125 Ntralloy 230 7500 100 Finish
Nitraloy 135 Nitralloy EZ 60 Rc .0002 max. 1/8
Nitratloy 135 Mod Nitratloy N to r'rnded
Nitralloy 225 Nitrex 1 65 c

15. CARBON STEELS, CAST Rough: 14

Low Carbon 5000 50 .001
ASTM A426: Grade CP1 to to IB10T100B
1010 1020 Carburized 7500 100 Finish: 1/8
Over and/or .0002 max
Medium Carbon
ASTM A352 Grades LL;A. LCB. 50 Rc Quenched
LCC Gradeand Tempered - *-

1030 1040 1050 ~i f ~ & ~ -1

See section 16 for Cutting Fluid Recommendations
See section 20 1 for additional information

8-95
8.6 Cylindrical Grinding
Cubic Boron Nitride Wheels
--" TRAVERSE i

WHEEL WORK INFEED Wheel WHEEL

SPEED SPEED od width I |DENTIFI-
MATERIAL NESS NESSCONDITION P S on a. per rev.
otwork II CATION

fpm fpm in/pass ANSI

16. ALLOY STEELS. CAST Rough 1/4

]
Low Carbon 5000 50 001
AST. A217, Grade WC9 to to 100T10
ASTM A352 Grades LC3 LC4 Carburized 7500 100 Finish 1
and/or 0002 max
ASTM A426 Grades CP2. CP5, ,,er
5
cP5biCP 1.CP12,CP 15. oC Quenched
CP21.CP22and Tempered
1320 4110 8020 r -t ;1. ......
2315 4120 8620 - -
2320 4320 2 '- 0O5 -t.ez.w - -4-z .
Medium Carbon
ASTM A27- Grades NI. N2.
U-60-30. 60-30. 65-35.
70-36. 70-40
ASTM A145 Grades 80-40.
80-50. 90-60. 105-85. ..S -
120-95.50125 175-45
ASTMA A216 Grades WCA,PEN

WCB. WCC 6
ASTMA217 GradesWC1. -

WC4. WC5, WC6

ASTM A352 Grades LC. LC2.
LC2-1
ASTM A356 Grades 2.5. 6.8.
9. 10
ASi M A389. Grades C23. C24
ASTM A486. Classes 70, 90.
120
ASTM A487 Classes IN.2N.
4N, 6N. SN. 9N. 1OW.DN. 10
20. 40, 4QA. 60. 7Q. 80
~
1WE "

IE:
90. 100
1330 4130 80B30 8640
1340 4140 8040 9525
2325 4330 8430 9530
2330 4340 8440 9535
4125 8030 8630W -;- -

17. TOOL STEELS, CAST rdsC-.5000 Rough-

001 11420
ASMA9 50
AST. A597 Grades CA-2.to BICOT100B
CD-2. CD-5. CH-12. CH- 13. 7500 100 Finish. I
CO-1. CS-5 Over Quenched 1/8

Tempered

See section 16 for Cutting Fluid Recommendations

See section 20 1for additional information

8-96
 Cylindrical Grinding 8.7
Diamond Wheels
TRAVERSE
WHEOK NED Wheel WHEEL
WHD-SEEE WOR D diE width IDENTIFI-
MATERIAL HR- CONDITION SED PED oda. per rev. CATION
NESS of work
fpm fpm in/pass ANSI
Bhn t ..-
48. MACHINABLE CARBIDES Rog: 1/5
!-erro-Tic 5500 40 .001
Ito to D100-L-100-6-1/8
68Rc Hardened 6500 50 Finish: 1/10
to and 0002 max.
72 Rc Tempered - r

Titniu Cabd 550 50 .002

94 RA

Ns_

See ~
20.1~fomditoaax'frto t Wrouion
240
Alnio I ough 1/6 D120N75--if
5500
.00 0
Alnio 11to t
Ainic 1116500 so Fnish
Alnio IV45 R1/12 D220N78-97/
_ _ .000 max
________Vto__AsCast
Ainico~~ V--8
8.7 Cylindrical Grinding
Diamond Wheels
TRAVERSE
SEDIwidth IDENTIFI-
WHEEL
HARD-SPEED WHEEL WORK
SPEED INFEED
on dia. Wheel
wit DNFI
MATERIAL HARD- CONDITION per rev. CATION
NESS ofwork

fpm fpm n/ pass ANSI

Bhn it'4;z ,; i_ W ________iT _L 7

55. GLASSES & CERAMICS 5500 Rough 1/4 D100-N100-M-18

to 0 00
Machinable Glass-Ceramic Finish.
6500 60
(MACOR)
250 6500 0 Fi. 1/8 D220-N100-M-1/8
Knoop Cast
100g p

PYROCERAM Rough 1/5 0120-N75-M-1/8

A5500 20 002
to to
700 6500 40 Finish 1/10 D220-N7t-M-1/8
Knoop -. 001 max.

--W 7
-. s __ __--

Glass Rough: 1/6 0 120N75-Mo 1/8

4500 20 .002
to to
tc 6000 40 Finish* 1/12 D220-N75-M-1/8
.0005 max.

Knoop ~1 6 0 1

Ceramics Rough: 1/6 D12G-N100-M- 1/8

5500 30 .002
Alumina (Aluminum Oxide)
Atumina-Mutlite to to
Aluminum Silicate Over 6500 40 Finsh 1/12 D220-N100-M-1i8
Beryllia (Bey:um Oxide)tt S00 Fired -

Magnesia (Magnesium Oxide)

Mulhite Knoop n4c, j
Silcon Carbide .- -, _ _

Silicon Nitride --
Thoria (Thorium Oxide)tt -meu - --
Titania (Titanium Oxide)
Titanium Diborideft
Zircon (Zirconium Silicate)
Zircoma (Zirconium Oxide)

. -_
57 OPITE Rough: 1/8 D 100-N 100- B- 1/8

,--v
57. COMPOSITES75 .001
Kevar 49 to to
6500 150 Finish: 11 60NG--/
.0005 max.

see section 16 for Cutting Fluid Recommendations t I CAUTION Toxic Material. refer to National Institute for Occupational
See section 20 1 to, addltonal information Safety and Health (NIOSH) for Precautions

8-98
 Cylindrical Grinding 8.7
Diamond Wheels
STRAVERSE
I Wheel WHEEL
WHEEL WORK INFEED width IDENTIFI-

MATERIAL HARD-
NESS CONDITION SPEED SPEED on dia. per rev. CATION
I ofwork

fpm fpm in/pass ANSI

Graphite Eooxy I Rough- 1/8 D120-N100-13-1/8

4500 50 002
to to
6500 60 Finish 1/12 D320-N1100-B-1/8
0005 max

-;Xjst
k-ogn A~23-f I~

Fiberglass Epoxy Rough: 1/8 080-M 100-B- 1/8

3000 50 002
Glass
(E)Glass
(S) to to I
4000 60
4006
Finish' /2 D2 110 1
Fnih- 1/12 131120-N100-8-1/8
0005 max

Boron Epoxy B o o n E p xy5 500 50 002

ough 1/8 D120-N100-B-1/8

to to
6500 1 60 Finish- 1/12 D320-N100-B-1/8
0005 max.
~OEM

58. FLAME (THERMAL) 5500 70 002

SPRAYED MATERIALS I to to
Spray65 100 Finish
Chromium Carbide 1/12 D220-N1I0-B-1/8
00- max.
Chromium Carbide-Cobalt Blend
Columbium Carbide T OEOR W
Tantalum Carbide___
Titanium Carbide
Tungsten Carbide
Tungsten Carbide-Cobalt
Tungsten Carbide
(Cobalt)-Nickel Alloy Blend

"A_ 2 - 27~~

See section 16 for Cutting Fluid Recommendations

See section 20 1 for additional information

8-99

. 7.
8.7 Cylindrica! Grinding
Diamond Wheelqs

TRAVERSE i
WHEEL WORK INFEED ".Wheel I WHEEL
SPEED SPEED on dia. width IDENTIFI-
MATERIAL HARD- CONDITION per rev. CATION
NESS of work
fpri fpm m/pass ANSI

58. FLAME (THERMAL) Rough 1/6 D120-N100-B-1,8

5500 70 002
SPRAYED MATERIALS
(cont.) to 10 1
Inorganic Coating Materials 1/12 1220-14100-8-118
Alumina (Pure) 000S.-nax.
Alumina (Grey) containing Titania
Alumina. Nickel-Aluminide
B!ends
Barium Titanate
Borontf
Calcium Tilanale
Calcium Zirconate
Chromium Disilicrdett
Chromium Oxidetf
Cobalt (40%). Zirconia Blend
Columbium (N'Cbium)ft ___

Glass (Kovar sealing)tf

Hexaboron Silicideft
Magnesia Alumina Spinel
Magnesium Zhconate
Molybdenum Disilicide
Mullite
Nickel (40%). Alumina Blend
Nickel Oxide
Rare Earth Oxides
Tantalum
Titania (50%). Alurnint Blend
Titanium Oxide
Tungsten
Yttrium Zirconate - -----
Zirconia (Lime Stabilized)
Zirconia. Nickel-Alummide
Blends
Zirconium Oxide (Hafnia Free,
Lime Stabilized)
Zirconium Silicate

See section 16 for Cutting Fluid Recommendations t r CAUTION: Toxic Matenal. refer to National Insiute for Occupational
See section 20 1 for additional information. Safety ano Health (NIOSH) for Precautions

8-100

-yN
 Internal Grinding 8.8
rA LWHEELI W INFEED Wheel HEE

HARD- A CONDITION I perrev. CATION*

NESS ! I f ofwork

_hn fpm ,inpass I ANSI

1. FREE MACPINING CARBON STEELS-
WROUGHT
Low Carbon Resulfurizd
I5000
to
5t I- 7
175
to
Ro00g
0005 1/
1/3
(I A1 A4V
I Hot Rolled. tormahzed. 6500 200 F-nish 6
11,8 50 PC Annealed. Cold Drawn .0002r' x
110 9 1119 1 m ax o r Q u e n c he d 7-;q"h.
-" - "

1110
ills 1215
1212 tZo jA5M
1215
Medium Carbon Resulfurized
-- L
Rog. 1/3
1132 1140 1145 5000 75 0005 A
1137 '141 1146 to to A60K
1139 1144 1151 Carburzed 6500 200 Finish.
Low Carbon Leaded Over and/or .0002max 116
10L18 12113 1215 50 Rc Quenched ano
11L17 12114 Tempered r.21'' 2 13
.
Meodiumn Carbon Leaded
20145 11137 '.11-44 ~-O~
10L50 11141 O3xl - Z91
2. CARBON STEELS,WROUGHT Rough: 1/3
Low Carbon 5000 75 .0005
Low Ca 12 to to A54MV
1005 1012 1019 1026 Hot Rolled. Normalized. 6500 200 Finish: 16
1006 1013 1020 1029 50 RL Annealed,Cold Drawn .0002max.
1008 1015 1021 1513 max. or Quenched _.
1009 1016 1022 1518 and Tempered -
1010 1,317 1023 1522 - -
1011 1018 1025
Medium CarbonI
C__rE
1030 1042 1053 1541 Rough
1033 1043 1055 1547 5000 75 10005
/3
1035 1044 1524 1548 to to A60KV
1037 1045 1525 1551 Carburzed 6500 200 Finish. 1/6
1038 ;04 152_6 1552 OC'e iad/o 1/62ma.
Over and/or .0002 max.
1039 1C49 1527 50 QunheRn an
1040 1050 1536 Quenced
Tempered *;1 1"I"3"
-
1060
Iligh Carbon
1074 1085 1566
1064 1075 1086 1572
1065 1078 1090
1069 1080 1095
1070 1084 1561

3. CARBON AND FERRITIC ALLOY STEELS Rough: 1/3

5000 75 .0005
(HIGH TEMPERATURE SERVICE)
to to A54MV
ASTM A369: Grades FPA. FPB.FP1. FP2.
FP3b FP5. FP7. FP9. FP 11. FP 12. FP21. 150 As Forged. 5i500 200 Finish: W6
to Annealed .0002max.
FP22
200 or
Normalized and Tempered

Maximum hole length is 2.5 times hole diimet,.

Maximum wheel width is 1.5 times wheel diameter
See section 16 for Cutting Fluid Recommendaltions.
,Wheel recommendations are for wet grinding 0 8- to 2-inch 120 2o 50
mm] diameter holes. For LARGER holes-use the same or softer
grade wheel. For SMALLER h6les-use a harder grade wheel. Also
see section 20 2.Grfndinq Guidelines.

8-101
 88 Internal Grinding
ITRAVERSE

HR-CONDITION
I WHEEL WORK
SPE PE
INFEED
Wheel
w
ni.Iperrev.
I WHEEL
It
IENTIFI-
CATION'
MATERIAL
NESS jof workc
fpm Pin in'pass ANSI
Bhn mls mfinm mm/pass - -

4. FREE MACHINING ALLOY STEELS. ouh 1/3

WROUGHT 5000 75 0005
10 to A60MV
Medium Carbon ReufrzdHot qolled. Normalized. 6500 200 Finish V
4140 50 R ~ Annealed. Cold Drewn .0002 may
4OSe max or QuenchedjRuh:-13
4142Te gh
4145Se ~~~and
Tempered 2 3-- .3 -

4147Te I3 ; -

4150
Medium and High Carbon Leaded
.0.a
Rough___ 1/3________
41130 411-47 511-32 86140 50ug0 75/30
41L40 41150 521-100500 to 7
to .05 IA60KV
411-45 43140 86120 Cabrzd6500 200 Finish
Over and/or .0002 max,
50 PC Quenched and - --'R~:~1) ---
Tempered 25 3 01U - --.-

5.ALYSTEELS, WROUGHT Rough: 1/3

.LOY ao 5000 75 .0005
4012 Ca 615 487 867o to A60MV
402 61
417 867Hot Rolled. Normalized, 6500 200 Firlish,
420 82 503467 Annealed. Cold Oravmr .0002 max 16
4024 4520 5015 8622 max. or Quenched 21-t- t
4118 4621 5115 8822 and Tempered Z 2 03 _
4320 4718 5120 9310 ---- - -~- ''
4419 4720 6118 948315
4422 4815 8115 94817 - -&.-

Medium Carbon
Ruh
1330 4145 5132 8640 4000 Rough00 1/3
1335 4147 5135 8642 10 10 A6OKV
1340 4150 5140 8645 Cruzd6 0 iih 1
1345 4161 5145 868345 Cv;abnid/o 600.000 Fmnsh1.
4027 4340 5147 8650Ovrado002m
4028 4427 5150 8655 5~ unhdad~ iog
4032 4626 5155 8660 Tmee =0'_2 O3
4037 50840 5160 8740 ___

4042 50844 51860 8742 ...-. = --

4047 5046 6150 9254- ___ _____OC~fm

4130 50846 81B45 9255

4135 50850 8625 9260
4137 5060 8627 94830
4140 50860 8630
4142 5130 8637 5= 7R
High Carbon
50100 51100 52100 M-50

Maximum hole length is2.5 times hole diameter.

Maximum wheel width is 1.Slimes wheel diameter.
See section 16 for Cutting Fluid Recommendations
*Wheel recommendations are for wet gninding 0.8- to 2-inch f20 to 50
mm) diameter holes. For LARGER holes-use the same or softer
grade wheel For SMALLER holes-use a harder grade wheel. Also
see section 20.2. Grinding Guidelines.

8-102
 Internal Grinding 8.8

E A TRAVERSE
INFEED Wdth IDENIFI-
WHEEL WOR.

MATERIAL HARD- CONDITION SPEED SPEEP on dia. per rev. CATION'

NESS of work
fpm fpm jnpass ANSI
____________________________ Bin _____________ fii n/S1m/M] fmm/pm~s ________ ISO
6.300M
HIGH STRENG 'H STEELS. WROUGHT .It 40 7 Rough
00 1/3
30V I Ito to A60KV
4330 Ann,aled. ' 6 2 1/6
4340 5 c I Notmahzec. I ,.002 max.
4340Si rMnx o OuencheO/
98BV40 I
D6ac and TemA6OKV
N.11
H13
1I
HP 9-4-2G
I. Rough- 11
HP 9-4-5
i-i 9-4'-30II
I 4000 75 0005
HP 9-4-45
to to A801V
H 9
5500 200 Finish: 16
GG02 1/x
Over 0 encheC
50R and i-~--- -

C Terr'ered - 3z

7. MARAGING STEELS, WROUGHT 0Rough: 1/3

ASTM A538 Grades A. S. C to A60KV
120 Grade 6
180 Grade I A6500 200 Fish: 1/6
Aealed .0002 max.
20 Grade
200 Grade max or -- -
200 Grade
300 Grade
Maraged 26
- -z;2zNM:
is
3__50
Grade ;N-9 " - -'- - - -
HY230 ->'-,

Rough /3
75 0005
4000
to to A80IV
5500 200 Finish:
.0002 max.
Over
50 Rc Maraged - s- . .__.._

GroupRough:
8. TOOL STEELS, WROUGHT 1 5000 75 o.00 1/3
to to A60MV
A2 H13 L6 P20 6500 200 Finish:
A3 H14 L7 P20 R Annealed /6
A4 H-19 01 S1 SOc or Oluenched .0002 mna.. -

A6 H21 02 S2 and Tempered ~~-~

A8 H22 06 S5 i
A9 H23 07 S6 I --
AI H24 P2 S7 j Z' .
H 0 H2 5 P4 W1 _ _ _ _ _ _ _r_ 1/3__ "-=----
H11 H26 PS %12 4000 75 .0005
H12 L2 P6 W5t
SAE J438b Types W108. WI09. W110. WI 12. 1o 10 Ainsh
W209. W210. W313 Over Gue.'iched I 0002 max.

SO R ~ and -

Maximum hole length is 2.5 times hole diameter

Maximum wheat width is 1 .5 imes wheel di:meter
See set ion 16 for Cutting Fluid Recommendations
*Whel recommendations are for wet grining 0.8- to 2-inch [20 to 50
mm] diameter holes. For LARGER oies-use the same or softer
grade wheel For SMALLER hole--use a harder gr.de wheel Also
see seClin 20 2. Gr-ndirg Guidelines

8-103

"
- , =--- -- ' --- - _'F- -: -: - - -
8.8 lntei nal Grinding

I WHEL WRK TRAVERSE'

Wheel WHEEL
WRKIINFEED
WSEL
MATERIAL HR-CONDITION SPEjSED nW. per rev. CATION,
NESS of
fprn fln :n pass jANSI
Bhn iws O_

8. TOOL STEELS. WROUGHT (coot.) Ro/3!

Group 11 to
500 000AEOL
D2 H-42 M42 -to 'to AL
D3 MI 1Ti10C I 1/06als
Aruieated 0 2.a 1/
1.1M2 T2 50 c
D5 3- TAJMax t
05 M3- T18 enoe
F2 M30 5
Rough. '
4000 75 .0005
I so to
1
ASOKV

50R Ouenchied 60n20 mrh /

8PCTempered -I

Rogh 1/34

MEe AEIo uenched 550 20 Fiih 1

M7 MA anCTempred

A73 M4S toII 0"

uenceW-
Q6M6o frJL.!
-
58 % enpered

M1
T5

f3 T6
IA3 a

is00 2.5; tims ie aet

See~ ecrnena~ ~
16Nut.gFi aecnd

sec0o
see~~~50 Gidlie Finishdi-

810e U.02mk
_ _ _ R,

Maximum I~e lengt-is-----------hol----__t-

 Internal Grinding 8.8

TRAVERSE
Wheel WHEE
WEF
WHEEL WORK INFEED Wh
SPEED SPEED on dla.
HARD. per rev. CATION
MATERIAL CONDITION
NESS of work
fpm fpm i/pass ANSI

Rough: 1/3
GroupIV 400( 7 .0005
M4 to to A60JV
TI5 6000 20 F:ush: 1/
50 R0 Annealed 0002 m 1/6
m or Quenched ,0-a
and Tempered .. ..

Rough: 11/3
4000 7 0005

50 Re Quenched 0 002 m. 1/6

to and rfl ,
58 Rc Tempeed . 1I. -. -

Rough: 1/3
4000 7 .0005

Over Quenched 0 002 m. 1/6

58 R c and iI/!.
Tempered , -

Rough: 1/
9. NITRIDING STEELS, WROUGHT 5000 75 .0005
Nitralloy 125o t A60K
Nitralloy 135 6 is.;
Nitralloy 135 Mod 200 Annealed, 6500 200 Finish. 1/6
Nitralloy 225 to Normalized 0002 max.
350 or Quenched
Nitrailoy 230
Nitralloy EZ
Nitralloy N a
Nitrex !
Rough: 11
75 .0005 /
4000
toto A81

05500 200 Finish:

MauRclwd00h2 h a
mIlm
to Ntrided

lo. ARMOR PLATE, SHIP PLATE, AIRCRAFT

PLATE, WROUGHT same ost
to005A0J

MIL-S- 12560 Gndg GileFinish

HY80 4RAnnealed 002m 1/6
or Quenched .02 m
HY100 45ax.
MIL-S-16216 and empered
HY180 1...

maximum hole length Is 2.5 times hole dism3ter

maximum Wheel width Is 1 5 times wheel diameter.
See section 16 for Cutt',ng Fluid Recommendations
-Wheel rez,mmendatlons are for wet 9dniding 0.8- to 2-inch f20 to 50
mini dianmeter holes. For LARGER holes-use the same or softer I
grade wheel. For SMALLER holes-use a harder grade wheel Also
see section 20.2, Grinding Guidelines.

8-105
8.8 Internal Grinding
TRAVERSE1

WHEEL WORK INFEED Wihe WDEEL

HARD- SPEED SPEED on dia. wit DNII
MATERIAL CONDITION per rev. CATION*
NESS at work
tpm fpm in/pass ANSI

12. FREE MACHINING STAINLESS STEEL%, Rough 1/3

WROUGHT 5000 75 0005
Ferritic to to IA60KV
430F 135 6500 200 rinish. 1/6
430r Se to Annealed ;g-.02mx
185 -Rm

Austenitic 500Rough 1/
5000 75 0005
203E2 to to C60KV
303 6500 200 Finish-
to3M Annealed or .0002 max.
303Pb
303 Plus X
303Se

Martensitic Ruh /
4168o t 6K
416 Pius X 60 0 iih
416Se151/
420FtoAnaeor.02mx
420F Se 20Cl rw
440F
440F Se

1u1n6~dReomndtos
Sea~ve
tonsh ~ sectio
~ ridn 160
WheeIarmaxe o5 ~
~ 8t -ic ~ 2 re0men0ton unce
mini~ ~ ~ ~ ~ ~ 7 diaete
hoeTFrLAGRmoesueehrsmeodofe

g13dSTIhESSFo STEALE ROUHoles-us a1a/erdewel.A

se tic 25.2. Grndn Guidline

405 434 8-106K to

 Internal Grinding 8.8

1TRAVERSE
WHEEL WORK INFEED Wihe WDETLI
SPEED SPEED on dia. wit Il
HARD-
MATERIAL CONDITION per rev. CATION*
NESS of work
tpm fpm in/pa ss ANSI

Austenitic Rough, 1/3

5000 75 0005
Nitronic 32 to to C60KV

Natrni 4021 6500 200 Finish

0002 max. 1/6
Nal 4 20
Nitronic 50 to Annealed 4-Lt2W 4 -4*-.
Nitrni 60 250

Rough: 1/3
5000 50 .0005
to to C60JV
325 6500 150 Finish: 116
to .0002 max
toCold Drawn scu 5 ' A7t

Martensitic Ruh /
403 440Ato tA6K
410 440B 60 0 iih
414 4400 135 6500 Finish:
2
420 501 to Annealed Z10 M
422 502 275 ~
431 Greek Ascotoy

Over Quenched 60 5 iih /

275an
Tempered

14. PRECIPITATION HARDENING500 7 .05

STAINLESS STEELS, WROUGHTto oA6K
15-5 PH AM-355 1060 0 iih /
17-4 PH Custom 450 to Solution Treated
17 7 PH Custom 455 200
17-14 CuMc, HNM
AF-71 PH 13-8 Mo
AFC-77 PH 14-8 Mo
Almar 362 (AM-352) PH 15-7 MO Rogh
AM-350 Stainless W
Vil 5 00 /

275 Solution Treated 650 10 Fns 1/

to or _
A40 Hardened

Maximum hole length is2 5 times hole diameter.

Maximum wheel width is 1 5 times wheel diameter.
$60 section 16 for Cutting Fluid Recommendations.
*Wheel recommendations are for wet grInding 0.8 to 2-inch (20 to 50
mm) diameter holes, For LARGER holes-use the same or potter
grade wheel. For SMALLER holes-use a harder grade wheel. Also
see section 20.2 , Grinding Guidelines.

8-107
8.8 Internal Grinding

TRAVERSE
WHEEL WORK INFEED Wheel WHEEL
SPEED SPEED on dla. width IDENTIFI-
MATERIAL HARD- CONDITION perwork
rev. CATION*
NESS of

fpm fpm in/pass ANSI

Bhn zzz:NNU:i13 -Z-2W~~T
15. CARBON STEELS, CAST Rough 1/3
Low Carbon to to A54MV
ASTMA426 GradeCP1 Annealed. 6500 200 Finish
1010 100 Normalized, 0002 max
1020 to Normalized and Tempered, .
Medium Carbon 300 or Quenched ->- L-.

ASTM A352 Grades LCA, LCB, LCC and Tempered

ASTM A356 Grade 1
1030 1040 1050
Rough 1/3
5000 75 0005
Carburized to
6500 to
200 Finish / A60KV'

Over
PCCuenched
50R and/orand } Z
Temrpered

16. ALLOY STEELS, CAST I 75 113

Lo;to to A60MV
ASTM A217 Grade WC9 Annealed, 6500 200 Finish
ASTM A352 Grades LC3, LC4 150 Normalized. 0002 max 1/6
ASTMA426 Grades CP2, CP5.CP5b, CP1i1, to Normalized and 7empered., - - _ -m-
CP12. CP15, CP21, CP22 400 or Quenched . I N
1320 4110 8020 and Tempered - ---
---

2315 4120 8620

2320 4320
Medium Carbon Rough
ASTM A27. Grades NI. N2. U-60-30, 60-10, 1/3
65-35, 70-36, 70-40
ASTM A148 Grades 80-40. 80-50. 90-60, to to A60KV
105-85. 120-95, 150-125, 175-145 Carburized 6000 200 Finish 1/6
ASTM A216 Grades WCA, WCB. WCC Over and/or 0002 max
ASTM A217- Grades WCl. W04. WCS. WOG 50 PC Quenched and -J
ASTM A352- Grades LC1. LC2,LC2-1 Tempered
ASTM A356- Graues 2, 5, 6,8, 9. 10
ASTM A389- Grades C23. C24
ASTM A488. Classes 70,90, 120
ASTM A487. Ciasses IN. I.N, 6N. 8N, 9N,
1ON. N, 10, 20. 40,40A. 60. 70, 80,
90, 10Q
1330 4130 80B30 8640
1340 4140 8040 9525
2325 4330 8430 9530
2330 4340 8440 9535 MM
4125 r'30 8630

7.rA ME

Maximum hole length is 2 5 times hole diameter.

Maximum wheel width is 1 5 limes wheel diameter.
See section 16 for Culling Fluid Recommendations.
-Wheel recomr , ndations are for wet grinding 0 8- to 2-Inch (20 to 50
mm] diameter holes Fc- LARGER holes-use the same or softer
grade wheel For SMALLER holes-use a harder grade wheel. Also
see section 20.2. Grinding Guidelines

8-108

_ _NIN S
 Internal Grinding 8.8

TRAVERSE
WHEEL WORK jINFEED JWheel
width
WHEEL
IDENTIFI-
HARD- SPEED SPEED on dla.
MATERIAL CONDITION Iper rev. CATION*
NESS ofwr
fpm fpm in/pass ANSI
Bhn ________ j7 _

17. TOOL STEELS, CAST Rough- 1/3

Group) 5000 75 0005
ASTMVA597: Grades CA-2. CH- 12. CH- 13. to to A60MV
CO-i. CS-s 0RAnae 6500 200 Finish: 1/6
maxCor Quenched .00 axm
and Tempered ~ ~~-- --

to toA80KV1
50 Rc Quenched600 20 Fns 1/

oe Qunchd .0002 max.

58 RIC Tempered

Group:
ASTM400 A75 Grde00020C- 1/3

205500 200 Finish:

48r 0 Quenched1/

56 and --
RC Tempered

SeGsronp 1 FudReomndlos .0or 1u/n

Whel re97ommendtos are2for weogrndn 0.-6o2-ncM20toV
~~
mm] ~ ~ ~ ~~hoeFFrLRGRhleisetesaeohsfe
d20ete 60
grade0 edr rd he.As
whe.FrSAL1/oe-s6
see~~~~~
Glelc ~ seto 2000 2.m~dn

to Annealed- -~
8.8 Internal Grinding
TRAVERSE
WHEEL WORK INFEED Wihe WDEETL
HARD- SPEED SPEED on dla. wit DNFI
MATERIAL CONDITION per rev. CATION*
NESS of work
fpm fpm ,in/pass ANSI
Bhn :ms.rn 1 m/as __ ISO_-
18. STAINLESS STEELS, CAST 500Rough: 1/3
Ferritic 50 7 .0005
ASTM A217- Grades CS. C12 to to A60KV
ASTM A296 Grades CB-30. CC-SO. CE-30. 135 6500 200 Finish 1/6
CA6N. CA-6NM, CD4MCui to Annealed Roughmax 3
ASTM A297 Grade HC 185
ASTM a.487 Class CA6NM -2 2 .013
ASTM A608- Grade HC30 o t 6K
- 005ma
C_____

Austenitic Ruh /
ASTM A296 Grades CF-3, CF-3M. CF-8, 5000 75 .0005C6V
CF-8C. CF-8M, CF. 16F. CF-20. CG-8M. to toIC6K
CG-l 2. CH-20. CK-20. CN-7M. CN-7MS 135 Annealed. j6t)00 200 I 1/6
ASTM A297- Grades HD. HE. HF. HH. HI. HK. to Normal17Pi 0002 mnax,
I HN. HP. HT. HU pin or . -Pih
ASTM A351- Grades CF-3, UI-3A. CF-3M. A at ~ ~ ~ 1
CF-3MA, CF-8, CF-8A. CF-8C. CF-8M. 6OV
CF-1 OMC. CH-8, CH-1 0, CH-20. CK-20, 3
~ ijgh-:, P;
CN-7M. HK-30, HK-40. HT-30 0iax _ _

ASTM A451. Grades CPF8A. CPF3. CPF3A.

CPF3M. CPF8. CPF8C. CPF8C (Ta Max).
CPF8M. CPF1OMC. CPH8. CPH 10. CPH2O.
CPK20
ASTM A452 Grades TP 304H, TP 316H. TP
347H -

ASTM A608: Grades H050. HE35. HF30.

HH3O. HH33. H135. HK3O. HK4O. HL3O.
HL4O. HN4O. HT5O. HU50

Martensitic Rough
.00 1/3
ASTM A217: Grade CA-i 5007500
AST A-iM.CA40to
A96 Gade C-1. to A6OKV
ASTM A26: Grades CAP7.C9.5M CCA54 13 6500 200 Finish- 1/
ASM42C7rae
C9 CC1515 Annealed. Normalized .0002 max 1/
ASTM A487: Classes CAl5a. CA-15M to o
25 Normalized and Tempered *10c-
~3

Over Wuenched

~~
See Oe 1600
sectiond mrClinalix.cmenain

Mmmae holents Fo LARimeholes-usmethsmeosfter

grade wheel For SMALLER holes-use a harder grade wheel Also

see section 20 2. Grinding Guidelines

8-110
 Internal Grinding 8.8

TRAVERSE
ORK
1WHEL INFED Wheel WHEEL
HR-SPEED SPEED on dia. width IDENTIFI.
MATERIAL HADCONDITION per rev. CATION*
NWEEORSNFE of work
fpm 1pm in/pass ANSI
_ii- vi Infivimm/pasis- ___

19. PRECIPITATION HARDENING I Rough. 113

STAINLESS STEELS, CAST 5000 50 .0005
to to A60JV
ASTM A351 Grade CD-4MCu 6500 150 Fin ish. 11
ACI Grade C8-7Cu 325 Solution Treated or .0002 max 16
ACI Grade CD-4MCu to Solution TreatedRh
17-4 PH 50and Aged --- -13
AM-355 2 ~ 1 J

33=M46 W~5Filh 14z

20. AUSTIENITIC MANGANESE STEELS, Rough- 1/3

CAST 5000 75 0005
to to A46JV
ASTM A128* Grades A. 13-1. B-2. 8-3. B-4. C, 6500 200 Finish:
D.E-1 E-2. F 150 02ma. 1/6
to Annealed
220 I cgU-

1
21. GRAY CAST IRONS Rough- 1/3
75 C46JV
Ferti48Clas2
Ferlc5000
to to Ior.002
SAS J431c. Grade G1800 As Cast. 6500 200 Finish, 1/6 A46KV
Pearl itic- Ferritic 4 IAneld0002m max.
ASTM A46Ciass
brax. or Quenched /
SAE J431c. Grade G2500 and TemperedN
ASTM A48 Classes 30. 35. 40 ~'
SAE J431ic Grade GZ~u_____ _________

Pearlitic + Free Carbides Rough: 1/3

ATA4.Cass4,50 5000 75 .002 C54JV
SAE J431c. Grades G3500, G4000 to to or
Pearlitic or Acicuiar + Free Carbides 5 As Cast, 6500 200 Finish: A60JV
ASTM A46. Classes 55. 60 toAnnealed 0002 max. /
52 RC or Quenched ~ ~ ~ u
and Tempered W2s2~~6

Rough: 113
5000 75 .001 C601V
to to or
4F CFae6500 200 Finish- 1/6 A601V
to or .02mx
60 Rc Induction Hardened - i3

Austenitic (NI-RESIST) Rough- 1/3 Rough:

ASTM A436- Types 1. 1v. 2. 2b. 3. 4. 5. 6 5000 75 .0006 A36HV
to to
106500 200 Finish: / Finish:
100 0003 max. 11 A60HV
to As Cast ~

Maximum hole length is265 times hole diameter

Maximum wheel wid~h! ' .5 limes wheel diameter.
See section 16 for Cutting Fluid Recumrnendations.
*Wheel recommendations are for wet grinding 0.8- to 2-inch [20 to 50
mm] diameter holes. For LARGF hioles-use the same or softer
grade whcel For SWALLE!1 holes-use a harder grade wheel. Also
see seclior, 20 2.Grinding Guidelines.

8-111
8.8 Internal Grinding
I I TRAVERSE~
WHEEL WORK INFEED Wheel WHEEL

MATERIAL
I HARD-
ICONDITION
SPEED SPEED ondla. width
per rev,
IDENTIFI-
CATION*
I NESS of work
pm
fp in/pass ANSI

22. COMPACTED GRAPHITE CAST IRONS Rough- 1/3

5000 75 002 C46JV
to to or
185 6500 200 Finish: / A46KV
0002 max.
to As Cast-
225 ~ ~ ~ z

23. DUCTILE CAST IRONS Rough: 113 C5V

Ferritic 5000 75 .002C5J
ASTM A536. Grades60-40-18. 65-45-12 to to or
SAE J434c: Grades D4018. 04512 Annealed. As Cast. 6500 200 Finish: 1/6 A6OJV
Ferritic- Poarlitic 52 Rc Normalized and Tempered -- _ 0002 max.
ASTM A536: Grade 80-55-06 max. or Quenched -

SAE J434c: Grade 05506 i

Peartitic- Martenhitic
ASTM A536: Grade 100-70-03
SAE J434c: Grade D7003______ ____________

Martensitic Ruh /
ASTM A536: Grade 120-90-02 50 5 .0 61
SA9.J434c: Grade DQ&T 1 oo
53 PCFlame 60 0 iih / 61
to or .02mx
V 'c Induction Hardened -

Austenitic (NI-RESIST Ductile)Rog: 13 ouh

ASTM A439: Types D-2. 0-28. D-2C. D-3. 00 7 .06A3H
D-3A. D-4. D-5. 0-58 o t
ASMA71 yeD-M106500 200 Finish- / Finish:
ASM 57: yp D2M12 0003 max - A6OHV
to Annealed-
275

24. MALLEABLE CAST IRONS Ro000 15.02/3J

Ferritic 5G 5 .0 5J
ASTM A47: Grades 32510. 35018 Malleablized 650 200 Fiis:Ar
ASTM A602: Grade M3210 60 0 iih / 6J
SAE J158, Grade M32 10ma.Mlebid

ASTM A220: Grades 40010. 45006. 45008. H-eat Treated

50005
ASTM A602: Grade M4504. M5003
SAE~ J 158. Grades M4504, M5003
Tempered Martensite Ruh 1
ASTM A220: Grades 60004, 70003. 80002. 50 6 .0 61
90001 t oo
ASTM A602' Grades M5503. M7002, M8501 6500 200 Finish- A601V 27
SAE J 158 Grades M5503. M7002. M8501 Over Flame .1(2mx /

Maximum hole length is2.5 times hole diameter

Maximum wheel width is1.5 times wheel diameter
3ee section 16 for Cutting Fluid Recommendations
*Wheel recommendations are for wet grinding 0.8- to 2-inch [20 to 50
min] diameter holes. For LARGER holes-use the same or softer
grade wheel. For SMALLER holes-use a harder grade wheel. Also
see section 20 2. Grinding Guidelines.

8-112
 Internal Grinding 8.8

TRAVERSE

WHEEL WORK INFEED Wihe WETFL

HARD- ~~SPEED SPEED on dla. wit DNII
MATERIAL AR-CONDITION per rev. CATION*
INESS of work
fpm fpm in/pass ANSI

25. WHITE CAST IRONS (ABRASION Rough 1/3

RESISTANT) 5000 75 .001
ASTM A632 to to C601V
Class 1.Types A. 8. C. D 60RAICt1 6500 200 Finish, /
Class 11.Types A. B. C. D. E 6RC A at .0002 maxI 16
Amax II.
Clas Tye Annedled or ~

-o-- --

27.
ALLYHROMUM-ICKE
CSTINS 500 5 Rough:- /
A2T. AHIGHGradesN
CrASONi. 500rO~ 75 .00 1/3

275clo 6500 150 Finish: 16

1175~~~000100kg0rdge 300 547

recomm rendtos a0r for wetgrNi 0o8- to2-nc 20to5

AWhee
holes ~ Forsh
mm] ~ LAG1h16-s
~~ am rsfe
h diae0e
see ~
~ 7 ~
~ grade~~~~ secso~202CGasgtudeie ~ ~ ~ ~ ~
whe.FrSALEaoe-sxahre.raewelAs 00
~ t

8-11A
1100 toColdDraw545
2618 646 or0002max
8.8 Internal Grinding

TRAVERSE
INFEED Wheel WHEEL
WHEEL WORK
SPEED SPEED on da. width IDENTIFI-
HARD- per rev. CATION*
MATERIAL CONDITIOE
NESS of work
fpm fpm in/pass ANSI

29. ALUMINUM ALLOYS, CAST Rough. 1/3

Sand and Permanent Mold to to C46JV
A140 2950 5140 A712 0 40 As Cast 6500 200 Pinist-
2010 B295 0 A514 0 D712.0 to or .0002max. 1/6
208.0 3080 6514.0 7130 125 Solution Treated
2130 3190 5200 771.0 500kg and Aged
2220 3550 5350 8500
224.0 0355 0 7050 A85O.0
242,0 B443.0 7070 B850.0 . .
Hiduminium RR-350 ,f

Die Castings
C443 0 5180

sand and Permanent Mold Rough: 1/3

328 0 356.0 to to A60HV
A332 0 A356.0 40 AS Cast 6500 200 Finish: 1/6
F332 0 357.0 to or .0002 max.
333.0 3590 125 Solution Treated - '-
354.0 500kg and Aged ~ ~ 3 4
Die Catings _ _

3600 A380 0 390.0 A413 0 ~S~

t360 0 383 0 392.0 A
380.0 A384 0 4130

30. MAGNESIUM ALLOYS, WROUGNT** 500h 1/3

AZ21A HK31A to to C46JV
AZ31B HM21A 50 Annealed. 6500 200 Finish:
AZ31C HM31A to Cold Drawn .0002 max.
AZ61A ZK40A 90 or Solution - - - :..

AZ80A ZK60A 500kg Treated and Aged

Rough: 1/3
31. MAGNESIUM ALLOYS, CAST 5000 75 .003
AM60A AZ91C ZE41A to to C46JV
AM100A AZ92A ZE63A 50 As Cast. 6500 200 Finish,
AS41A EZ33A ZH62A to Annealed
AZ63A HK31A ZK51A 90 or Solution
AZ81A HZ32A ZK61A 500kg Treated and Aged ;
AZ91A KiA
AZ918 0E22A

Maxirmum hole length is 2.5 times hole diameter. 11CAUTION Potential Fire Hazard Exercise caution in grinding and
Maximum wheel width is 1.5 times wheel diameter disposing of swarl. Do NOT use water or wate.-miscible cutting
See section 16 for Cuttirq Fluid Recommendations fluids for magnesium alloys
*Wheel recommendations are for wet g.fndrng 0 8- to 2-inch (20 to 50
mm] diameter holes. For LARGER holes-use the same or softer
grade wheel For SMALLER holes-use a harder grade wheel. Also
see section 20 2.Gnnding Guidelines

8-114
 Internal Grinding 8.8

TRAVERSE
WHEEL WORK iINFEED Wheel WHEEL
SWORKI nFEED width IDENTIFI-

[Rough
r
MATERIAL HARD- CONDITION SPEEDISPEED on di pe rev. CATION'
NESSof wrork
1pm fm in/pass ANSI
NES of/3o
Bhn mL mimAmpsisO
32. T'TANIUM ALLOYS, WROUGHT 400 50 0005 1/3
C mmerciglly Pure to to C60JV!
99.5 5000 150 Finish
992 110 .0002max 1/6
99.0 to Annonw,
989 275 t - 4 -h ___

Ti-O 2Pd Z
TzCODE-12 -- Z '_ =-t

Alpha and Alpha-Beta Alloys Rough: 1/3

Ti-SMn 4000 5o -0005
gn
o0 to
Ti- 1A-8V-SFe
Ti-2AI- I tSn-SZr- 1Mo 300 5000 150 Finish 16
Ti-3AI-2.5V tO Annealed 02 max. .
T.-SAI-2Sn-2Zr-4Mo-4Cr (Ti-17) 380 .
Ti-AI-2 5Sn R0 M"6:

Ti-SAI-2 5Sn ELI Jo :9i14 OO-

T.-SAI-6Sn-2Zr-IMo MEW
Ti-6AI-2Cb- 11a-0 8M. - -
Ti-6AI-4V Rough: 1/3
Ti-6AI-4V ELI 4000 50 uOO
Ti-6AI-6V-2Sn to to Cbu,.v-:
Ti-6Al-2Sn-4Zr-2Mo 320 5000 150 Finish- 116
Ti-6AI-2Sn-4Zr-2Mo- 25Si to Solution Treated .0002 max.
Ti-6Al-2Sn-4Zr-6Mo 4to and Age , -
Ti-7Al-4Mvo 5
Ti-SAI- 1lMo- 1V 01 1

SesAlosRough. 1/3
Beta Alloys 40 0 00
T:-3AI-8V-6Cr-4Mo-4Zr 4o 50 0005
Ti-8Mo-8V-2Fe-3AI to to F10sh:
T- 11 5Mo-6Zr-4 5Sn 275 Annealed 000 mns 1/6
Ti-OV-2Fe-3A1 to or
Ti-13V-1 lCr-3A 350 Solution Treated -

Rough.
4000 50 .0005 13
to to C60JVt:
3503
350 5000 150 Finish: 1!6

Solution Treated 0002 max.

to
440 and Aged
0- .
v-

33. TITANIUM ALLOYS, CAST#f Rough:

Commercially Pure 4000 50 0005
990 to to C60V:
Ti-0 2Pd 150 As Cast 5000 150 Finish: 1/6
ASTM 8367 Grades C- 1,C-2. C-3, C-4. to or 0002 max.
C-7A. 0-78, C-8A. C-88 250 As Cast
and Annealed

Maximum hole length is 2 5 times hole diameter. tUse friable (green gnt) silicon carbide
Maximum wheel width is1.5times wheel diameter. #*CAUTION Potential Fire Hazard Exercise caution in grinding and
See section 16 for Cutting Fluid Recommendations disposing of swart
'Wheel recommendations are for wet grinding 0.8- to 2-Inch [20 to 50
mmJ diameter holes For LARGER holes-use the same or softer
grade wheel For SMALLER holes-use a harder grade wheel Also
see section 20.2. Grinding Guidelines

8-115
8.8 Internal Grinding
(tRAVERSE
WHEEL WORK INFEED Wheel WHEEL
SPEED S on dIa. width IDENTIFI-

MATERIAL NESS CONDITION per rev. jCATION'

of work
fpm fpm in/pass ANSI

33. TITANIUM ALLOYS, CAST#* (cont.) Rough- 1/3

Alpha and Alpha-Beta Alloys to 50 C60000T
Ti-SAI-2.SSn to
Ti-6AI-4V 300 As Cast 5000 15) Finish- 1/6
Ti-6A-2Sn-42r-2Mo to 0,0002 m~ax
Ti-8AI-tMo-1V 350 As Cast _ 2L

ASTM B367 Grades C-5. C-6 and Annealed I - 3 -t

34. COPPER ALLOYS,WROUGHT 5000 75 1/3

101 116 143 182 to to C4J
102 119 145 184 6500 200 Finish: 1/6
10, 120 147 185 10 60 .0002max
105 121 150 187 to Annealed ,-
107 122 155 189 70 R,
109 125 162 190
210 127 165 191
111 128 170tt 192
113 129 172ff 194 R 1/3
114 130 173ft 195 5000 75 .002
115 142 175ff to to C461V
60 R 6500 200 Finish: 1/6
to C:.:--"
,,,*,2,,. ..

510 6

Rough: 1/3
210 332 368 464 5000 .002
220 335 370 465 toC,16J3V
226
230 340
342 377
385 466
467 0R 6 500 200 .0002 max.
Finish: 6

240 34 411 482 to Annealed ;

260 350 413 485 70
268 353 425 667 :
270 356 435 687

280 360 42 688

314 365 443 694 Rbugh:
316 366 444 5000 75 .002
330 367 445 to to cacV
W0 o A 6500n 200 Finish uon

to Cold DrawngdweFSAEhesaaegehlA
100 R B _-

J Rough, 1/3 X

i
505 613 632 5000 75 .002
,51 6438to to C46JV
511
521 618
619 642
651 10R 6500 200 FinEsh:
.0002 max.
524 623 655 to AnneaWds
544 624 674 70 Re

608 625 675

610 630 -

Maximum hole length is2.5 times hole diameter. t Use friable silicon carbide.
(green grit)
Maximum wheel width is 1.5 times 'wheel diameter. ft CAUTION: Toxic Material. refer to National Institute for Occupaticnal
See section 16 for Cutting Fluid Recommendations. Safety and Health (NIOSH) for Precautions.
*Wheel recommendations are for wet grinding 0.8- to 2-inch 120 to 50 #:CAUTION: Potential Fire Hazard. Exercise caution in grnng and
mm) diameter holes For LARGER holes-use the same or softer disposing of swaf.
grade wheel. For SMALLER holes-use a harder grade wheel. Also
see section 20.2. Grinding Guidelines.

8-116
 Internal Grinding 8.8

TTRAVERSE
Wheel WHEEL
WHEELI WORK INFEED I width IDENTIFI-
MATERIAL NESS CONDITION Dper re. CATION

Bhnfpm fpm nass ANSI

34. COPPER ALLOYS, WROUGHT (cont.)

(mater;s listeo fnpreceding page)
j 5000
to 775 o.Ih:
.0 113 C4JV

60 6500 200 Fin.sh: 116

to Cold Dvawri 010 tri;x

~I
1!3
706 752 500 75 002
710 754 to to C 4L.11
7,5 75? I 6500 200 I F.ins 116
745 782 ;otoRe I ,.nealed . e-

R ou h:- 1/3
5000 75 GC
to to -;46JV
60 A 9 6500 200 Finish:
to Cold rawn
100 R

35, COPPER ALLOYS, CAST

801 814 824ff to to C46JV
803 815 825ff 40 200 Finish: 16
805 817ff 826ff to
200
jC3sl002max.
807 818t. 827ff
809 820ff 828tf 500kg Heat Treated -.-
811 821ff
813 822ff

t a

S34 55 to, to A54KJV

833 854 36.5

836 8723inish: 257 ME

8885P- 874to
844 862 876 500kg

848 863 878

852 8-5,4 879
853 865
Is 2.5 times hole .iametet. i t CAUTION. Toxic Material, refer to National Institute for Occupational
Maxirnc whetlength
Maximum hole v6idth is 1.5 times whieel diameter. Salet) ano Health (NIOSH) fo, Precautions
See section
Wheei 16 for Cuttingdre
reconrnendattonm fo'rRecommendations
Fluid .wet grinoig 0 8- to 2-inch 1-10to 56,
mmn diameter holes. For LARGER h.ies-use the same or softer
grade wheel. For SiiALLER holes-use a rarder grade wheel. Ams
see section 20.2 Grinding G'jidetines.

8-117
7
 8.8 Internal Grinding

TRAVERSe WHEEL
WHEELj WORK INFEED wih IENTIFI-
HARD- SPEED SPEED on ela. w IN
MATERIAL HERD CONDITION per rev. CATION
NESS of work i

'hnpci , ANS

35. COPPER ALLOYS, CAST (cont.) " 1/3

902 916 93 948 to to [
903 917 935 952 40 ? w00 F
,'00 1n-s.
905 922 937 953 !a i .0032max.
97 923 938 954 110 As C ast
910 926 943 956
911 927 944 95711
913 928 945 958
915 S32 947 P ouh 1.
SM 10075 00O2
eto o I I I A54KV
115%1 As 00)
Cast I 1Fs.
0002 may.. 1/
50Ckg Heat Treatod ORI

962 I Rcugh 113

62 1 500 0 75 .002 1
64 5 6
93to
6 500 1
to
20D ~
F n sh "
IC. V

966ff to 0002 ma U.

m 974
973 10As Cast -

Rough. 1/3

500O 75 .002
to 10 A54KV
Over As Cast WRO.
A000S6IK0 116
N10e or

Nickel1201 6000 150 Finish:

Nickel 205 80 Annealed .0002max. 1/6
Nickel 211 to or
Nickel 220 10Cl rw
Nickel 230 7

ONE 4Rough: 1/3

MONL .'!y 005000 50 .0005
MONEL Alloy 401 to to
MONEL AI'oy 4C4
MONEL Aloy R405 115 Annled. 1/6
to Col Drawn .0002max
ASTM A296. Grades CZ-100. [A-35
ASTM A494: Grades CZ-100. M-35 240 or
Cast

Maxrium hole length s 2.5 times hole diameter. t tCAUTION Toxic Mateal. refer to Natonal Instdtue for Occupational
Maximum, wheel width is 1.5 tus wheel diameter. Safey and Health (NIOSH) forPrecautions
See section 16 forCutting Fluid Recommendations
*Whel recoumendations are for wet grinding 0 8- to 2-inch (20 to 50
mm) dkirmeter holes. For LARGER holes-use the same or softer
grade wheel. For SMALLEF. holes-use a harder grade wheel. Also
see section 20 2.Grinding Gudelines

, 8-118

I
---- - -m - II - - I - - -I - - - _
 Internal Grinding 8.8

1 RAVERSE
IWheel whdL%
WHEEL -
WDEN
WHEEL WORK INFEED
SPEED SPEED on dla.
HARD- per rev. CATION'
MATERIAL H CONDITION
NESS 'o.work
fpm fpm In/pass ANSI
Rough /3Bhn
DURANICKEL Alloy 301 6000 50 Ruh5
5000 so 0006
MONEL Alloy 502 to to C60JV
MONEL Alloy K500 6000 ISO Fiish-
NI-SPAN-C Alloy 902 150 .0002 max. 1/6
PERMANICKEL Alloy 300 to Solution Treated V

.0002 max.,

5000 50 .0005
to to C60JV

330 6000 150 Finish 1/6

tct2 As.0002 max.
60S Aged i ?4-tvt45iz

37. BERYLLIUM NICKEL ALLOYS, Rough: 1/3

AND CASTtI
WROUGHTBrush Aloy 260 5000 50 .0005
to to A46KV
Berylco 440 6000 150 Finish.
Berylco 41 200 As Cast .0002 max 1/6
Berylco 42C to or
Berylco 43C 250 Solution Treated
Brush Alloy 20C
Brush Alloy 22CW-
Brush Alloy 2600C

toto0 to A60JV
253tHardened00 0 FiAesh- 1

283R Hardened .0002 max /

452R Aged

47o16N-2
0 Hardd .0002 max.
340 ---A-KI5! -- -
;Ieae g
to or

Nitinl 60on ti s eowg , 2 0 W

seestIon2.2 GrNidIn Guidelnines

Nitiol 6~i-41 1 10 8a1191

Wough .002
see section 16 foriting d HudRecmen
-. ~~t ~ - -~---'--
34
or
Aneae
.

grade wheel FoALL EROUGHT

holes-use aough:
h
8.8 internal Grinding

TRAVERSE
Wheel WHEEL
INFEED width IDENTIFI-
WHEEL WORK
HARD- SPEED SPEED on dl3 i dt DNII
MATERIAL
MATERIALNESS CONDITION per rev. CATION*
fpm fpm m/pass of wor
ANSI
n %ar ogh
38, NITINOL ALLOYS, WROUGHT (cont.) 50 5 1 /3
(materials hlsted on preceding page) 5000 to C60JV

48 P C 150 0002 rmax

Finish 1/
1/6
to Quenched 0 .002 rnax
52 R c A ..

39. HIGH TEMrERATURE ALLOYS. Rough. 1/3

WROUGHT AND CAST 3000 50 .0005
to to A60JV
Nickel Base,Wrought
AF2-1DA 200 Annealed 4000 max 1/6
Astro'oy to orf00 a
hayes Alloy 263 390 Solution Treated

Incoloy Aticy 901

,ncoloy Ailo 903
Inconel Alloy 617
Inconal Alloy 625 Rough,
Inconel Alloy 700 3000 .0005
Inconel Alloy 702 to A60JV
Inconel Alloy 706 300 4000 Finsh 1/6
Inconel Alloy 718 to Soulion Treated 0002 max
Inconel Alloy 721 475 ano Aged
Inconel Alloy 22
Inconel Alloy X-750
Inconel Alloy 751
M252
Ninonic 75
Nimonic 80
Nimonic 90
Nionin 9b 4
Rene 41
Men 63e wts tm-ei

Rene
Udimet95500 Cutting Fluid.Recommendatons --------
(Idimet 700
Udimet 7 10...... ". . - -
Urilemp 1753
Waspaloy

Maximum hole length Is25 times hole demeter

maximum wheel width is 1.5 times wheel diameter.
See section 16 for Cutting Fluid Recommendations.J9
*Wheel recommendations are for wet grinding 0 8- to 2olnch (20 to 50
mmni diameter holes For LARGER holes-use the same or softer
grade wheel. For SMALLER holes-use a harder grade wheel Also
see section 20 2,Grinding Guidelines

8-120

- ~--. -
_.=- -- --
 internal Grinding 8.8

F TRAVERSE
WHEEL
WHEIOK IFC Wheel
SPEED SPEED ondia. wit DNil
HARD- per rev CATION*
MATERIAL CONDITION
NESS of work
fhl
pm 1pm in/pass ANSI

Nike Nicke Bas, WrughtRough, 1/

Bse Wouht3000 50 .0005
Hastello,, Alloy B to to A60JV
Hastelloy Alloy B-2 j4000 150 Finish: 1/
Hasteiloy Alloy C 140 Annealed 1002 max.
Haslelloy Alloy C-276 to or
Hastelloy Alloy G 220 Solution Treated ?- . .

Hastelloy Alloy S ~~* ~ _

Hastelloy Alloy X ~
Incoloy Alloy 82504______ IA _

Incotoy Alloy 804

Inconel Alloy 600300 5 .05 1/
Inconel Alloy 601 t oAW
Ref racialoy 26
40 5 iih
Udimel 630 240 Cold Drawn .0002 max. 1/
to or
310 Aged

Nickel Base, Wrought 5 0 /

TD-Nickeitt500 tA0J
TO-Ni-Crtt15 Fish
1801/
10 As Polled.02ma
200

Nickel Base, Cast300 s .05 /

B-1900 300 50 .0005
GMR-235 400610Oinsh
GMR-235D 200 As Cast1/
Hasteiloy Alloy Btor
Hastlloy Alloy C 425 Cast and Aged
Hasteiloy Alloy D
IN-100 (Rene 100) A
IN-738 A
IN-792______
Inconel Alloy 713C
Inconel Alloy 718
M252
MAR-M200
MAR-M246 W
MAR-M421 ;S
MAR-M432
Rene 80
Rene 125
SEL _______

SEL 15
TRW VI A
Udimet 500
Udimet 700
ASTM A296, Grades CW-12M. N-12M. CY-40
ASTM A297: Grades HW. HX
ASTM A494: Grades N-12M-1. N-12M-2.

CY-40. CW 12M- 1, CW- 12M.2

ASTM A608: Grades HW5O, HX50
Maximum hole length Is2.5 times hole diameter. ftCAUTIJN, Toxic Material, refer to National Institute for Ocri-pational
Maximum wheel widin is1.5 times wheel diameter. Safety and Health (NIOSH) for Precautions.
See section 16 for Cutting Fluid Recommendations __
-Wheel recommendations are for wet grinding 0.8- to 2-Inch [20 to 50
mmj diameter holes. For LARGER holes-use the same or softer
grade wheel. For SMALLER holes-use a harder grade wheel. Also

8-121
8.8 Internal Grinding

-T TRAVFRSEi
Wheel WHEEL
WHEEL WORK iNFEED
WHEELWORK
NFEE width IDENTIFI.
SPEED SPEED on ddia. width IDCATION=
HARD-
MATER'AL NESS CONDITION per rev. CATION
of work I
fpm fpm in/pass ANSI
Ehn iM_____________
i rc~~~~ 'S~
39. HIGH TEMPERATURE ALLOYS, Rough. 113
WROUGHT AND CAST (cont.) 3000 50 0005
to to A60JV
Cobalt Base, Wrought
AiResist 213 180 4000 150 Finish i1/6
laynes Alloy 25 (L605) to Solution Treated m. -
Haynes Alloy 188 230 I t&
J-1570 7'.
tAAR-M905
MAR-M918 I __ti~n
x

V-36 Rough. 1/3

3000 50 .13005
to to A60JV
270 4000 150 Finish- 1/6
to Solution Treated 0002 max
320 and Aged -

Cobalt qse, Ctst Rough: 1/3

ArResist 13 3000 50 .0005
to to A60JV
Ai~esui 215
FSX-414 220 As Cast 4000 150 Finish: 1/6
HS-6 to or +-
HS-1 -4290 Cast and Age
HOWMET #3 1i Ni
MAR-M302 _
MAR-WM322 _____

MAR-M509 Rough. 113

NASA Co-W-Re 3000 50 .0005
WI-52 to to A60JV
X-45 290 As Cast Fi
00 x. 116
to or
425 Cast and Aged . -

iron Base, Wrought 3000 1/3

A -286 to to .00JV
Discaloy
Incoloy Alloy 800 180 4000 150 Finish,
to Solution Treated .0002 max.
Incoloy Alloy 800H
Incotoy Atoy 801 230
Incoloy Alloy 802 NA
N .155
V -57 .
W-54652
16-25-6 Rough:
3000 so 0005
19-9DL
to to A60JV

250 4000 150 Finish: 1/6

Solution Treated 0002 max.
to
320 and Aged

Maximum hole length Is 2.5 times hole dlam3ter.

Maximum wheel width is 1.5 tlmes wheel diameter.
See sectIoit 16 for Cutting Fluid Recomrendatlons.
'Whee! recommeidatlons are for wet grinding 0.8- to 2-inch [20 to 50
mi.] diameter holes. For L .RGER hales-use the same or softer
grade wheel For SMALLER holes-use a harder grade whbel Also
see section 20 2, Grinding Guidelines.

8-122
 Internal Grinding 8.8

TRAVERSE
WHEEL WORK INFEED W'he WDETFL
HARD- SPEED SPEED on dla. wit DNII
MATERI L CONDITOON perrev. CATION*
NSSS of work
fpm fpm rn/pass ANSI
Bhn ~i/2~/nn fa~____ tO
40. REFRACTORY ALLOYS, WROUGHT, Rough 1/3
CAS, PM~50 001
CASTlrn
P/ M f 4000 to A60JV
0103 170 ' Fiih 1/6
C129Y to IStress 0005 mnax
Cb- lZr 225 Relieved -- Zj,- _-glr
Cb-752 a-2
FS-85 y_2 F_ =
FS-291 -

Molybdenum~" 50 Rough. 1/3

5 001
Mo 4000 to A60JV
Mo-50Re 150 Finish
TZC 220 116
TZM to Stress 0005 max
290 Relieved gi AWe4
~~NOW

Tantalum" og /
ASTAR 8110C5 J
T-111400 tA6J
T-222 20015 Fish 1/
Ta-IOW to Stress 00 a
Ta-Hf 250 Relieved
Ta633

Tungsten" ogh /
85% density 20 toC60H-V
93% density 10 Pressed and Sintered, 150 Finish: 1/
100% density to Forged. .02mx
320 or
Arc Cast

Tungsten -2Thorla** ftRog* /

260 Pressed10 Fish 1/

to and002mx
320 Sintered

Maximum hcte length is 2 5 times hole diameter. *Due to the brittleness of refractory alfcys. cracking. chipping. flaking
Maximum wheel width Is 15 limes wheel diameter and breakout tend to occur, particularly on tie edges of the ma-
See section 16 foi Cutting Fluid Recommendations chined surfaces
*Wheel recommendalloi.s are for wet grinding 0 8- to 2-inch (20 to 50 ttICAUTION Toxic Matenial. refer to National Institute for Occupational
mm) diameter holes For LARGER holes-use the same or softer Safety and Health (NIOSH) for Precautions
grade wheel For SMALLER holes-use a harder grade wheel. Also t CAJTION: Potential Fire Hazard Exercise caution in gninding and
see section 20 2. Grinding Guidelines disposing of swarf

8-123
16 8.8 internal Grinding
TRAVERSE
WHELWOK INFEED Wheel WHEEL
HARD- SPEED SPEED on dla. width IDENTIFI-
MATERIAL CONDITION per rev. CATION*
N E Sfpm fpm in/pass o w rk ANSI

40. REFRACTORY ALLOYS, WROUGHT, Rough 1/3

CAST, PIW* (cont.) 50 0005
Tungsten Alloys" 2000 to C60HV
GE-218 260 15 ins 116
WiS5MO to As Cast 00 a
W-5Re 320 w

Tungsten Alloys"'Rug /
Gyromet50 05
Mallory 2000200 tC6H
W-1OAg29Prse002mx
W-7Ni-4Cu t n

Tungsten Alloye ouh /

Anviloy 1100 5 00
Anviioy 1150300 t 6H
Anviloy 1200 290 Pressed15 Fish 1/

320 Sinte~ed

45. ZIRCONIUM ALLOYS, WROUGHTftRog. /

Zr-2%HI (Grade 11)300 t 8K
Zr-0.001%Hf (Grade 21) 10 Fns
Zircaloy 2 (Grade 32) 140 Rolled.1/
Zircaloy 4 (Grade 34) I o Extruded
280 or Forged

47. POWDER METAL ALLOYS Ruh

Copper 50 5 .0

50 RF 6500 200 Finish. 1/

to As Sintered
70 R

Brasses Rough: 1/3

CZP-02 18-T 50 51 0
CZP-0218-U 60 0 iih / -
CZP-0218-W 35 RH 650.00 Fmnxs
0 .
9OCu-lOZn tOAs Sintered
9OCu-1OZn-0.5Pb 81 R
70Cu-3OZn
68.5Cu-3OZn-1 .5Pb

Maximum hole length is2.b times hole diameter. *Due to the Lrdlieneas of refractory alloys. cracking, chipping, flaking
Maximum wheel w~dth isI.5 times wheel d-ameter. and breakout tend to occur, particularly on the edges of the ma-

See sectloi. 16 for Cutting are

FluidforRecommendations. chined surfaces
'Wheel ecommendations
mini diameter holes For LARGER wet grinding
holes-use0 8-the
to 2-Inch
same [20 to 50
or softer dispo~sing ofPotential
#*CAUTION swarf Fire Hazard. Exercise caution in grinding and
grade wheel. For SMALLER holes-use a harder grade wheel. Also Grinding of low density parts is not recommended because surface
see secton 20.2. Grinding Guidelines porosity will be reduced or lost.

8-124
 L/

Internal Grinding 8.8

WOK
WHEE INEED ITRAVERSE
Wheel JWHEEL
WORKD
WHD-SEEL onFEdi width IDENTIFI-
MATERIAL HD.CONDiTION SED PED oda. per rev. jCATION*
NE S pm fpm in p ass o w rk ANSI

Bronzes Rough 1/
CT-0010-N 5000 75 002
CT-0010-R to to C46JV
CT-0010-S 308RI 6500 200 Finish 1/6
95CL-5A1 to As Sintered 00O02max

OR5 2 50

Ou am~ ; '. - -z

Copper-Nickel Alloys Rough- 1/3

CZN- 1818-T 5000 75 002C4J
CZN-18 18-U to t0CoJ
22
CZN-1818-W RH 6500 200 Finish- 1/6
CZNP- 1618-U to ASitrd002 ma>- s
CZNP-1618-W loop As PMVIW
9OCu-IONt _ __

62Cu- l8Ni- l8Zo-2Sn ~~

Nickel 50 Rough 113

5000 50 0005
to to 060KV
6500 150 Finish 1/
0002 max 16
4588B As Sintered

Nickel Alioys Rog- 1/3

67Ni-300u-3Fet toC0V1
6500 Finih.O11
10
34 RB 0002 max.
to As Sintered-
50 RB ~~

Refractory Metal IL'seRog 1/

87W-13Cu
85W- 15Ag 10 Fns 5
74W-26Cu 1011/
72.5W-27 5Ag to As Sintered 0
65W-35Ag 260 1 w i -
56W + C-44Cu
55W-45Cu QV
50W + C-5OAg

-J5

Maximum hole length IS2 5 limes hole diameter. Grinding of low-density parts is not recommended because surface
Maximum wheel width Is 1.5 times wheel diameter. porosit will be reduced or lost
See section 16 for Cutting Fluid Recommendations
-Wheel recommendations are for wet grinding 0.8- to 2-inch 120to 50-E
mm] diameter holes For LARGER holes-use the same or softer 9i
grade wheel. For SMALLER holes-use a harder grade wheel. Also _!
see section 20 2. Grinding Guidelines w

8-125
8.8 Internal Grinding
TRAVERSE
WHEEL WORK INFEED Whdth WDEELIF
HARD- SPEED SPEED on dia. it DNII
MATERIAL CONDITION per rev. CATION*
NESS of work
fpm fpm in/pass ANSI
Bhn rn/s rn/mmj mm/pass ISO,

47. POWDER METAL ALLOYS (cont.) Rough 1/3

Refractory Metal Base 400 50 001
6 o3A400 to A60JV
5OMo-50Ag 75 R 15 iih 1/6
8 0005 max
to As Sintered v-. --
82 R13 54-15, -O-2 - --.- .

lrons 500Rough- 1/3 C4J

F-0000-N5000 75 002C4J
F-0000-P to to or
F-0000-A 50 6500 200 Finish: 1/6 A46KV
F-00Sto 0002 max.
p.0000-S
F-0000-T50g
67 As Sintered ~R~i

Steels Rough. 113

F-0008-P 5000 75 .0005
P-0008-S to to A54MV
F-0005-S 101 ASitrd6500 200 Finish- 1/6
As Sitered0002 max.
F0-0205-S to o
P0-0208-P 426 Heat Treated~
F0-0208-S ~3~ O3-
P0-0508-P

FN-0205-S____ ________ C ~ m x
FN-0205-T
FN-0405-R
FN-0405-S
FN-0405-T
PX- 1005-T
FX-2008-T .- -

Stainless Steels Ruh /

SS-303-R 00 7 .05
SS-304-11 o oC6K
SS-316-8 107 As Sintered 60 0 iih /
SS-410-R to or .000_max
285 Heat Treated

an4um Alloys Ruh /

90 5A-5Sn-40u500 7 03
88t ' iSn-4Pb-30u o oC-6.1
Al-m jr-0 6Si-0.25Cu 55 RH Solution Treated.02 ax
AI-0 6Mg-0.4Si to
AI-4 4Cu-0 8Si-0.4Mg 98 RH and Aged

Maximum hole length is 2 5 timres hole diameter. Grinding of low-density pans is not recommended because surface
Maximum wheel width is 1.5 limes wheel diameter. porosity wilt be reduced or lost
See section 16 for Cutting Fluid Recommendatiurs
*Wheel recommendations are for wet grinding 0.8- to 2-inrh [20 to 50
mini diameter holes. For LARGER holes-use the 9sme or softer
grade wheel. For SMALLER holes-use a hA.,d1z;.ade wheel. Also
see section 20 2. Grinding Guidetiries.

8-126
 Internal Grinding 8.8

TRAVERSE
WHEEL WORK Wihe
INFEED W
IHEEL
MAEILHARD- SPEED SPEED wit
on dia. DNII
MAESSA CONDITION per rev. 1 CATION*
NESSof work
fpnm fpm in/pass ANSI
Bhn mi/s rn/mi ;miriipas]' fSOJ-
48. MACHINABLE CARBIDES Rough 1/3
Fer-Tc4000 50 0005
teor to A60JV
4 040 6000 150 Finish 1/6
Rc 0002 max.
to AnnealedRoh

511318

t
68 R, Hardened
to and
70OR, Tempered -- ~-

49. CARBIDES Rog- 1/3 Ruh

Titanium Carbide 5000 50 .0005 C60KV
Tungsten Carbide to to
89 R 6000 100 Finish: 1/6 Finish:
tA ___ .0002 max C12OJVt

94 RA A3- -

50. FREE MACHINING MAGNETIC ALLOYS Rough, 1/3

Magnetic Core Iron-FM (up to 2.5% Si) 5000 75 .001
to to A60LV
1856500 200 Finish: 1/
.0002 max.
to Wrought - -

240 ~-

Hi Perm 49-FM 50 50 Rough: 1/3I

to to C60KV
185 6000 150 Finish: 116
.0002 max.
240 Wrought -5 ~~i ~ Z '

51. MAGNETIC ALLOYS Rough: 1/3

5000 75 .001
Magnetic Care Iron (up to 4% Si) to to A60LV
156500 200 F~nish: 116
.0002 max.

240 Wrought

Maximum hole length is 2.5 times hate diameter. tUse diamond wheel. see section 8.10.
Maximum wheel width is1.5 times wheel diameter. tOiamond wheel is preferable. see section 8.10
See section 16 for Cutting Fluid Recommendations.
*Wheel recommendations are for wet grinding 0 8- to 2-inch 120 to 50
mini diameter holes For LARGER holes-use the same or softer
grade wheel. For SMALLER holes--use a harder grade wheel Also
see section 20.2. Grinding Guidelines

8-127
8.8 Internal Grinding

I TRAVERSE
WORK
WHEEL INFEED -
w
ofee
width HErk
IDENTfl'-
HARD- ISPEED SPEED on dia.
MATERIAL CONDITION per rev. CATION'
NESSof work
1pm fpm in/pass ANSi
Bhn Lz 113-Iiipss
st r
51. MAGNETIC ALLOYS (cont.) 5000 50 Ruh5
5000 50 0005
Hi Perm 49 to to C60KV
HyMu 80 6000 150 Finish
185 0002 max 6
to Wrought --
240

Rough. 1/3
Alnco I 5000 50 .0005
Alnico :! to to A60JV
Atmco III 6000 150 Finish:
Almco IV 45 C .0002 max. 1/6
Ainico V to As Cast -
Atnico V-7 58 RC ~~_ ~ A
Alnico XII
Columax-5
Hyflux Alnico V-7 , .

52. FREE MACHINING CONTROLLED Rough: 1/3

EXPANSION ALLOYS 5000 50 .0005
to to C60KV
Invar 36
125 Annet6000
Annealed 150 Finish. 16
.0002 max.
to or
220 Cold Drawn N M -.

X-11: 11
53. CONTROLLED EXPANSION ALLOYS 5000 50 .0005
Invar to to C60KV
Kovar
125 Annealed F
000 as.
to or .02mx
250 Cold Drawn -

54. CARBONS & GRAPHITES

Mechanical Grades 5000 .0005
to 50 C36KV
40 6500 Finish-
to Molded .0002 max. 1/6
or -
100 Shore Extruded
Shorez

Rough- a1
Brush Grade Carbon 5000 .0005
to to C36KV
8 6500 Finish
to Molded .00 a, 1/6

90 or4
Shore Extruded

Maximum hole length is 2 5 times hole diameter.

Maximum wheel width is 1.5 times wheel diameter
S-e section 16 for Cutting Fluid Recommendations.
'Wheel recommendations are for wet grinding 0 8- to 2-Inch [20 to 50
mm] diameter holes. For lARGER holes-use the same or softer
grade wheel For SMALLER holes-use a harder grade wheel. Also
see section 20 2. Grinding Guidelines.

8-128
 Internal Grinding 8.8

TRAVERSE
WHEEL WORK INFEED Whe IDETFI
SPEED SPEED on dla. wit DNI-
HARD- per rev. CATION1
MATERIAL CONDITION
NESS of work
fpm fpm in/pass ___ANSI

Bhn ~ WAi$
*ms
Graphite Rough og
5000 0005 31

55. GLASSES & CERAMICS 50 50 Rough- 1/3

Glass 00 50 .0005
480 to to C80Jv
to6500 150 Finish,

Porelin nael5000 50 .0005 1/

Cs.Mld. 6500 150 Finish- 1/

Wlrecoammenti ons are foteondn .. o2Ic 2 o

mini~~~~~60 fe holesh: 10aet0 FoiAREnhissshhesmeo

Selicon 20rid2.GKdnPGieie
gria whlor SMALeR oe-seahre gaewel lo 8
8.8 internal Grinding
TRAVERSE
WHEEL WORK INFEED Whdth I WEELFI
on dia. wdh DNII
MATERIAL II HARD-
ESCONDITION
NESS
SPEED SPEED
per rev.
of work
CATION*

torn fpm in/pass ANSI

Birn ~ ~ - 4O
A-w~m~~~m/
56. PLASTICS (cont.) 50/30 Rough
Thermosetting Plastics 500 50 C4001
6500 150 Finish- 1/6
.0005 max.
-Cast MI h 113

Rough: 1/3
5000 50 001
10 t0 C46KV
6500 150 Finish. 1/6
0005 max.

Rough. 1/
5000 50 .001
t0 to C36LV
6500 150 Finish: /
.0005 max.
Laminated .-

58.FLAE ~Rough*
ThEMAL 1/3
58 LM TERIALS SPRYE 5500 50 .0005
Sd5
MATRALy~ to t0 C80HV
Chromium Carbide 650000 2 max. 1/6
Chromium Carbide-Cobalt Blend-- __ .02mx
Columbium Carbide ~---
Tantalum Carbide ~_.1'
Titanium Carbide --

Tungsten Carbide
Tungsten Carbide-Cobalt ____ ________

Tungsten Carbide
(Cobatt)-Nickel Alloy Blend

Maximum hole leigth is2.5 limes hole diameter. Diamond wheel is preferable for flamne
sprayed carbides and cc 510-
Maximum wheel width is1.5 times wheel diameter. ics. see section 8.10.
See section 16 for Cutting Fluid Recommendations.
'Wheel recommendations are for wet grinding 0 8- to 2-Inch 120 to 50
mm] diameter holc.- For LARGER holes-use the same or softer
grade wheel. For SMALLER holes-use a harder grade wheel. Nlso
see section 20.2. Grinding Guidelines.

8-130
 Internal Grinding 8.8

TRAVERSEf
WHEEL WOFK INFEED Wheel WHEEL
SPEED SPEED ondla. i dth CATION
MArERIAL HARD-
NESCONDITION prrv AIN
NESS of work
fpm fpm in/pass ANSI
Bhn n/ -rn/in /mmi
Rough
_
1/ _ S.i.
Inorganic Coating Materiais 5500 50 0005
Alumina (Pure)
tO to C601Vl
Alumina (Grey) containing Titania
Alumina. Nickel-Aluminide Blends 6500 100 Finish 1/6
Barium Titanate .0002max 1/
Borontt oih-
Calcium Tilanate
Calcium Zirconate
Chromium Disilicidetiai1~~
Chromium Oxideft
Cobalt 140%). Zircont Blend
Columbium (Niobium)c
Glass (Kovar sealing)Tt
Hexaboron Silicidef
Magnesia Alumina Spinet
Magnesium Zirconate .
Molybdenum Disilicide
Mull1o -=

Nickel (40%). Alumina Blend - :

Nickel Oxide M -N IB
Rare Earth Oxides
Tantalum
Titania (50%). Alumina Blend
Titanium Oxide
Tungsten
Ytrium Zirconate
Zirconia (Lime Stabilized) _ -- :-

Zirconia. Nickel-Aluminide Blends Offl-

Zirconium Oxide (Hafnia Free. Lime Stabilized)
Zirconium Slicate

Sprayed Metals (Group I) Rough: 113

5500 50 0005
Co-Cr-B Atloy (Self Fluxing)
to to C6JV
Ni-Cr-B Alloy (Self Fluxing)
Nickel Chrome Steel (Special) 65Dm 150 Finish 1/6
Stainless Steel .0002 max

Sprayed Metals (Group 1) Rough: 1/3

Bronze
Chromium 6o to C8OKV
Chomiu 6500 150 Finish: 1/6
cobalt .0002 max. 1
Nickel
Molybdenum
Monet -

Sprayed Metals (Group III) Rough: 1/3

Carbon Steel I~. to to C60LV.,

Precipitatio-, Hardening Steel 650 150 Finish: 1/6

.0002max.

Maximum hole length is 2-5 irmeshole diameter. Diamond whael is preferable for flame sprayed carbides and ceram-
Maximum wheel width is 1 times wheel diameter. ics: see section 8.10.
See section 16 for Cutting Fuid Recommendations t CAUTION, Toxic Material. refer to National Institute for Occupational
20 to50
*Wheel recommendations are for wet grinding 0 8- to 2-ri 1cU Safety and Health (NIOSH) for Precautions.
mm) diameter holes For LARGER holes-use the $'.e or softer
grade wheel. For SMALLER holes-use a harder gi. cf. wheel. Also
see section 202. Grinding Guidelines.

8-131
8.8 Internal Grinding
TRAVERSE
OR
WHEL
WHEELWORK
I NFEED Wheel WHEEL
idthIDENTIFI-
MAEILHARD- CNION SPEED SPEED on dia. ervCAIN
NESS Jof work
fpm inpassANSI
frn
Bhn - i 'lkttmlpma.
59. PLATED MATERIALS 30D 50 u~ 3
1D5
Ctiromium Plate:30 00I
10 to A80HV
4000 150 Finish.
-~~~ 0002mrax 16

5000 so 000 3
,NickelPlate to to A60KV
Silver Plate
5 o rih 16

-0005 m-fuc o

61.RUBERRoug't 113
500050 001
to to C3OIV
6500 15,0 Finish: 11
.0005 ax

-Whe~aecorifiadstos
foCe gidn 08 oJ-n (2 o5 toe
mm)~~
AGE~ ~ oa-us ~h ari rs 1iaete 116o
grad whet.
a arde
Fr grae
SALLE hols-us 0.Als
werc setin_0.____gGudeins

8-13-
 Internal Grinding 8.9
Cubic Boron Nitride Wheels
TRAVERSE
WORK INFEED Wheel WHEEL
WHEEL
SPEED SPEED on dia. width IDENTIFI-
HARD.
MATERIAL CONDITION per rev. CATION
NESS of work
I pm fpm in/pass ANSI

1. FREE MACHINING CARBON I Rough: 1/3 B120TB

STEELS, WROUGHT 5.000 80 0005
Low Carbon ReaulfurizedI to to
oCab 118 OCarburizd 10.000 150 Finish. 1/8 B180TV

1108Over and/or 007 max.

1109 1119 50Rc Quenched r935Z
1211 z8Z
1110

Medium Carbon Reaulfurized - -,- -__,_______ . t t-. _,_._ ,_.S - .__-__-__

1137 1141 1146

1139 1144 1151

Low Carbon Leaded
11L7 114 1146t
101 114L 115 -

Low Carbon Leaded

2. CARBON STEELS, Rough 1/3 120T6

WROUGHT 5,000 80 .0005

1005
1008 1012
1015 1019
1021 1026
513'A Over Carbunzed
and/ar002mx 10,000 150 Finish. 1818T

1009 ,016 1022 1518 and Tempered . , ' '' .".,

1010 1017 1023 1522
1011 108 1025
Medium Carbon Leaded VIN IW,
103010042 1053 1541
1033 1043 1055 1547
1335 1044 1524 1548
1037
1O39 1045
1049 1525
1527 1551 .000

1040 1050
High Carbon 1536 to , to >ff
1060 1074 1085 1566
1064 1075 1086 1572 - R
1065 1078 1090
1069 1080 1095
1070 1084 1561

107 14 55 15

See section 16 for Cullig Fluid Recommendations

Se: section 20 1 for addional information.

3 18-133
1 1 12 1548
8.9 Internal Grinding
Cubic Boron Nitride Wheels
TRAVERS
WHEEL WORK INFEED Wheel WHEEL
HARD- SPEED SPEED on dia. width I IDENTIFI-
MATERIAL CONDITION per rev. CATION
NESS of work
fpm tpm in/PCIss ANSI
Bhn r/mi
mms- mm/*pas- - - - ANSI
4. FREE MACHINING ALLOY 5.000 80/00 812T
STEELS, WROUGHT500 80 05
Medium Carbon Resulturized to to
4140 Carb~urized 10,000 1! Finish 1/8 B180TV
41OeOver and/or .0002 max.
4140Se50 Rc Quenched - ~- is T2O
414Teand Tempered ; -: -4- a --.
z Oi3
414S5e
4147Te to- to . -

4150 46A--ilh::
Medium and High Carbon - _______ .00IflMax. - 81 8T
Leaded
A1L30 41147 51132 861.40
41140 41L50 521100
411-45 43140 86L20

5. ALLOY STEELS, WROUGHT Rough- 1/3 B12OTB

Low Carbon 5,000 80 .0005
to to
4012 4615 4817 8617 Carbur'zed 10,000 150 Finish: 18881
4023 4617 4820 8620 Over and/or.02ma. 18B8T
4024 4620 5015 8622 50 0002 maxche
4118 4621 5115 8822 Qece ~~Rt91 j3~'B2T4..

4320 4718 5120 9310 an Ternere )!C-4

0ir-
4419 4720 6118 94155#z ~ ~ '*~.- -~y-.'

4422 4815 8115 94817 ~-' 1 -

Medium Carbon - ________ - - si~~ ia~ - ~ --- .-

1330 4145 5132 8640

1335 4147 5135 8642
1340 4150 5140 8645
1345 4161 5145 86845
4027 4340 5147 8650
4028 4427 5150 8655 .

4032 4626 5155 866~0 - -- ~ -

4042 50844 51860 8742 ~. .- '

4047 5046 6150 9254 -

4130 50B46 81645 9255

4135 50B50 8625 9260
4137 5060 8627 94830
4140 50860 8630

High Carbon 2-M-0-- -

50100 51100 52100 M-50 5-,t.' -a~

OW - w__

See secticn 16 for Cutting Fluid Recommendations

See 6ction 20 1 for additional information

8-134
 Internal Grinding 8.9
Cubic Boron Nitridie Whteels
TRAVERSE WEE
WHECL WORK INFEED D4iI Iit
MATERIAL HARD. CONDITION SPEED SPEED on dia. I per rev. CATION
NESS pn fp n/pas of work AS
Shn ~r/i- i/i
6. HIGH STRENGTH STEELS, Rough 1/6120TB
WROUGHT 5.'000 80 0005
to to
300M Hit 10,000 150 Finish
4330V H13 Over Quenched .0002 max. 1/8iS1OTV
4340 HP 9-4-20 50 Rc and Tempered ~oi~i& 1OB-
4340Si HP 9-4-25 -' 2 z2
98BV40 HP 9-4-30 '7o
M~ac HP 9-4-45 4 Fnlh> --

7MARAGING STEELS, 000513 12T

WROUGHT 5,000 '0 Rogh005 i2T
120 Grade to 10
180GrdeC00O 150 Finish: 1/8S180TV
200 Grade Over 17 .002max.
250 Grade * . aae Rbhj
300 Grade 2' 4 3 -

350 Grade tO '

HY2?n ,-

ASTM A538 Grades A, 6, C O rnL-- -e'

S. TOOL STEELS, WROUGHT 80 Rough: 1/3 B120TB

5,000 80 .0005
A2 H14 M1O P20 to to
A3 H19 M30 P21 10,000 150 Finish: 18B8T
A4 H1M3 Si Over Quenched 0002 max. ____

A6 H22 M34 82 50 R, and A sw ~ -- -W4

A7 H23 M36 S5 Tepeed-
*%8 H24 M41 S6 Teprd5a,

A 10 H26 M43 Ti
'), H42 M44 T2 _
D3 L2 M46 T4
D4 L6 N147 T5
05 L7 01 T6____________
rl M2 06 T15 -

Fl2 M3-1 07 Wi ME ~
HIO M3-2 vz W2
Hil M4 P4 W5I
H12 AB P5 '

H13 M7 P6- R

SAE J438b Types IN108. W 109.

Wi 10. Wi 12. W209. W210,

See section 16for Cutting Fluid Recommendations - -~ 4~ ~= - -

See section 20 1 for additional intormaton

8.9 internal Grinding
Cubic Boron Nitride Wheels
TRAVERSE
WORK INFEED Wheel WHEEL
WHEEL
SPEED SPEED on dia. width IDENTIFI-
HARD- per rev. CATION
MATERIAL CON" 1" -
NESS of work

fpm fpm in/pass ANSI

Bhn rAMMIrnir
'-IiW
Owlo"* MM _ _ _

9. NITRIDING STEELS. Rough i/3 8120TB

5.000 80 0005
WROUGHT to toI
Nitralloy 125 10,000 150 Finish
Nitralloy 135 60 Rc 0002 max /8 B180TV
Nitralloy 135 Mod to Nitded 5 --
Nitralloy 225 65 R9
Nitra.loy 230 t
Nitralloy EZ - - I
Nitralloy N S
Ni rex 1

13. STAINLESS STEELS. R ough' 1/3 a 120T8

WROUGHT 5,000 80 0005
Martenaiticto o
403 440A 1/8 B180TV
4408 Over Quenched 0002 max.
410
414 440C 275 and I -4 4.,
420 501 Tempered -
3422 502

431 _

Greek Ascoloy

Rough 13B2T
15. CARBON STEELS,CAST 5,000 80 .0005
Low Carbon t
ASTM A426 Grade CP1 Carbunzed 10.000 150 Finish

1010 Over and/or 0002 max. 1/8 B180T,

1020 50Rc Quenched --.
Medium Carbon and Tempered A
ASTM A352. Grades LOA. LOB.

ASTM A356 Grade 1

1030 1040 1050

See section 16 for Cutting Fluid Recommendations

See section 20 1 for additional information

8-136
 Internal Grinding 8.9
Cubic Boron Nitride Wheels
TRAVERSE
WHEEL WORK INFEED I WheWHE
HARD- SPEED SPEED on dla. width
per rev.
I IDENTIFI-
CATION
MATERIAL NES CONDITION
NESS of work
fpm fpm in/pass ANSI

16. ALLOY STEELS, CAST Rough 1/3 B12OTB

Low Carbon5,0 8005
ASTM A217 Grade WC9to o
ASTM A352 Grades 103, LC4 Carburized 10,000 150 Finish a
00 1888T
ASTIA A426* Grades CP2. OPS. Over and/or
CP5b, CPI 1,0CP12. CP1S, 61'Qunhe
CP21, CP22 and Tempered
1320 2320 4120 8020 rm I
2315 4110 4320 8620
Medium Carbon
ASTM A27 Grades Ni,N2.
U-60-30.,60-30, 65-35,
70-36. 70-40
ASTM A148. tQrades 80-40.
8o-5o, qo-eo. 105-85.
120-95.,150-125, 175-145
ASTM A216. Grades WCA.
woe, woo
ASTM A217 GradesWCW.l,
WC4, WOS. WC6 _____________

ASTM A352 Grades [-Cl. [02.

[02-1
ASTM A356 Grades 2, 5. 6. 8,
9. 10
ASTM A389 Grades 023. 024
ASTM A486 Classes 70. 90.
120
ASTM A487. Classes iN. 2N.
4N, 6N. 8W. 9N. ION, ON. 10.
20. 40. 4CaA. 60.,70.80.,_______
90. 100
1330 4130 80830 8640
1340 4140 8040 9525
2325 4330 8430 9530
2330 4340 8440 9535
4125 8030 8630

17. TOOL STEELS, CAST Ruh1/3 8120T8

ASTM A597, Grades CA-2.
00-2. 00-5. CH- 12, CH- 13.1000 50 Fns
Over Quenched

See section 16 for Cutting Fluid Recommendations

See section 20 1 for additional information

8-13720
 - PEC=i t PAGE BLANK-NOT FILfLW

Internal Grinding 8.10

Diamond Wheels
TRAVERSE
WEEL WORK INFEEDe
WHEO
SPEED on dla.D widtn IDENTIFI-
MATERIAL HR-
HARD- CONSPEED
CONDITION per rev. CATION
NESS of work

fpm fpm in/pass ANSI

Wlin _____ JOE___ -t____ ANI12
48. MACHINABLE CARBIDES 1
30
1 Rough
001 3
ASD100-R100-B
Ferro-Tic Fero-~cto 1200 to
1500 50 Finish, 6 ASD150-R100-B*
68 A0 Hardened I0003 max
to and 7 0003 max
72 Rc Tempered

IRough3 10R53
49. CARBIDES 5000R D150-R75-
Titanium Carbide
Tungsten Carbide:TugtnCrie6000 to to
100 Finish
89 RA 60002 max 6 D220-R75-B
to .00-a

51. MAGNETIC ALLOYS Rough 3 D100-NIOO-M

to to
Magretic Core Iron (up to 4% Si) ,

Pi Perm 49 6000 60 Finish:

HyMu 80 185 .001 max 6 D220-N100-M
to
240
Wrought0
V- 12NUN7z2
7-~
WX

AlnicoRough 3 D -N75-M
Atco5000 30 .003
Alnico II to to
Almico
Alnico 1][
IV 45 R c 6000 40 Finish
001 max 6 D220-N75-M

Atnico VtoACatL
Atnico V-7 58 Rc
1W 91Mi
49 ~ ~ _
Alni~zo XII
Columax-5 P 1D
Alnico V-7WM- .y-lux

55. GLASSES & CERAMICS 5000 50 003 D100-N100-M

Machinable Glass-Ceramic to to
(MACOR) 5500 100 Finsh-
250 550 10an . 6 D120-N100-M

boog

Knoop Cas
S seto
ee 0 1Rough: PYROERA 400 50 .001 3 Dat0-N100-M
to to
Se1eto010ogulngFudRcomnain Mea-oae i 0 nn
704500 100 Finish," 20NO-
700o .0002 max. 6 D2.N 0 -

See section 16 for Cutting Flid Recommendations IMetai-coateo diz.nond

See section 20 1 for additional information

8-139

- - n- -__________
8.10 Internal Grinding
Diamond Wheels
TRAVERSE
Wheel WHEEL
WORK INFEED Wheel WDET-
WHEEL wit DNI-
HARD- SPE:-D SPEED on dia.
MATERIAL HARD- CONDITION per rev. CATION
NESSI of work
fpm fpm in/pass ANSI
Bhn rr" V:pR
55. GLASSES & CERAMICS Rough- 3 DiOO-R50-M
4000 50 .001
(cont.)
480 to to
Glass
4500 100 Finish- 6 D220-R50-M
530 - .0002 max.
Knoop Ink 51 -7 r

-oo qt$i 3 M%
6000 15 FYh

Mica Rough: D100-N75-8

5000 50 003
to to
6000 150 Finish: 6 D220-N75-
.001 max.

Pocii nmlRough. 3 D800-N 100-M

Ceamcs4000 so .001

AunuSdaeOvr4500 100
e Irt-
Finish:6D20ROM
-
.0005 max. 6D0-N0-

Seesecin 16 utingidecto to T

Almnesa (lmgneum Oxide)

Ao aMul
l ie
Aluminu S~rilide Ove
4noop
to
50
to
.00

6
.a -=
D10NO-
-

M~agnia (aneium Oxide) no

Tria (Beryium Oxide)__
Silicon DNioridet

Zircon (Zirconium Silicate)

I-
Zirconia (Zircorium Oxide)

Sehscon 20itrditinlinomtinSfeyadHelh(NOH-frPecuin

See section 16 for Cutting Flied Recommendation's ttCAUTION* Toxic Material. refer to National Institute for Occupational
See section 20 1 for additional information Safety and Health (NIOSH) for Precautions

8-140-,
 Internal Grinding 8.10
Diamond Wheels

TRAVERSE
Wheel WHEEL
WHEEL WORK INFEED width IDENTIFI-
SPEED SPEED on dta.
MATERIALHARD-
NESS CONDITIONper rev.
of work CATION

fpm fpm in/pass | ANSI

8hn I 'N,
58. FLAME (THERMAL) SPRAYED Rough 3 D150-Nl10-B
MATERIALS 5000 50 002
Sprayed Carbides to to
Chromium Carbide 6000 100 Finish 6 D220-N100-B
Chromium Carbide-Cobalt Blend .0005 max
Columbium Carbide -A
Tantalum Carbide - _ --
Titanium Carbide
Tungsten Carbide
Tungsten Carbide-Cobalt
Tungsten Carbide
(Cobalt)-Nickel Alloy Blend

Inorganic Coating Materials .0023

h50 D120-N10-B
Alumina (Pure)
Alumina (Grey) containing Titania 60 to
Alumina. Nicket-Aluminide D220-Nl10-B
Blends .00 ma. -
Barium Titanate
Borontt
Calcium Titanate
Calcium Zirconate
Chromium Disilicidef
Chromium Oxidett
Cobalt (40%). Zirconia Blend
Columbium (Niobium)tt
Glass (Kovar sealing)t1
Hexaboron Silicidett
Magnesia Alumina Spine W
Magnesium Zirconate
Molybdenum Disilicide
Mullie
Nickel (40%). Alumina Blend t
Nickel Oxide
Rare Earth Oxides
Tantalum
Titania (50%). Alumina Blend
Tdanium Oxide
Tungsten
Yttrium Zirconale
Zirconia (Lime Stabilized)
Zirconia. Nickel-Aluminide
Blends
Zirconium Oxide (Hafnia Free, -

Lime Stabilized)
Zirconium Silicate

See section 16 for Cutting Fluid Recommendations tt CAUTION- -oxic Material. refer to National Institute for Occupational
See section 20 1 for additional information Safety and Health (NIOSH) for Precautions

8-141
 pjC1~iiG PAcE BLAC-NOT FLUXED

Centerless Grinding 8.11

IWHEEL THRUIFEED INFEED IDWEELFI

CATINT
MATERIAL jHARD- I SPEED OF WORK' on dia.
CATION-
NESS CONDITION
f pm inmin in pass ANSI

1. FREE MACHINING CARBON STEELS, Rlough

Low Carbon Resulturized 5500 50 005M

1108 11na
111
i 50 R~c
Hot Rolled. Nor malized
Annealed, Cold Drawn
6500
-
150 IFinish
10015 max
1109
1110 1211 mxor Quenched Ruh
1115 1212 and Tempered 428; 113-

1117 121533 3 ms.

Medium Carbon Resulturized_______ __ O3 x ______

1132 1140 1145 Rough

117to to A60LV
L139 Le
1144o 1e Couied 6500 150 Finish
LowCaronLeaedOver and/or 0015 max
10L18 121-13 121-15 50ORc Quenched and Iog
11L17 12L14 Tempered e2842 =---'13 I 1,
Medium Carbon Leaded --- -- AOL
10L45 111L37 111L44 Y3

2. CARBON STEELS, WROUGHT Rougt,

Low Carbon 5500 50 005
10 102 11 106to to A60MV
105 01119 106Hot Rolled. Normalized. 6500 150 Finish
1006 1013 1020 1029 50 RC Annealed. Cold Drawn 0015 max,
1008 1015 1021 1513 max or Quenched 5
1009 1016 1022 1518I ,.

1010 1017 1023 1522 ~ Ra B 5;5irpee

1l 1018 1025 ___

Met'-m Carbon ----

1030 1042 1353 1541 38ma.

Rough
1033 it.", 1055 1547 55ousogh
1035 1044 1524 1548 550 50 005L
1037 1045 15 1551 Carburized 6500 150 Finish
1038 1046 1527 55 Over andlof _00 15ma
1039 149152 ORC Quenched and Io;g
1040 1050 1536 Teprd .8
High Carbon - 60V
1060 1074 1085 1566
1064 1075 1086 1572 3' 8 '' 1
1085 1078 1090
1069 1080 1095
1070 1084 1561

3. CARBON AND IFERRITC ALLOY STEELS Rough

(HIGH TEMPERATURE SERVICE) 5500 50 .005
oA6M
ASTM A3b2 Grades FPA. FPS, FF 1. FP2.to
FP3b. FF5. iF7. FF9, FF11. FF12, FF21. 150 As Forged, 6500 150 Finish-
FF22 toAnnealed .0015 max
200O or Normalized_
and Tempered ~ 8

See section 16 for Cui. 'ig Fluid Recommendations

'See section 8 12 for %VonkTraverse Rates As recommended starting
conditions-use a regulating wh'eel angle with a positive inclination of
3 and a regulating wheel speed of 2510o40 rpm
tWfieel recommendations are for wet gninding 0 8- to 2-inch (20 to 50
mm] diameter work For LARGER diameter work-use a softer grade
and/or coarser grit whee! For SMALLER diameter work-use a
harder grade wt'.eel Also see section 20 2. Grinding Guidelines

8-143
8.11 Centerless Grinding
WHEEL
WHEEL THRUFEED I INFEED
SPEED OFWORK* ondla. ICENTIFI-
HARD-
MATERIAL NESS CONDITION CATrONt
RN fpm in/mn in/pass ANSI

Rough:
4. FREE MACHINING ALLOY STEELS,
WROUGHT
to to A60MV
tedium Carbon Resulfurized Hot Normalized.
Rolled. Cold 6500 153 Finish
4140 50 Rc Annealed. Drawn 0015 max.
4140Se max or Quenched -
4142Te
4145Se and Tempered
4147Te
4150
Medium and High Carbon Leaded
4'L30 41L47 31L32 86L40 5500 50
41L40 41L50 52L100 to to A80LV
41L45 43L40 86L20 Carburized 6500 100 Finish
Over and/or 0015 max.
50RC Quenched and
Tempered

Rouh.
5. ALLOY STEELS, WROUGHT
to 50 A00M
Low Carbon
4012 4615 4817 8617 Hot Rolled. Normalized. 6500 150 Finish
4023 4617 4820 8620 50 RC Annealed, Cold Drawn .0015max.
4024 4620 5015 8622 max. or Quenched- - - - -

4118 4621 5115 8822anem rd

4718 5120 9310 and Tempered
4320
4419 4720 6118 94B15
4422 4815 8115 94B17
Medium Carbon
4145 5132 8640 Ruh
1330 .005
4000 so
to A80LV
1335
1340 4147
4150 5135
5140 8642
8645 to
1340 4150 5140 8645 Carburized 6000 150 Finish:
1345 4161 5145 86845 Over and/or .0015 max
4027 4340 5147 8650

4028 4427 5150 8655 50Rc Quenched and - - - --

4032 4626 5155 8660 Tempered

4037 50B40 5160 8740
4042 50844 51B60 8742
4047 5046 6150 9254 1
4130 50B46 81B45 9255
4135 50850 8625 9260
4137 5060 8627 94B30
4140 50B60 8630
4142 5130 8637
High Carbon
50100 51100 52100 M-50

Rd

See section 16 for Cutting Fluid Recommendations

*See section 8.12 for Work Traverse Rates As recommended starting
conditions-use a regulating wheel aigle with a positive inclination of
3* and a regulating wheel speed of 25 to40 rpm
tWheel recommendations are for wet gnnding 0 8- to 2-inch 120 to 50
mm) diameter work. For LARGER diameter work-use a sofler grade
and/or coarser grit wheel. For SMALLER diameter work-use a
harder grade wheel Also see section 20.2. Grinding Guidelines

8-144
 Centerless Grinding 8.11

INFEED WEL
WHEELITHRUFEED
MATERIAL HARD SOFIDNTIFI-
CONDITION SPEED 1 on dla. CATIONt
f mi/m in/pass ANSI

Bhn M
6. HIGH STRENGTH STEELS, WROUGHT Rough
300M 550 50 005 1

to A60MV
4330V
4340 Annealed. 6500 150 Finish
4340Si 50 13
C
Normalized
98BV40 max or Quenched
D6ac and Tempered
H1l
H13
M aw
HP 9-4-20
HP 9-4-25
HP 9-4-30 50
HP 9-4-45 to A80KV
600 150 Fiih
Over Quenched .
Tempered . -. -

7. MARAGING STEELS, WROUGHT 0Rough

to to A6MV
ASTM A538- Grades A. 8.C 60 150 Finis
120 Grade mas
50 R Annealed 60
180 Grade m
max. or
200 Grade
250 Grade Maraged
300 Grade
350 Grade
HY2?0 I.
400 50 .0
to to A80KV
6000 150 Finish
Over
50Rc Maraged

50
S. TOOL STEELS, WROUGHT
Group Ito A60MV
H13 L6 P20 1
A2
A3 H14 L7 P21 50 R Annealed
AA H19 01 Si 50 Annea5ledx
A6 H21 02max or Quenched
02 2 and Tempered
A8 H22 06 $5
A9 H23 07 $6
A10 H2A P2 $7
H10 H25 P4 W1
H26 P5 W2
H11
P6 .:5 50
H12 L2
to A60LV
SAE J438b: Types W108. W109, W1 10. W1 12.
6000 150ncheis15
W209. W210. W310
Over Quenched 01 a
50Fad-- Tempered

ee section 16 for Cutting Fluid Recommendatns

*See section 8 12 for Work Traverse Rates As recommended starting
inclination of
conditions-use a regulating wheel angle with a positive
31 and a regulating wheel speed of 25 to 40 rpm
J Wheel recommendations are for wet gnnding 0.8- to 2-inch [20 to 50
mm) diameter work For LARGER diameter work-use a softer grade
and/or coarser grit wheel For SMALLER diameter work-use a
harder grade wheel Also see section 20.2. Grinding Guidelines

8-145

= . . = . .
8.11 Centerless Grinding
WHEEL THRUFEED INFEED WHEEL
CONDITION SPEED OFWORKI on dia. CATIONF
MATERIAL HARD-
NESS
fpm in/mm in/pass ANSI
n
Bhn __ __ _ _ iS Ii hi* I
57nI - ISO

8. TOOL STEELS, WROUGHT (cont.) Rough:

Group 11 5500 50 .005
to to A60MV
D2 H42 M42 6500 150 Finish:
D3 M1 Ti 50 RC Annealed .0015
.001 max.
max.
D4 M2 T2 max or Quenched
D5 M3-1 T4 and Tempered
Fl M10 T8
F2 M30

Rough:
4000 50 .004
to to A60LV
6000 150 Finish.
50 Rc Quenchec .001 max.
58RPC Tempered T9
5NY

Rough:
4000 50 .003
to to A8OKV
6000 150 Finish:
Over Quenched .001 max.
58 RIC and
TemperedI .'

Rough:
Group III
5500 50 .005
A7 M41
to to A60LV
07 M43 D7M36500 150 Finish:
50 R Annealed .015 max.
M3-2 M44
M6 M46 mxCor Quenched -- .0 1 mx
M7 M47 and Tempered i" ;
M33 T5
M34
M36 T6 --

Rough:
4000 5z0 .004
to to A80KV
5R Qunhd6000 1,50 Finish:
50 Rc Quenchedmax.
to and
58 Rc Tempered

to to A80JV

Over Quenched
58 Rc andd
Tempered

See secton 16 for Cutting Fluid Recommendations

'See section 8 12 for Work Traverse Rates As recommended starting
conditons-use a regulating wheel angle w.th a posdve inclination of
3* and a regulating wheel speed of 25 to 40 rpm
tWheel recommendations are for wet grinding 0 8- to 2-inch 120 to 50
mm) diameter work. For LARGER diameter work-use a softer grade
and/or coarser grit wheel For SMALLER dameter work-use a
harder grade wheel Alto see section 20.2. Gnnd ng Guidelines 4

8-146
 Centerless Grinding 81

~WHELTRIED IFE WHEEL

IDENTIFI-
MATRIA
MATRIL
j HRD
ESSCONDITION
SEEL THWRFEE
jEDonl.
onFEdi
CATION'

NES pm~iii
fh 2 n/pass ANSI'

M4 j 40001
10
50
to
.004
A60KV
T1
T 6000 I 150 Finish-
50 R ~ Annealed 001 max,
maxCor Quenched -
and Tempered

Pough:
4000 50 003
to *10 A:1JV
50P Qechd5500 150 F;nish-
50 aCunchd .001 max
5Rc Tempered

Rough:
4000 5.' .002
to to A8OIV
5500 150 Finish:
Over Quenched .001 max
58 R,. and
CTempered __

9. NITRIDING STEELS, WROUGHT 50 50 Rough:

Nitrlloy1?55500 so 005
Nitraltoy 135 to t-- A60LV

Nitrallo', 135 Mo.20Annealed. 6500 150 Finish:

to Normalized .___0015max.
Nitratl'.y 225
Nitra'loy 230 350 or Quenched__ __

Nitr~~lloy EZ and Tempered i 11

Nit.,alloy N -

Nitrex 1 I--. -- ~-
I Rough:
Z000 50 .003
Ito to A8OJ'/
60ORc b000 150 Finish:
to max.
.irdd001
65 Rc ~~=~~.~~

M2FRiEE MACHINING STAINLESS STEES, Rough.

WROUGHT 5500 50 01
Fwlif to 10 A60LV
430F 135 6500 150 Finish:
4301- Se to Annealed .01 max

See section 1,, for r~iling Fluid Recommendations

*See section 8.12 for Work Traverse Rates As recommended starting
condtions-use a regu~ating wheel angle withaa positive inclination of
3 anda regulating wheel speed of 25 to040 rpm
tWneel recommendations are for wet grinding 0 8- to 2-inch 120 to 50
mm diameter work For LARGER diameter work-use a softer grads
and/or coarser grit wheel For SMALLER diameter work-use a
harder grade wheel. Also see section 20 2. Grinding Guidelines

8-147
8.11 Centerless Grinding
1 1WHEEL
WHEELI TIIUFEED INFEED IDENTIFI-
MATERIAL HARD- CONDITION SPEED OFVIORK* n ias CATION-.

12. FREE MACHINING STAINLESS STEELS,

{ Bhn
fpm inimin inps
1Pog
I ouh
ANSI

WROUGHT (cont.) 550 50 005L

Austeinific t oC0-
203EZ 135 Annealed 60 ~ iih
303 to or 1 00 15mx
303MA 275 Cold Drawn M E - __

303Pb :M- W;_

303 Plus X
303Se ____ .__________ -- ' - _ - -

MartenaificRog
416 Plus X 5 10 Fish
416Se 135 I Annealed.01ma
420F to or
42OF~e 240 Cold Drawn . __

440F
440F Se

Over Quenched .05mx

13. STAINLESS STEELS, WROUGHT 5WRuh

405 tot3A4L
409 43613 015mx
429 442 to Annealed
430 446 185

Austeriic 50 0 -0
201 308 317to o 0L
202 309 321 6W 10 Fnh
301 309S 3.30 135 Annealed 01mx
302 310 34.7 to or
302B 310S 34E1 275 Cold Drawn
304 314 384
304L 316 3815
305 316L ~-
Ruh _
Austernic
Nitronic 32
Nitronc. 33 60 5 iih
Nitionic 40 210A
NitrOnoc 50 to Annealed
Nitronic 603 250

See section folr Cuttng Fliwd Recommendations

*See section t 12 for Work Traver" Rates As recommended starting
conditions-uj. regulating wthee; angle with a positive inclination of
31 arid a reguts'iig wheel speed of125 to040 rpm
twheel recomme- dations are for wet grnnsg 0 8-to 2-inch 120 to 50
min] diameter work. For LARGER diameter work-use a softer grade
andlor coarser grit wheel. For SMALL.ER diameter work--use a
harder grade wheel. Also see section 20.2. Grr--' ng Guidtlines, -4
 Centerless Grinding 8.11

WHEEL
WHEEL THRUFEED
SP INFEED
I IDENTIFI-
MATERIAL HARD- CONDITIONSPEED OF WORK* on dln. CATIONT
NESSCODTN ANSI
fpm in/mi n/pass
Bhn __ _ _ _ _ _ __ ~ Q
Vjj~
Rough:
13. STAINLESS STEELS, WROUGHT (cont.)
Austenitic (cont.) 5500 50 005
60 100 Finis
(materials listed on preceding page)
325 0 0

to Cold Drawn .05mx

375

Martenaitic 5ogF
5to .00L
403 440A
to t
410 440B
135 6500 150 Finish:
414 440C
420501 to Annealed
422 502 275
431
Greek Ascoloy

Quenched
Over
275 and

Rough:
14. PRECIPITATION HARDENING
STAINLESS STEELS, WROUGHT to
50 -

15-5 PH 6500 150 Finish:

16-6 PH 150
17-4 PH to Solution Treated
17-7 PH 200
17-14 Cu Mo
AF-71
AFC-77
Atmar 362 (AM-362)
AM-350 5500 50 .005
AM-355 to to A60KV
AM-363 6500 150 Finish
Custom 450 275 Solution Treated
Custom 455 to C,
HNM 440 Hardened
PH 13-8 Mo
PH 14-8 Mo
PH 15-7 Mo
Stainless W

See section 16 for Cutting Fluid Recommendations

*See section 8 12 for Work Traverse Rates. As recommended starting
conditions-ure a regulating wheel angle with a positive Inclination of
3. and recommendations
tWheel speed
a regulating wheel are for wet to 40 rpm.
of 25grinding 0.8- to 2-inch [20 to 50
mm] diameter work. For LARGER diameter work-use a softer grade
and/or coarser grit wheel For SMALLER diameter work-use a
haider grade wheel Also see section 20.2. Grinding Guidelines

8-149
 8.1 Centerless Grinding
I H~no
CONDITION
WHEEL 1 THRUFF.ED
SPED OWORK
SEDO-OK"
INIFFED
on ~a.
WHEEL
IDENTIFI-
CATIONt
MATVRI-
MAEIL Sfprn Jrn/min in/pass ANSI
_________________________ hn ________~ r~i ~ Ii~~
15. CARBON STEELS, CAST IRough
Low Carbon 5500 50 005
AiM 46Grd P1to to A60MV
AS OIAnnealed.
A26Gad Normalized, 6500 150 Finish
1010 100 Normalized and 0015 max
1020 to Tempered. W4q;a Z'
Medium Carbon 300 or Quenched :3_
ASTM A352: Grades LOA, LCB. ICC and Tempered RV~
ASTM A356: Grade 1 A
1030 1040 1050 ~ ~ 10______3

Rough
5500 50 005

Carburized 6500 150 Finish.

Over and/or .01 a
50 RC Quenched and ;_
Tempered

16. ALLOY STEELS, CAST -y

Low Carbon550 s 5
ASTM A217: Grade WC Aneaed Nomaizd 650650 Fiis
ASTMV A352: Grades LC3. L04 150 Anoraled anizd, 50 10 Fns
ASIM A426: Grades CP2. CP5. CP5b, CF'1 , to Normlized ad.0 5MX
CP 12, 0P 15, CP2 1, CP22 400 or Quenched
1320 4110 8020 and Tempered
2315 4120 8620
2320 4320
Medium Carbon
ASTM A27' Grades N1, N2. U-60-30, 60-30
65-35. 70-36, 70-40400 0 05
ASTM A148: Grades 80-40, 80-50, 90-60,to uA8V
105-85, 120-95, 150-125. 175-145 Carburized 6000 150 Finish:
ASTM A216. Grades WCA. V/GB. WCC Over and/or.01ma
ASTMV A217. Grades WC I, W04. WC5. WC6 50 RIc Quenched and
ASTMV A352, Grades L1 102. 102-1 Tempered
ASTM A356* Grades 2. 5, 6, 8. 9. 10
ASTM A369.: Grades 023. 024
ASTM A486: Classes 70, 90, 120 ____

AST IA487. Classes IN, 2N, 4N. 6N. 8N. 9N,

I, DN. 10. 20. 40, 40A. 60. 70, 80.
ik; 100
1330 4130 80830 8640
1340 4140 8040 9525
2325 4330 840 9530
2330 4340 8440 9535
4125 8030 8630ME Z

17. TOOL STEELS, CAST Ruh

Group 1 50 50 .0
ASTMVA597. Grades CA-2, CH- 12, CH-i13.to oA6M
COl, 0S-5 50 RAnnealed 60 5 iih
max. or Quenched
and Tempered

See section 16 for Cutting Fluid Recommendations

*See section 8 12for Work Traverse Rates As recommended starting
conditions-use a regulating wheel angle with a positive inclination of
31 and a regulating wheel speed of 25 to 40 rpm
tWheel recommendations are for wet grinding 0.8- to 2-inch (20 to 50
mm) diameter woik. For LARGER diameter work-use a softer grade
and/or coarser grit Yheel For SMALLER diameter work-use a
harder grade wheel iso see section 20.2. Grinding Guidelines

8-150
 Centeriess Grinding 8.11

WHEEL THFIUFEED INFEED WEETLI

MATERIAL HARD- CONDITION SPEED OF WORK* on dia. CATIONt

NESfpm in/min in/pass ANSI

17. TOOL STEELS, CAST (cont.) Rough-

Group t (cont.) 4000 50 .004
to to A60LV
(materials listed on preceding page) 6000 150 Finish:
50 R% Quenched 001 max.
to and 7prl~t~ ~t
58 RC Tempered 4! ZT..-

Rough:
4000 50 .003
to to A60KV
6000 150 Finish:
Over Quenched .001 max
58 R and
Tempereo E7_

A597 Grades CD-2, CD.5

ASTMV 50 0 .0

2005 ax
to Annealed
250

48 Ri Quenched600 10 Fns

56 RG Temipered

4000 50 .003
6000 150 Finish:
Over Quenched.01mx
56 Tempered

18. STAINLESS STEELS, CAST Ruh

Ferritic 50 0 .0
ASTIA A217. Grades C5. 012to o 6L
ASTM A296, Grades CB-30. 00-50. CE-30. 135 6500 150 Finish-
CAMN CA-6NM. C04MCu to Annealed .05mx
AS1 M A297: Grade HO 1850
ASTM A487, Class CA6NM .4
ASTM A608: Grade HC30

See se.;tion 16 for Cutting Fluid Recommendations

*See section 8.12 for Work Traverse Rates As recommended starting
conditions-jse a regulating wheel angle with a positive inclination of
30 and a regulating wheel speed of 25 to 40 rpm.
t Wheel recommendations are for wet gninding 0 8-1to2-inch [20 to 50
mm] diameter work For LARGER dianmeter work-use a solte. grade
and/or coarser grit wheci For SMALLER diameter work--use a
ha.rder grade wheel. Also see section 20 2. Grinding Guideline-

8-151
8.11 Centerless Grinding
1 WHEEL
IDENTIFI-
WHEEL THRUFEED INFEED
*
SPEED OFWORK on dla. CATIOIt
MATERIAL HARD-
NESS CON'.:'TION CATIONt
fpm in/mm in/pass ANSI

18. STAINLESS STEELS, CAST (cont.) Rough:

Austenitic 5500 50 .005
to to C60LV
ASTM A296: Grades CF-3, CF-3M. CF-8,
CF-8C,CF-8M, CF-16F, CF-20, CG-8M. 135 Annealed, 6500 150 Finish:
CG-12, CH-20. CK-20. CN-7M, CN-7MS to Normalized .0015 max.
ASTM A297: Grades HD, HE,HF. HH. HI, HK. 210 or
HL, HN. HP, HT,HU As Cast, ,
ASTM A351: Grades CF-3, CF-3A, CF-3M,
CF-3MA, CF-8,CF-8A, CF-8C, CF-8M, "
; F-1OMC. CH-8,CH-10,CH-20. CK-20,
CN-7M, HK-30, HK-40, HT-30
ASTM A451" Grades CPF8A, CPF3. CPF3A,
CPF3M, CPF8, CPF8C, CPF8C (Ta Max.),
CPF8M, CPFIOMC, CPH8, CPH10,
CPH20, CPK20
ASTM A452: Grades TP 304H, TP 316H, TP
347H
ASTM A608: Grades HD50, HE35, HF30,
HH30, HH33, H135, HK30,HK40, HL30,
HL40,HN40, HT50,HUSO

Martensitic Rough0
ASTM A217: Grade CA-155
ASTM A296. Grades CA-15. CA-15M. CA-40 Annealed, to to A60LV
ASTM A426' Grades CP7, CP9. CPCA15 Normalized 6500 150 Finish:
135 or.0015 max.
ASTM A487: Classes CA15a. CA-15M or
to Normalized -

225 an
Tempered

Rough"
5500 50 .005
to to A60KV
6500 150 Finish:
Over OverQuenched
Qenche.0015 max.
275 and .
Tempered - -

19. PRECIPITATION HARDENING All

STAINLESS STEELS, CAST 5500 50 .005
ASTM A351" Grade CD-4MCu
325 Solution Treated 6509 150 Finish:
ACI Grade CBD-4Cu to or .0015max
17-4 PH 450 Solution Treated --

AM-355 and Aged

See section 16 for Cutting Fluid Recommendations

*See section 8.12 for Work Traverse Rates As recommended starting
conditions-use a regulating wheel angle with a positive ;nclination of
30 and a regulating wheel speed of 25 to 40 rpn
tWheol recommendations are for wet grinding 0 8- to 2-inch [20to 50
mm] diameer work. For LARGER diameter work-use a softer grade
and/or coarser grit wheel. For SMALLER diameter work-use a
harder grade wheel Also see secton 20 2,Grinding Guidelines

8-152
 Centerless Grinding81

WHEEL THRUIFEED INFEED WETLI

MATERIAL HARD. CONDITION SPEED OFWORK* on dla. CATIONt

fpm in/min in/pass ANSI
Bhn W Wg-MJ ~
21. GRA,:CAST IRONS Rough
Fernitic 5500 50 .005 C46LV
ASTM A48: Class 20 t0 to or
SAE J431c: Grade G18C0 As Cast. 6500 150 Finish A60KV
Pearlitic- Ferritic 45 FI Annealed .0 a
ASTM A48* Class 25 max. or Quenched
SAE J431c: Grade G2500 and Tempered
Pearlitic
ASTM A48: Classes 30. 35. 40
SAE J43 Ic: Grade G3000
Parlitic + Free Carbides ouh
ASTMV A48- Classes 45. 50 50 0 .0 5K
SAE J431c. Grades G3500. G4000 t oo
Pearlltic or Acicular + Free Carbides 45 R As Cast. 50 10 Fiih 6J
ASTMV A48: Classes 55. 60 to C nnealed .01 a
52 Rc or Quenched k-

48 Rc FlameFish

60R Induction Hardened

Austenitic (NI-RESIST) Ruh

ASTM A436- Types 1, l b. 2. 2b. 3. 4. 5. 6 50 0 .0

006500 150 Finish:

250

22. COMPACTED GRAPHITE CAST IRONS Ruh

185 6500 150 Fish

255

See section 16 for Cuflng Fluid Recommendations.I

*See section 8.12 for Work Traverse Rates As recommended starling

conditions-use a regulating wheel angle wih a positive Inclination of
3* and a regulating wheel speed of125 to040 rpm
tWheel recommerdations are for wet grinding 0.8. to 2-inch [20 to 50
mm] diameter work. For LARGER diameter work-use a softer grade
and/or coarser grit wheel. For SMALLER diameter work-use a
harder grade wheel Also see section 20.2. Grinding G jidellnes

8-153
8.11 Centerless Grinding

WHEEL THRUFEEEG INFEED WDEETLF

MATERIAL NES CONDITION SEDOWOK onda CATIONT

fprrr In/Mir. in/pass ANSI
Bhn r/r mmn mnps S
23. DUCTILE CAST IRONS Rough.
00
Fertcto to C54KV
ASTM A536 Grades 60-40-18, 65-45-12 Annealed. As Cdst' 650 10 Ftisn
SAE J434c Grades 04018. D4512 52 Rc Normalized and 0015 max
ASrrtM
A53
c rade805506ma Tempered
ASMA3
05-6orid Quenched - iu._-----
SAE J434c Grade 05506 an TepMe

ASTM A536 Grade 100-70-03

SAE J434c Grade 07003 O8R(
Martensitic Rough
ASTM A536 Grade 120-90-02 5500 50 004
SAE J434c Grade 0Q&T to to C60JV
6500 150 Fin~ish:
53 Rc Flame 001 max,
to or ~-
6Rc Induction Hardened

Austen'itic (NI-RESIST Ductile) Rough

ASTM A439 Types D-2. 0-28. 0-20. 0-3, 550 t0 005L
0-3A. 0-4, D-5, 0-58 to0 tSO FiniLh
ASTM A571 Type 0-2M 120 6500 150 F axs
to Annealed 001 ma
275

24. MALLEABLE CAST IRONS Rough-

Ferritic 5500 50 005
to to C54KV
ASTM A47 Grades 32510. 35018 Malleablized 6500 150 Finish
ASTM A602 Grade M32 10 52 R c Or 05 a
SAE J158 Grade M3210 a alalie
Pearlitic ma anald
ASTM A220 Grades 40010. 45006. 45008. Heat Treated -'-
50005 ~
ASTM A602 Grade M4504, M5003 --

SAE J 158- Grades M4504. M5003 35 - -

Tempered Martensite Rough.

ASTM A220 Grades 60004. 70003. 80002. 5500 50 .004
90001 to !0 C60JV
ASTM A602 Grades M5503. M7002, M8501 6500 150 Finish
SAE J158- Grades M5503. M7002. M8501 Over Flame 01mx

Cls Hardened
InduTyecAmao 9p- z 2t

See secio
mmnain 16 for CuMnalldR

aoreuatn
AST And 2 whelsee 2 t 0 p

S~eel ecm ~ion

for are wutnli
etogrindins812ic 2 o5

mm] diameter work For LARGER diameter work-use a softer grade

and/or coarser grit wheel For SMALLER diameter work-use a
harder grade wheel Also see sectio-n 20 2. Grinding Guidelines

8-154
 Centerless Grinding 8.11
INFEED WHEEL
WHEEL THRUFEED
I I IDENTIFI-

MATERIAL HARD- CONDITION SPEED OFWORK ondla. CATIONt
NESS
fpm in/Mm in/pass ANSI
. _hn
___ ___ ___ Bh __ ___~~___i1n
55 Rough
26. HItH SILICON CAST IRONS
Durron to to C60JV
Duriclor 6500 150 Finish.
ASTM A58
52 Rc As Cast ~ti- 001
0 maxa

Rough
27. CHROMIUM-NICKEL ALLOY CASTINGS
5500 50 005
ASTM A560 Grades 50Cr-50Ni. 60Cr-40Ni to to C60KV
6500 150 Finish
275
max
As0015
375

Rough
28. ALUMINUM ALLOYS, WROUGHT
EC 2218 5252 6253 to to C54JV
1060 2219 5254 6262 30 Cold Drawn 6500 150 Finish,
1100 2618 5454 6463 I to or 0015 max
1145 3003 5456 6951 I 150 Solution Treated XWSI V 7fg-=.
1175 3004 5457 7001 500kg and Aged
1235 3005 5652 7004
2011 4032 5657 7005
2014 5005 6053 7039
2017 5050 6061 7049
2018 5052 6063 7050
2021 5056 6066 7075
2024 5083 6070 7079
2025 5086 6101 7175
2117 5154 6151 7178

Rough
29. ALUMINUM ALLOYS, CAST 5500 50 005
Sand and Permanent Mold to to C54JV
A140 2950 5140 A7,12 0 40 As Cast 6500 150 Finish
2010 82950 A514 0 D712 0 to or .0015 max.
2080 3080 B5140 7130 125 SolutionTreated -
2130 3190 5200 7710 and Aged Sa- -k
2220 355.0 535.0 8500
224 0 C355 0 705.0 A850.0
2420 84430 7070 B850.0 - -
Hiduminium RR-350
Die Castings
C443 0 5180

See section 16 for Cutting Fluid Recommendations

*See section 8 12 for Work Traverse Rates As recommended starting
conditions-use a regulating wheel angle with a positive inclination of
3' and a regulating wheel speed of 25 to 40 rpm
tWheel recommendations are for wet gnnding 0 8- to 2-inch (20 to 50
mm] diameter work For LARGER diameter work-use a softer grade
and/or coarser grit wheel For SMALLER diameter work-use a
harder grade wheel. Also see section 20 2, Grinding Guidelines

8-155
8.11 Centerless Grinding
WHEEL THRUIFEED INFEED WEELIF
MATERIAL HARD- CONDITION SPEED OF WORK* on dla. CATIONt
NESS fpm in/min in/pass ANSI
Bhn
P_111W WII-
29. ALUMINUM ALLOYS, CAST (cont.) .
Sand and Permanent Mold 50 0 .0
328 0 3560 40 As Cast 6500 150 Finish
A332.0 A356.0 to or .05mx
F332 0 357.0 125 Solution Treated
333.0 359.0 500kg and Aged - -

354.0
Die Castings
360.0 A380.0 3900 A413.0
A360.0 383.0 3920
3800 A384 0 4130

3D. MAGNESIUM ALLOYS, WROUGHT# ouh

AZ21A HIK31Ato o 6K
AZ31B HM21A 50 Annealed. 6500 150 Finish:
AZ31C HM31A to Cold Drawn.01ma
AZ61A ZK40A 90 or
AZ80A ZK60A 500kg Solution Treated -- .

and Aged

31. MAGNESIUM ALLOYS. CAST# ouh

AM60A AZ91C ZE41Ato oC6K
AM100A AZ92A ZE63A 50 As Cast. 6500 150 Finish:
AS41A EZ33A ZH62A to Annealed.01ma
AZ63A HK31A ZK51A 90 o
AZ81A HZ32A ZK61A 500kg Solution TreatedR
AZ91A K1A adAe
AZ91B OE22A

32. TITANIUM ALLOYS, WROUGHT# 9

Commercially Pure 40 0 .0
995550 IO Fns:N
99.2 110 55005 150. FJih
99.0 t0 Annealed j
98.9 275
Ti-0.2Pd
TiCODE- 124

See section 16 for Cutting Fluid Recommendations t Use friable (green grit) silicon carbide.
*See section 8 12for Work Traverse Rates As recommended starting #CAUTION: Potential Fire Hazard. Exercise caution in grinding and
conditions-use a regulating wheel angle with a positive inclination of disposing of swart. Do NOT use waler or water-mis. ble cutting
31 and a regulating wheel speed of 25 to 40 rpm. fluids for magnesium allc/s.
tWheel recommendations are for wet grinding 0.8- to 2-inch [20 to 50
mmi diameter work. For LARGER diameter work-use a softer grade
andior coarser grit wheel For SMALLER dMameter work-use a
harder grade wheel. Also see section 20 2. Grinding Guidelines.

8-156
 Centerless Grinding 8.11

MATERIAL
HARD
NEA RD. ISPEED
CONDITION
fpm
J I T
WHEEL THRUF5ED
0F WORK.
_
in/min
_

1
INFEED
on dla.
i n/pass
_
WEELFI
CAIt
_
ANSI
8 n~___ _ _ _ __ _ _ ~i/0718!O~
Alpha and Alpha-Beta Alloys
Ti-8Mn
tRough
I4000 50 .001
Ti- 1AI-8V-5Fe iIto Ftos C6OKVi
Ti-2AI-1I lSn-5Zr- IMo 300 5500 150 Fns
Ti-3lAi-2 5V !Aneld.00 ,05 max

Ti-5A1-2 5Sn ELI sg~~

Ti-5Al-6Sn-2Zr-1I~lo 28 Riiih-
Ti-6At-4V I ough-
Ti-6AI.4V ELI 4000 50 001
1a -A[-6V-2Sn to to C6OKVf
Ti-6, 2Sn-4Zr-2Mo 320 5500 150 Finish
Ti-6AI-, -i-4Zr-2Mo-.25Si to Solution Treated .0005 max
Ti-6A1-2Si r6M 440 and Aged Ea
Ti-7AI-4Mvo

Beta Alloys Rough-

Ti-3AI-8V-6Cr-4Mo-4Zr 4000 50 001
Ti-8Mo-8V-2Fe-3AI to to C60KV*
Ti- 11.5Mo-6Zr-4 5Sn 275 Annealed 0005 max.
Ti-1OV-2Fe-3At to or
Ti 13V-llCr-3At 350 Solution Treate d 1W-

350 5500 50 Finish-

to Solution Treated .0005 max.
440 and AgedWA NO

33. TITANIUM ALLOYS, CAST# ouh

40 0 .0
Conmmercially Pure
99.0 t oC0~
Ti-0 2Pd 150 As Cast 5500 150 Finish:
ASTM 8367. Grades C-i1. C-2. C-3, C-4. to Of
C-7A. C-7B. C-8A. 0-88 250 As Cast
and Annealed Z

Alpha and Alpha-Beta Alloys 4000h

400 50 .001A
Ti-WA-2.5Srnt oC0~
Ti-6At-4V A at50 S iih
Ti-6A-2Sn-4Zr-2Mo 300 As Cast5 550ax.Fnih
Ti-8AI1l4o-1V to o
ASTM 367: Grades C-5. C-6 350 As Cast
and Annealed ~ .

See section 16 tor Cutting Fluid Recommendations 4Use triable (green grit) silicon carbide
'See seLtion 8,12 for Work Traverse Rates As recommended starling #CAUTION Potential Fire Hazard. Exercise caution in grinding and
conditions-use a regulating wheel angle with a positive inclination ot disposing of Swart
30 and a regulating wheel speed of 251to40 rpm.
tWheel recommendations are for wet gninding 0 8.to 2-inch (2^~ to 50
mm] diameter work For LARGER diameter work-use a sofner grade
and/or coarser grit wheel For SMALLER diameter work-use a
harder grade wheel Also see section 20 2. Grinding Guidelines
I

8-157
8.11 Centerless Grinding

WHEEL THRUFEED INFEED IWHEEL

IDENTIFI-
HAD-SPEDOFOR ndL
MATERIAL HARD- CONDITION DOF WORK* on da. CATIONt
NESS fpm in/Mm n/pass ANSI

5hnI Rough
34. COPPER ALLOYS, WROUGHT
OR5500 50 005
101 116 143 162 to to C54KV
102 119 145 184 6500 150 Fmnsh-
104 120 147 185 10 R e 0015 nax
.05 121 150 187 to Annealed .
107 122 155 189 70 R
R
109 125 162 190- - __ ___

110 127 165 191 -

111 128 170ff 192 , -0 1
113 129 172ft 194 Rough
114 130 173ff 195 5500 50 005
115 142 175., to to C54KV
60 R8 6500 150 Finish
0015 max
to Cold Drawn
100 RB

Rough
210 332 368 464 5500 50 005
220 335 370 465 to to C54KV
226 340 377 466 6500 150 Finish.
230 342 385 467 10 Re 0015 max.
240 349 411 482 to Annealed - --
260 350 413 485 -- T79
268 353 425 667-
270 356 435 687
280 360 442 688 .
314 365 443 694 Rough
316 366 444 5500 50 005
330 367 445 to to C54KV

(500 150 F aishx

60 Re
Cold Drawn U max.
to
100 R

Rough:
505 613 632 5500 50 005
510 61 - 638 to to C54KV
511 618 642 6500 150 Finish:
521 619 651 10 R e .0015max
524 623 655 to Annealed
544 624 674 70 R8
608 625 675
610 630

Rough:
5500 50 .05
to to C54KV
F ish
t00o Cold Drawn 6500 r,'
.00 15 max.

100 R

See section 16 for Cutting Fluid Recommendations ttCAUTION Toxic Material. refer to National Institute for Occupational
.See section 8 12 for Woik Traverse Rates As recommended starting Safety and Health (NIOSH) for Precautions
conditions-use a regulating wheel angle with a positive inclination of
3. ai.d a regulating wheel speed of 25 to40 rpm
Iheel recommendatons are for wet gnnding 0 8- to 2-inch [20 to 50
mmj diameter work For LARGER diameter work-use a softer grade
and/or coarser grit wheel For SMALLER diameter work-usa a
harder grade wheel Also see section 20 2.Grinding Guidelines

8-158
 Centeriess Grinding 8.11
WHEEL
IDENTIFI-
WHEEL THRUFEED INFEED

MATERIAL HARD-
NESS CONDITION SPEED OFWORK ondla. CATIONt
fpm in/m I Inpass ANSI

Rough 0
5500 50 005
706 752
710 754 to to C54KV
715 757 6500 150 Finish
725 770 10 Ra 0015 max
745 782 to
70%R-
Annealed
j kkm

Rough
5500 50 005
to to C54KV
60 6500 150 Finish-
0015 max
to Cold Drawn W
100 R
goug

5500 50 Rough
35. COPPER ALLOYS, CAST
5500 50 005
801 814 824ft to to C54KV
803 815 825ff 40 6500 150 Finish.
805 817ff 826ff to As Cast .01 a
807 818ff -'2t 200 or
809 820ff 828ff 500kg Heat Treated AZ
811 821ff
813 822ff

Rugh:
P 1

5500 50 .005
to to J A60LV

6500 150 Fnish-

34 R c to Het Trated.0015 max.
45Rc HetTetd

Rough.
833 854 867 5500 so .005
834 855 868 to to C-54KV
836 857 872 35 6500 150 Finish:
838 858 874 to
842 861 875 200 As Cast
844 86250k
848863 878
852 864 879
853 865
Rough:
902 916 934 948 5500 50 .005
903 917 935 952 to to C54KV
905 922 937 953 40 6500 150 Finish:
907 923 938 954 to .0015 max.
909 925 939 955 100 As Cast
910 926 943 956 500kg
911 927 944 957
913 928 945 958
915 932 947
See section 16 for Cutting Fluid Recommendations tfCAUTION Toxic Material. refer to National Institute for Occupational
*See section 8 12 for Work Traverse Rates As recommended starting Safety and Health (NIOSH) for Precautions.
conditions-use a regulating wheel angle with a positive inclination of
3- and a regulating wheel speed of 25 to 40 rpm
tWheel recommendations are for wet griding 0 8- to 2-inch [20 to 50
mm] diameter work For LARGER diameter work-use a softer grade
and/or coarser grit wheel For SMALLER diameter work-use a
harder grade wheel Also see section 20 2. Grinding Guidelines

8-159
 8.1 Centeriess Grinding
WHEEL THRUFEED INFEED WDEELFI
MAERALHARD- ODIINSPEED 1 OFWORKO ondla. CAETIFIt
MATERIAL NESS CNIINCTO'
f pm L n min in'pass ANSI
Bhn I um j-in ffrn/p~
35. COPPER ALLOYS, CAST (cont.) 550 50 o005
(materials listed on preceding page) to t A60LV
6500 150 Finish
Over As Cast 0015 max
100 or
500kg Heat Treated ~Rui

962 550 50 3~
005
963 to to C54KV
964 50 6500 150 Finish:
9661t to 0015 max
973 100 As Cast ~ ~ ~ ~
974 500kg -t3 -

976
978 .
..i~
993 _ _

Rough:
5500 50 .005
to to A60LV
Over ACat6500 150 Finish:
100 osfas .00 15 max.
500kg Heal Treated ~-

36. NICKEL ALLOYS, WROUGHT AND CAST Rough:

Nickel 200 to t 6K
Nickel 201 6500 150 Finish:
Nickel 205 80 Annealed .00 15 max.
Nickel 211 to or
Nickel 220 170 Cold Drawn
Nickel 230

MONEL Alloy 400 55ough:00

MONEL Alloy 401to o06V
to 1 6I
MONEL Alloy 4C4
MONEL Alloy R405 115 Annealed, 6500 150 Finish:
ASTM A296 Grades CZ-100. M-35 to0 Cold Drawn .00 15 max.
ASTM A494: Grades CZ- 100. M-35 240 or - ,-.

Cast ia

DURANICKEL Ahioy 301 50 0 .0

MONEL Alloy 502to oC6K
i IONEL Alloy K500 60 5 iih
NI-SPAN-C Alloy 902 150 60 5 iih
PERMANICKEL Alloy 300 to Solution Treated A
320

See section 16 for Cutting Fluid Recommendations t tCAUTION Toxic Matenial. refer to Nation~al institute lar Occupational
*See section 8 12 for WobrkTraverse Rates As recommended starting Safety and Heat.%(NIOSH) for Precautions
conditions-use a regulating wheel angle with a positive inclination of
3? and a regulating wheel speed of 2510o40 rpm
tWheel recommendations are for wet grinding 0 8- to 2-inch (20 to 50
r.m) diameter work For LARGER diameter work-use a softer grade
and/or coarser grit wheel, For SMALLER diameter work-use a
harder grade wheel Also see section 20.2. Grinding Guidelines

8-160
 Centerless Grinding 8.11

INFEED WHEEL
IWHEELf THRUFEED
0
MATERIAL HARD-SS CONDITION SPEEOj OF WORK ondla. CATIONt
N fpm nmin inpass ANSI

36. NICKEL ALLOYS, WROUGHT AND CAST Rough

(cont.) 5500 00
(materials listed on preceding page) 33 500
60to 15o0
to Finish
nC60KV
.01max,
330 Aged

Rough
37. BERYLLIUM NICKEL ALLOYS,
5500 50 005
WROUGHT AND CASTtf to to A60LV
Berylco 440 6500 150 Finish
Berylco 4 lC 200 As Cast 0015 max.
Berylco 420 to or
Berylco 43C 250 Solution Treated
Brush Alloy 2000
Brush Alloy 220C
Brush Alloy 260C Roug_
Rough-
5500 50 .003
to to AGOKV
6500 150 Finish
283 Hardened 001 r.'ax.
425 AgedA fl- - tz

Rough-
5500 50 002 I
to to A6OJV
6500 150 Finish:
47 R C Hardened .001 max
to or
52 RA
0 ge

Rough:
38. NITINOL ALLOYS, WROUGHT 4000 50 003 C60KV
Nitinol 55Ni-45Ti to to or
Nitinol 56'Ji-44Ti
Nitino6Ni-40T
Ndino1 60Ni40Ti 26000
210 Wrought 150 Finish-
M01max. CA60PB
to o
340 Anae

Rough:
4000 so .001 C60XIV
to to or
4R 6000 150 Finish- CA60PB
to Ounched.0005 max.1
to Qece
52 Ac0

See section 16 for Cutting Fluid Recommendations ttCAUTION Toxic Material. refer to National Institute for Occupational
*See section 8.12 for Work Traverse Rates As recommendd starting Safety and Hea'th (NIOSH) for Precautions
conditions-use a regulating wheel angle with a positive inclination of
3- and a regulating wheel speed of 25 to 40 rpm
tWheel recommendations are for wet gnnding 0 8- to 2-inch (20 to 50
mm] diameter work For LARGER diameter work-use a softer grade
and/or coarser grit wheel For SMALLER diameter work-use a
harder grade wheel. Also see section 20 2. Grinding Guidelines

8-161
8.11 Centerless Grinding
iWHEEL' THRUFEEDI INFEED WHEEL
HAD-SEE Ie O WR o IDENTIFI-
MATERIAL NESS- CONDITION SPE FWR* o ~. CATION-.
fpm jin min IfnIpass ANSI
Bhn &sI~ums mia ?l~
39. HIGH TEMPERATURE ALLOYS., Rough.
WROUGHT AND CAST A60O5000
Nickel Salli,Wrought I to InA6K
AF2-1DA 1 200 4001IO Fns
Anricalec
Astroloy
I I
to I Sou0nrae
t
0
PIa

Haynes Alloy 263

Incoloy Alloy 901 ZOO-
Incoloy ;Jltoy 903 I~D a~ n~ ~ A~
Inconiel Alloy 6 17 I> -

Inconel Alloy 625 fRough-

Inconel Alloy 700 3000 50 003
Inconel Alloy 702 to to A60CV
Inconel Alloy 706 300 4000 1&50 jFinish
Inconel Alloy 718 toSolution Treated 00ma
Inconel Alloy 721 45and Aged
Inconel Alloy 722
Inconel Alloy X-750
Inconel Alloy 751 -Sr
M4252
Nirnonic 75
Nimonic 80
Nimonic 90I
Nimonic 95I
Rene 41II
Rene 63 ..
Rene 77I
Rene 95I
Udiinet 500
Udimet 70u
Udimel 710 ,

Unitemp 1753
Waspa'oy

Nickel Same, Wrought Rih

Has'leiloy Alloy 8B00 50 .0
Hastelloy Alloy 8-2 I
Hastelloy Alloy C1440- 15 vi)
Haslelloy Alloy C-276 nel-W1mx
1-astelloy Alloy G 20Slto rae
Hastelloy Alloy S
Hastelloy Alloy X
Incoloy Alloy 804
Incoloy Alloy 825
Inconel Alloy 600 Ruh
Inconel Alloy 601_, D
Relractalov 26to oA6K
Udimet 63040 IS Fish

See srction 16 for Cutting F!Lui Recommendations

'See section 8 12 ior Work Traverse Rates As re-comcbended starting
-orndtions-use a regulating wheel angle with a Posiive :rclination of
31 and a regulating wheel speed of 25 to 40 rpmn
tfheel recommendations are for wet grinding 0-8- to 2-incm (20 to 50
mmj diameter work For LARGER diameter wok-use a softer rad
and/xr coarser grit wheel For SMALLER diameter work-use a
harder grade wheel Also see section 29.2. Grtiding Guidelines

8-162
 Centeriess Grinding 8.11
WHEEL THRUFEED INFEED WETL
HARD SP~r)OF WRK* on ie. IDENTIFI-
MATERIAL HARD-
NESS CONDITION SPEE' OFWORK ondia. CATIONt
fpm inmin in/pass ANSI
__
_ __
__ _ __ _ __ _ Bhn _____ %i: ~iMhW'~b7~~~ Z1i
t5ough:
Nickel Bass, Wrought
5500 50 .005
TP-Nickelff
to to A60KV
TD-Ni-Crtt
8 6500 150 Finish.
As Rolled 0015 max.
10

Base, Cast Rough.

B-Nickel
1900 3000 50 .003
to to A60KV
GMR-235
GMR-235D 200 As Cast 4000 150 i
Hastelloy Alloy 8 to or .001 max.
Hastell-, Alloy C 425 Cast and Aged - -
Hastelloy Alloy D
IN-100 (Rene 100)
IN-738
IN-792 _r_____________,-_"___,_ tow____
Inconel Alloy 713C
Inconel Alloy 718
M252
MAR-M200
MAR-M246
MAR-M421
MAR-M432
Rene 80
Rene 125
SEL i
SEL 15
IRW VIA
Udimel 500
Udimet 700
ASTM A296' Grades CW-12M, N-12M, CY-40
HX
ASTM A297: Grades HKlW
ASTM A494: Grades N-12M-1. N-12M-2,
CY-40, CW-12M-1. CW-12M-2
ASTM A608: Grades HW50.HX50

Cobalt Base, Wrought Rough.

AiResist 213 3000 50 M3
Haynes Alloy 25 (L605)A60KV
180 4000 150 Finish:
Haynes Alloy 188
J570 to Solution Tred .001 max.
MAR-M905 230
MAR-M918
S-816
V 36
Rough:
300 50 .003
to to A,60KV

270 4000 150 Finish:

to Solution Treated .001 max
3&0 and Aged '-

See section 16 for Cutting Fluid Recommendations ttCAUTION, Toxic Material. ref( -to National Institute fur Occupational
*See soction 8 12 for Work Traverse Rates As recommended starting Safety and Health (NIOSH) fin Precautions
conditions-use a regulating wheel angle with a positive Inclination of
3 a. . a regilaling wheel speed of 25 to40 rpm
tWhbel recommendations are forwet grinding 0.8- to2-inch (20 to 50
min]diameter work For LA.:,t-R diameter work-use a softer grade
and/or coarser grit wheel For SMALLER diameter work-use a
harder grade nheel Afr-' see section 20 2. Grinding Guldelinv.

8-163
 -- . . ..."'
P. - . .. . . - = i

8.11 Centerless Grinding

WHEEL THRUFEED INFEED WHEEL
OF WORK* on dia. CATIF
HARD- C TSPEED
MATERIAL CATIONt
NESS CONDITION
fpm in/mn m/pass ANSI
Bhn _ t-- l..t
Rough:
39. HIGH TEMPERATURE ALLOYS, 3000 50 003
WROUGHT AND CAST (cont.) to to A6KV
Cobalt Base, Cast 4000 150 Finish
220 As Cast 00
F ax.
AiResist 13
Aiflesist 215 toorY.01mx
FSX-414 290 Cast and Aged v J'
HS-21
HS-31 (X-40)
HOWMET #3 04. ;-01!al
MAR-M302 Rough:
MAR-M322 3000 50 .003
MAR-M509 to to A60KV
NASA Co-W-Re 290 As Cast4000 150 Fish:
WI-52 to A Cs .001 max
X-45 425 Cast and Aged MENEM

Iron Bas, WrouRough:

A-286 3000 50 .003
Discaoy to to A60KV
Incoloy Alloy 800 180 4000 150 Finish
Incoloy Alloy 800H to Solution Treated . max.
Alloy 802
Incoloy Alloy 801 230
23
,

V-57
W-545
16-25-6
1g-9DL 3000 50 .003
to to A60KV

4000 150 Finish-

250
Solution Treated .001 max.
to
320 and Aged .~-n'

Rough:
40. REFRACTORY ALLOYS, WROUGHT,
CAST, PM' 50 .001
00 to A60LV
Columblum t. 4000
C 103 170 ISO Finish:
to Stress .0005 max.
C129Y
Cb-lZr 225 Relieved -
Cb-752
FS-85
FS-291
WC-3015 ..

in VA

See section 16 for Cutting Fluid Recommendatiors ** Due to the brittleness of refractory alloys, cracking, chipping, flaking
*See section 8.12afor Work Traverse Rates As recommended starting and breakout tend to occur, particularly on the edges of the ma-
conditions-use regulating wheel angle with a positive inclination of chined surfaces 2
3* and a regulating wheel speed of 25 to 40 rpm ttCAUTION- Toxi- Material, refer to National Institute for Occupational
tWheel recommendations are for wet grinding 0 8- to 2-inch (20 to 50 Safety and Heaith (NIOSH) for Precautions
m1 diameter work For LARGER diameter work-use a softer gr-de ::CAUTION* Potential Fire Hazard. Exercise caution in gnnding and
and/or coarser grit wheel For SMALLER diameter work-use a disposingofswarf
harder grade wheel Also see section 20 2. Grinding Guidelines.

8-164
 Centerless Grinding 8.11

WHEEL THRUIFEED INFEED WDEELFI

HARD.-ODTO SPEED OF WORK* on die. CAETIFI

MATERIAL AOt
NESSCODTO
fpm ;n/mmn in/pass ANSI
Bhn im' Iffioo __1O,
Molybdnuma*Rough.
Molbeu* 2000 .,0 .001
Mo-50Re to to A60MV
TZC 220 4000 150 Finish.
TZM to Strez-s 0005 max
290 Relieved !0_g 5 " 1

Tantalum" Rough
ASTAR 1110 2000 50 .001
T-111 to to A60KV
T-222 o 4000 150 Finish
Ta-lOW to Stress .0006 max.
Ta-Hf 2510 Relieved
Ta63

Tungsten** Ruh
85% densityso 01
93% densiity200 tC7V
96% densily Pressed and Sintered.
100% density to -orgeo..03ma
320 o
Arc Cast ~ -

Tungsten - 2Thorla*0 Rogh

260 Pressed 0005 max.

to aild
320 Sintered

Tungten lloy " 50 .00

SE-eti168 o utn li eomna~n u Otebit~ns frfatr los rcig hpig lkn

Se scton812fo
Rte ecmmnddstrtngan
s WrkTavrs 2000uIIe' to ci priulry nte deso hV a

hardeadewhlo Also se etin2 2 rndn ieie

Tungsen Aloys8-1ug5
 * . - n- - - * ,-rw u,.Jin..O -

8.11 Centerless Grinding

THRUFEED INFEED
1 WHEEL
WDE -
WHEEL
HR-SPEED OF WORK* on din. DNII
MATERIAL HARD- CONDITION CATIONt
fpm in/mm in/pass ANSI
Bhn _________ _ Lffl/t%4
k- n/mqlnc -yi ast-1
Rough
40. REFRACTORY ALLOYS. WROUGHT,
CAST, P/M* (cant.) 50 001
uge )
oy 2000 to C701 V
Tungsten Alloys" 150 Finish
Anviloy 1100 290 Pressed 0005 max
Anviloy 1150 to and , .< .:
Anviloy 1200 320 Sintered

U Rough
44. URANIUM, WROUGHTtf
4000 75 005 C46JB
to to or
56 RA 6000 125 Finish C46KV
002 max
to Annealed
58 RA

Rough Rougtr AT8

45. ZIRCONIUM ALLOYS, WROUGHTt 50 0nt or hA60RB
50 001 or CA60R8
Zr-2%Hf (Grade 11), 3000 to i
Zr-0 001%Hf (Grade 21) ISO Fm,5h Finsh-
Zircaloy 2 (Grade 32) 140 Rotled. 0005 max CA80PB
Zircaloy 4 (Grade 34) to Extruded - -
280 or Forged -&

Rough,
47. POWDER METAL ALLOY Rough
5500 50 005
Copper
to to 5K
50 PR- 6500 150 Finish"
50 Rr0015 max.
to As Sintered Wpm r ,M ,

Brasses Rough-
5500 50 005
CZP-0218-T
CZP-0218-U to to
35 RH 6500 150 Finish
CZP-0218-W .0015 max
90Cu-1OZn to As Sintered

Rough-
Bronzes Rough
5500 50 005
CT-0010-N
CT-0010-R to to C54KV
CT-0010-S 30 RF 6500 F.h max
95Cu-5AI to As Sintered - ___ 0
77Cu-l5Pb-7Sn-1Fe-1C 75 RFAs-intered -

See section 16 for Cutting Fluid Recommendations *Due to the brittleness of re'ractory al!oys, cracking, chipping, flaking
*See section 8 12 for Work Traverse Rates As recommended starting and breakout tend to occur, particularly on the edges of the ma-
conditions-use a regulating wheel angle with a positive inc;inaton of chined surfaces
30 and a regulating wheel speed cf 25 to 40 rpm ttCAUTION Toxic Material, refer to Natior.al Institute for Occupational
tWheel recommendations are for wet gnnding 0 8- to 2-inch [20 to 50 Safety and Health (NIOSH) for Precautions
mm diameter work For LARGER diameter work-use a softer grade ttCAUTION Potential Fi e Hazard Exercise caution in gnnding and
and/or coarser gnit wheel For SMALLER diameter work-use a disposing of swarf
harder grade wheel Also see section 20 2. Grinding Guidelines Grinding of tow-density parts is not recommended because surface
porosity wilt be reduced or lost

8-166
 Centerless Grinding 8.11

WHEEL THRUFEED INFEED WHEEL

MATERIAL HARD- CONDITION SPEED OFIWORK on dla. CATIONt

NESS I fpm in/mm I in/pass ANSI

Copper-Nickel Alloys Rough.

CZN-1818-T 5500 so 005
to to C54KV
GZN-1818-U
22 Rh 6500 150 Finish.
CZN-1818-W .00 15 max.
CZNP-1618-U to As Sintered .00c m .
CZNP-1618-W 100 RH #t-K:, r t ";
900u-1 i' -

620u- l8Ni- l8Zn-2Sn R

Nickel 500 50 Rough

5500 50 .005
to to A46KV
6500 150 Finish.
.00 15 max
45 R3 As Sjtered

Nickel Alloys Rough:

67Ni-30Cu-3Fe 5500 50 005
to to C60JV
34 R8 6500 150 Finish
0015 max
I to As Sintered - r~-
50 R0 745~'r r",

Relractory Metal Base Rough,

87W- 13Cu
85W- 15Ag 2000 to C70LV
74W-2bCu 101 150 Fnish:
72 5W-27.5Ag to As Sintered 0 max.
65W-S5Ag 260
56W+C-44Cu
55W-45Cu
51W-49Ag
50W + C-5OAg

Refractory Metal Base Rough-

-00 5 0 A60MV
6lMo-39Ag
6Mo-3Ag to to
Mo-5Ag Re 4000 150 Finish,

As Sintered.0005 max.
to
82 R

See section 16 for Cutting Fluid Recommendations Grinding of :ow-density parts is not recommended because surface
*See section 8 12 for Work Traverse Rates As recommended starling porosity will be reduced or lost
conditions-use a regulating wheel angle with a positive inclination of
30 and a regulating wheel specd of 25 to 40 rpm
tWheel recommendations are for wet grinding 0 8- to 2-inch [20 to 50
mmj diameter work For LARGER diameter work-use a softer grade
and/or coarser grit wheel For SMALLER diameter work-use a
harder grade wheel Also see section 20 2. Grinding Guidehne

8-167
 8.11 Centeriess Grinding
WHEEL
WDEF
WHEEL THRUFEED INFEED
I' E*L I IDENTIFI-
MATERIAL HARD- CONDITION SPEED OFWORK* on dIe. CATIONt
NESS
1pm in/mm in/pass ANSI
Bhn * Mr7*'
'h 1 . .

47. POWDER METAL ALLOYS (cont.) Rough

Irons 5500 50 .005 C46LV
F-0000-N to to or
F-0000-P 50 6500 150 Finish: A60KV
F-0000-R to .002 max.
F-0000-S 67 As Sintered W _ _4
F-0000-T 500kg t-wd

SteelsRough.
5500 50 005
FSteels
F-08S6500 to to
150 Finish A60NV
F-0008-S
F-0005-S 101 As Sintered 001 max
FC-0205-Stor
FC-0208-P 426 Heat Treated
FC-0208-S
FC-0508-P
FC- 1000-N
FN-0205-S
FN-0205-T
FN-0405-R
FN-0405-S
FN-0405-T
FX-1005-T
FX-2008-T

Stainless Steels Rough.

0 00
SS-303-R550
SS-304-R to to C60LV
107 As Sintered 00
F ax.
SS-316-R or .01 max
SS-410-R to
285 Heat Treated -

Aluminum Alloys Rotigh:

90 5AI-5Sn-4Cu 5500 50 005
88A!-5Sn-4Pb-3Cuto oC5V
_6500 150 Filsh
AI- 25Cu
1 Mg-0Si-0 55 R V-
SeectionM0482oWkr Soluon Treated .0015 max
A-4.4Cu-0 8Si-0.4Mg 25 to40rpm 98 R and Agedat

Ruh
49. CARBIDES
I itanium Carbide550 001
w i c t 10 C60KV0o
Tungsten Carbde 6500 60 Finish: _,
89 R A.0003 max.
to _

See section 16 for Cutting Fluid Recommendations, Grnng of low-densily parts is not recommended because surface
*See section 8 12 for Work Traverse Rates As recommended starting porosity will be reduced or lost /
conditins-Jise a regulating wheel angle with a posite inclination of -
3 . and a regulating wheel speed of 25 to 40 rpm
tWheel recommendations are for wet grnng 0 8- to 2-inch 120 to 50
mini diameter work For LARGER diameter work-use a softer grade
and/or coarser grit wheel. For SMALLER diameter work-use a
harder grade wheel Also see section 20.2, Grinding Guidelines

8-168

-~~~~~~~~~~~~~~
- - - --- - -- - -l--- ------- __ _ _ __ _
 Centerless Grinding 8.11

WHEEL THRUFEED INFEED WHEEL

HARD SPED OFORK* on cla. IDENTIFI-
MATERIAL HARD- CONDITION SPEED OFWORK ondla. CATIONt
fpm in/nin in/pass ANSI
Bhn _ _ **5 h
A__ J,,
50. FREE MACHINING MAGNETIC ALLOYS Rough
5500 50 005
Magnetic Core Iron-FM (up to 2 5% Si)
to to A60LV
6500 150 Finish.
185 0015 max
to W0015 max

240

Hi Perm 49-FM Rough

S5500 50 005

185 6500 150 Finish

to Wrought
240
Cre ron(u to4%
Magetii)to to C60MV

0015 max

51. MAGNETIC ALLOYSRough

Magnetic Core Iron (p to 4% Si)to 60V
185 6500 150 Finish
toW0015 max
H=Pem 95500 240 50 005

Hi Perm 49Rough
HyMu88600V to to

185 6500 150 Finish-

to Wrought .001 max
Alcoi5500 240 50 .005

Alnico I 56 .003
Atnico II
Alnico IV151R 6500 150 Finish-
Alnico IV 4
Alnico V-7 b8OR
Atnico XII
Columax-5 7:
Hyltux Alnico V-7

52. FREE MACHINING CONTROLLED 5500 so500

EXPANSION ALLOYS 50 50 C60LV
Invar 36 Inar366500 150 Finish-
125 Anneaed .0015 max.
to o
220 Cold Drawn

See section 16 for Cutting Fluid Recommendations.

*See section 8 12 for Work Traverse Rates As recommended starting
conditions-use a regulating wheel angle with a pcstve inclination of
30 and a regulating wheel speed of 25 to 40 rpm
tWheel recommendations are for wet grinding 0 8- to 2-inch (20 to 50
a softer grade
mm] diameter
and/or coarserwork
grit For LARGER
wheel SMALLERwork-use
For diameter diameter work-use a
harder grade vheel Also see secton 20 2. Grinding Guidelines

- -- -- - - -.- 8-169 r -- -
8.11 Centerless Grinding
INFEED IDENTIFI-
WHEEL THRUFEED
SPEED OFWORK onda. CATIONF
MATERIAL HARD-
MAERA NESS COND:TIONCAIN
fpm
fS inm/m in/pass ANSI

53. CONTROLLED EXPANSION ALLOYS Rough

5500 50 005
Invar 'o to C60LV
Kovar 6500 150 Finish:
125 Annealed 0015 mex
to or
250 Cola Drawn

54. CARBONS & GRAPHITES

Mechanical Grades A0
4C 6500
Rough
.005

':7insh
to Molded Oct max

Shore Carbon Extruded - - _ -

Brus Grad

900 or
GraeRough:
GaSe CA5000
h .005
to 50 C36NV
8 6500 Finish
90
to
or
Molded 001 max

Shore- Extruded - -

GrpieRough Rough-
Grphte5000 005 C36JV

to 50
6500 Finish: Finish,
001 max- C60JV

55. GIASSES &CERAMICS Ruh

Gas5500 50 002

Knoop

to to C0LV

.001 "max.

to 6500 150 Finish.

See section 16 for Cuning Flid Recommendations

*See section 8 12 for Work Traverse Rates As recommeiideC; starting
conditons-use a regulating
3Pend a regulating wheei
wheel speed of angle with a positie inclination of
25 to 40 Rpm
tWheetrecommendatons are for wet gnndmg 0 8- to 2-inch 20 tc Z
mm] diameter work For LARGER diameter work-use a softer grade
and/or coarser grit wheel For SMALLER diameter work-use a
harder grade wheel Also see section 20 2. Grinding Guidelines

8-170
__________________ _______
 Centerless Grinding 8.11
I WHEEL
WDENF
WHEEL THRUFEED INFEED

MATERIAL HARD- CONDITION SPEED OFWORK* on dla. CATIONf

NESSIj
NS fpm in/min in/pass ANSI

Ceramics Rough: Rough:

Alumina (Aluminum Oxide) 5500 to50 001 C46KV
AfmiaMulieto
Alumina-Mullte 6500 150 Finish: Finish:
Aluminum Silicate Over .0002 max. 080KV
Beryllia (Beryllium Oxide)tt 800 Fired .000 ma
Magnesia (Magnesium Oxide) Knoop Z-

Silicon Carbide .
Silicon Nitride RO
t
Thoria (Thorium Oxide)tt -S
Titania (Titanium Oxide)
Titanium Diborideff
Zircon (Zirconium Silicate)
Zirconia (Zirconium Oxide)

56. PLASTICS Rough:

5000 5 005-020
Thermoplastics to to C60KV

Cast, Molded. 6000 30 Finish:

Extruded. .003 max.

Filled and Molded

Themostting l'hrm~mtin Pa~k 5500 5 Rough

.005-.020
to to C46KV
6500 30 Finish

Cast .003 max.

Rough:
5500 5 .005,020
to to C46MV
6500 30 Finish:

Molded .003 max

Rough:
5500 5 .005-.020
to to C36NV
6500 30 Finish:
.003 max.
-- Laminated

See section 16 fur Cutting Fluid Recommendations tt CAUTION. Toxic Material. refer to National Institute for Occupational
*See section 8 12 for Work Traverse Rates As recommended starting Safety and Health (NIOSH) for Precautions
conditions-use a regulating wheel angle with a posive inclination of
3 and a regulating wheel speed of 25 to 40 rpm
tWheel recommendations are for wet grinding 0.8- to 2-inch 120 to 50
mm] diameter work For LARGER diameter work-use a softer grade
ane/or coarser grit wheel. For SMALLER diameter work-use a
harder grade wheel Also see section 20 2. Grinding Guidelines

8-171
8.11 Centerless Grinding
T WHEEl.
THRUFEED INFEED WET-
WHEEL
SPED OWORK on ia. IDENTIFI-
HARD
MATERIAL I SHARD
NESS CONDITION SPEED OFWORK ondla. CATIONt
fpm in/mm in/pass ANSI
_________________Bhn 29t_____________ -T

58. FLAME (THERMAL) SPRAYED Rough:

MATERIALS 5500 20 I .001
t
Sprayed Carbides
6500 90 Finish.
Chromium Carbide
Chromium Carbide-Cobalt Blend 0005 max
Columbium Carbide
Tantalum Carbide
Titanium Carbide
Tungsten Carbide
Tungsten Carbide-Cobalt
Tungsten Carbide (Cobalt)-Nickel Alloy Blend

Inorganic Coating Materials

5500 20 001
Alumina (Pure)
to to CS01V
Alumina (Grey) containing Titania
Alumina. Nickel-Alummnide Blends 6500 90 Fnish.
.0005max.
Barium Tilanate
Borontt
Calcium Titanale
Ca.;ium Zirconate
Chromium Disilicide-t
Chromium Oxidett
Cobalt (40%). Zirconia Blend
Columbium (Niobium)tt
Glass (Kovar sealing)tt
Hexaboron Silicidet
Magnesia Alumina Spine[
Magnesium Zirconate
Molybdenum Disiicide
Mullite
Nic,.el (40%). Alumina Blend
Nickel Oxide .__
Rare Earth Oxides
Tantalum
Titania (50%), Alumina Blend
Titanium Oxide
Tungsten
Yttrium Zirconate
Zirconia (Lime Stabilized)
Zirconia. Nickel-Aluminide Blends
Zirconium Oxide (Hafnia Free. Lime Stabilized)
-0-
Zirconium Silicate
Sprayed Metals (Group I) Rough:
Co-Cr-B Alloy (Self Fluxing)
Ni-Cr-B Alloy (Self Fluxing) to to C60JV
Nickel Chrome Steel (Special) 5
Stainle,s Steel C05 max._

See section 16 for Cutting Fluid Recommendations t tCAUTION Toxic Material. refer to National Institute for Occupational
*See section 8 12 forWork Traverse Rates As recommended starting Safety and Health (NIOSH) for Precautions
conditions-use a regulating wheel angle with a positive inchratirn of
3* and a regulating wheel speed of 25 to40 rpm
$Wheel recommendations are for wet gnnding 0 8- to 2-inch (20 to 50
mm)diameter work For LARGER diameter work-use a softer grade
and/or coarser grit wheel For SMALLER diameter work-use a
harder grade wheel. Also see section 20 2. Grinding Guideliies

8-172
 Centerless Grinding 8.11
WHEEL THRUFEED INFEED WEETLF

MAERALHARD- ODTO SPr ED OF WORK* on dla. CAETINI

MATERIAL ~NESS CNIINCTO-
fpm in/Min in/pass ANSI
Bhn Aw __ NOW
-

Sprayed Metals (Group 11) 550ou20 00

Bronze550 2011
Chromiumto t 6K
Cobalt650 9 Fish
Nickel.00ma
Molybdenum
Monet

Pondiption Ha rdeuing weel angle Wit Fiontieinliatono

C~herommedation are0for o nh[2o5 0e0n2ng08

harder grade wheel Als se.003n2 2 rndnuieie

to o173K
 - PfRECEDi' PjACZ BLANK-NYT FILLMD

Centerless Grinding-Work Traverse Rates 8.12

APPROXIMATE THRUFEED WORK TRAVERSE RATES
REG. REG. inches per minute*
WHEEL WHEEL
ANGLE DIA. Regulating Wheel Speeds

10 15 20 25 30 40 50 70 90 125 160
inces* rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm

80 4.4 6.6 8.8 11.0 13.2 17.5 I 21.9 30.7 39.5 548 702
85 4.7 7.0 9.3 11-6 140 186 233 32.6 41 9 58.2 74.6
9.0 49 7.4 99 123 148 19.7 24.7 34.5 44.4 61 7 78.9
95 52 78 10.4 13.0 15.6 20.8 260 365 46.9 65.1 83.3
10.0 5.5 82 11.0 13.7 16.4 21 9 274 38.4 49.3 68.5 87.7
10.5 5.8 1 8.6 11 5 14.4 17.3 230 28.8 40.3 51.8 72.0 92.1
1 j 11.0 60 90 12.1 15.1 18.1 24.1 30.2 422 54.3 75.4 965
11.5 6.3 95 126 15.8 189 252 31.5 44.1 56.7 788 100.9
12.0 66 99 13.2 164 19.7 263 32.9 46.0 59.2 82.2 1053
125 6.9 10.3 13.7 17.1 20.5 274 34.2 47.9 61.6 85.6 1097
13.0 7.1 10.7 14.3 17.8 213 28.5 35.6 49.8 64.1 890 114.1
13.5 7.4 11.1 14.8 185 22.1 29.6 36.9 51.7 66.5 924 118.5
.114-0 76 11.5 154 19.2 22.9 30.7 38.3 53.6 69.0 95.8 122.9
80 8.8 13.2 17.5 21.9 263 35.1 43.9 61.4 78.9 109.6 140.3
85 9.3 14.0 18.6 233 28.0 37.3 46.6 652 83.9 116.5 149.1
9.0 99 14.8 19.7 24.7 29.6 39.5 493 69.1 88.8 1233 157.9
9.5 10.4 15.6 20.8 26.0 31.2 41.7 52.1 72.9 937 130.2 166.7
10.0 11.0 164 21.9 27.4 32.9 i 439 54.8 76.7 98.7 137.1 1754
10.5 i 11.5 17.3 230 288 34.5 460 57.6 806 1036 143.9 184.2
20 11 0 12.1 181 24.1 302 1 36.2 48.2 603 84.4 108.5 150.8 193.0
11 5 112.6 189 25.2 31.5 37.8 50.4 63.0 883 1135 157.6 2017
12.0 13.2 19.7 26.3 32.9 395 52.6 65.8 92.1 118.4 164.5 210.5
12.5 13.7 20.5 127.4 I332 j41.1 548 68.5 96.0 123.4 1713 219.2
130 14.3 21.3 28.5 33.6 42.8 57.0 71.3 99.8 128.3 174.2 228.5
13.5 14.8 22.1 29.6 33.9 44.4 59.2 74.0 103.7 133.3 177.0 236.7
14.0 I 15.4 22.9 30.7 34.3 46.1 61.4 76.8 107.5 138.2 183.9 245.5
I
8.0 1 13.2 19.7 26.3 329 39.5 52,6 658 92.1 118.4 164.4 210.5
8.5 14.0 21.0 28.0 34.9 41.9 55.9 69.9 97.8 125.8 174.7 223.6
9.0 14.8 22.2 29.6 37.0 44.4 592 74.0 103.6 133.2 185.0 236.8
9-5 156 23.4 31.2 39.1 46.9 62.5 78.1 109.3 140.6 195.3 249.9
10.0 16.4 24.7 32.9 41.1 493 65.8 82.2 115.1 148.0 205.5 263.1
10.5 17.3 25.9 34.5 43.2 51 8 69.1 863 120.9 155.4 2158 276.2
30 110 18.1 27.1 362 45.2 54.3 72.3 904 1266 162.8 226.1 289.4
11.5 18.9 28.4 37.8 47.3 56 7 75.6 94 5 132.4 170.2 236.4 302.6
120 19.7 29.6 39.5 49.3 59.2 78.9 987 138.1 177.6 2466 315.7
125 20.5 309 41.1 51.4 61.6 82.2 1028 143.9 185.0 256.9 3288
13.0 21.3 32.1 42.8 53.4 64.1 855 106.9 149.6 1924 267.2 341.9
13.5 22.1 33.4 44.4 55.5 665 88.8 111 0 155.4 199.8 277.5 355.0
14.0 229 34.6 46.1 57.5 69.0 92.1 115.1 161.1 207.2 287.8 368.1

8.0 175 26.3 1 35.1 ,.38 52 6 70.1 87.7 122.7 157.8 219.2 280.5
8.5 18.6 27.9 37.3 16.G - 74.5 93.1 130.4 167.7 232.9 298.1
9.0 19.7 29.6 39.4 493 59.2 789 98.6 1 138.1 177.5 246.6 315.6
9.5 208 31.2 41.6 52.1 62.5 83.3 104.1 145.7 187.4 260.3 333.1
10.0 21.9 32.9 43.8 54.8 65.7 87.7 109.6 153.4 197.2 273.9 350.7
10.5 23.0 34.5 46.0 57.5 69.0 920 115.1 161.1 207.1 287.6 368.2
40 11.0 24.1 36.2 48.2 603 723 964 120.5 168.8 217.0 301.3 385.7
11.5 252 37.8 50.4 63.0 75.6 100.8 1260 176.4 226.8 315.0 403.3
12.0 26.3 394 52.6 65.7 178.9 1052 131.5 184.1 236.7 328.7 420.8
12.5 27.4 41.0 54.8 68.5 82.2 1096 136.9 191.7 246.5 342.4 438.4
130 28.5 426 57.0 71.3 85.5 114.0 142.4 199.4 256.4 356 1 456.0
135 29.6 44.2 592 74.1 88.8 118.4 147.8 207.0 266.2 369.8 473.6
14.0 30.7 45.8 61.4 769 92.1 122.8 153.3 214.7 276.1 383.5 1 491.2
*To convert inches per minute to millimeters per minute multiply by 25 4
'To convert inches to Millimeters multiply by 25.4.

8-175

. ... . . ..- -=-.

8.12 Centerless Grinding-Work Traverse Rates
1 APPROXIMATE THRUFEED WORK TRAVERSE RATES
REG. REG inches per minute0
WHEEL WHEEL
ANGLE DIA. Regulating Wheel Speeds
10 15 20 i 25 30 40 50 70 90 125 160
inches' rpm rpm rpm rpm rpm rpm rpm 1rpm rpm rpm rpm
80 1219 32.9i 43.8 I 54.8 657 87.6 109.5 153.3 1972 2738 3505
85 1 233 349 I465 I582 698 93.1 116.4 162.9 209.5 2909 3724
90 246 37.0 49.3 I 616 739 98.6 1232 172.5 221 8 308.0 394.3
9.5 1 26.0 390 52.0 65.0 780 104.1 1i301 182.1 234.1 3252 416.2
100 274 41.1 54.8 68.5I 82.1 109.5 136.9 191.7 246.4 342.3 4381
105 288 43.1 575 71'9 1 86.3 115.0 143.8 201.3 2588 3594 4600
50 110 301 4521602 753 90.4 120.5 150-6 2108 271 376.5 481.9
115 315 472 630 i 78.7 945 126.0 1574 220.4 283.4 393.6 503.8
120 32.9 49.3 6571 821 986 131.4 164.3 230.0 295.7 4107 5257
1 12.5 343 51.3 685 85 5I 1027 136.9 171.2 2396 1 308.0 I 4278 547.6
13.0 357 53.4 1 71 2 889 106.8, 142.4 1781 2492 1 320.3 1 444.9 5695
13.5 371 554 740I 92.3 110.9 i 147.9 185.0 258.8 3326 4620 1 591.4
140 38.5 57-5 1 '6.7 95.7 i 115.0 1 153.4 191.9 1 268.4 344.9 479.1 613.3

8.0 26.3 394 52.5 657 78.8 105.1 1314 I 1839 236.4 328.4 4203
8.5 27.9 41.9 558 69.8 83.7 111.7 139.6 195.4 251.2 348.9 4466
90 296 443 591 739 88.7 118.2 147.8 206.9 2660 369.4 4729
S 9.5 312 46.8 624 780 93.6 124.8 156.0 218.4 280.8 393.0 499.2
100 32.8 49j3 65.7 02-1 98.5 131.4 1642 229.9 295.6 4105 525.4
105 34.5 51.7 69.0 86.2 I 103.4 137.9 172.4 241.4 1 310.3 431 0 551 7
60 11 0 36.1 54.2 72.2 90.3 108.4 144.5 180.6 252.9 3251 4515 5780
11.5 37.8 56.6 75.5 94.4 113.3 151.1 188.8 264.4 339.9 4721 604.2
12.0 39.4 59.1 78.8 98.5 118.2 157.6 197.0 275.8 354.7 492.6 i 630.5
12.5 41 0 616 82.1 102.6 123.1 164.3 205.2 2874 369.5 5131 656.8
13.0 I 42 6 64.1 85.4 106.7 128.0 170.9 213.4 298.9 384.3 533.6 683.1
I 13-5 44.2 66.6 88.7 110.8 132.9 177.5 221.6 310.4 399.1 554.1 709.4
140 458 1 69.1 92.0 114.9 137.8 184.1 229.8 321.9 413.9 574.6 735.7
I 45.97.6 t 73.
8.0 30.6 45.9 61.3 76.6 91.9 122.5 153 1 214.4 275.7 382.9 490.1
8.5 325 1 48.8 65.1 81.4 97.6 1302 162.7 227.8 292.9 406.8 520.7
go 34.5 1 511 68.9 86.1 103.4 137.8 172.3 241 2 310.1 4307 551.3
95 36.4 54.6 72.7 90.9 109.1 145.5 181.9 254.6 327.4 454.7 582.0
10.0 383 57.4 76.6 95.7 1149 153.1 191.4 268.0 344.6 478,6 612.6
10.5 402 603 80.4 100.5 1206 160.8 201 0 281.4 361.8 502.5 643.2
70 11.0 421 632 84.2 105.3 1263 168.5 210.6 294.8 379.0 526.4 673.8
11.5
120
44.0
159
660
68.9
88.1
91.9
110.1
114.9
132.1
137.8
176.1
183.8
220.1
229.7
308.2
321.6
396.3
413.5
5504
574.3
j 704.5
735.1
125 47.8 71.8 1 95.7 119.7 143.5 191.5 239.3 335.0 430.7 598.2 765.7
13.0 49.7 74.7 1 99.5 124.5 149.2 199.2 248.9 348.4 447.9 622.1 796.3
13.5 51.6 77.6 103.3 1293 154.9 206.9 258.5 361.8 465.1 6460 826.6
14.0 535 80.5 107.1 134.1 160.6 214.6 268.1 i 375.2 482.3 - 669.9 857.5
8.0 1 35.0 525
52.5 j770.0 8744j04.559.6
104.9 139.9 174.9 2448 3148 437.2 5
8.5 37.2 55.7 743 92.9 111.5 148.7 185.8 2601 3345 464.5 594.6
90 39.3 59.0 78.7 98.4 118.0 157.4 196.7 275.4 354.1 491.9 629.6
9.5 41.5 62.3 83.1 103.8 124.6 166.1 207.7 290.7 373.8 519.2 664.6
100 437 65.6 874 1093 131.2 174.9 218.6 306.1 393.5 546.5 699.5
10.5 45.9 68.9 91.8 114.8 137.7 183.6 229.5 321.4 413.2 573.8 I 734.5
80 1110 48.1 72.1 96.2 120.2 144.3 192.4 240.f 3367 432.8 601.2 i 769.5
11.5 50.3 75.4 1006 125.7 150.8 201.1 251.4 352,0 4525 628.5 804.5
12.0 52.5 78.7 104.9 131.2 157.4 209.9 262.3 3673 472.2 1655.8 j 8395
125 54.7 820 1093 136.7 164.0 218.6 273.2 3826 491.9 6531i 874.5
130 569 85.3 1136 142.2 170.6 227.4 284.1 397.9 511.6 710.4 909.5
135 59.1 88.6 118.0 147.7 177.2 236.1 295.0 413.2 -31 3 737.7 944 5
91
14.0 61.3 .9 122.3 153.2 183' q 244.9 305.9 428.5 551.0 7650 979.5
*TO convert inches per minute to millimeters per minute multiply by 25.4
'Toconvert inches to millimeters multiply by 25 4.

8-176
 Abrasive Belt Grinding 8.13

I i i i __
CONTACT WHEEL
__

; HARD- I ABRASIVE GRAIN BELT

MATERIAL NESS CONDITION OPERATION TYPE SIZE SPEED* TYPE' i HARDNESS
I A tpmn i I Ourometer
Bnz -~ d _:% _ ris - _____

CARSON STEELS. Al2 O,.

ALLOY STEELS, IHot Rolled. Roughing AiO 3-ZrO, 24-60 1 4000-5500 SR 70-95
Ii
j
AND Normalized. i I
TOOL STEELS; 1 100 Annemled. Polishing A12 0i j 80-320 4500-6500 SR. SFR 20-60
WPOUG4T to ColdDrawn
AND
CAST
45 Rc
I neoc'hed0

Z.-d Tempered
L z4W 4 - -SR___ 2040
~
A~O~- ________ ____ ___ 20S
- - AO1
20 I I
I Roughing AI203 ZrO, 40-80 i 2500-4500 1 SR 70-95
45 R, Quenced Polishing A1203 1 100-320 3000-4500 SR. SFR I 20-60
to Quand ,- ____'t -
56R I Tempered - -- A 4

_
_J
STAINLESS STEELS, A1201
WROUGHT i Roughing AIO-ZrO- 36-60 2000-4000 SR 7C-95
AND Anne . I I
CAST
GRYCSR SI 135 or Polishing AI2O 3 ' _
8u-1 0 _ __ -4o
300-5500 SR. SFR 20-60
0to cluenched - -- I -_J- -!
56 Rc
FI ad I 3 .1000- SR SR 7-5
Tempered - ~ .--

GRAY CAST IRONS o RAIO. SLC- 24-50

DUCTILE CAST IRONS 3Rough A2 OC-Zr2

O I 24-60 5000-9000 SR,SFR 70-95
IRONS
Ito
100 U
I Al I Polishing Al 0 I 80-180 ' -00 1 SR SFR 20-60
_

I 400 Treate

ALUMINUM ALLOYS. iAIS 20R

WROUGHT AND CAST Cold Drawn Roughing

MAGNESIUM ALLOYS' 30
AsDl
or Polishing
i Al O-r i

AlOSC i 100-240
I
24-80
I
500"500

5000-2300 SR.SFR
SR
'

I
7
70-95

20-60
WROUGHTANDCAST to Solution N _ . _

IS0 Treated - - - -- - -_
1500kg and IRUdl
ai.Al ~4 25-33 zSII-SFR ~7095
_
I Aged

TITANIUM ALLOYS.": I
AND
Aneld
jAnSolio I Ruhn
I~Sic. AJ 0 - 2 3 ~ I1
CAST 1 10 Tieatd 'I Polishing SIC 100-240 12M02500 SR. SFR 20-60
to o
40 Solution k~g A
,4= 1 0 ~--- ~~

See section 16 for Cutting Fluid Recommendations =IRHD (International Rubber Hardness degrees) is aplxoxenatey equal to
Use lower values of BELT SPEED when good surface integrity is the duro'meler 'eadcrig
required_ -CAUTION Potential Fire Hazard Exercise caution in gr'ndiigz and da
SR-Serrated Rubber. SFR-Smooth Face Rubber. B-Buff Type posing .fswar Do NOT use water or water-mzscibe -ut?.i-g fliisds for
Serrations are usu~lly at 45" angle. aitrough some heav, stock removal magnesiu'm aigoys
operations use 60- Widths of lands and grooves vary fro.,n narrow lands
and wice grooves for fast aggressive cuts to wide lands and narrow
groo- es for intermediate and fi' ishing operations dependingn upon wori.
piece shape and opeating conditions

-~0 05~-~

S-ill
8.13 Abrasive Belt Grinding

CONTACT WHEEL

HARD- ABRAS!VE GRAIN I BELT

MATERIAL NESS CONDITION IOPEkATrION TYPE SIZE ) SPEED' TYPE, HARDNESS
tpm Durometer
/8
rnn RO'
COPPER ALLOYS,"
WROUGHT Roughing A120 3, SIC 280 2000-4500 SR. SFR 70-95
AND1248
CAST 10 R, Annealed Polishing A120,- Sir, 100-240 4000-60C0 SR, SFR, 8 20-60
to or-
100 R, Cold Drawn SI 248 03- a8R 705

_____________
_____ :~ls~n I~ SC 10 20 20-30- $ F B - 20.60__:
HIGH TEMPERATURE IA1 203
ALLOYS, WROUGHT Roughing A1203 -ZrO 2 40-80 20910-4500 SR 70-95
AND CAST 1
140 Polishing A1201 100-24C 3000-5500 SRSFR 20-60
Nickel, Cobalt to All fir -
and Iron Base 475 A,6~thI~ 4-0 1-3,

ZINC ALLOYS,I
CAST Roughing Al203 SIC 150-220 5000-10,000 SR B 40-95
8Polisning Ai203 SIC 220-320 5000-10,000 SR,6 20-60
to As Cast Aw- ' Q ~

See section 16 for Cutting Fluid Recommendations *IRHO (lrternational Rubi~er Hardness degrees) is approximately equal to
"Use lower al~es of BELT SPEED Wh~en good su'face integ'ity is the durometer reading
required "CAUTION Beryllium-copper alloys are Toxic Materials, refer to National
'SR-Serrated Ruober, SFR-Smcrotl, Fape Rubber, B-Buff Type Institute for Occupational Safety and Health (NIOSH) for Pracao-oor- --
Serrationq , !_5ufl 2!'~i~ ' nn'gf, 3n~ieavy MtOCKremov.:
some.g section 6 itifor specific beryllium-copper alloys indicated by"
operations use 60' Widths of lands and groov.s vary from narrow lands
and wide grooveb for fast aggressive cuts to wide lands and narrow
grooves for Intermediate and finishing operations, depending upor Work-
piece shaoe and operaiing conditions

8-178
 Thread Grinding 8.14

THREADS WHEEL WHEEL WOR&

HARD- PER INCH IDENTIFI. SPEED SPEED
MATERIAL NESS CONDITION CATION
PITCH (P) ANSI fpm fpm
Shn -nn; O- ms /m
1. FREE MACHININ03 CA.RBON STEELS, 4 to 12 A90RB 8500
WROUGHT 13 to27 A120SB 9000 40
Low Carbon Reaulfutized Hot Poiled, Normalized, 28 to 63 A 180T8 9500
1112150 Rc Annealed, Cold Urawn 64to 80 A220UB 10000
1108 11121max cr Quenched ~
"A9010-;
1109 1117 1212
1118 1213
~andTempered A2s -A t2
115 1119 1215 A2O'
Medium Carbon Resulfurized 4t12 A10K
1132 1140 1 1454to1 IOV 70
1137 1141 1146 13 to 27 A150JV 7500 6
119 1411Ciburized 28 to 63 A220MV 8500 6
1139 1144o 11ad1 Over a~nd lor 64 to 80 A240PV 9000
Lo5a0o
ede PC Q~ienched and 10K~ 8-
pa,&2
10118 121-13 12115 Temnpered ~ ~ ~ SJ
111-17 12L 14 -~b4~ A2M
Medium Carbon Leaded -A2Pf -'

,0145 111.37 11-44

10L50 11141

2. CARBON STEELZ WROUGHI o1 A0B 80

Low Carbon13t27 A1SB S0 4.
1V05 1012 1019 1026 Ho' Rottucd. N(. -nalized. 2810o63 A18OTB 9500
01
106 02012 RC Anneated. Colc Drawn 64 to 80 A220U8 10000
1008 1015 1021 1513 fl3.o Qb-e
1009 1016 1022 1518 , adTmee
I1010 1017 1023 1522
Medium Carbon 4' to 12 A 100KV 7000
1030 1042 1053 1541 Iabne
13to 27 A150JV 7500 60
1033 1043 1055 1547 Cabrzd28 to 63 A220MV 8500
13 104 12 158Over and 'or 641to80 1A240P.1 90C
1037 1045 1525 1551 CQuenched and
1038
1039
'1046
1049
1526 1552Tepre . 4A &
1527
1040 1050 1536 _

High Carbon
1060 1074 1085 16
1064 1075 1086 1572I
1065 108 1090
1069 1080 109E
1070 1084 156' j '

3. UARBON AND FIERRITIC ALLOY STEELS 4 to 12 A90AB 8S00

(HIGH TEMPERATURE SERVICE) 13 to 27 A120SB 9000 40
ASTMA A369 Grades FPA. FPB. FPI1 FP2. 150 As Forged. 281063 A18OTB 9500
FP30. FP5. FP7. FP9, FPI 1. FP12. FP21. Ateo~ 618 20U 00
FP22 200 or Noirmatized-
and Tempered

see section. 16 for Culting Fluid Recommendaticri

Sse se-.tior 20 for aduilionat information

8-179
8.14 Thread Grinding
THREADS
THREADS IDENTIFI- WHEEL WORK
HARD- PER INCH SPEED SPEED
MATERIAL NESS CONDITION CATION
PITCH (P) ANSI fpm fpm
Elm 2VEN4 toii12 1A3-
A9ORBi i8500w !- A
4 to 12 A90RB 800
4. FREE MACHINING ALLOY STEELS,
WROUGHT 13 to 27 A120SB 9000 4.0
Hot Rolled. Normalized. 28 to 63 Ai80TB 9500
Medium Carbon Reaulfurized 50 Rc Annealed, Cold Drawn 64 to 80 A220UB 10000
4140 4145Se max or Quenched
41403e 4147Te
4142Te 4150 and Tempered q k$ .ssr -

Medium and High Carbon Leaded

41130 41L47 51132 86L40 4 to 12 A100KV 7000
41L40 41L50 521100 13 to 27 A150JV 7500
41L45 43140 86L20 Carburized 28 to 63 A220MV 8500
Over and/or 64 to 80 A240FV 9000
50 Rc Quenched and .
Tempered...........

4 to 2 A90SB 900
5. ALLOY STEELS, WROUGHT
Low Carbon 40
Hot Rolled, Normalized, 28 to 65 A180TB 9500
4012 4615 4817 8617 50OR 0 Annealed. Colo Drawn 64 to 80 A220U3 10000
4023 4617 4820 8620 max or Quenched
4024 4620 5015 8622
4118 4621 5115 8822 and Tempered
4320 4718 5120 9310
4419 4720 6118 94815 . --
8115 94817 4 to 12 A100KV 700
4422 4815
Medium Carbon to 63
13 to
28 27 A220MV
A150JV 8500
7500 6.0
13 415
53 860Carburized
1330 4145 5132 8640 Over and/or 64 to 80 A240PV 9000
1335 4147 5135 8642 50 Quenched and
1340 4150 5140 8645
1345 4161 5145 86B45 Tempered .. -

4027 4340 5147 8650

4028 4427 5150 8655
4032 4626 5155 8660
4037 50840 5160 43740
4042 50844 518360 8742
4047 5046 6150 9254
4130 50846 8"eB45 9255
4;35 50350 8625 9260
4137 5060 8627 94630
4140 60B60 8630
4142 5130 8637
High Carbon -S
50100 51100 52100 M-50
jA

I I
B

See section 16 for Cutting Fluid Recommendations

Soe section 20 for uooihnal information

8-180
 Thread Grinding 8.14

THREADS WEETLI WHEEL WORK

MARD- PER INCH DNII SPE SED
MATERIAL NESCNIINCATION SPE SED
NESCODTINPITCH (P) ANSI fpm fpm
Bnnin i O mm&
6. HIGH STRENGTH STEELS, WROUGHT 41to 12 A90RB 8500
300M 131o27 A120SB 9000 4
4330V Ani eated. 28 to 63 A180TS 9500 40
4340 50 RC] Normalized ,64 to 80 A220'JB 10000
434013%ma or Quenched -

98BV40 and Tempered

06ac
Hil ht6~5
H13 '4 to 12 A100KV 7000
H-P 9-4-20 13 to 27 A150JV 7500 6
HP 9-4-25 28 to 63 A220MV 8500 6
HP 9-4-30 Over Uuenched 64 to 80 A240PV 9000
H9--550 R0 and MI!
HP94-5Temperedwi

7. taARAGItu STEELS, WROUGHT 4 to 12 A90RB 8500

ASTM A538: Grades A. 8. C13o A20E 90 40
Anae 8t 10B 90
120 Grade
180Grde50 Aeae 641to80 A220UB 10000
200 Grade max or
L
250 Grade
300 Grade w M_
350 Grade
1KV 70
HY2304to1

8. TOOL STEELS, WROUGHT 4t 2 A0B 80

Group I 3t 7 A2$3 90

A4 1-19 01 Sina and Tempered

A6 H21 02 q,
A8 H22 06
09 H23 07
A10 H24 P2 4t 2 A10V 70
H1O H25 P413t27 A10V 50 .
H1I H126 Pb v vrQece 2 o6 20V 80
H12 L2 P6 W5 Ove 6080
tunce A240PV 9000
SAE J438b. rypes Wi108, W 109. Wi 110.W 112. 50 Rc Temere
W209. W210, W310

Gop114 to 12 A90RB 85004

Grou 3027
to A120SB 9000
D2 H42 M42 2 o6 1OB 90
D3 M1 Ti 50RAnnealed 608 A2OB 10000

05 M3-1 T4 and Tempered

F1 M10 T8
F2 M30
Lsee sec!!cn 16 for Cutting Fluid Recommendations
See section 20 for additional information

8-181
8.14 Thread Grinding
THREADS WHEEL WHEEL NORK

HARD- PER INCH SPEED SPEED

MATERIAL NESS CONDITION CATION
N PITCH (0) ANSI fpm tpm
3 1ntyli_
F
Shn _____________ 2iiit~

8. TOOL STEELS, WROUGHT (cont.) 4 to 12 A100KV 7000

Group 11(cont.) 13 to27 A150jV '500 60
(materials listed on preceding page) 50 R c Quenched 64 'o 80
28 to 63 A220MV
A240PV 8500
9000
0 and a36'<
58 Rc Tempered . te j .-

4 to 12 A100KV 7000
13 to27 A150JV 7500 I
28 to63 A240MV 8500 60
Over
58 Ro
Quenched
and
Tempered
V 64 to80
-- -
A280PV
-I
_
--- - -
9000
-

to
1412 A90RB 85(
Group III 13 to27 A120SB S,5C0
A7 M33 M44 28 to 63 A18OTB 9500
D7 M34 M46 50 R c Annealed 64 to80 A220UB 10000
M3-2 M36 M47 max or Quenched - ..
M6 M41 T5 and Tempered N -
M7 M43 T6Ioa

4to!2 A100KV 7000 4.0

13 t 27 A150JV 7500 40
28 to6S A220MV 8500 60
5 Quenched 64 to80 A240PV 90100 60
to and --
58 RC Tempered

4 to 12 A!00KV i000 40
13 to27 A150JV 75G0 40
26 toS3 tk24GMV 8500 6.0
58 RC
Over and
Quenched
Tempered
64 to30 A230PV 9000 60

Group IV 41t 12 A90RB 8500

M4 13 to27 A120SB 9000
M4 23 to63 Ai80TB 9500
T15 50R Anneated 64 1o 80 A2206B 10G0
max orQuenched
and Tempered ..-

4 to 2 AIODKV 7000 40
13to2 7I A150JV 7500 40
28 to 63 A220Mv" 8500 60
0 c Quenched 64 to80 A240PV/ 9000 60
to and
58 RC rernpered -

See section 16 for Cutting FIL.,d Recommeidations

See section 20 foraJditional information

8-182
 Thread Grinding 8.14
WHEL WHE WR
THREADS IDN I WEEWR
HARD- PER INCH INTF- SPEED ISPEED
MAERALNESS I CONDITION CATION

PITCH (P) ANSI tpmn fPm

8hn -m111401- 4 /8- j
8. TOOL STEELS, WROUGHT (Cont.) 4t12
4! A100KV
A 7000 40
GruV(ot)13 to 27 A 150JV
17500 40
pge
(mteiaslite n reedn uechd28 to 63 A240Mv 8500 60
Grop V (on.)Overhd 64 to 80 A28CrN 9000 60
58o R1OV [and 1
58 Rc Tempered t5 AOVI 36 1

9. NITRIDING STEELS, WROUGHT 4C2 AOB 80

Nirlo 12 13 to 27 A12OSB 9000 4
Nitralloy 135 200 Annealed, f28 to 63 A18OTB3 9500 4
Nitraltoy 135 Mod toNraie 6- 80 A20U 10000
toNra-e 6t 0 A2U
Nitralloy 225 350 or Quenchedl 61o.5 A9RBV- 48
Nirlo 3 nd Tempered I2o~
Nitralloy 23
EZ4 A~~~~
Nitralloy N
Nitrex I4to 12 jA100jv
r-'7000 4
6R,13 to27 A15OKV 7500
28 to 63 A22OMv 8500 6
to itrde 64 to 80 A24OPv 9f000
65 NRrdd6o5 Ai~l~~6

12. FREE MACH4INING STAINLESS STEELS, 4t 2 AOB 80

13 to 27 A120SB 9000
WeROUGHT 28 to 63 A18OTB 9500 40
Fertc135
43Ft neld64 to 80 A220U8 1000
430F Se 185 ASCAIo2S ltrtlA3 __

203EZiti
tutnii 4to 12
13 o 27
A90RB
A12SB
850 1
9000 4
I 3 nnae 28 to 63 A180TS 9500 4
303Z
303MAAneae 64 to 80 A220U8 10000
303MA t
275b Cold or
Drawn
303 Pius x
303Se .~ T;W
_ -8

Martens itic
416 42OF Se
1J4t 2
13 to 27
AOB
A12OSB
80
90
416PS X
41Se
440F
440F Se
135
to
I Annealed
or64
to6
I8
to80
A8T
A220L8
35 0
000
4

42F240 Cold Drawn ~ j~

- OMIU
4 to 12 A100K' 7000
13 t o27 A150KV 7500
to 63 A220Mv 8500 60
OeQunhd28
27er Quenchd 64 to 80 A240PV 900

Sce27 sscndo
e~nmna,
16frCtigFud

see section 10 for Cddttinal

Flidnfo m nd i

8-183
8.14 Thread Grinding
HREADS WEL WHEEL WORK
MATERILCONITIO CATION
HARD-
NESS C PE INCH IID NTF SPEED SPEEDI
PITCH (P) ANSI fpm 1pm
______________________ Shn I_______%i?
, 41012' 1 A90RB '--500
13. STAINLESS STEELS, WROUGHT 1127 A90R8 8000
Ferritic 131o27 A120KV 9000 4.0
405 434 135 28 to 63 A180TB 9500

40964 to80 A220UB 10000

429 442 185 , At
430 46I____

4 to 12 A90RB 8500
201 t34 30 3013 to 27 A12CSB 9000
201 304L 305 330 28 to 63 A180TB 9500
202 305 314 347 135 Annealed 64 to 80 A220UB 10000
301 308 316 348 o or -
302 309 316L 384 275 Cold Drawn - ## -
3022 309S 317 385
304 310 321

to 12 A0RB 8500
Austeniic4
Nitronicit 13 to 27 A120SB 9000
N~r mc3 2 064 281o63
to 80 A18OTB
A220UB i 9500
10000
Nitronic 33 210
Nilronic 40
Nitronic 50
Nitronic 60
to
250
Annealed
W - . q -4;?:

41to12 A90RB 8500

13 to 27 A120SB 9000 4.
3 28 to 63 A180T9 9500
32. 64 to 80 A220UB 10000

to
C o ld D ra w n
r
--.

Mrnitc13 12
to27 A90B 8500
Martensitic4 to A120SB 9000 4.
403 440A 28 to 63 A80TB 500
410 z- "g 135 64 to80 A220UB 10000
414 4400 to Annealed
420 501 275 r- 2
,
422 502
431 P
Greek Asoloy 41o12 A100KV 7000
13 to27 A150KV 7500 -3
28 to63 A220MV 8500 4
Over Quenched 64 to 80 A240PV 9000

Tempered

X
-t

See section
16 forCutting
FluidRecommendations
20 for
See section additional
information

21

8-184
 Thread Grinding 8.14

THREADS WHEEL WHEEL WORK

HARD- PER INCH IDENTIFI- SPEED SPEED
MATERIAL CONDITION CATION
I PTCH (P) ANSI fpm fpm

14. PRECIPITATION HARDENING I 1 o 127 A1ORB 89000

STAINLESS STEELS. WROUGHT i4.0
'5-5 PH AM355 150 28 tc63 A18OTB 9500
,55
M35
H "064 to 80 A220UB 10000
'6-6 PH AM-363 to Solution Treated 64t80 A2U 100
17-4 PH Custom 450 200
17-7 PH Custom 455
17-14 Cu Mo HNMV
AF-71 OH 13-8 Mo t
AFC-77 PH 14-8 Mo
Almar 362 (AM-362t PH 15-7 Mo 131o27 A150KV 7500 60
AM-350 Stainless W 275 Solution Treateo 28 to 63 A220MV 8500
I 64 to 80 A240PV 9000
I to Ior
4A0 Hardened

15. CARBON STEELS, CAST 4 to 2 A90B 900

Low Carbon Annealed. Normalized, 28 to63 A180TB 9500
ASTM A426 Grade CP1 100 Normalized and 64 to 80 A220UB 10000
1310 to Tempered,---
1020 300 or Quenched -

Medium Carbon and Tempered -NW

ASTM A352 Grades LCA, LC, LCC

ASTM A356 Grade 1 4 to 12 A 100KV 7000
1030 1040 1050 13 to 27 A150KV 7500
Carburized 28 to 63 A220MV 8500
Over ano/or 64 to 80 A24OPV 9000
50 P050 RIc Quenched and
TempertC!

16. ALLOY STEELS, CAST

Lew CarbAn Lo abnAnnealed Normaized. 28
13 to
to63
27 A 180T8
A120S 9500
9000 40
ASTM A217 Grade WC9 150 Normalized and 641080 A220U8 rnooo
ASTM A352 Grades 103. LC4 to Tempered. 64t-0 A2U GO
ASTM A426 Grades CP2. CPS. CP5b. CP1 1. 400 or Quenched
CP12, CP15.CP21, CP22 aid Temperad
1320 2320 4120 8020
2315 4110 4320i=.c=.
8620 i J 4to 12 A10V 7O0
Medliumt Carbon13t2750
ASTM A27 Grades N 1.N2. U-60-30 60-30. rued to 63 A22OMV 7560
-eCarburzed
65-35. 70-36, 70-40
ASTM A148: Grades 80-40. 80-50. 90-60. Over and/or 64to80 A240PV 9000
105-85. 120-95. 150-125. 175- 145 50 A0 QLuenched and - --

ASTM A216. Grades WCA. 618,WCO Tempered Z

ASTM A217. Grades WC1. WC4. WC5.WC6
ASTM A352" Grades LC1. LC2 LC2-1 _
ASTM A356 Grades 2. 5 6. 8. 9. 10
ASTM A389 Graces C23. C24
ASTM A486 Classes 70. 90. 120
(matenals continued
on next page) 3

See section 16 fcrCutting Fluid Recommendatons

See section 20 for additional information

4.

8-185
8-8
8.14 Thread Grinding
I ~THRED _.NTF-
READS WHEEL WHEEL WORK
HARD- PER INCH 1TE I SPEED SPEED
MATERIAL CONDITION CATION
NESS PITCH (P) ANSI fpm I pm
S hn ~-m~~rma
16. ALLOY STEELS, CAST (cont.)
Medium Carbon (cont.)
(materials continued from preceding page) 1 I
ASTM A487 Casses IN. 2N. 4N. 6N. 8N. 9N
ION )N. 10. 2. 40. 40A, 60. 70.,80 - 0 M
90. 100 -XV iS
1330 4130 80830 8640 ' , ?
1340 4140 8040 9525
2325 4330 8430 9530
2330 4340 8440 9535
4125 8030 8630

4 to 12 A9088 8500
17. TOOL STEELS, CAST
Group! 13 to 27 P120SB 9000 40
28 to 63 A18OTB 9500
ASTM A597 Grades CA-2. CH-12. 5-13.
0 Rc Annealed 64 to 80 A220U6 10000
CO-ma or Quenched M 4
and Tempered-

4 to A100KV 7000
13 27 A150JV 7500
28 to 63 A220MV 8500 60
50 c Quenched 64 to 80 A240PV 9000
to and
58 Rc Tempered OEMA%
,4iV!SI-

4 to 12 A100KV 7000
13 to 27 A150JV 7500J 6.0
28 to 63 A240MV 8500
Over Quenched 64 to 80 A,280PM 9000
5 CTempered

Group II Gru 14 to 12 A9RB 8500

1 o2 10B 90
ASTM A597 Grades CD-2. CD-5 200281'o63 18 t 3 A18TB
A 180TB 900
9500 4.0
to Ann~ealed
250- 64 to 80 A220UB 10000

4So12 A100KV 7000

13 to 27 A150JV 7500 60 --
48R28 to 63 A220MV 8500
m
*8c and
Quenched 64 to 80 A240PV 9000

See section 16 for Cutting Fluid Recommendations

See section 20 for additional information

8-186
 Thread Grinding 8.14

THREADS WHE WHEEL WORK

MATERIAL
HR.PERCONDITION 4
INCH ID....IFI
CAT,.. ION
SPEED SPEED
MAERALHES PITCH (P) 1 ANS I fp' ! fpm

Shn . . . .- - . . . - .. ..
17. TOOL STEELS, CAST (cont.) !4 to 12 A100KV i7000
Grou II cont) i13 to 27 A150JV 75G0
Gru I cot)28to 63 A240MV 8500 i 60
(materials isted on preceding page) Over ] Ouence- 64 to 80] A280PV 9000

18. STAINLESS STEELS, CAST i40 tO 2 A0RB 8500

Ferfitic] 13 to 27 tA120SB 9000 40
ASTM A217 Grades C5. C12 135 !28 to63 A180TB 9500
64 to 80 A220UB 10000
CA6N, CA-6NM. CD4MCu 185 --.,_-:
ASTM A297: Grade HC w---
ASTM A487. Class C~aNM ] ' '

ASTM A608 Grade HC30 .;-

Autnfc4 to 12 A90RB 8500

ASTM A296 Grades 017-3. CF-3M. CF-8. 3o7 A10B 90 4.0
CF-SC. CF-M. CF-16. CF-20 CG-8M. 135 Annealed, 28 to 63 A18TB 9500
CG-12. CH-20, CK-20, CN-7M. CN-7MS to Normalized 64 to 80 A220UB I - ' .
ASTM A297" Grades HD, HE, HF.HH.HI, HK. 210 Or -
H,. ,.HT. HU As Cast
ASTM A351 : Grades CF-3, CF-3A, CF-3M, - .-.=__. -- -'--.----- " -
CF-SMA, CF-,S. CF-SA. CF-SC, CF--0,,. , -- .-. - , z-
CF-!0OMC. CH-8, CH-1 0, CH-20. CK-20.
CN-7M,HK-30. HK-40. HT-30
ASTM A451: Grades CPFSA. CPF3. CPF3A.
CPF3M. CPFS,CPFSC. CPF8C (Ta Max ),

ASTM A452. Grades TP 304H. TP 316H, TP

347H

AS iM; ,;usbradesHDS0.HE35. HF30.

HH30. HH33, H135 HK30, HK40. HL30.
HL-40. HN40. HTEO0.
HUS0

Matesiic4 to 12 A90RB 8500

ASTM A217. Grade CA- 15 13t 7 A 2 S 0 0 40
ASTM A296 Grades CA- 15. CA- 15M. CA-40 135 Annealed, 28 to 63 A180TS 9500
ASTM A426. Grades CP7, CP9. CPCA15 to Normalized 641o80 IA22US 10000
ASTIM A487: Classes CA 15a, CA- 15M 225n or Normalized
Tmrd

See section 16 for Cutting Fluid Recommendations

See section 20 for additional information

8-187
8.14 Thread Grinding
THRED WETLI WHEEL IWORK

HARD. IPERINCHI ID
CATION
I SPEED ISPEED
MATERIAL NESS CONDITION
IPITCH (P) ANI!m p
p
-- .- : IA S p
Shn

18. STAINLESS STEELS, CAST (cont.) 4 to 12 1AIOO0KV 17000

Martensitic (cont.) '.13to 27 Al50JV 750 6
(materals listed 0n preceding pg)Over Qunhd64 to 80 A240PV 9000

19. PRECIPITATION HARDENING I 4t12 A90RB 8500

STAINLESS STEELS, CAST 13t 7 A20B 90 .
325 I Solution Treatd2to6 1TB 90
ASTM A35 1. Grade CD-4MCu
ACl Grade CB-7Cu to or 64 to 80 A220UB 10000
ACl Grade CD-4MCu 450 solution Treated ~ f
17-4 PH adAe
AM-355

21. GRAY CAST IRONS4to1 RB $0

Ferritic13t27 A2S 900 4
ASTM A48- Class 20 As Cast. 28 to 63 A180TB 9500
SAE J431c Grade G1800 R
45R Annealed 64 to 80 A22OUB 1000
Pearitc- Ferritic max or Quenched .

ASTM A48- Class 25 and Tempered

SAE J431c: Grade G2500
Pwroific
ASTM A48- Classes 30. 35. 40 ci A0B 80
SAE J431c Grade G3000 7 A2S of
Pearlitic + Free Carbidles 45RAs Cast. 2810o63 A180TB 9500
ASTM A48 Classes 45. 50 *0 Annealed 64 10 80 A220JB 10000
SAE J43 1c: Grades G3500, G4000 5 rQece
Pearifi'c or Acicular + Fro* Crurbide 2n orQenchred
ASTM A48: Classes 55. 60

Austenitic (NI-RESIST) 4o2 A0B 80

ASTM A436 Types 1. 1b. 2. 2b. 3. 4. 5 6 1 o2 10
100 6410806 Al2U 1000
to As Cast 6 o8 20
250

22. COMPACTED GRAPHITE CAST IRONS 4t 2 A0

1528 to63 A18OTB 9500

toAs Cas 6.4,o80 A220UB 10M0
255

See section 16 for Cutting Fluid Aecommenda-ions

See section 20 for additional information

8-188
 Thread Grinding 8.14

tWHEEL WEL WR
THREADS IWEL WR
E INCHISPE IDENTIFI. PE PE
HARD- PER SED
MATERIAL NESS CONDITION CATION
PITCH (P) ANSI Ipm !_pm
Bhn
23. DUCTILE CAST IRONS 4.12 1 A90RB i 8500
Ftnitic AneldA a*, '3 to 27 Ai.20SB 9000 4
ASTM A536. Grades 60.40.18. 65.45-12 AnaeAsCs. 28 ic 63 A 180-F3 9500 j4
SAE J434c. Grades E4018. D4512 s2RNrazdao 64 to 80 A22oUB ooI
Fealitic- Peerlitic max' Tempoered
ASTVM A536: Grade 80-55-06 and Tuerncee
SAE J434c: Grade D5506
Psaritic- Martensitic 5__________
ASTM A536. Grade 100-70-03
SAE J434c, Grade 07003
Martensitic
ASTIV A536: Grade 120-90-02
SAE J434c: Grade 00&T

Austenitic (NI-RESIST Ductile)4to1 A9R 8

ASTM %A439.Types 0-2. 0-2B D-2C. 0-3. 1 o2 10B 90
102 o6 10B 90 -
0-3A. 0-4. D-5. 0-SB
ASIM AS?71: Type D-2MtoAnae64o80 22U 100 -

24. MIIALLEABLE CAST IRONSII

Iorii Malleabfized 28 to26 Al8T 9M0

A62 80T
R Annea32led5
o 64 to 80 A220UB 100

NScEl 118 170d Co2!dan

ASTM41 1220 Arades 851.0506508

MON0LA00
y40
MONEL All 02
Grd M404 ?neleA28t06038T 90
mee Aloy111Cod rwn64t 8sAiU8 100
ASTM A220. Grades 6000 7003, 24002
ASTM A602- Grades M550. M02.35 Cas

P~cM8501a
SEsetiJ18 Grae M55t03. M70id
See ~ ~~ ~ ~ ~ ~ ~ ' SetoA01radtonl'joraf

12(
36. WOUGT AN CAS
CKELALLOS, 4,o28O1895
____
_____
8.14 Thread Grinding
" THREADS j E IWHEEL I WORK
HARD. PER INCH DPEED SPEED
MATERIAL CONDITION CAI IN
I PITCH (P) ANSI , i
j Bhn
! t ~i ,41I 2 AgoP-
______
,.O
36. NICKEL ALLOYS, WROUGHT AND CAST I1 :o 27 A120SB "9C0.
(coo.) 28to63 AI80TB z
DURANICKEL Alloy 301 1 64 to 80 220UB , 4w
MONEL Alloy 502 to0 Solution Treated
MON EL Alloy K500 i 2 I40
NI-SPAN-C Alloy 902 I 29
PERMANICKEL Alloy 300LS o2R5 -

I IY40~ 90 118 8500

RD13 to 27 A120SB 9000 40
A18UTB 9500
28 to63
30 Ct641o80 A220UB 110000
I to Ag ed ---
I 360rs t ':-

37. BERYLLIUM NICKEL ALLOYS, 4o2 A0B 80

WROUGHT AND CAST 13 to 27 A120SB 9000
Beryco 440
28 to 63 MS8TB 1 9500 40
200 As Cast 644 1080
to 12 A220U
ASORB 10000
Be.tycG AlIC to o 8500
Berylco 42C 250 Solution Treated r - ___

Berylco 43C
Brush Alloy 2000-
Brush Alloy 220C 4 01 90B 80
Brush Ailoy 2600
3t 7 A2S 00 4
283 Hardened 64 to 80 A22OUB 10000
t425 Aged- *r- --

S13 to 27 A180KV 7500 6.0

47 Rc Hardened ;648 to
to 63
80 A240MV
A320PV 8500
9000
to or -
52 RC Aged 0-7

See section 16 for Cutting Flu:d Recommendations CAUTION Toxic Material, refer to National Institute for Occupational
See section 20 for codtonal information Safety and Heath (NIOSH) for Precautions

8-190
 Thread Grinding 8.14

THREADS WHEEEELP
IDE'JTIFI WEL WP
THARD- PER INCH SPEED SPEED
MATERIAL NESS CONDITION CATION

PITCH (P) ANSI :,

39, HIGH TEMPERATURE ALLOYS. '2"

WROUGHT AND CAST '3w27 AIC0 ."
Nickel Be, Wrought 21'6 03 A80T 0.3
AF2.1IDA lnonej Aloy 75'.4 8 Ao
ASIroo M252 -. 0Somj*,o 7'ealec
-iayrnes Alloy 263 I4,m011c 75

N102 r'Jrrnc 80___________ ____ 3

1hcrrloy Al-,, 9C I Nrnr 90_______________ ____________
-colo Aboy 903 NvJn-n- 94 4- 1o2 A90SB .
'-oeAkij 6 17 Pene 4~1 27 A ',00 is
.r~on Aloy 25 ene632:-o 63 A',BOT8
'loonel Alloy 702 Rene 77 62 to 80 A280T
inconel Alloy 702 Riene 500 a,. 1oore
;rconei; Alloy 718 Udirnel 70~ ~
inconei Alloy '21 Udirne: 7'0-
1-co-el Alloy 722 Unte-to 1753
inconei Alk~j X-750 wasoelioy II

Nickel Base, Wrought 02

-iaSe1'o~ Ma 8 .z:o 27 I 100
AIy625lc63 IAi8OT 9000
la~iyAlloy B-2 1 'reje 64 10 PO3 A260TE 1I -
Hasteiloy Alloy C jI--
Hastelloy Alloy C-276 t 220 Su-.* ra tW7
H-:as*,elloy Alloy G I
Hasielloy A:loy S
,astezoy Alloy x I___________ ___

A, -, 4100zto12 A9,uS8
inccWoy Alloy 825 1 131to27 (A1OOTB I

-ionl lly
01240idDa 28 63 Ao, 40
I nase Ada 0-6 o A8T
Fleffacialoy 26 I 310 1 A'- '--=
Udelnet 6301

Nickel Bae, Wrought 1 142 A5S

TD:N,eltt '3 o27 IWTSB
TDN-Ct 641,)80 A28OT8
I 2W0

See sectbon 161for CLIbzng Fluta Reconrnetdalmm I l CAL.TO' Tox .aenal reft to Natonv .url4je for 0--curat'orli
See sect~on 20 'or adr11ona; .nfomzonr Safety anc H4ea~n (%NOSHI
for Pecautsons

8-191
8.14 Thread Grinding

THREADS WHEEL WHEEL WORK

HARD- PER INCH IDENTIFI SPEED SPEED
MATERIAL NESS CONDITION CATION
PITCH (P) ANSI fpm fpm

39. HIGH TEMPERATURE ALLOYS, 4 to 12 A90SB1

WROUGHT AND CAST (cont.) 13 to 27 A100TB 9000 to
Nickel Base, Cast 200 As Cast 64 to 80 A280TB 4.0
8-1900 to or
GMR-235 425 Cast and Aged x .. 9M 9
GMR-235D" I'll .
Hastelloy
Hastelloy Alloy
Alloy B
C _-"--___ ____.__-- -
Hastelloy Alloy D
IN-100 (Rene 100)
IN-738
IN-792
Inconet Alloy 713C
Inconel Alloy 718
M252
MAR-M200 "'I
ME 1 .
MAR-M246
MAR-M421
MAR-M432
Rene 80
Rene 125
SEL
SEL115N
TRW VI A
Udimnet 500
Udimet 700
ASTM A296 Grades CW-12M, N-12M. CY-40
ASTM A297 Grades HW, HX
ASTM A494. Grades N-12M-1, N-12M-2,
CY-40. CW-12M-1, CW-12M-2
ASTM A608: Grades HW50, HX50

Cobalt Base, Wrought 4 to 2 A90SB

AiResist28 to 63 A18TB
Haynes Alloy 25 (L605) 180 64 to 80 A28OTB
Haynes Alloy 188 to Solution Treated
J-1570 230
MAR-M905
S-81015
MAR-M918

V-36 4 to 12
13 to 27 A10B 9000 to

270 28 to 63 A18OTB
to Solution Treated 64 to 80 A28OTB
320 and Aged

See section 16 for Cutting Fluid Recommendations.

See section 20 for additional information.

8-192
 Thread Grinding 8.14

THREADS WHEEL WHEEL WORK

HARD- PER INCH IDENTIF- SPEED SPEED
MATERIAL NESS CONDITION CATION
PITCH (P) ANSI fpm fpm
Bhn _______
4 tO12 A90S58
Cobalt Base, Cast 13 to27 A00TB 15
AiResist 13 2810to63 A180TB 9000 to
AiResist 215 220 As Cast 64 to 80 A280TB 4.0
FSX-414 to or 64 tA8
HS-216 290 Cast and Aged '
HS-31 (X-40) A O f ?
HOWMET #3 E ,i4,Ao G
MAR-M302 4 to 12 A90SB
13 to 27 A100TS 15
MAR-M322 4.0
28 to 63 A180TB
MAR-M59 As Cast 64 to80 A280T8
NASA Co-W-Re 290
to or

X-5 425 Cast and Aged

Iron Base, Wrought 4 to 2 A90SB

A-286 13 to27 A180TB 9000 to
Discaloy 180 64 to 80 A280TB 4.0
to Solution Treated 64 t8 A T
Incoloy Alloy 800
Incoloy Alloy 800H 230
Inzoloy Alloy 801
Incoloy Alloy 802V
N-1 55
V-57 4 to 12 A90SB 1.5
W-545 13 to27 A100T 9
16-25-6 250 28 to63 A180TB 4.0
19-9DL to Solution Treated 64 to 80 A280TB
320 and Aged2R

4 to 12 0SB 8500
47. POWDER METAL ALLOYS
Irons 13tto 637
28 A2S 00 4.0
F-0000-N 50 A18OTB 9500
F-0000-P to 64 to 80 A220UB 10000

67 As Sintered -
F-0000-R
F-00u0-S 500kg
F-0000-T
4 to 12 A90B 80
50
Stel
F-00e8- 13 to 27 A120S8 9000 4.0
F-0008-P 28 to 63 A18OTB 9500
F0008- 101 As Sintered 64 to 80 A220UB 10000
F-0005-S to or
FC-0205-S 426 Heat Treated
FC-3208-P
FC-0208-S
FC-0508-P
FC- 1000-N
FN-0205-S
FN-0205-T
FN-0405-R
FN-0405-S
FN-0405-T
FX-1005-T
FX-2008-T
See section 16 for Cutting Fluid Recc' omendations.
See section 20 for additional information.

8-193
8.14 Thread Grinding

*'THREADS WHEL WHEEL WORK

MAEILHARD- CONDITION PER INCH CAETIN
CTO SPEED SPEED
MAEILNESS
PITCH (P) ANSI fpm fpm
Bhfln n
47. POWDfER METAL ALOS(cont.) 4 to 12 A90RB 8500
lLOY
AtilssSe 131027 A120SB 9000 4.
Stailes Stels28 to 63 A18OTB 9500 4.
SS-303-R 107 As Sintered 64to 80 A22OUB 10000
SS-304-R to or - -r
SS-316-P 285 Heat Treated -pj

48. MACHINABLE CARBIDES 4to 12 D240R100B1/8 4500

Ferro-Tic131o27 0320T100B31/8 5000
5500 1.
1
Fero-Tc 8R Hrdeed281063 D400V1008l/B
68 R Harened6410o80 0400V10081/8 6000
to and
70 Rc Tempered AfeTiO~DO1
SU2~

49. CARBIDES 41to 12 D240R100B1/8 4500

Titanium Carbide 13 to 27 D32OT100BI/8 5000 1.
Tunstn arid SRA28 to 63 D400V10081/8 5500
Tunstn Crbde 9 A6410S 80D400VV100B /8 6000
to-

51. MAGNETIC ALLOYS4to1 A20V 70

Atnico 1I3t 7 A8K 50 6
Alnico 11 45 Rc 64 to 80 A320PV 9000
Alnico III 10A Cs
Atnco v 8 R0 -,Mi-
R01R-- R -
MOM-
R5
Atnico IV 5RRK
Ain ico V A7I
Alnico XI7

Hyttux Atnico V-7

See section 16 for Cutting Fltuid Recommendations

See section 20 for additional information.

8-194
 SECTION 9

INTRODUCTION TO
NONTRADITIONAL MACHINING

9-1
 FPRECIMIZG PAGE BLANK-NOT FIL1I)

INTRODUCTION TO NONTRADITIONAL MACHINING 9

NONTRADITIONAL MACHINING is a generic designa- TABLE 9-1 Current Commercially Available
tion applied to those material removal processes that have Nontraditional Material Removal Processes
recently emerged. have not beer, used extensively here- MECHANICAL
tofore. ,.are new to the user. These processes aie some- AFM - Abrasive Flow Machining
timeziabe'ed inonconventional, layless or nonmechanical. AJM - Abrasive Jet Machining
The designation "nontraditional" reflects a high degree of HDM - Hydrodynamic Machining
personal
tihe bias. and its use depends upon the experiences of
individuialLS LSG - -LoSresGidn
Low Stress Grinding
RUM - Rotary Ultrasonic Machining
TAM - Thermally Assisted Machining
Thirty-one nontraditional machining processes have been TFM - Total Form Machining
selected for inclusion in this handbook. They have been USM - Ultrasonic Machining
grouped for discussion according to their primary energy WJM - Water Jet Machining
mode: that is. Mechanical. Electrical. Thermal or Chem-
ical. as shown in table 9-1. While many more non- ELECTRICAL
traditional machining processes exist in lboratory use, ECD - Electrochemical Deburring
these thirty-one represent those processes which have ECDG - Electrochemical Discharge Grinding
emerged from the laboratory since the early 1940"s. are ECG - Electrochemical Griading
available or are in use cemmercially. and have machin- ECH - Electrochemical Honing
ability data and information which are available in the ECM - Electrochemical Machininq
public domain. i7cp - Electrochemical Polishing
ECS - Electrochemical Sharpening
Nontraditonal processes provide manufacturing engineers ECT - Electrochemical Turning
with additional choices or alternatives to the traditional or ES - Electro-streamM
conventional mechanical and abrasive material removal STEMW --Shaped Tube Electrolytic Machining
processes. Figure 9-1 and table 9-2 demonstrate the rela-
tionships among the conventional and the nontraditional THERMAL
machining processes with respect to surface roughness. di- EBM - Electron Beam Machining
mensional tolerance and metal removal rate. It is impor- EDG - Electrical Discharge Grinding
tant to note that carefully selected and properly applied EDM - Electrical Discharge Machining
nontraditional machining processes offer some unique ca- EDS - Electrical Discharge Sawing
pabilities and fresh opportunities for cost improvement in EDWC - Electrical Discharge Wire Cutting
the field of material removal. LBM - Laser Beam Machining
LBT - Laser Beam Torch
The state of the art for nontraditional machining proces,es PBM - Plasma Beam Machining
is still in a period of rapid change. !t can be expected,
therefore. that many of the values, ranges and limitations CHEMICAL
expressed in the data presented can be exceeded. The data CHM - Chemical Machining
comprise publicly available information circa 1979. A ELP - Electropolish
check with knowledgeable process vendors is recom- PCM - Photochemical Machining
mended before proceeding with or rejecting any of these TCM - Thermochemical Machining (or TEM-Thermal
material removal processes. The Machinability Data Cen-
ter monitors developments and collects data for these proc-
esses Inquiries are welcomed.

9-3

=
9INTRODUCTION TO NONTRADITIONAL MACHINING

0
0 c

cv~ toi
2 c U

Lio 0 c__

0,
-~ ~
0)
L)

- - - - - - - - - - - Z5Li0
CL Cl)
tv 0
0)o

0) - E
00 o > ca c

C =CA a) (D

0)0
o~~ (>0

0 0 0 0 - .5
-n :cE 'o

-i, 0
LL0 0 aj W- E S C cl
-W U) 0o-c

c0

o 0)C

2 2Z 0
0
0 0) o0 -2> o 0

01
02~~~~~ m2222w
~ -
a 2 oomZ LZc
ui~~~~~~ ~ ~ -XM
~ ~ 0 LLU (n U
ax-oI 1 a1
2 i D w w w wWCw w j 0 i . w o or
0 a

.C C)

Q9-4
C cu EN O- E~~~~~ 0 Cc .2
 INTRODUCTION TO NONTRADITIONAL MACHINING 9
TABLE 9-2 Comparison of Material Removal Rates and Dimensional Tolerances for Conventional and Nontraditional
Machining Processes

MAXIMUM'
I I I ACCURACY=
- AT MAXIMUM
I RATE OF TYPICAL PENETRATION IMATERIAL TYPICAL
1 MATERIAL POWER CUTTING RATE PER REMOVAL MACHINE
PROCESS IREMOVAL CONSUMPTION. SPEED MINUTE ATTAINABLE RATE INPUT

I in'min hp/in3/min fpm in in in hp

cm3 /min kW/CM3/min J r/min mm -mm - mm kW

Conventional 200 1 250 -0.0002 0.005 30

Turning 3300 0.046 76 -0.005 0.13 22

Conventional 50 10 10 -0.0001 0,002 25

Grinding

OHM
_____
I
1490
820

30

-
- I 3.46-3

-
-0.001

0O.02
- 0.0025--

0.0005

0.013
-
-0.05

0.003-

0.075
20

I 10 20 50 10 0.02 0.1 , 200

PBM _ 24052.4. 10
64 1-5- -,254_

ECG
I 2 2 0.25 I
I
-0.0002 0.0025
-- = . 4

33 0.091 0.084 - -0.005 --. 6 -

1 160 -0.5 0.0005 0.006 20C
ECM
16.4 7.28 - 27. 003 _015 . 5
0.3 40 -0.5 0.00015 0.002 15
EDM
4.9 -1.82 4 2.7, - 0.004:0.51

200 0.0002 0.0015 15

USA0.05 -0.02

USM~ 0.w2 9.10= -- - 0000

0.0005 10,000 200 6 0.0002 0.002 10

EBM 0:60082 -455 16 5~~-

0.0003 60,000 -4 0.0005 0.005 20

9-5
 SECTION 10

MECHANICAL NONTRADITIONAL
MACHINING OPERATIONS

10.1 Abrasive Flow Machining-AFM ....... ...................................................... 10-3

10.2 Abrasive Jet Machining-AJM ..... .. ..._ ........ ........... ........ 10-15
10.3 Hydrodynamic Machining-HDM .......... ................. <.......................... ...... 10-21
10.4 Low Stress Grinding-LSG .................................. < .............
m ................ 10-37
10.5 Thermally Assisted Machining-TAM ......... .............................. ............... 10-39
10.6 Total Form Machining-TFM .................................... ................................... 10-41
10.7 Ultrasonic Machining-USM and Rotary Ultrasonic Machining-RUM........................10-43
10.8 Water Jet Machining-WJM........................ ..... ........................................ 10-65

10-11
 PRECEING PACE BLAIe-NOT FILLhD

Abrasive Flow Machining-AFM 10.1

PROCESS SUMMARY Practical Applications
Edge finishing. radiusing. deburring. polishing and minor
surface material removal are accomplished with AFM. It is
not a mass material removal process. but it is particularly
useful for polishing or deburring inaccessible internal pas-
sages. Materials from soft aluminum to tough nickel alloys
Upper] are being processed with AFM. Removal of undesired lay-
media ers produced by thermal processes such as EDM. LBM. or
chamber NNnitriding is also achieved with AFM. Polishing can quickly
improve 30- to 300-micronch R., 10.8 to 7.6 yml finishes to
one-tenth of the original roughness. Radii from 0.001 inch
10.025 mml to 0.060 inch I1 5 mml can be produced. Holes
smaller than I164-inch 10.4 inml diameter are sometimes
difficult to process with AFM Blind-hole polishing is im-
Npractical because AFM requires flowing media-

Operating Parameters

TABLE 10.1-1 Typical Values for AFM Operating

Parameters
FLOW
* tMedia
viscosity: Stiff to fluid (see tables 10.1-2 and 10.1-4)
Viscous grtsize: =8 to = 1000 (see table 10.1-3)
abrasive starting
media temperature: 900 to 125OF [320 to 520C]
grit types: See table 10.1-2

L
Lower" Flow
:media pressure: 100 to 3000 psi [700 to 20.000 kPa]
chamber volume: 3 to 100 fluid ounces (100 to 3000 mlJ
rate. 2 to 60 gal/min [7 to 225 Limin)

draulically operated Strokes 1 to 100

pistons

Figure 10.1-1 AFM schematic.

Principles
Abrasive flow machining (AFM) is the removal of material
by a viscous, abrasive media flowing-. under pressure. Material Removal Rates and Tolerances
through or across z- workpiece. Figure 10.1-1 contains a The greatest material removal action will occur at the
schematic presentation of the AFM process. The grit- point(s) of maximum flow restriction. AFM processing
loaded media of polymeric-base material is selected for its times frequently range from one to five minutes. Stock
viscosity and type and proportion of grit. in order to suit removal can be uniform within 10 percent of the stock re-
the part shape and the intended action-deburring. polish- moved and uniform within each passageway. but out-of-
ing. radiusing. Generally. the putty-like media is extruded roundness will not be corrected. Production rates of 1000
through or over the workpiece with motion usually in both pieces per hour for multiple-fixtured small parts have been
directions using from one to one hundred flow rev-rsals per achieved. Usually only a few thousandths inch of material
fixture load. Aluminum oxide, silicon carbide. boron car- are removed by AFM. as demonstrated in tables 10.1-5
bide or diamond abrasives are used. The velocity of the ex- and 10.1-6. Where passageways of dissimilar size are adja-
truded media is dependent upon the principal parameters cent. stock removal will also be dissimilar, but fixture de-
of viscosity. pressure. passage size and length. sign can sometimes provide compensation.

10-3
10.1 Abrasive Flow Machining-AFM

Surface Technology stricting passage to be abraded. Fundamentally. viscosity

Surface roughness to 2 microinches R., 10.05 ml can be ob- must be high enough to maintain extrusion-type flow and
tained and dimensional tolerances to a few ten-thousandths high enough to hold the abrasive grains at the outermost
inch can be achieved Control of the volume of media flow surface of the extruding *slug' with sufficient force to allow
is of major importance to quality control Surfaces are typi- the abrasive to cut the edges and/or surfaces of the re-
cally smoothed to 1/10 the prior roughness. in terms of mi- stricting passage. At the same time. the media must be soft
croinches R.. Unidirectional lay is evident after a few enough to flow at a reasonable rate. at the extrusion pres-
sttokes of the machine. No metal smearing results from the sure available, in order to perform the finishing operation
AFM process. Action occurs on both the peaks and the val- in an acceptable cycle time.
leys on the surface. The abrading action can leave residual
stresses under 0.001-inch deep 10.025 mini in the surface
layers. Surface layers altered by prior processes are
smoothly removed by AFM. Machining Characteristics
More uniform deburring than can be accomplished with
hand tools is a significant quality advantage for AFM.
Equipment and Tools Careful post-operation cleaning is recommended. This
Low-, medium- and high-pressure systems are available in cleaning can readily be accomplished by an air blast or im-
a range from 100 to 3000 psi 1700 to 20.000 kPal Tooling mersion in an agitated solvent.
is usually needed to direct. confine or sometimes control
the flow paths. Hardened steel tooling directs the flow so Machining action is gentle and continuous, and the burrs or
that the major restriction occurs where material removal is .chips" are retained in the media. The media can tolerate
desired. Ceramic or urethane inserts can minimize the tool as much as 10 percent of its volume in "chips" or foreign
wear that is experienced in some cases material. The media life is limited at the point at which a
substantial number of the grains become dull. Recondition-
Many types of abrasives and viscosities are available as ing of the media can be accomplished by measured addi-
media. Media viscosity relates directly to the size of the re- tions of abrasive grit and lubricant.

10-4
-~ . i- -- --. --- ~ -- ~ -
 Abrasive Flow Machining-AFM 10.1
SELECTED DATA

TABLE 10.1-2 Abrasive Flow Media Designations TABLE 10.1-3 Grit Sizes Used in AFM

Viscosity Grade or Base*'- GRIT SIZE AVERAGE PARTICLE SIZE

LV or 500 -low f in Pin,
LMV or 300 - low-medium
MV or 200 - medium 8 I 0.1817 4.15
HMV or 100 - high-medium 10 0.1366 3,470
HV or 50 -high12O032,5
114 j 0.0830 -2,110
Grit Type': 16 j 00655 1660
A -Aluminum oxide 2 02 .4
B -Boron carbide 25 ' 0.0408 -1035
C - Silicon carbide (in ANSI 874.13 standard) 30 0.036592
D - Diamond 35 0.028071
S - Silicon carbide (in some manufacturers' nomenclatures) 45 I 0.0200 58
50 I 0.017042
Media Nomenclature (One system)- 60 0.0160 40
70 0.0131 -2
D075-20A(30)-36A(40)-700A(30) 80001528
Manufacturer J 90 00085 1?~
Media base (viscosity)-] 100 00068 173 7
Abrasive grit size -J10005 4
140 0,004812
Abrasive grit type -10003 6
Parts by weight to base (this amount of abrasive 200 0.0026 6
in 100 parts of base) 230 0.00248
'Number and letter codes are not necessanly of equal viscosity-see 270 0.00175 ~ 1
manufacturers recommendations. 325 0.001 28
'See section 3.14 for grit hardness 400 0.00090 2
500 0.00073
600 0.00057 1
800 0.00044 1
900 0.00038 1
1.000 0.00032 8

10-5
10.1 Abrasive Flow Machining-AFM

TABLE 10.1-4 Guide to Media Seiection

(Viscosity grades for passageways with 2:1 length-to-widtr, ratio)
PASSAGE WIDTH; EXTRUSION PRESSURE
in m Low ,o High

1,"64 0.4 ... LV

1/32 0.8 LV- LMV
116 1.6 . LV_ - LMV... - MV
1 '8 3.2 LVLLMV__ MV__ - HMV
1 4 6A LMV_ MV-._ HMV__ HV
1.'2 12-8. MV-- HMV_ HV
1 254 HMV . HV
2 -50.8 HV
SOURCE Extrude Hone Corporation
NOTES As usable media extrusion pressure increases '-he, viscosty
media grades may be used
Itpassage lergth is substantially shorter than two times passage width
highe' viscosity media or lower extrusion pressure miy be used
If oassage length is substantially longer than t%.o times passage wid'th
lower viscosity media or higher extrusion pressures may be required
Media slug flow rates affect uniforf/ny of stock removal and edge radius
size
Slow slug flow rates (speed of abfasive slug passing through ,estricting
passage) are best for uniformly removing material on close tolerance
parts
High slug flow rates produce larger edge radii
'See table 10 1-2 for explanation of viscosity grade codes

TABLE 10.1-5 AFM Cutting Test Results for Cold Rolled Steel Discs-10 Full-Reverse Cycles

Conditions:
hole length .......................................................... ............................................... 0-25 inch [6.25 m m ]
hole diameter ................................................... 0-125 inch (3.18 mril] lon.inal-initially

number full reverse cycles ............................ ................................................ 10

equipment ...................................................... Dynetics HL15
initial media temperature ........................................... 30-DC (86F)

Media (moderately fast):

base polymer 100 (high-medium viscosity) ....................................................... 565%
36-grit siz. white aluminum oxide (A) or black silicon
ezmbide (S)or boron carbide (B) ................ ............................................... 37 8%
700-grit size. black silicon carbide (S) ................ ....................... 5.7%
T I-
MEDIA TOTAL INITIAL FINAL STOCK
GRIT TYPE PRESSURE TiME DIAMETER DIAMETER INCREASE RADIUS REMOVAL
psi min inch inch inch inch milligrams

Aluminum oxide 300 18.0 0.127 0.141 0.0.- 0.020 Ill

400 3.8 0.127 0.145 0.018 0.020 176

5W 1.8 0.127 0.153 0.026 0.040 293

Silicon carbide 300 22.7 0.126 0.144 0018 I 0.020 168

400 4.2 0.127 0.149 0.022 I 0.025 239
500 2.0 0.127 0.153 0026 i 0.030 293

Boron carbide 300 19.3 I 0126 0.160 0020 I328 30.034

400 3.8 0.125 1 0.164 0.039 0.020 344
500 1.6 0.126 1 0.173 0.047 - 0.040 540

SOURCE- W B. Perry. Fropere and capabiles of low pressure abrasive flow mediae. Technical paper MR75-831. Society of Manufur Engineers.
1975.

10-6
 Abrasive Flow Machining-AFM 10.1
TABLE 10.1-6 AFM Cutting Test Results for Cold Rolled Steel Discs-30 Full-Reverse Cycles

Conditions
hole lenqth .................. ........................ 0.25 inch [6.35 mm]
hole diameter ................................................ 0.125 inch (3.18 mm] nominal-initially
number of full reverse cycles ............. ................. 30
equipment .... ..................................... Dynetics HL15
initial media temperature .................................... 25C (77F)
media pressure ....... ........ .... .....I.................
450 psi [3100 k Pa]

Modia
base polymer ..............................................64.5%
60-grit size, black silicon carbide (S)... ... ................. 21.3%
..............
700-grit size, 'lack silicon carbide (S) ......................... 14.2%
base poiyrier ............. 100, 200, 300 (see table 10.1-2 for viscosities)
................................... .......
or
base r,-'-,mer ...... .....................................56.5%
36-grit size, black silicon carbide (S) ........................... 37.8%
700-grit size, black silicon carbide (S) .........................5.7%
base polymer .. ......... .................... 100, 050 (see table 10.1-2 for viscosit!es)
.........................................

MEDIA
TOTAL
TIME
INITIAL
DIAMETER
1 FINAL
DIAMETER RADIUS
min inch inch inch

Size 60 grit, Base 300 4.0 0.125 0.136 0.045

Size 60 grit, Base 200 4.4 0.125 0.138 0.040
Size 60 grit, Base 100 7.7 0.126 0.153 0.020

Size 36 grit, Base 100" 4.1 0.125 0.189 0.040

Size 36 grit, Base 100* 16 0.249 0.267 0.055
Size 36 grit, Base 050 22 0 0.373 0.408 0 040

SOURCE: W B. Perry, Technical paper MR75-831, Society of Manufacturing Engineers, 1975.

* Same media as intable 10.1-5.

Stock Removal and Flow Rates1 1. Stock removal per unit time increases substantially with
increasing extrusion pressure (figures 10.1-2 to 10.2-4).
One of the attractive features of AFM is the wide variety of 2. Media flow rate increases with increasing extrusion
available and easily adjustable process parameters. The ef- pressure. Note: Flow rate increases proportionally with
fects of changing some of these parameters for specific extrusion pressure, or logarithmically, as indicated in
niedia compositions are illustrated in figures 10 1-2 to figure 10.1-5.
10.1-7. These data come from simple laboratory tests on
cold-rolled-steel samples and are intended only to provide 3. Flow rat-, inci eases as media temperature increases (ig-
"'guidelines" for use in actual production situations. The m- ure 10.1-6). Note: In the tests conducted in preparing
terrelationships of various parameters depend greatly on this graph, stock removal per unit volume of flow did
the characteristics of a given media composition. A few not change with changes in flow velocity over the range
widely different media compositions were examined in or- covered by the graph.
der to formulate general rules that can be applied to AFM.
Parameter relationships are also affected by the size and 4. Increasing hole length reduces both flow rate and diam-
length of the flow passages. The data in figures 10.1-2 to eter change per unit flow (figure 10.1-7).
10.1-7 are limited to the examination of round holes ma-
chined normal to the test piece surfaces. The general rules These general rules apply for each of the medias examined,
which emerged are as follows: but the degree of application varies. These variances re-
flect differences in the content of base materials, lubricants
and/or plasticizers as well as differences in the size and
'Based on text ann figures from L J Rhoc..des. Extrude hone-edge and percentage of grit. The relative size and length of the flow
surface finishing-capabilities and costs. Technical paper MR77-366. passage also is likely to have an effect on these relation-
Society of Manufacturing Engineers, Dearborn. Ml, 1977 ships.

10
10.1 Abrasi aw Machining-AFM

0 008 [0.2mm] Hl egh020i 63 m

0 007

0.00

S 0.004
E
Ca
3 0003

0.002 ___/ _00ps

0,001

0
0 60 120 180 240 300 360 420 480 540
Time. sec
Figure 10.1-2 Stock removal rates for AFM of cold-rolled-steol samples using media 70 (633) at three
extrusion pressures. (From L. J. Rhoades, Extrude hone-edge and surface finishing-capabilities and costs,
Technical paper MR77-366, Society of Manufacturing Engineers, Dearborn, MI, 1977. p. 14)

0.009

0.008 .(0.2 mm]-

0.007 ____
1200 psi 900 pi'
0.006 _____(6200 kPa) -

1200 psi

0.0

2 0,004
E 600 psi

0002 .......

Hole dia. 0.250 in [6.35 min]

A
0.001 Hole length 0.250 in (6.35 mm]_
Media temp 90OF [32 0 C)

1) 60 120 180 240 300 360 420 480 540

Time, sec

Figure 10.1-3 Stock removal rates for AFM of cold-rolled-steel samples using media 36 (564) at four
extrusion presstires. (L. J. Rhoades, p. 14)

10-8
 Abrasive Flow Machining-AFM 10.1

0009
600 psi /
0008 (02 mm] - 600psi
(4100 kPa]
0007 A-,
C I500 psi,00

0006 1-e- ___s

_/_ _ _ / Hole 500 psi _ __"

!~00 0005
Z -/M0

_'0 ! ,
S0003
E 400 psi
0)
0023 1000oF--[8 c

-. 0 Hole dia. 0 040 in [1 mm]

0.001____ Hole length 0 080 in [2 mm]
0.00
0 .0_Media temp 900 F-[320 C]
Z.;_ 1000 F---[380 C]
0 lk_________________

0 60 120 180 240 300 360 420 480 540 600

Time, sec

Figure 10.1-4 Stock removal rates for AFM of cold-rolled-steel samples using media 100 (356) at three
extrusion pressures. (L J Rhoades, p 15)

55

5.0 . Hole dia. 0.040 in 1 m] - __

Hole length 0 080 in [1 mm]
45 "Media temp 90 0 F [380C] -

4,0
E 3.5 -

; 30

.2 2.5
2.0

15
1.0 -

05
0
0 100 200 300 400 500 600 700
[7] [14] [21] [28] [35] [42] [49]
2
Extrusion pressure, psi [kg/cm ]

Figure 10.1-6 Media flow rate versus extrusion pressure. Test conditions same as figure 10.1-4 (L. J.
Rhoades, p. 16)

10-9 j
10.1 Abrasive Flow Macnining-AFM
1250
Hoie dia 0 250 in (6.35 mm)
1200 Hole length 0,250 in (6.35 mm]
Pressure 900 psi
1150

0 1100

S 1050

S 1000

950 ""000,00

3.3% Increase in flow rate

per degree F I

in3/s 2.A. 30 3.5 4.0 4 5 (74 cm1/s]

Linear in/s 40 50 60 70 80 90 (230 cm/sJ
Flow rate

Figure 10.1-6 MAedia flow rate versus temperature for AFM of cold-rolled-steel samples using media 70
(633). (L. J. Rhoades, p.-16)

0009 1 1 1
U08
2 1,11Hole
0 dia. 0.040 in [1 mm]
Media 100(356)
0007 - - Media temp. 900 F [320 C]
Media pressure 400 psi
E- 0.006 --

CU
S 0,005 - - ---- __ -

C)

S 0.003

Rhads p." 15)i

10i
 Abrasive Flow Machining-AFM 10.1

Hole Enlargement

600
(20 oz)

400
E
cc)

: 200
200
4 l
Operating Conditions

Pressure: 900 to 1,100 psi [63-78 kg/cm2]

STemperature: 900 to 1000 F (32 to 380C1
Media: EX 32011 (304)
Hole depth. 0.100 to 0.150 in J2.54 to 3.81 mm]
0I I I 1
0.005 0.006 0.007 0.008 0.009
10.23 mm]
Diameter increase, in

Figure 10.1-8 Hole diameter increase as a function of media volume. Data from enlarging 0.015-inch
diameter laser drilled holes in a nickel alloy. (Courtesy of General Electric Company)

10-11
10.1 Abrasive Flow Machining-AFM

SPECIFIC APPLICATIONS DATA

TABLE 10.1-7 Specific Applications Data for Abrasive Flow Machining

Work material* Stainless Steel Hardened Die Steel Tungsten Carbide

Workpiece
configuration

Deburr 12 drilled hole Radius & remove recast Draw die poIshing
intersections layer from extrusion die

Media
type Dynetics D080-20S(50)- Extrude Hone MV70S Extrude Hone HV30pD
36S(50)-700S(40)

git type. Silicon carbide Silicon carbide Diamond

grit size 50 parts-20 grit; 70 grit 30 micron

50 parts-36 grit,
40 parts-700 grit

volume 10-inch stroke 3 passages, 6,000 in3 1,500 in 3

Pressure, psi. 450 450 800

Media temperature, 'F. 80 110

Process time- 90s 4 min 3 to 8 mmn

Number strokes
(one way) 6 20 30

Pieces per fixture: 1 1 1

Material removed
(Dimension
changed) 0.001 inch per surface 0.00075 inch per surface 0.001 to 0.002 inch

Surface roughness
change, pin R.- 63 to 16 75 to7 25-35 to 6-8

10-12
 Abrasive Flow Machining-AFM 10.1

TABLE 10.1-7-Continued
Work material. Cast Stellite High Strength Steel AISI Type 02 Tool Steel

00
V/orkpiece
configuration:

Jet fuc, swirler polish. Thread deburr Polished retainer

radius & deourr se, * pockets

Media
type. Dynetics D060-20B(35)- Extrude Hone MV70S Extrude Hone MV24S
36B(35)-700(45)

grit type: Boron carbide Silicon carbide Siiicon carbide

grit size: 35 parts-20 grit; 70 grit 24 grit

35 parts-36 grit,
45 parts-700 grit

volume: 12-inch stroke 1,000 in' 5,600 in3

Pressure, psi: 450 600 1,400

Media temperature, IF: 80

Process time: 3 mm 2 min 7 min

Number strokes
(one way): 6 4 14

Pieces per fixture" 3 1 1 (6 to 8 practical)

Material removed.A
(Dimension 3
changed): Polished 0.0002 inch per surface 0.002 inch per surface

Surface roughness
change,pin R.: 63 to 12 40to8 100 to 10

10-13
10.1 Abrasive Flow Machining-AFM

TABLE 10.1-7-Continued

Work material. Cast Nickel Alloy Cast Nickel Alloy

Workpiece
configuration,

1- 1-o 015 in
0.032 in dia

(section)
Remove recast from Removal of recast &
small holes add radii to hole

Media
type. Dynetics D250-220S(50) Extrude Hone VLV320S

grit type: Silicon carbide Silicon carbide

grit size: 50 parts-220 grit 320 grit

volume: 1.000 ml 480 ml

Pressure, psi: 475 1.100

Media temperature, 0F. 95 110

Process time: Controlled by volume, not Controlled by volume, not

strokes and time strokes and time

Number strokes Controlled by volume, not Controlled by volume, not

(one way): strokes and time strokes and time

Pieces per fixture: 1 1

Material removed
(Dimension
changed). 0.004 inch on diameter 0.005 inch on diameter

Surface roughness
change, pin R.: 50 to 16

10-14
 Abrasive Jet Machining-AJM 10.2

PROCESS SUMMARY

Filters Powder supply

& mixer

regulatorExas
~Hood

t ==: Hand holder

(li ,
Foot control Nozzle
LJ valve ,

V Vibrator FWorkpiece -""

Figure 10.2-1 AJM schematic.

Principles medical appliances. Parts machined from nylon, Teflon-.

and Delrin" may also be deburred. The cleaning of irregu-
Abrasive jet machining (AJM) is the removal of materJl lar surfaces, such as holes that break through threads, is
through the action of a focused, high velocity stream of fine one advantage of the ability of the abrasive stream to fol-
grit or powder-loaded gas The gas should be dry. clean low contours. Drilling holes in metal is not a viable appli-
and under modest pressure. Figure 10.2-1 shows a cation because the walls will have significant taper. and the
schematic of the AJM process The mixing chamber some- drilling speed is very slow.
times uses a vibrator to promote a uniform flow of grit. The
hard nozzle is directed close to the workpiece at a slight Hand-held nozzles, template guides. pantograph guides. or
angle. The operation should be enclosed in a dust hood or motorized fixtures are used for simple and intricate shapec
be near an adequate exhaust collector. Cutting is con- or holes in sensitive, brittle, thin or difficult materieis.
trolled by type of abrasive, gas pressure. rate of abrasive Discs as small as 1/16-inch 11.6 mini diameter and discs up
flow, angle of and closeness of nozzle to workpiece, and du- to 1/4-inch 16.35 mini thick have been cut in glass without
ration of application. Masks of copper. glass or rubber are the occurrence of chipping. Other good applications for
sometimes used to control overspray or the etching pattern. AIM are insulation stripping and wire cleaning without af-
fecting the conductor, and micro-deburring. as on hypoder-
mic needles. Frosting glass. trimming circuit boards. and
trimming silicon and gallium are routine. Removal of films
Practical Applications and delicate cleaning, such as the removal of smudges from
antique documents. is also possible. Hybrid circuit resistor
Cutting. deburring, cleaning. deflashing and etching of and cdpacitor trimming is a typical production application
glass. ceramics, or hard metals can be accomplished with in the electronics industry.
AJM. It may also be used for deburring of cross holes, slots.
and threads in small precision parts that require a burr-free
finish, such as hydraulic valves, aircraft fuel systems and *TradcmarkE.I DuPontdcNemours&Co..inc.

10-15

- -- - -' .- a- - -
10.2 Abrasive Jet Machining-AJM
Operating Parameters Figure 10 2-4 illustrates the factors that can influence ma-
terial removal. These data were taken on plate glass of 450
to 510 Knoop hardness using a 0 018-inch 10 46 mini diamn-
eter nozzle, air as the gas at 75 psi 1517 kPal. and 1/'32-
inch [0.79 mini nozzle tip distance (ntd) from the workpiece
(unless otherwise expressed) Silicon carbide abrasive
TABLE 102-1 Typical Values for AJM Operating would cut at approximately the same values
Parameters
Because of the small amount of abrasive flowing through
Abrasive the nozzle, it is possible to be very selective in material re-
types AIUmMum oxide for aluminum and brass moval The radius on holes, slots, grooves, and threads
Silicon carbide for stainless steel that are deburred abrasively will vary from sharp to 0 010
and ceramic ich 10.25 min depending on abrasive used and blast t-me.
Bicarbonate of soda for nylon, Teflon', I
Delrin' and light cleaning It is common for micro-abrasive blasting to be a secondary
Glass beads for polishing deburring operation after rechasing threads. reaming
holes, or using a wheel to remove the heaviest burrs. A
size- 10 to 150pm, well classified and clean practical minimum cut width is 0.005 inch 10.13 mini. Tol-
quantity i to 5 g/min for fine work erances are typically =OC05 l0.13 mini with =0.002
5 to 10 g/min for usual cuts inch I z0.05 mm possible with good fixturing and motion
10 to 20 g/min for heavier cuts control. Taper is present in deep cuts.

Carrier gas
types, Dry air, carbon dioxide, nitrogen, nitrous
oxide, helium (Do not use oxygen) Surface Technology
quantity- Up to 1 0 fttlmin [28 L/min) Surfaces generated by AJM have a random "grainness'"or
pressure 30 to 190 psi [207 to 1,310 kPa] matte texture. Surface roughness ranges from 6 to 63 mi-
croinches R. [0.15 to 1.6 taml depending on grit size. as
velocity. 500 to 1,100 ft/s [152 to 335 m/s] demonstrated in tables 10.2-2 and 10.2-3.

Nozzle The AJM process is cool cutting; heat sensitive alloys are
material. Tungsten cabide or sapphire not affected. Constant motion of the nozzle is necessary to
tip distar~r prevent unwanted grooves on the surface. Cleaning of the
(ntd) to wo,. 0, inches [2.54 to 76 mm] (see surfaces of softer materials may be necessary to remove
-s 10 2-2 and 10 2-3 any imbedded particles of grit. Cleaning is also required to
opening- .... r 0.005 toO0 046 inch [0 13 to 1.2 remove
wrpeegrit from crevices or internal passageways in the
mm] workpiece.
Rectangular size 0.003 x 0.020 to
0.026 x 0 026 inch [0.075 x 0.50 to
0 65 x 0.65 mm]
operating Equipment and Tooling
angle: Vertical to 600 off vertical The equipment consists of four parts: (1) an apparatus
which stores. mixes and propels the abrasive: (2) a work
chamber: (3) a dust collector: and (4) a dry gas supply. A
complete system is available for a modest investment.
Single- or dual-tank. bench-top apparatus is available. The
work station should provide sufficient illumination for the
operator. The dust collector should be a commercial unit of
at least 3/4 horsepower with a cloth-bag filter that can 4
handle fine powder particles as small as 40 microinches
Material Removal Rates and Tolerances 11 pnl. The gas supply of at least 100 to 125 pounds per
AJM is -ot a mass material removal process: it is a finish- square inch 1690 to 862 kPal must be dried to a moisture
ing pr "s The typical removal rate for plate glass is content of less than 50 parts per million. It is possible to
0.001 inch per minute 116.4 mm 3/min!. The speed of use bottled carbon dioxide or nitrogen as a dry gas supply.
drilling ,.. ,.ass is impressive: however, higher hardness ce-
ramics cut at approximately 50 percent higher rates and The nozzle tips are normally made of tungsten carbide.
metals cut at lesser rates, as low as 10 to 25 percent that of Their life will vary depending on the type of abrasive and
glass depending on the metal properties. Tumbling, vibra- the operating pressure used. Tip life of 8 to 15 hours with
tory or larger recirculating blast cabinets may be more silicon carbide and 20 to 35 hours with aluminum oxide is
practical for large parts. The rate of material removal is af- reasonable.
fected by several factors. including abrasive type and par-
ticle size, nozzle opening, nozzle-to-work-surface distance, Abrasive powder must be clean, dry, and very well classi-
nozzle angle. and particle velocity. Generally, the larger fled. It is not practical to reuse abrasive powder because
the particle and the higher the velocity, the faster the mate- contamination and worn grit will cause a decline in cutting i
rial removal, rates.

10-16

_ _ __ -- Vag
 Abrasive Jet Machining-AJM 10.2
Machining Chacteristics
The powders used in AJM are nontoxic. but adequate dust
control is needed Silica dust produced during AJM may be
a health hazard Commercial grades of abrasive powdlers
are not suitable for AIM because they are not classified
closely enough to assure proper flow and they may contain
some silica dust. Ordinary shop air should not be used with-
out adequate filtration to remove moisture and oil. Oxygen
should never be used as the propelling gas because it may
produce a violent chemica! reaction when combined with
the workpiece rhips or the abrasive.

SELECTED DATA

TABLE 10.2-2 Surface Roughness for Glass Processed TABLE 10.2-3 Sim'Mu.Ze iiougniac:s for 316 Stainless
with AJM Steel (A#%r; aied) Processed with AJM
GRIT SIZE SURFACE ROUGHNESS :,ial surface was ground to 18.5 pin R. [0.47 pm])
ABRSIV
TYEI- GRIT SIZE SURFACE ROUGHNESS
_________On
R.____________ ABRASIVE TYPE ;npnR

xd 11mnm
00 25 1to2 8 O~o5 Almnmoid0!0 8t
Almnu1'xd 00 64to28lmiu oxide 400 8to 20~~~
2000 0 38 to 55 G4to1iO1000 10 21
lto 25C_ J
2000 is to38 ~.Bo09
Silicon carbide 800 - 2~ 12 to 20 b0tO5
2000 ~5717 to34 ~3oJ
Glass bead 2000 ts 12 to38 9 I
SOURCE: Comco Incorporated.

10-17
10.2 Abrasive Jet Machin ing-AJ M

C-~
In

CoJ OD jCC

-l (7)'SCI

~r LXf. c
E -~ k.)

'a oo

z O ) CU)Cl
E Cl

2f E CUi 0~ CIOc

cc E )I~c ~ ~
(0 0
w Co T, Ci
C~ o oC) F
C

CU co

-1 0 C ~ 0 ~

N C;

00

Cw r -

0)
o0 0N0(0 0o
00 '

1,,: x 0xx

10-1
~----
.- - -- ~- ~ j
 Abrasive Jet MachiningAJM 10.2

0
6 cE cE cE cE
EOo 0 6F: -

T(0 TD
C C/

'NN
I II
I NII

II I !0
I -
E

SI !I E

I --
o oj II
i -D
I, I
0
C))

00 00

I Im
CL

10-19
 10.2 Abrasive Jet Machining-AJM
24 ------ ,

20
oxide 2asM

8I -
Malerial Paegss20
.aea;oagis
4 I
Ivq :1- 30 s
0
0 4 8 12 16 20 24
~~~10 l ~ l ~ l j
283693
132' 132 22
Abrasive flow 9 min f zm 1 Nozzle distance -i :20 'ni
A Abrasive flow effects on cutting speed
8 (u!*larg rate as I unio, of rlozz-ie
thDcisidflce ir'td,

40 Material Plate glassI

E 32 Aluminum oxide 50,~ m 32 Maeall'e as

24
Aluminum oxide. 27-.m
Aluminum oxide. 27 am 2
16
-
7EI
j ~ Abraive flow 10 9-m mn
I Alumninum oxidle 10-m 2 8
0'
0 26I 8 10 12 0
14 16 18 20 75 90 100 110 20 130
Abrasive flow g mmi (07oz-inf) Nozzle Pressure psi 1&30 kPaJ
C Effect of grit size on cutting speed
0 Effect of gas Pressure on culting speed

Figure 10.2-4 Factors affecting material removal

sive jet machining techniques and related AJMV rates for AJM. (Adapted from W-Kulischenko.
equipment, Technical paper MR68-524. Society Abra-
turing Engineers, Dearborn, Mi. 1968. op. 4-5) of Manuiac-

10-20
 Hydrodynamic Machining--HDM 10.3

PROCESS SUMMARY
Controts

Miyer (
Pump Sapphire
and
.,._ dtor [ nozzle
Hydraulc Un t
Jet

Workpiece i:i

Standoff
distance
Drain

Figure 10.3-1 HDM schematic.

Princip!es Operating Parameters

Hydrodynamic machining (HDM) removes material by the
impingement of a high-velocity fluid against the workpiece
(see figure 10.3-1). The coherent jet of water or water with TABLE 10.3-1 Typical Values for HDM Operatng
additives (to aid coherence or prevent freezi::g) is propelled Taetesr
at speeds up to M1.,1ach 3 thereby cutting or shearing the
workpiece. A synthetic-sapphire nozzle controls the jet Fluid
stream and establishes the standoff distance which is im- type: Water or water plus additives-well filtered
portant for controlling the cutting depth. Relatively small
volumes of fluid are used. The fluid is pumped to the de- additives: Glycerine, polyethylene oxide, long-chain
sired operating pressure aided by a hydraulically driven in- polymers
tensifier and an accumulator tank smooths out the pulses. pressure: 10 to 60 ksi (69 to 415 MPa]
The cut can be initiated at any point on the workpiece and
the kerf (width of cut) is insensitive to dwell of the jet. The jet
"chips" enter the exit stream. The power density in the velocity: 1,000to3,000 ft/s [305 to915 r/min] (figure
stream can reach 6.5 x 108 watts per square inch 11010 10.3-4)
watts/rnm 2 l. flow Up to 2 gal/min [7.5 L/min] (figure 10.3-5)
jet force on
workpiece: 1 to 30 lb [4.5 to 134 N] (figure 10.3-4) A

Practical Applications Power: Up to 50 hp [38 kW] available;

1ures10.3-4, 10.3-5. 10.3-6,
The ability of HDM to cut very thin, soft metals or non- 13
kerf
metallic materials in any position with a very narrow
leads to many form-cutting applications, such as those de- Cutting rates-
scribed in tables 10.3-3, 10.3-4 and 10.3-5. A cutting or traverse rates: See table 10.3-2 and figures 10.3-7, 10.3-9,
deburring action can be initiated at anv point on the work- 10.3-10, 10.3-11
piec-. HDM can be substituted for a carbide slitting saw.
Since it is a non-dulling tool, HDM can produce a better Nozzle
edge cut. The narrow kerf can result in material and cost material. Synthetic sapphire most common, also
savings. The low level cutting temperatures allow the proc- hardened steels, 17-4 stainless
essing of wood and paper products, such as cutting 3/4- diameter: 0.003 to 00 15 inch [0.075 to 0.38 mm]
inch 119 mm acoustic ceiling tile at 250 feet per minute 176
n /mini using a 45,000 pounds per square inch 1310 MPaI angle: Perpendicular to positive rake angles of 301
jet. HDM has been used to cut furniture for,-is of 1/2 inch (figures 10.3-2 and 10.3-18)
112.5 mml laminated paperboard, 1/2-in,'hi 112.5 mini as-
bestos brake shoe linings and 3/4-inch 119 mini thick shoe Kerf wiuh: 0.003 to 0.016 inch (0.075 v) 0.41 mm]
sole material. Some work has been done with thin, mild
steel; however, cutting of hrd metals isstill experimental Standoff
using pressures above 100,000 pounds per square inch 1700 distance: 0.1 to several inches [2. to 51. min]; 'Ainch
MPal. Scribing of maskants foi chemical machining is a 10.3-17)
productive application. -

10-21
10.3 Hydrodynamic Machining-HDM
General Observations Surface Technology
" Increasing nozzle diameter improves performance and Edge quality depends upon how easily the workpiece frac-
increases horsepower requirements (figure 10 3-12) tures Soft materials cut smoothly and crushable materials
can be sit with high quality edges Test cuts are recom-
" Increasing pressure increases penetration, quality of cut mended before selecting the final operating parameters
and horsepower requirements. The high energy density of the jet stream causes a slight
rise in temperature which may melt some types of plastics
" Lower pressure reduces edge quality and delamination at low traverse rates, but the temperature is not high
effects enough to be a concern for paper-type materials Tendency
to delaminate layers of composite materials during cutting
" Traverse rates are directly it lated to cost and rates of can be elimmated by reducing the cutting rate
production.

" Increased standoff distance decreases oenetration and in- Equipment and Tools
creases noise (figures 10 3-16 and 10.3-17). Machine and hydraulic components are available for
HDM; however, a general-purpose machine tool is not
" Additives can increase cutting performance and reduce regularly available Each application is engineered to meet
cut width (figures 10.3-16 and 10.3-17) the requirements as found by sample test cuts made to de-
termine !he exact values for the key operating parameters.
* Smaller nozzles produce finer cuts. Equipment generating pressures up to 60,000 pounds per
square inch 1415 MPaI is commercially available with con-
" Larger nozzles are needed for slicing thicker materials. trols, filters and hydraulic seals of reasonable durability. A
drain and sump need to be provided close to the workpiece.
" Lower traverse rates improve the quality of cut. The jet stream does not dull and nozzle life is respectable,
provided there is good filtration of the fluid Filtration
" Cutting performance can improve with positive rake down to 0.5 micrometer (20 yin) followed by deminerahza-
angles. tion and deionization is recommended to reduce erosion of
the nozzle. There is little frictional drag in the cut and vir-
tually no forces at right angles to the jet; therefore, holding-
fixture requirements are minimal Multiple jets have been
arrarged for multiple cuts

Use of NC or CNC is helpful with HDM. Recent equipment

Material Removal Rates and Tolerances has reached 4-by-5-foot I .2 x 1.5 ml table size with speeds
Cutting rates depend on the work material (table 10 3-4) of 15 inches per second 1380 mm/sl and acceleration to top
and vary directly with the horsepower applied and in- speed in 0.2 second.
versely with the material thickness Rates up to 6,000 feet
per minute 11,830 rn,'minl have been attained on paper
products. Slots and through cuts are common. Removal Machining Characteristics
rates for various materials are shown in figures 10.3-7 to The "chips" mix in the fluid so dust is eliminated; therefore,
10.3-13. The lack of sensitivity to dwell allows contours to explosion and fire hazards are reduced. Air entrapped in
be controlled to an accuracy limite- only by the machine the jet stream can create considerable noise with some
elements. The kerf is about 0.001-inch 10.025 mm) !arger work materials. The noise level increases with standoff dis-
than the orifice utilized. For composite materials, the best tance but can be reduced by using certain fluid additives or
combination is a high-pressure je' from a smali nozzle oper- certain rake angles. The noise levels are generally below
ating at a slight rake angle and close to the workpiece Ta- the OSHA requirements Periodic preventive maintenance j
per can be a factor if too large of a standoff distance is is very desirable for equipment operating at these pres-
used. sures.
1

10-22

- . - - - f
 Hydrodynamic Machining-HDM 10.3
SELECTED DATA TABLE 10.3-2 Steps To Select HDM Operating
Parameters
There are several valid techniques for selecting operating -3,10 3-4 and
parameters for HDM The steps in table 10 3-2 are recom- 1 Can workpiece materal be Tables 10 3
mended as one logical sequence Supporting data come machined by HDM? 10.3-5
from the other figures and tables in accordance with the 2 Cutting rates User's process or production
terms as explained in figure 10.3-3 required requirements
3 Nozzle size and pressure Test cuts or table 10 3-4,
figures 10.3-7,
10 3-8,
Positive /10.3-13
Pressure is usually less than
rake 65 ksi [450 MPa].
Nozzle size is approximately
0 001 inch [0 025 mm]
/less than cut width.
4 Cutting rates Table 10.3-4 and
'I figures 10.3-7,
/ oz 10.3-9,
103-10.
Nozzle Nozzle 10.3-11
motion 4/: Rate is approximately
,./it inversely proportional to
thickness being cut
5 Flow rate Figure 10.3-5

Workpiece 6 Power Figure 10 3-5 or 10 3-6

7. Standoff distance 0 to 0.5 inch [0 to 0.13 mm],
smallest distance is best
8 Rake angle (straight- Figures 10.3-2,
Figure 10.3-2 HDM nozzle angles. line cutting only) 10.3-16,
10.3-17,
10.3-18
9 Fluid additives Figures 10.3-16 and 10 3-17
10. Confirm parameters Trial cut of specimen
selected Check surface material.
quality, wetting, and
kerf width for
acceptability

ey %X Traverse
feed

Standoff
Nozzle distance
diameter / .
Rake Jet
/angle velocitytfi

.",,,\\\V"Lb,\ \,
\ Penetration
\Workpiece depth

Figure 10.3-3 HDM parameter terminology.

10-23
 I --

10.3 Hydrodynamic Machining-HDM

TABLE 10.3-3 Partial List of Materials Successfully Cut Plywood-to 1-inch [25 mim] thickness
with HDM Poplar
(With some maximum thickness of cut) Polycarbonate-to 0.25-inch [6 mm] thickness
Polyester fabrics and carpets
Abrasives-coated papers, cloth Polyethylene sheets
Acoustic tile Polypropylene tubes
Acrylic plastics Polystyrene
Aluminum Polyurethane foam-to 1-inch [25 mm] thickness
Aluminum honeycomb Rocks
Asbestos brake linings Roofing (composition, asbestos, rolls, shingles)
Asphalt base materials Rubber (foams, reinforced shoe soling, tire tubes)
Bakery products Shoe leather
Boron-aluminum composite Silicone rubber-to 2-inch [50 mm] thickness
Boron-epoxy composite Slag
Boron-polyester composite Steel (mild and thin)
Box board Styrofoam
Brake linings Styrene foams
Brass Suits
Carbon bricks and electrodes Synthetic rubber
Carpets Teflon-to 0 37-inch [9.5 mm] thickness
Ceramic foam Urethane foams
Coal
Concrete Vinyl sheets
Copper Vinyl edge foam-to 1-inch [25 mm] thickness
Cork
White granite
Delrin Wood (fiber tiles, fiber padding, particle board, paneling veneer)
Epoxy-Kevlar
Fabrics, automotive
Fabrics, "soft" materials (except doubleknit fabrics)
Fiberglass-epoxy composite
Fiberglass insulation-to 5-inch [125 mm] thickness
Fiberglass-Nomex core sandwich-to 0.75-inch [19 mm]
thickness
Fiberglass reinforced phenolic-to 0.5-inch [12.5 mm] thickness
Firebrick
Ford (frozeni meats, vegetables)
Furniture components

Glass-polyimide
Glass fiber reinforced polyester
Graphite
Graphite-epoxy composite-to 0.625-inch [15.9 mm] thickness
Gypsum boards
Insulating materials
Kevlar and epoxy-to 0.5-inch [12.5 mm] thickness
Laminated plastics
Lead
Leathers
Lucite plate-to 0.5 inch-[12.5 mm] thickness
Maple
Micarta-to 0.37 inch [9.5 mm] thickness
Mild steel
Mineral fibers (acoustic tile)
Neoprene rubber, 50 Shore hardness-to 2-inch [50 mm]
thickness
Nomex honeycomb-to 3-inch [75 mm] thickness
Nylon (brushes, carpets)
Oak
PVC
Paper-corrugated board, liltars, impregn-:ed, coated, laminated
newsprint
Plastics
Plexiglass

10-24
 L/

Hydrodynamic Machining-HDM 10.3

TABLE 10.3-4 HOM Cutting Rates for Several Materials

NOZZLE CUTTING
MATERIAL THICKNESS DIAMETER PRESSURE SPEED
in in r a ins k
VIM
in
W1_____ON_0003_ in15 bar0 in/s
055a
ABS plastic 0.11 003 O5 250t 5
Acoustic tile 0.75 1 0.010 O ~~3100 ~3O~ 3200 0
Aluminum honeycomb 1 25- -L;; 4200 _33

Automotive carpet 1 layer 420R 118 _

Automotive vinyl 13 layers 801E:1-Ck 4200 165

Boxboard (white lined chipboard) 0016 00 t15 17
Boxboard (white lined chipboard) 0025 170000.aQj 3174
Boxboard (white lined chipboard) 0.035 ~OI~
0.005 2440 24
Brake shoe material 0.5 4200 16
Corduroy 14 layers ~ I ~4200 74

Cotton nylon fabric 50 layers 420 126 NO

Crepe 10lyr iai -4200 166

Ethyl polyvinyl chloride 0.12 350 8

Fiberglass epoxy 0.3 .010 4120 0.1

Graphite epoxy 0.067 !W 0.008 3801

Graphite epoxy 0.3 .010 jQ2- 4120 AW 05 *t
Graphite epoxy 0.273- 0014 I ~~4120 .421
Graphite epoxy prepreg 13plym ~ 30 39.0
Hardwood pulp sheet 0.004 _ 2480 275

Kevlar epoxy 0.01123805 05 ~#

Kevlar epoxy 0.25 ~0 014 ]Rk 4120 0.8
Leather 0.175 _0 .002 R- 303003
Newsprint 0004 yt7 585 ~o ~ 420
Nylon tire fabric 00,32 __4200 44I~ 166

Plywood 0.25 ~ 4200 ~4r 67 W Q

Plexiglass 0.4 0.015 t:_ Sj. 12 2.7
Polycarbonate 0. .1 :9 4120 4 99- S
Polyethylene (high density) 0.12 _ 000 2860 0.36
Polypropylene gasket 16 4200 100

Polypropylene (40%) glass fiber 0.25 4200 M1.

Rubber belt (cotton reinforced) - 0002 2960 0.92960
Styrene (high impact) 0.12 0.0103 -9W!ZE 2480 053
Tisuepaer2 ply 1000 7100
Transite (asbestos cement) 0 75
Wood veneer 01 -420016

10-25
10.3 Hydrodynamic Machining-HDM

TABLE 10.3-5 Parameters for Hydrodynamic Machining of Various Nonmetallic Materials

NOZZLE
MATERIAL THICKNESS OPENING FEED RATE
in cm in tinmm in/min
Plywood 0.25 .0012 200
0.37 . 0012 %*- VR3 100
1.0 0.012 60
Foam rubber 0.5 0.008 m2iff2i 1000 est.
0.5 0.012 -4 1000 est if!- g'
4.0 0.012 1000 est. V
Neoprene, 50 Shore 0.5 0.012 600 est.
G so u , S2.0 0012 100
Greysi0icone rubber,40 Shore 0012 i S5 2 500 est
Fiberglass and epoxy 0.25 0012 120
Fiberglass and phenolic 0.25 0.012 150
Circuit board 0.090 0.008 P l 60
Fiberglass and Nomex core 0.5 0.012 360
0.75 0.012 340
3__
Nomex core only 2.0 O6 0.012 300
Kevlar and epoxy 0.25 0.012 100
Graphite and epoxy 0.25 0.012 40
ABS 0.090 _ 0.012 - 300
Polycarbonate 0.092 0.012 340

These feed rates can be extrapolated inversely on a nearly linear basis as the material thickness is reduced. That is,if a 0.25 inch
[0.6 cm] thickness can be cut at 200 in/min [5 m/min], a 0.125 inch [0.3 cm] thickness can be cut at 400 in/min [10 m/rin].
SOURCE. E.J.Buck and D L Zeulow, New techniques in water let cutting, Technical paper MR79-376, Society of Manufacturing Engineers, Dearborn, MI,
1979, p.5
NOTE- The above materials were cut at awater pressure of 55,000 psi 13800 kg/crn'.

10-26
 Hydrodynamic Machining-HDM 10.3

::oo 900m/s] 3 F( 11 4
L/min
2500

Nozzle diameter 0 02 in to 5 mm]

> 2000 2

o
1500
(D
W
.2 0 015 in1

1000 ~ 0 0 lin

500K
0 005 in

I 0
0
3 10 20 30 40 50 60 [420 MPa) 0 1000 2000 3000 '900 m/s]
Jet velocity, ft/s
Nozzle pressure, ksi

Jet velocity versus Nozzle flow versus

nozzle pressure jet velocity

Nozzle
diameter
100 [75 kW] 002 i
[0.5 mm]
80
40 - f177N]
60 015 in

40 Nozzle diameter
0 02 in
30 [05mm]
0 010 in
S20

3,

0 2

44
0 005 in
10 000in-

2 11 0 , 0 01i

0005 in
1 0f
1000 2000 3000 [900 m/s) 0 1000 2000 3000 [900 m/s

Flow, ft/s Jet velocity, ft/s

Jet power versus Force on workplece versus

nozzle flow jet velocity
(let perpendicular to work)

Figure 10.3-4 Operating parameter relationships in HDM. (From K. F. Neusen, High velocity fluid jet cut-
ting and slotting, Technical paper MR76-691, Society of Manufacturing Engineers, Dearborn, MI, 1976, pp.
8-10)

10-27

il
10.3 Hydrodynamic Machining-HDM

f37.8 L/min] 10

6
6 COJ

N--
4

3
, 3 -

o 2.5

01.
Q)
E

G 9 N4
E 8
,J7
0C

6 " .00.1

2.5

1.51
0.1
10,000 1.5 2 2.5 3 4 5 6 7 8 9100.000
[689 MPaj

Pressure, psi

Figure 10.3-5 Pressure versus flow rate with various nozzle sizes. Knowledge of two variables enables
determination of two other variac,,.as. For example: (Note heavy lines) if a cutting pressure to 60,000 psi
is required, it can be obtained using a flow rate of approximately 1.5 gal/min with a 0.014-inch diameter
stream. (Courtesy of Flow Equipment Company)

10-28
 Hydrodynamic Machining-HDM 10.3
100,000 N 1X % 1
[689 MPa]

50,000 1

ai 10,000
:3

N Flow,,gal/mI

0001 0 . .105.n1 0 0
1.0 /mn

0.400 -1 0.8

0080-
0.060-
0.040 r-0.6
v 0.020- 300 fts[90M/]
0Lea 2J~0.4 25
0.010 -a

0.008 -2-00

0006 - - - -0.2

0.004 --
5052
l Aluminum 0
0.002- 0 1 2 3
Traverse veiocity in/s 7 m /s
0.001

Jet velocity. ft/s

(at 1.70 In/s [43 mm/si traverse speed)

Figure 10.3-7 Slot depth for various materials (fixed nozzle 0.0094-inch diameter of 17-4 stainless
steel. 60,000 psi pressure, plexol-201 fluid). (From K. F. Neusen, pp. 10-11)

10-29
10.3 Hydrodynamic Machining-HDM

00 60.0 (000365 in
40010 - 0*
40.0
lOOI(3.9,n)
/ #/ I-
200 ,

4.2000
10 (3.94 in) 4 i

60 2 4 100 2
E 40
E 4 Z- ."F-,, q, E 60.
E
+ 0 Ma]
4Z d e
20 - qC .

A4'Q) 0
10 F 0- E
0un o oat) 2

4 /At1.0 P

2 C?0.6 V C
e -8
Exi Dm0.4
pesur, kbr
0 xt rssre
r.ba Ian

1103

0.6 'CO' 0.2 A

0.4
L-J--L---LJLLJL/0.1
0.2 I d
1 2 4 6 10 1 2 4 5 10
[1 0 MPal [1 0MPal
Exit pressure, kbar Exit pressure, kbar

Fluid: 1:1 mix H,0 and glycerine

Nozzle: Hardened steel, 0.15 mm (0.006 in) diameter
(unless do otherwise designated)
Standoff distance: 3 mm (0.12 in)
Angle: 900 to workpiece
Feed rate: 1.0 mm/s (0,039 mins)

Figure 10.3-8 Depth of cut and material removal rate at different HDM pressures. (From 0. Imanaka et
al, Machining with continuous liqu!d jets at pressures up to 10 kbars, Proceedings of the international confer-
ence on production engneering, 1974 (Part 1). p.28. Japan Society of Precision Engineering, 1974)

10-30
 Hydrodynamic Machining-HDM 10.3
0.7
0.7 PoplarI
1
Pressure. 50,000 psi [345 MPaj
06 Nozzle diameter: 0.006 in [0.15 mm]
06
C
-15 mm]
0

CL
0) 0.5"
0.4

M =25% (moiture)

0 0.1 0.2 [5 mim/s] 0.3

Feed rate, in/s

05 1
Poplar
Pressure: 35,000 psi [240 MPa]
04 Nozzle diameter: 0.005 in [0.13 mm]

[10 mm]

o
0.3

M = 25% (moisture)

0 .2 .---
O M 12 %/
0_ I II

0 0.2 0.4 0.6 0.8 [20 mms] 1.0 1.2

Feed rate, in/s

Figure 10.3-9 Feed rate and depth of cut for poplar at two levels of moisture content and two levels of
HDM pressure (cut perpendicular to grain, 2 mm standoff distance, nozzle at 900, fluid = H20). (M. P.
dePlessis and M. Hashish, High energy water jet cutting equations for wood, Concordia. Univ., Montreal.
Quebec. 1976)

10-31
10.3 Hydrodynamic Machining-HDM
0 75 ,l 25 4 mm I.J Delrin 075 Potycarbonate
3A0in) Direc127om Nozzle diameter (0 3 in) Nozzle diameter
Of CL 0 076 in007m
E (0 003 inj 000 n
\ 60 ksi __25_4_mmE_60___
-050 05

00

o 02541 a0235B
B276 30

0
0 10 20 30 40 0 10 20 30 40
(16 ir)(1 6 in)
Feed rate cm/s Feed r -in/S

15~ Detrin 15 1 Potycarbonate

Nozzle diameter (0 6 in) Nozzle diameter
0 127 mm E0 127 mm
105 (0 in)__ (00sto05
in)
01
-(0 4 in)
00 _50
60 ksi414 Ma
05
4030 276 -

30 6 --207

0 10 20 30 40 0 10 20 30 40
(1 6 in) (1 6 in)
Feed rate cm/S Feed rate. cm/s

fDelrifl
20
F Nozzle diameter
0178 mmn6
20
(0 8 in)
Potycaroonate
Nozzle diameter
018m
15 60ksi (0 007in) ( 0 n
E (0 6 in) E

0 5
10 10
0 040

05345

0 10 20 30 40 0 10 20 30A
(16 in) (16 in)
Feed rate. Cm/S Feed rate. Cm/S

Figure 10.3-10 Depth of cut versus feed rate at various pressures. Deirin-Polycarbonate; saphire
nozzle, 0.38 mm above surfac3; fuid = H20. (U. H. Mohaupt and D. J. Burns, Machining unreinforced
polymers with high-velocity water jets, Experimental Mechanics 14 (April 1974): pp. 154-155)

10-32
 Hydrodynamic Machining-HDM 10.3
10 Plexiglas 20 Plexiglas
4 mmj-.
*~25 Nozzle diameter (068 in) Nozzle diameter

Y -A -
06 T
mm0
n) (
1
003
7 m 0
4(0
127 mm
005 in?
075 ?"#1 5
(0 3 in) m

050
0 05
50.5
CD

45-05
3027 "' 130--, 276

---- 007
0 1-
20

0 05 10 15 20 0 05 10 i5 20
(0OCin) (0 6 in)
Feed rate. Cm/s Feed rate, cm/s

Figure 10.3-11 Depth of cut versus feed rate at various pressures. Plexiglas. (U H. Mohaupt and D.J
Burns, p. 155 )

0.2 Workpiece thickness (polystyrene)

15 mm] -

C I V

S0.1
C

a-

Traverse rate: 4 in/s

0 20 40 60 80
[550 MPa]
Pressure. ks;

Figure 10.3-12 Effect of nozzle oriface diameter on workpiece penetration. (Courtesy of Grumman
Aerospace Corporation)

10-33
10.3 Hydrodynamic Machining-HDM

50
Work material. Polystyrene
Traverse rate. 4 in/s [100 mm/s]

0 215 mm] 40
Workpiece thickness (polyst 0.187 in

T 30
PI

0.1 in f2.54 mm

No 0 0.1 0.2 0.3 0.4 0.5

4-, Nozzle orifice diameter. mm (0.020 in)

,Q

-I Figure 10.3-14 Nozzle horsepower versus nozzle

Cdiameter for plastic casing at 4 in/s traverse veloc-
0.1 ity for fixed penetration. (Courtesy of Grumman
o Aerospace Corporation)

(-

75

Q,
Nozzle orifice diameter: (D
0.4 mm (0.016 in)\
",

N 50
0
Z
0.
0 20 40 60 80 -
[550 MPa] C

Pressure. ksi I
5
Figure 10.3-13 Effect of jet pressure on work- .0
piece panetration. (Courtesy of Grumman Aerospace 0 50 100 150 200 250
Corporation) Standoff/Nozzle orifice diameter ratio

Figure 10.3-15 Effect of standoff distance on pen-

etration depth. (Courtesy of Grumman Aerospace
Corporation)

10-34
 Hydrodynamic Machining-HDM 10.3
0.12

0.10 -[2.54 mm]-,

00

0.08

e)e

*~ 0.06

' Water only

*/,'"
0.0
0.04o -5000 ppmn PEO
v2500 ppm PEO
CV 01250 ppm PEO
0.02
Pressure: ^5 ksi [240 MPaj A 625 ppm PEO

i 0 1 2 3 4 5 6

[100 mm)
Standoff distance, in

Figure 10.3-16 Width of cut versus standoff distance for aluminum. *PEO Polyethylene oxide.
(Courtesy of Grumman Aerospace Corporatior)

0.05 'Pressure: 35 ksi'(240 MPa]

o Water only
0.04 05000 ppm PEO " ___--_

[1 mm] 02500 ppm PEO

G_
o1250 ppm PEO / /
( 0.03 A 625 ppm PEO . _-___

ca
0 02 /
(D 0.02'

0.01

0.
0 1 2 4 3 5 6
[100 mm]
Standoff distance, in

Figure 10.3-17 Penetrcion depth versus standoff distance for aluminum. *PEO = Polyethylene ox-
ide. (Courtesy of Grumman Aerospace Corporation)

10-35
- - , - r ~- - -....-. '- - -- !
10.3 Hydrodynamic Machining-HDM
0.060
90 ksi [620 MWa]

0.050

CL

m70 ksi 483 MPal

C -__ __]_ ........... _ ___
.2

Cutting rate: 0.25 in/s (6.5 mm/sI

Nozzle orifice diameter: 0.5 mm (0.020 in)
0.020 {

0 5 10 15 20
Jet angle, degrees

Figure 10.3-18 Effect of jet angle on penetration depth for steel cut under water. (Courtesy of Grum-
man Aerospace Corporation)

10-36
 Low Stress Grinding-LSG 10.4
PROCESS SUMMARY careful consideration of the total process.ng sequence and
the proper placement of LSG within it
To maintain an acceptable level of productivity. LSG pa-
rameters should be applied only to the removal of the last
INFEED few thousandths inch of material from the workpiece (see
table 10.4-2) LSG should not be applied "all over" the
workpiece. It should be considered for use only on critical
areas, and then only if it is the final process affecting the
"as shipped" surface. Note that heat treatment, shot peen-
Abrasive ing or other post-grinding processing may affect the ground
wheel surface or may make LSG unnecessary

Lubricant Productivity loss may also be relieved by an experimental

to Air investigation to determine what increase in the downfeed
scraper or infeed rates can be tolerated above those rates specified
in table 10.4-2. Table 18 3-17 Grinding f-arameters for
IN-100 Turbine Blades (see section 18 .) provides data
-Ai C ig nozzle which show that no cracks were produced ,,-ing a feed rate
Workpiece of 0.002 inch 10.05 niml after certain low-stress-grinding
parameters were adooted. Feed rates should not be in
creased, hc-vever, without doing the necessary experimen-
TABLE tal work for each particular alloy and situation. General-
izations about the grinding of sensitive alloys are
dangerous.
Figure 10.4-1 LSG schematic.

Operating Parameters

Principles TABLE 10.4-1 Typical Values for LSG Operating

Low stress grinding (LSG) is an abrasive' material removal Parameters
process that leaves a low magnitude, generally com- (Parameters are listed in descendmg order of s ig n fi c a n c e for low
pressive. residual stress in the surface of the workpiece (Preteraris in esce rde
Figure 10 4-1 shows a schematic of the LSG process. The stress generation i the vorkpiece surface)
thermal effects from conventional grinding can produce PROCESS PARAMETERS GUIDELINES
high tensile stress in the workpiece surface. By careful se- -
lection and .ontrol of the operating parameters, the the'- 1 Grinding wheel Frequent and coarse to maintain
mal effects are miniimized, thereby reducing the residual dressing technique sharpness Maintain sharpness
stresses, the attendant distortion and the possible reduction of dressing tool. Avoid dwell in
in high-cycle fatigue strength. The process parameter using crush, roll, or single-point
guidelines can be applied to any of the grinding modes sur- dressing tools
face, cylindrical, centerless, internal, etc. Additional de- 2 Wheel speed Low, under3,500 fpm [1,050 rn/min].
scription, details and data on LSG arc provided in section
18.3, Surface Integrity, in the discussion of abrasive mate- 3 Downfeed (or infeed) 0 0002 to 0.0005 inch/pass [0.005
ial removal processes. rate to 0.013 mm/pass] with
programmed reduction from
conventional rates.
Practical Applications 4 Grinding fluid Oil-base fluid is preferred.
Grinding burn, distortion and cracking always have been
associated with the improper use of abrasive processes, 5. Wheel classification Opengrade
Soft (G, H(6ororI*).
structure more).
particularly when grinding high strength steels, high tem- Open ste (6 or ore).
high Grain size (60 or coarser)
perature alloys, titanium alloys and other sensitive alloys.
Low stress grinding eliminates these effects by reducing 6. Table (workpiece) High, 50 fpm [15 m/min] and up
the specific energy input. LSG should be used only on criti- speed Crossfeed is preferred to
cal or highly stressed areas of a workpiece, such as those plunge motion.
areas subjected to high cyclical stress or stress-corrosion 7. Grinding fluid Adequate to high fluid flow.
enviro-iments. The enhanced surface integrity, minimal flow control Assure placement of fluid
distoi tion and minimal residual stress in surfaces produced between wheel and workpiece
by LSG are important on highly loaded structural com- Flow controlling nozzle design.
ponents As always, careful attention to the entire sequence Reduce air film on wheel.
of manufacturing processes is necessary to avoid reduction *Cyllndrical grinding frequently requires use of harder wheels (with J
in the surface integrity produced in a component. Note that grade prevalent), however, the other parameters must be selected to com-
it is possible to reduce or eliminate the need for LSG by pensate for this extra hardness

10-37
10.4 Low Stress Grinding-LSG
Material Removal Rates End Tolerances Equipment at,, .---
Material removal rates are low, but good productivity can Conventional gri: ". ,quipment can be used to produce
be attainedby successively reducing conventional material LSG results. ' I . necessary to modify the equipment
removal rates to LSG levels as the finished dimensions are to obtain the, - , I lower wheel speeds and higher table
approached Typical tolerances that can be obtained are in speeds The lov ,nfeed rates usually are attainable on a
the 0 0002 inch 1 0.005 mml range. well maintainec macnine If it is not practical to modify
some mach;' condition to secure the desired operating pa-
rameter, it still possible to attain LSG results. In this
Surface Technology case all of the other parameters should be at their best lev-
Surface roughness values are typical of those attainable by els to compensate for a deficiency in one of them.
fine grinding and range from 16 to 32 microinches Rt tO. 4
to 0 8 pml. Plastically deformed debris, distortion and re-
sidual strebs are minimal or absent The low residual-stress
levels frequently are compressive, which further enhances Machining Characteristics
the high-cycle-fatigue strength The absence of micro- Results from LSG are typical of those attained by any fine
cracks also contributes to high surface integrity A test gentle grinding operation Cleanliness of the lubricant,
specimen or check of the results from LSG is desirable. Ei- workpiece and machine are important, and it is most desir-
ther the distortion produced in a ground, thin test strip or a able to assure that a continuous, full stream of lubricant
simple metallographic examiration of the surface taken reaches the interface between the wheel and the work-
parallel to the lay can be a useful quality assurance test. piece. A closely fitted nozzle box is helpful.

SELECTED DATA

TABLE 10.4-2 Typical Infeed Schedule for Producing Surfaces by Low Stress Grinding
... INFEED RATE
STEP WORKPIECE STOCK REMOVAL*
inch/pass
Rough Grinding From raw material dimension to up to 0.002
within 0.010 inch [0.25 mm] of
desired final dimension--
Dress wheel
Semi-finish Grinding From 0.010 inch [0.25 mm] to 0 0003 to -
.. 0.001 inch [0 025 mm] of fina
size final 0 00066

Dress wheel Optional

Finish Grinding From 0 001 inch [0 025 mm] to 0.0001 to --
(to low stress levels) final size 0.0002 k- 0
Optional:
at final size, with continued I 2 to 4 spark-out passes
application of grindihg fluid _

NOTE For additional data and description of low stress grinding, see abrasive machining discussion in section 18 3, Surface
Integrity
*Data apply to the radius for cylindrical grinding and to the depth for surface g-Inding.
'This roughing rate should be such that roughness, tears, cracks, or microcracks in the surface are of lesser magnitude than
the material remaining to be removed by the finishing and semi-finishing cuts.

10-38
 Thermally Assisted Machining-TAM 10.5
PROCESS SUMMARY TABLE 10.5-1 Energy Density of Heat Sources
DENSITY
HEAT SOURCE

Electron beam 6 5 x 101 1x

Laser beam 65 x109
Plasma arc 6.5 x 101 i io .
- Electric arc 6.5 x 10' i X10
Oxyacetylene torch 6.5 x 101 0-
Plasma
torch

Practical Applications
Softned one-WorkieceHard-to-machine and high -temperature alloys are all candi-
dates for "hot machining" or TAM Work materials with
hardness ranges of 40 to 70 Rc should be considered for
TAM. Poor thermal conductivity in the material can re-
duce the heat loss between the time of heat application and
Plasma torch % the time of cutting. Aluminum. coppcr, and titanium with
connection thru their relatively high heat conductivities are not good candi-
brush rii date materials for TAM Most of the applications have
been for turning, however, experimental work has involved
milling and slotting. Cuts of long duration have the greatest
Figure 10.5-1 TAM schematic. potential for economic benefit from the addition of TAM.

Operatln6 Parameters
The heat source (plasma torch) parameters are added to
the conventional turning parameters. The standoff dis-
tance, angular position and shieldings for the torch are usu-
ally fixed by adapters to the machine tool. A careful bal-
ance between heat input, cutting depth and speed are
needed to be sure that adequate, but not excessive, temper-
atures are achieved at the necessary depth in the work-
Principles piece surface at the instant of the cut.
Thermally assisted machining (TAM) is the addition of sig-
nificant amounts of heat to the workpiece immediately
prior to single-point cutting so that the material is softened,
but the strength of the tool bit is umimpaired (see figure
10.5-1). A steep temperature gradient is necessary, so the Material Removal Rates and Tolerances
heat transfer properties of the work material are impor- Conventional turning tolerances apply equally to thermally
tant High energy density in the heating source is a prime assisted machining but material removal rates increase be-
necessity Table 10.5-1
erlheat sources Whilelists the energy
resistive densities
heating for sev-
and induction asete
cause themach i iss softened.
worltpiece softened. r Theear
shear res
forces re re-
are re-
eral betsucsWierssiehaigadidcin duced, however, the depth of the softening zone governs
heating offer possibilities, the plasma arc offers the most the maximum depth of cut at which improved rates can be
practical and effective method for external heating at the attained. Table 10.5-2 lists improved rates of cutting
required rates The plasma arc has a core temperature of attained.
14500F l8000CI and a surface temperature of 6500OF
13600*Cl The torch can produce 2000'F I1100Cl in the
workpiece in approximately one quarter revolution of the
wurkpiece between the point of application of the torch
and the cutting tool This temperature will soften many
high temperature alloys. The depth of heat penetration Surface Technology
must be sufficient to secure material softening to the depth When the heat input and cutting rates are properly bal-
expected to be used by the cutting tool. Warm surfaces are anced, the work material below the cut is usually not
not helpful-the temperature must reach the softening re- heated enough to alter the metallurgical structure. The sur-
gion for the work material. The residual temperature in the face roughness, plastic deformation, residual stresses, etc.,
workpiece usually is only 100' to 200F 1350 to 100 0 CI associated with conventional turning apply equally to
Temperatures in thin wall sections may be higher. TAM.

10-39
10.5 Thermally Assisted Machining-TAM

TABLE 10.5-2 Comparison of Conventional Turning with TAM

CONVENTIONAL
MATERIAL TURNING TAM

Nimonic 115 35 500

Austenitic chrome/manganese 10 500
Stellite, soft 5 -_, 400
'.
Stellite, hard grind only 350 X
Hard steel, 50 R, grind only 500
Inconel 718, STA 100 400
18% Mn steel 35 200
Waspaloy 90 400 *R
Rene 41 28 415
15

Equipment and Tooling Machining Characteristics

Retrofitting adapters are available for applying plasma TAM has characteristics similar to conventional single-
torch TAM to single-point, heavy-duty lathes Capacities to point cutting A significant amount of noise may be pro-
4 kW in heating are available Shrouds or screens are de- duced by the plasma torch, so suitable muffling may be nec-
sirable to contain the very hot chips. Standard tool bits are essary. Protection from the chips is desirable because they
applicable: however, consideration should be given to us- may reach the 1000F 1550C) temperature range. Eye pro-
ing cutters with higher temperature capabilities, such as tection from the arc is recommended.
tungsten carbide. cermets. Borazon"-CBN or ceramics.
The machine tool and fixtures should be rigid enough to ac-
cept the higher cutting speeds used.

j 10-40j
 . . . - I i I l l I-

Total Form Machining-TFM 10.6

PROCESS SUMMARY same master by adjusting the orbiting cam action. Redress-
ing of worn electrodes can be accomplished in a few min-
utes. Using special fluids, TFM can polish surfaces pro-
duced by EDM Foundry cores can be generated with
TFM

Ram force

reciprocation Operating Parameters

Ram platen TABLE 10.6-1 Typical Values for TFM Operating

::::' Cuting master,..,.,.*.* Parameters

Abrasive master: Steel die cavity with an untouched EDM
...peFlusing surface or epoxy loaded with silicon
Workpiece fluid carbide grit.

Worktable I
3600 Orbiting cam
Grit size- ~ (#180
100toprovides
--20 a good balance between
cutting rate and reasonable finish.)

(adjustable offset) Ram

force: Upto 1000 psi [6.9 MPaJ.
Orbiting drive Normal operation is below 500 psi (3 5 MPa].
motor
reciprocation Once per second.
0.10-inch [2.5 mm] amplitude.
Figure 10.6-1 TFM schematic. Orbit offset: 0.020 to 0 180 inch [0.5 to 4 5 mm] is typical,
up to 0 25 or 0.50 inch [6.5 or 12 5 mm]
is available.
Fluid- Filtered oil type comparable to EDM oiis for
machining graphite electrodes.

Principles Material Removal Rates and Tolerances

Total form machining (TFM) is a process in which an abra- Rates of material removal are determined by the ram force,
sive master abrades its full three-dimensional shape into the reciprocating offset and to some extent by the grit size .
the workpiece by the application of force while a full-circle, and fluid flow rate. For three-dimensional forms, a com-
orbiting motion is applied to the workpiece via the work- parison with profile milling of graphite shows an average
table (see figure 10 6-1). The cutting master is advanced saving in machining time of 90 percent with TFM. A 0.10-2
into the work until the desired depth of cut is achieved. inch 12.5 mml redressing of a graphite EDM electrode can
Uniformity of cutting is promoted by the fluid which contin- be accomplished in 15 minutes with TFM. The sharpness
uously transports the abraded particles out of the working of an inside corner is limited to the radius of the orbit set-
gap. Adjustment of the orbiting cam drive controls the pre- ting. Outside corners can be as sharp as the master. Toler-
cision of the overcut from the cutting master. Cutting ac- ances are only slightly greater than those of the master.
tion takes place simultaneously over the full surface of
abrasive contact
Surface Technology
Practical Applications The characteristics of the machined surfaces are related
Easily abradable. chalky. granular or friable materials are directly to the fineness of the abrasive grit used in the cut-
candidates for three-dimensional (or two-dimensional) ting master and to some degree to the extent of the orbiting
forming or cavity-sinking operations by TFM. TFM can offset. For graphite, the surface roughness produced is of-
rapidly prepare graphite electrodes for EDM, and both the ten sufficiently good so that the electrode can go to the
roughing and finishing electrodes can be made from the EDM machine without any benchwork being necessary.

10-41
10.6 Total Form Machining-TFM
Equipment anr Tooling to secure the mirror image needed. Several other tech-
Equipment is regu..riy available in several sizes, with table niques for preparing the cutting master are available from
sizes up to three feet (900 mini square and up to 18 inches the equipment builder.'
1460 min of ram travel. Orbiting offsets up to 0.50 inch
112.5 minI are available Filtered fluid systems accompany
the machine or are built into the base. Machining Characteristics
The preparation of the abrasive cutting master, with ap- The fluid flow in TFM eliminates the dust associated with
propriate overcut allowances, can start from a full-scale conventional profile milling of graphite or other friable
model and use a double-reverse, plastic-molding technique materials

IC Krauter, 1976. EDM and TFM, The ideal marriage in a production die
sinking center. Technical paper MR76-702. Society of Manufacturing Egi-
neers. Dearborn, MI.

10-42
 Ultrasonic Machining-USM 10.7
and R-tary Ultrasonic Machining-RUM

PROCESS SUMMARY tical depth-to-width ratio is 2 51 Holes as small as 0.003-

inch 10.076 mml diameter have been made. Current prac-
tical limits are 3 5-inch 189 min diameter tools operating in
2 5-inch 164 mini deep cavities Trepanning is preferred to
solid drilling. Threading of ceramics can be accomplished
Magneto stictive
r
with a rotary tool or part Slicing. coining, dicing, lapping,
transducer engraving. deburring. broaching, boring and trepanning
operations are also practical. An ultrasonic assist is some-
times helpful in the performance of conventional drilling.
grinding and drawing operations.

Operating Parameters
Feed or
spndle thrust TABLE 10.7-1 Typical Values for USM Operating
* Parameters

Power. 200 to 4000 watts

To Frequency. 10 to 40 kHz (most frequently 20

kHz)
high
frequency Tool cone
power Abrasive
type: Boron carbide (most frequently)
Abrasye To(see tables 10.7-5 and 10 7-6)
slurry Toot
Workpiece Cooler size: 100 to 2000 (see table 10 7-10)
concentration. 20% to 60% by volume ,nwater (use
Fix\r~
%'*%x
,
\lower J
percentage for the larger
tools). Oil is used sometimes for
Tank Pump finishing
flow: Ample, sharp and cool (replenish as
becomes worn) (35' to 40OF
Figure 10.7-1 USM sciematic. 121 to5 0 C] desirable)
Vibration amplitude: ' 0005 to 0.0025 inch [0.013 to
Principles 0 063 mm] (mean diameter of
Ultrasonic machining (USM) is the removal of material by grit should be approximately
the abrading action o"a grit-loaded liquid slurry circulaqing equal to the vibration ampli-
between the workpiece and a tool vibrating perpendicular tude)
to the workface at a frequency above the audible range (see Tool tip force- 1 to 100 lb. [0.45 to 45 kg' 'generally
figure 10.7-1). A high-frequency power source activates a less than 10 lb [4.5 ol])
stack of magnetostrictive material, which produces a low
amplitude vibration of the toolholder. This motion is trans- Tool material: Mild steel, 303 stainless steel,
mitted under light pressure to the slurry which abrades the molybdenum
workpiece into a conjugate image of the tool form. A con-
stant flow of slurry (usually cooled) is necessary to carry Overcut and cutting gap: Approximat3ly 2 times grit size
away the chips from the workface. The process is some-
times called ultrasonic abrasive machining (UAM) or ima- Wear ratio: 0.7:1 to 1000.1 (see table 10.7-16)
pact machining. Feed rate: 0.002 to 0.10 in/min [0 05 to 2.5
A prime variation of USM isthe addition of ultrasonic vi- mm/min] (sensitive to debris
accumulation in gap, to sharp-
bration to a rotating tool-usually a diamond-plated drill. ness of gnt and depth of cut)
Rotary ultrasonic machining (RUM) substantially in-
creases the drilling efficiency. A piezoelectric device built
into the rotating head provides the needed vibration. Mill- Depth of cut: Up to 25 inches [64 mm]
ing-. drilling-. threading-, and grinding-type operations are Area of cut: Up to 3 5-inch [89 mm] diameter
performed with RUM (table 10.7-15 and figure 10.7-15). Accuracy: 0.001 inch [0.025 mm] typical;
0.0002 inch 0 005 mm]
Practical Applications possible
While USM can cut any material, conductive or non-
conductive, metallic. ceramic or composite. it is most effec- Taper: Up to 0.005 inch/inch [0.005
tive on materials harder than 40 -1c.Holes, slots and ir- mm/mm]
regular shapes can be oroduced in delicate ceramics. Tool Surface roughness. R.: 20 to 30 pin [0.51 to 0.76 pm]
wear and taper in the cut can be limiting factors. A prac-

10-43
10.7 Ultrasonic Machining-USM
and Rotary Ultrasonic Machining-RUM
Material Removal Rates and Tolerances Equipment and Tools
Respectable machining rates combined with accuracy and USM equipment for cavity sinking or piercing is available
good finishes can be achieved for very hard work materials, in a power range from 200 to 2400 watts arid. with special
Vibration amplitude and frequency. area of cut, and static engineering order, up to 4000 watts. The most common
load are principal considerations: however, abrasive size frequency is 20 kHz which can be adjusted about plus or
and type. work material brittleness, and depth of cut are minus 10 percent to attain better tuning for specific tooling
also important. The rate of penetrstion is inversely propor- Special attachments or equipment adaptations provide ul-
tional to the area of the cut and j- )ortional to the grit size trasonic assist for conventional drilling, grinding, forming
and the square of the amplitude of vibration. Trepanning of and drawing. Tool material and grit are matched to the ap-
cavities or holes is preferable to the use of solid tools. Cut- plication. and for the best productivity, great care should
ting rates increase with the hardness of the abrasive grit. It be exercised in selecting and maintaining the amplitude of
is essential to maintain a good flow of fresh. sharp grit at vibration. The tool should be designed to resonate at the
the cutting interface and to flush this face free from ch~ps desired frequency for best results, and it must be strong
and accumulations of debris. Excess static load can com- enough to resist fatigue failure. Tool materials are selected
pact the grit and slow the penetration rate. on the basis of ductility and toughness rather than hard-
ness. The overcut between the tool form and workpiece
The delicate touch of USM. while slower in volume re- shape is approximately equal to twice the size of the abra-
moval rate. can be especially valuable for reducing manu- sive grit. Tool storage needs attention in order to reduce
facturing losses of fragile workpieces. Breakout and chip- nicks and scratches that can cause early fatigue failure.
ping of exits of cuts can be a problem. Thin parts often are Most forces are low. so workpiece clamping can be min-
cemented to a sacrifice plate. imal. Fixturing should be positive so as to eliminate vibra-
tion of the workpiece. The slurry recirculation system
Accuracy is typically --0.001 inch 140.025 mini and can should have cooling capability.
achieve -0.0002 inch I=0.005 mml with special care.
Typical operating conditions are listed in table 10.7-3. The RUM equipment is available in a range of sizes and acces-
rate of removal and other specific operating conditions are sories as well as in portable units. Practical limit to tool
dependent upon the work material characteristics, as dem- weight is 1.4 oz 140 gl. The rotary heads provide capability
onstrated in table 10.7-20. for threading.

Surface Technology
Surface roughness decreases and finish improves with
smaller size grit and smaller vibration amplitudes or higher Machining Characteristics
frequencies (see figures 10.7-3 to 10.7-5). USM typically There are no unusual safety considerations in USM. and
achieves roughness values of 20 to 30 microinches Ra 10.51 the simplicity of the operation reduces the training or skill
to 0 76/pml. Side walls of deep cavities can be rougher than requirements. A good flow of slurry is desirable in order to
the bottom face. There ;s no heat-affected zone, and there maintain the cutting rate. Replenishment of the grit is
are no chemical or electrical alterations in the surfaces pro- needed at regular intervals. With water-based slurries, a
duced. The multitude of small impacts imparts a shallow, rust-preventive treatment is desirable following the wash-
compressive residual stress to the surface This residual out of the slurry. The proper choice of tool material and
stress promotes an increase in the high cycle fatigue abrasive grit will result in satisfactory wear ratios between
strength of the work material after USM (see section 13.3. the workpiece and the tool. Taper in deep cuts can be re-
table 18.3-7). Side-wall channels can occur from the action lieved by the use of roughing and finishing tools. Because ,A
of cavitation but will only be approximately the size of the tool wear occurs mostly on the bottom face of the tool, pro-
abrasive grit. file precision is maintained.

IN
10-44 0
 Ultrasonic Machining-USM 10.7
and Rotary Ultrasonic Machining-RUM
SELECTED DATA
There are several valid techniques for selecting operating
parameters for USM. The steps in table 10.7-2 are recom-
mended as one logical sequence Supporting data come
from the other figures and tables in accordance with the
terms ai explained in figure 10 7-2

Average
grit size

Tool Spindle holder

wear 0 L th-ust hle

0
OO_- " feed Vibration From
0-O o- so IIIpump slurry

/
Overcut -0 0 Slurr

" '
C "J Working
gap
', -
22.Vibration 0, O000l Workpiece

am
ltd
.w Taper
0
Chips
K4
Tool H
face area

Figure 10.7-2 USM parameter terminology

3
I! #
I
I
10-45 1i

I
-' - ~---- -- --
10.7 Ultrasonic Machining-USM
and Rotary Ultrasonic Machining-RUM
TABLE 10.7-2 Steps to Select USM Operating TABLE 10.7-3 Typical USM Operating Conditions
Parameters
SEMI.
ITEM DATA PARAMETER ROUGHING FINISHING FINISHING

1. Workpiece material; From engineering drawings or Tolerance,

type, hardness, met- specifications inch :0.001 :0.0005 :0.00025
allurgical state Preferably hardness greater i
than 40 Rc. I
See table 10.7-4. Roughness,
microinch R0 30 25 20
2. Configuration. finish From engineering drawing-
and tolerance Maximum contours depth-to-
width = 2.5-1 G;it s.ze
Maximum dimension 4 inch number 230 400 800
[100 mm]
Minimum width cut 0.003 inch Grit average
[0.076 mm]
Limited by tool type and size. inch 0 00248 0 00090 0.00044
shape. Consult machine
vendors. Grit average
3. Area of cut From engineering drawing: size. micron 63 23 11 2
Calculate from part
configuration. Abrasive
Minimize area by use of tre- concentration, % 55 45 35
panning where possible.
4 Select type abrasive Tables 10.7-5 to 10.7-10 Overcut,
5. Select abrasive grit Table 10 7-10; figures 10.7-3 to inch 0.005 0.002 0.0005
size 10.7-5
Base on surface roughness and Machine
tolerance needs. stroke 0.0025 0.0015 0.0005
6. Select %concentra- Figure 10.7-6 -

tion of slurry Lower %'s for larger tool areas

Water base generally oil c-
alcohol sometimes used
when water will dissolve
workpiece.
7 Select tool material Tables 10.7-11 and 10.7-12
8. Estimate: Tables 10.7-13 to 10.7-15: fig-
penetration rate ures 10.7-7 to 10.7-11
vibration amplitude
static load
9. Select tool design Allow overcut of 2 times grit
size.
Figure 10.7-12
10. Select equipment Table 10.7-19
size
11. Verify vibration fre- Trial cut and tuning of system.
quency and ampli- Establish wear rate.
tude. Refine other
operating settings.
12. Select depth of cut Depth of cut or stroke equals
drawing requirements plus
tool wear allowance.
Measure or estimate wear ratios
Tables 10.7-16, 10.7-17 and
10.7-18; figures 10.7-13
and 10.7-14

10-46
 Ultrasonic Machining-USM 10.7
and Rotary Ultrasonic Machining-RUM
TABLE 10.7-4 Materials That Have Been Successfully Machined Ultrasonically

Agate Composites Limestone Silicon carbide

Alumina Cold rolled steel Lithium fluoride Silicon nitrite
Aluminum oxide Ebony Micarta Stainless steel-hardened
Barium titanate Ferrite Molybdenum Steatite
Beryllium oxide Formica Molybdenum disilicate Steel-hardened tools
Boron carbide (fused) Garnet Mother of pearl Ti-6AI-4V
Boron composites Germanium Plaster of paris Tungsten
Brass Glass Pyrolytic graphite Tungsten carbide
Calcium Glass-bonded mica Quartz Thorium oxide
Carbides Graphite Ruby Uranium oxide
Carbon Hardened 1095 steel Sapphire Uranium carbide
Ceramics High pressure laminates Silicon Zirconium oxide

TABLE 10.7-5 Abrasives Used in USM TABLE 10.7-7 USM Cutting Speed Index for Brittle
Work Materials
KNOOP RELATIVE (Soda glass, using 100 mesh B4C abrasive = 100)
ABRASIVE HARDNESS CUTTING POWER
ABRASIVE
Diamond 6500-7000 1.0 Boron Carbide Silicon
Cubic boron nitride (CBN) 4700 0.95 WORK MATERIAL - Carbide
Boron carbide (BC) 2800 0.50-0.60 100 200 400 100
Silicon carbide (SiC) 2480-2500 0,25-0.45 mesh mesh mesh mesh
Aluminum oxide (AI20 3) 2000-2100 0.14-0.16 Soda glass 100 90 77 85
Hysil 73 66 54
B9 borosilicate glass 86
Ferroxcube IIIC 37 34
Ferroxdure (demagnetized) (32)
Quartz crystal (57)
Fused alumina 19
Synthetic sapphire 19
Synthetic ruby 18
Flint stone (72)
Barium-titanate ceramic 110 109
TABLE 10.7-6 Selection of Abrasive Ceramic 507 (38) 35
ABRASIVE WORK MATERIAL Garnet (58)
Feldspar (40)
Boron carbide Tungsten carbide, metals, high density Spinel (48)
ceramics, minerals, semi and precious Slate 67
stones. Mycalex (240) (200)
Silicon carbide Low density ceramics, glass silicon, germa- -

nium. mineral stones. SOURCE: E. A Neppiras and R.0. Fosketi. Ultrasonic machining. Philips
Technical Review 18 (1956-57). p 372.
Aluminum oxide Glass. low density, sintered or hard powder NOTES: Tool used was mild steel H-form. 1/2-inch 112 7 mm) square,
compounds, limbs 1/16-inch (1.59 mml thick. see figure 10.7-9.
Numbers in parentheses are estimates, interpolated from measurements
SOURCE. G E Littleford. Machining by ultrasonics, 1971. under somewhat ddferent conditions.

10-47
10.7 Ultrasonic Machining-USM
and Rotary Ultrasonic Machining-RUM
TABLE 10.7-8 USM Cutting Speed Index for Metais
(Soda glass, using 100 mesh BAC abrash e =100)

1 ABRASIVE

WORK MATERIAL j.
I Boron Carbide
T
fsilicon
Carbide Alumina
IDiamond
j Sand Powder
100
mesh
220
mesh
00o
mesh
100
mesh
220
mesh
(grit size
0.012 In)
I(grit size
0.001 In)

odlas100 90 77 85 65479
Bas(omon yellow) j 6.6 5.6

K.E. 672 (approx AISI 01). R. 66 1.4 1.3

C.S.K .R 62 j 3.9 3.6
K.E. 672 (approx. 4151 01). R. 61 2.2 2.1 1.48 0.1 0.1
K E. 672 (approx. AISI 01). Rt.58 1.7
Stainless steels
18% Cr. 8% Ni. 0.1 %C 2.1 1.9
3 5% Cr. 8.4% W. 0.35% V. 0.3% C 1.2 1.1
Carbon-chrome bearing steel (heat-treated) 1.4
Sintered tungsten carbide. R. 76 4.1 35 2.55 0.2 0.2 4.3
Tungsten 4.8 4.
Stellite 4.0 3.7
Germanium single crystal (31) (28)
Titanium (4.0)
Berylium 1 (7)

SOURCE. E A Neppiras and R. D FosIkett. p 371.

NOTE: Same tool used as in table 10.7-7. Numbers in parentheses are estimates interpolated from measurements under somewhat dillerent conditions.

TABLE 10.7-9 USM Cutting Speed Index for Ceramic Work Materials
(Soda glass. using 100 mesh 84C abrasive =100)
[ _____________________ABRASIVE_____

WORK MATERIAL Boron Carbide Silicon Carbide Alumina

_________ 100 mesh 400 mesh 100 mesh 400 mesh 600 mesh 220 mesh

Chemical porcelain 70 14 53.5 11 2 25

Temperadex* 60 10 45 7.5 - 20
Fa-radex* 55 7 41 5 - 2
Vulcanex* 190 51 168 44 2 62
Z.Z porcelain 90 j 32.5 75 26 2 10 3
H.T. porcelain 45 24 41 22 - 8
Frequentite*
Soda glass J 47.
100-
754
45 so
807
26 -
6
20
70

SOURCE: E A Neppiras and R. D.Foskett. p.371.

*.)TE: Tool used was mild steel, circular. 1/4-inch [6.5 minI diameter.
*Trade names ot proprietary materials.

10-48
 Ultrasonic Machining-USM 10.7
and Rotary Ultrasonic Machining-RUM
TABLE 10.7-10 Grit Sizes Used in USM
PARTICLE SIZE
GRIT SIZE

Roughing__
120 0.0056 -_ M.
140 0.0048
170 0.0034
200 0.0026
230 0.00248 X
270 0.00175
325 0.00128
400 0.00090

Finishing
500 0.00073
600 0.00057
800 0.00044
900 0.00038
1000 0.00032 .
1200 0.00022

NOTE. In estimating tool size with respect to tolerances required, the

abrasive particle diameter can be cnnsidered as an overcut factor. For
example, ifa 1/4 inch 16.3 mm] diameter hole was being drilled with USM
(using 180 grit), the diameter of the hole in the workpiece would be equal
to 0250 [6.350 mm] + 2 times 0.0034 [86 pm x 101] or approximately
0.257 inch [6.53 mm].

30 - - 800 400 220 100

mesh mesh mesh mesh

25 400
'EN Sides (glass)
. -- 20 3007.6 gm) _ __

,300

i 1,0
1' 200
(40/.gin) al
"''b Bottoms (glass)

. ~ 1 00 1 1 8 39- 500 - c 20090 ( c5

~~~ (41~tn
0 0 Igo
'b0-0I
. F,0 (tungsten carbide)
SidesBoto
140 ;-40 320 420 600 800 1000 0_o Boto (tnse arbide
size
0rit 0 0.002 0004 0.006 0 008 [02mmI

Average grit particle size, in

Figure 10.7-3 Surface roughness versus grit size
of boron carbide abrasive. Work material key: x =
glas,; o = silicon-semi-conductor; A = mineralo- Figure 10.7-4 Roughness height versus grit par-
ceramic; 0 = hard alloy steel. (D.C. Kennedy and ticle size for holes in glass and tungsten carbide.
R.J. Grieve, Ultrasonic machining-a review, Produc- (E. A.Neppiras and R. D.Foskett, p.378)
tionEngineer 54 (1975), p.485)

10-49
10.7 Ultrasonic Machining-USM
and Rotary Ultrasonic Machining-RUM
1000 --
008ToISet
n

800 -To eto

2 006 1 i
7mrnl
1
t? 600 Ej12
Cj
c (imm] - B4 C, 1I'~0mesh
S 400 90.04

< 20- - - -- -- SiC. 220 mesh

0F
002 4~_
0 8
[576m
25crato~/:>
3000 0005 20

Figure 10.7-5 Grit size versus surface roughness. Cnetain yvlm

Smaller particles produce smoother finishes; larger
particles cut faster. (Data modified from A. L. Roses, Figure 10.7-6 Penetration in glass as a function
Techniques of ultrasonic nmachining, Tool and Manu- of slurry concentration. (E.A. Neppiras and R. D.
facturing Engineer 46 (1969): 71-75) Foskett, p.373)

TABLE 10.7-11 Effect of Tool Material on Cutting Rate

(Soda glass work material; B 4C abrasive; optimum static load at 20 kHz)
CUTTING RATE," in/min

TOOL MATERIAL TOOL SHAPE Amplitude =0.002 In Amplitude =0.001 In

Abrasive Abrasive Abrasive Abrasive
100 mesh 400 mesh 100 mesh 400 mesh

Copper -Circular,

Brass (BSS 251)

1/2 in dia.
Circular, 1/2 in dia
0.063
0.090
0.020
0.028
0.016
0.022
1 0.006
0.008
Mild steel (EN2) Circular, 1/2 in dia. 0.086 0.022 0.021 0.007
Silver steelt Circular, 1/2 in dia. 0.074 0.022 0.020 0.008
Stainless steel
(18% Cr. 8%Ni. 0.1% C) Circular, 1/2 in dia. 0.071 0.020 0.018 0.006
Tungsten carbide Triangular, 1/8 in base 0.156 0.100 0.038 0.030
Mild steel (EN2) Trian~gular 1/8 in base 0.150 0.102 0.036 0.029

(18%...--8% 0.1% C) ----

 Ultrasonic Machining-USMV 10.7
and Rotary Ultrasonic Machining-RUM

> C(0 LO0 0 N L

0

.2 CO CO B -,

C ~ L CJ( COt CD C
0o
0
00 00 0r
U)C0
C. S) I E 6 , Lt i Ci'D NC

0I f(-O ~ ~ CO (0 toCD

- CO':O

0 m (0 CO
0 (0 -

C':

0 0
C 00CO 0)0 0 (nl
CO
3 toL
0(U)4 - - C':
?L U-)
(00) -N C W
D 00
0 -0 --

on 0 ') .1 to

S
- \
0O
0
"
C
~O~C\- 0- CO0
0

00

coo C;0

) CO ,
C6C
a C C
CCE- Ecn
EE E E~
S'C''EN .E .r C7? *
C ;NZ )
-Z C C C C 0

-- ~ ~
oNCJ N'
,-- ~ ~ c

0* 0'~.

Cu
Cda C

000
6 00 0 X 0 W wT

ui In1
S0 _C E o1
0 5 - C

:1 z) 10 >

_j 'U3C 0 < C
0
0 OL 5E(O~

~~v>~0 <~0

10-51
10.7 Ultrasonic Machining-USM
and Rotary Ultrasonic Machining-RUM
TABLE 10.7-13 Material Removal Rates for Various TABLE 10.7-14 USM Material Removal Rate Index
Work Materials (Cutting soda glass at 0.060 in/min [1.52 mm/man] = 100)

WORK MATERIAL MATERIAL REMOVAL RATE WORK MATERIAL INDEX

in'/min mmImln-
Soda glass 100
Carbon 0.015 2468- Ceramio 70
Glass 0.016 202 Silicon 60
Ceramics 0.005 ungsten c~arbide
T8 4
Silicon 0005 Stainless steel 2
Germanium 0,006 9
Quartz (crystal) 0.007 115l SOURCE G E Littleford, Machining by ultrasonics, 1971
Fe'rrite 0.01423
Tungsten carbide 0.00025
Tc:)l steel (hardened) 0.0002
Stainless steel (hardened) 0.0002
Boron carbide (fused) 0.00025 l ~4'
Pyrolytic gr'aphite 0.010 j 6

TABLE 10.7-15 iotary Ultrasonic Machining (RUM) with Rotating Diamond Impregnated Tool
WORKDRLDETMAHNG
MATERIAL DIAMETER OFCTTIME CONDITIONS

99.9 Alumina 0.042 0.250 130 20 kHz frequency

0.125 Ai~ 0250 .~20 3000 rpm
0.20 0 250 .154-2 120 grit core drill
0.37 025 30diamond tool
pressure
Glass .02 ___ 050 120

erie0.0802 0.500 ~ '

Brn0.250 040
700

composite 0.250 0.500 192

SOURCE W R Tyrrell, A new method for machining hard and brittle materials, SAMPE Quarterly 1 (January 1970), 55-59

10-52
 Ultrasonic Machining-USM 10.7
and Rotary Ultrasonic Machining-RUM
[051mm] b
004 lm]()0020
STool section

S003
-, 000163
--- c0015-
To I section
0

E 16 35 mm)
C) _ ___ ____ C)
0 02 0 0010
~~~Tool Section 112i

001

0 xi
00002 1- Too000

0 1 2 3 4 5 0 2 4 6 8 10
[1 82 KgJ [3 64 Kg]
Static load. lb Static toad 110

Figure 10.7-7 Penetration rate as a function of static load for (a) various amplitudes ( ) and (b)various
tool areas. (E.A.Neppiras and R. D. Foskett, p.369)

0 046

003 __________ 06Tool Section

St 1/4 in ' *
6 635im)l~
16

E 1mm) _ __

002
0 C
;E
0

001
C)S

0 1

0 0 00005 0001 00015 0002

0 5 10 15 20 10 051 mml
Frequency kHz Amplitude in

Figure 10.7-8 Penetration rates in glass as a function of (a) frequency, for a peak to peak amplitude of
0.001 25 inch [0.038 mm] and constant static load; and (b) amplitude, for four operating frequencies and
constant static load. (E.A Neppiras and R D Foskett, p.369)

10-53
10.7 Ultrasonic Machining-USM
and Rotary Ultrasonic Machining-RUM
0020 1051mm) 100n esh Tool Section

400 mesh
H ,r
127m
7mm)

1
0015 4'2sn'" [l 59mm)
If [12 7mmj

5 '=500 mesh

0 0010
! I ==.3-- 600 mesh

0 005

0 _j
0 25 50 75 100 125
Time seconds

Figure 10.7-9 Penetration rate as a function of time for varioIs grit sizes. Grit sizes given in British
Standard Sieves (American Mesh sizes are essentially the same.) (E.A Neppiras and R D.Foskett,
p. 370)

o 7
x . Material Limestone
a, Tool width 3/4 in 19 1mm)
Cut depth 1/2 in [12 7mmj
6Voltage 1100

3200 W 3200W
2500 W3000W
W 250 3000 W 4 Angle
Power of to
1500 attack
2000 W
No3 No6 No7 tO0 toa

t '-J A 2000

1 25 n "- 125 in 4
1 in

06 250 lb static force No 6

2-- (1100 NJ
C)3

-," c- NO 7
2 *" 5 cmtrn,n -

cm/s
1 2 3 4 5 6 7

0 2 4 6 8 10 I
0 0.5 10 1s 20 2 5 in/S
Time seconds Cutting speed

Figure 10.7-10 Drilling and layer removal rates for medium Indiana limestone processed with IJSM.
Left, depth of drilling versus time for three types of tools operated at 10 kHz; right, specific energy at
various cutting speeds and angles of attack at 10 kHz. (From K. F Graff, Application of sonic power to
rock cutting. Ultrasonics international 1973 conference proceedings. pp. 31. 33)

10-54
 Ultrasonic Machining-USM 10.7
and Rotary Ultrasonic Ma'shining-RUM

0 120

S 0 080 [2mm]

0
*60040

0 20 40 60 80 100 120 140

Time. seconds

0.003

S 0 002

0)

0 0100 020030
[2 54mm]
Diameter of tool. in

KEY DIAMETER OF CUTTING

TOOL RATE
in ~m~ if/s --mmI~s--v

A 0.0625 *1.W9, 2.3 5

o :3.125 '31. 1158 -40
x 0.180 .45 11 2
0 .250 ,83~ 07 1

Figure 10.7-11 Cutting rates for stainless steel tools into ceramic work material. b'p. determining
rates for various size tools; bottom, rates as a function of jol diameter. (J Krawczyk, Ultrasonic grinding
techniques in microminiaturization, Report No TR-958, D:amond Ordnance Fuze Labora'ories, Washington,
DC. 1961)

10-55
10.7 Ultrasonic Machining-USM
and Rotary Ultrasonic Machining-RUM

Tungsten Carbide Soda Glass

0020 [0 51 mm) 1 1 0020 10 51 mmi

- 10mesh1 mesh 0100

2 0015 2oms 0015~
0 10 ms 0
C)- (trepanned a
0. ~~holes) ed
e -~s
00141!- -
- 0
220 mesh
o 0010 0 -s 6 D 010 IOoit:
Z) -. 0

0
000 400 mesh
800 meSh
0

00
0 01 02 03 04 CE 0 0 3 0

Depth of cut. in i2mlDepth of cut in (o2m

Figure 10.7-12 Overcut values for tungsten carbide and soda glass work materials cut with B4C abra-
sive at various depths. (E. A. Neppiras and R, 0. Foskelt, p. 374)

TABLE 10.7-16 General Wear Ratios

APPROXIMATE WEAR RATIO
(ratio of depth of cut
tloss of tool size)
TOOL MATERIAL ____ orkpiece Materials

Glass ISteatite ITungsten~

carbide Ceramic

ICold
Brass
Annealed low C steel
rolled steel
Stainless steel
Tungsten carbide
40-50
100
100
150
1000
10
35
40
0.7
1.1
39
28
0.9
40

100
75
75
_

SOURCE. J. Krawczyk. Report No. TR-958. Diamond Ordnance Fuze Lab-

oratories. 1961
NOTE General cutting conditions 1/4-inch diameter mild sleet toot: 20
kHz, 320 grit 8CC: 1-1 /2 lb pressure.

10-56
 Ultrasonic Machining-usm 10.7
and Rotary Ultrasonic Machining-RUM
TABLE 10.7-17 Representative USM Penetrating and Tool Wear
Rates at 700 Watts Input
MAXIMUM
RATIO PRACTICAL AVERAGE
MATERIAL STOCK REMOVED MACHINING PENETRATING
TO TOOL WEAR AREA RATE*
in- cOe in/min m~i

Glass 100.1 4.0 -25,8; 0.150 38

Ceramic 75:1 3.0 .ij9.-4' 0.060 15.
Germanium 100.1 3.5 228 0085 ... 71&
Tungsten carbide 1.5:1 1.2 77 0010 02
Tool steel 1:1 0.875 .56': 0.005 c,'0.13!
Mother of pearl 100:1 4.0 ~ 8 0.150 '3B
Synthetic ruby 2:1 0 875 -586 0.020 -1
Carbon-graphite 100:1 310 i,19Al4 0.080 2-i.-0
Ferrite 100:1 35 26 0.125 ~1
Quartz 50:1 3.0 19 4 r0 065 16z
Boron carbide 2:1 0 875 5 0 008 0A20:
Glass-bonded -
mica 100:1 3.5 ]22:6 0.125 13~

SOURCE. Data from Raytheon Company, Impact grinders for ultrasonic machining. 19'61
NOTE. Toot material was cold rotted steel in all cases, 320 mesh Boron Carb'de was
used in all cases
*1/2-inch (12 7mm) diameter tool. 1/2.'nch (12 7 mm) deep

TABLE 10.7-18 Representative USM Penetrating and Tool Wear Rates at 100 Watts Input______

SOLID BEST STOCK

TOOL FORCE CUTTING ABRASIVE/ REMOVAL
MATERIAL DIAMETER RATE WATER RATIO
in b ~RATIO BY WORKPIE
in lb -A in/mm iiZnn VOLUME (vs) TOLL

Glass
Aluminum oxide
Tungsten carbide
j 0.25
0.25
025
~83~' 1
5
1
~ O4~
L_45t0,
0.075
0010
0.002
L 5
A9

C
>
'
' 14101
1.41
1.41
13:1
1:1

N5W+N-'R- 0.0 - A 14 10I

Carbon 0.25 0.5 0.10 1.4.1 200:1
Germanium 0.25 1 0.110 141 100:1 -4

Silicon
Quartz
j 0.25
0.25
1
3
tW.-6g 0.110
0.070
Z?-
ILI
1.4 1
1 4:1154:1
100:1
Glass j0.125 1 ~---A' 0.125 41
11. 100:1

Aluminum oxide 0.125 1 _U 0251

0.0030
Carbon 0.125 05 0.250021101
Germanium 0.125 ~ _0.125 v- 0.25-1 "00:1

Slicon 0.125 10.125 0.25:1 100:1

Tugtncarbide 0.125 1 0.004 0.2:11

SOURCE: Data from Raytheon Company. Impact grinders 1w, ultrasonic machining. 1961.
NOTE: Tool material was cold roiled steel in all Cases: =.320 mesh Boron Carbide was used in alt cases

10-57
10.7 Ultrasonic Machining-USM
and Rotary Ultrasonic Machining-RUM

TABLE 10.7-19 Equipment Size

(Estimate of watts required for 20 kHz equipment using 120 mesh B4C abrasive and optimum
parameters)
CUTTING RATE

G13sS Hard Alloy Germanium WATTS

n 3,minx 10-' mm 3imin 3
in /minx 10-' mm3/min in3/min x 10-4 mm 3/min

92 150 3.1 5 31 50 250

214 350 4.9 8 61 100 500-600
490 800 122 20 122 200 1000
900 1500 183 30 183 300 1500
1800 3000 45.8 75 427 700 4000

llI* I I"
300 1 T T 1 1
200 - - -4 S--- 4-

100 - FM ste hrome steel

50 1K Carbides
- 40 Brass-- l- - --
B 30 -
20 ...
Durai Ruby
I ,0 Sapphi:re Mother of pearl
I Spinet
__rrl '
Z 4 - - -- ' Agate-......
1
3

8 Ferriteu

02 O__Z
05

01 02 020405 1 2 3 4 5 0 20 30 4050 100 200-300 500 100

Machining rate. percent

Figure 10.7-13 Tool wear versus machining rate. Relative wear rate of stcaI tool in various work mate-
rials. 100% is 5 mm/min (0.20 in/min) in glass. (M. Aoithan and V. C. V-nkatesh. Tool wear phenomenon
in ultrasonic drilling. Proceedings of 5th all India machine tool design and research conference, University of
Roorkee. 1972, p. 625)

10-58
 Ultrasonic Machining-USM 10.7
and Rotary Ultrasonic Machining-RUM
18 VVV7
16
1 ~ 4

142

E (0040mn)
Work material Glass
e. Work material
-08

0 j thickness 6 5mm (0 26 i
I Tool material Mild steel
06 Tool size

I
outer diameter 5mmn (0 20 in)
04 - 1nner diameter 4mm (0 16 in)
Abrasive
02- typ SIC
~grit size 280
0 - [FrequenecyY20kHz
0 20 40 60 80 100 120 140 160 180 200 220
Metal removal rate mm/min

0 400 800 1200 160 2000 2400V2800O3200O3600 4000 4400

Cutting time Seconds

Figure 10.7-14 Tool wear versus machining rate and cutting time. (M. Adtthan and V C Venkatesh.
p 627)

11
7
10
Without ultrasonics

C Scatter band --
00

5O2 04 70600

44

105
10.7 Ultrasonic Machining-USM
and Rotary Ultrasonic Machining-RUM

TABLE 10.7-20 General Recommendations of Conservative Starting Conditions for USM

WORK MATERIAL
PARAMETER Glass Ceramics Hard Metals Composites (e.g., Tungsten
(40-60 R) glass epoxy) Carbide Stone
Roughing Finishing Large area Small area

mild mild stainless stainless mild tool

Tool material steel steel steel steel tooil steel mild steel steel steel

Abrasive
Type BeC 84C BC B4 C sic B4C B4C A12O,
Size 320 500 320 180 240 320 240 180
Percent concentratiorn 20 60 20 40 I 50 40 50 20
Carrier fluid H20 light oil H20 H20 H20 HO H20 H20

Power
Frequency. kHz 20 20 20 20 20 20 20 10
Watts 700 100 40C 200 500 300 500 1000
Amplitude.
in 0.002 0.001 0.002 0.001 0 0005 0.0015 0.0005 0 004
[mm] [0.051] [0,0251 [0.051] [00251 [00131 (0.0381 [0.013] [0.102]

Spindle thrust. lb 5 2 2 1 4 2 4 10
[kg] [2.27] (091] [091.45 [182] j [091] [1.82] [4.54]

Material removal j
Rate, I
n/min 0030 0.015 0.004 0005 00002 0.016 0.0003 0.15
[mm/min] [491) [246) [65.5] 181 9] [32.7] I [262) [4.9) [2458
Penetration.
in/mi 0 150 0.075 0.020 0.025 0001 0.080 0.0015 0.150
[mm/min] [381] [1.90] [0 51] [0 64] [0 025] i i2.0] [0.038] [3.81]
Relative percent* 100 50 15 20 6 50 4 500
Depth of cut. in 0.5 0.5 0.1 01 0.25 0.1 01 10
[mm] [12.7] [12.7] [2.5] [2 5] [6 4] [2 5] [2.5] [25.4]

Cutting time. minutes 34 6.8 5.0 4.0 250.0 12.5 660 66

________ ,I___

Wear ratio (work to tool) 100 200 75 75 75 100 2 150

Tolerance. in 0.0010 0.0005 0.0010 00010 0.0015 0.0010 0.0005 0.0020

[ mm] [0 025] [0.013] [0.025 .025] [0.038] [0.025] [0.013] [0.051]

uin 40-60 )0-40 40-60 40-60 10-20 40-60 10-20 60-80

S.... [1-1.5] O 5-1 11 5] [1-1.5] [0.25-0.5] [1-1.5] [0.25-0.5] [1.5-2]

NOTE. Based generally on a tool face area of 0.2 in' i1 29 cm']

*Based on soda glass as 100%

10-60
 Ultrasonic Machining-USM 10.7
and Rotary Ultrasonic Machining-RUM
SPECIFIC APPLICATIONS DATA

TABLE 10.7-21 Specific Applications Data for Ultrasonic Machining

Work material: Tungsten Carbide Phenolic Molding Carbon

Workpiece
configuration:

Q.in 0.020 in j 4 in
0 . 0.40 in 3in
Draw die i

2176 holes. 0.029 x 0.035 in

Abrasive
type: B4C BC A120 3 SiC

grit size- 320 600 400

percent
concentration: 50
Power supply
frequency, kHz: 20 20 20 20

power, W: 600

amplitude, in: 0.0015

Spindle thrust, Ib: Controlled feed rate

Depth cut in: 0.187 0.187 0.190 0.040

Cutting time. min. 15 10 2 10

Wear ratio (work to tool): 0

Tolerance, in: -0 0002 =0.001 for size, 0.0005

0.0025 for depth

Surface roughness,
pin R0: 22 15 16

Remarks, Roughing cut, Finishing cut, Bottom hole. Very delicate part.
trepanned, 0.4992-inch
%6-inch OD tool size.
ID. Through hole.
Through hole.

if
10-61
ca
10.7 Ultrasonic Machining-USM
and Rotary Ultrasonic Machining-RUM

TABLE 10.7-21-Continued
Work material Silicon Nitrite Glass-Graphite Epoxy Glass
Composite
Workpiece
configuration 0 1nOD Oa
109 inOD %0 ,at2f,
Q 9 in ID Qi21

Rings - trepanned from i

block 23. slots 0 025 x 0 060 in to
0.025 x 0.375 in

Abrasive
type. SIC B.C Ei-C

grit size- 240 280 200

percent I
concentratiop 50 140 35

Power SUDply
frequency kHz
I 20 1 20 25

power. W 1 600 300

amOitude, m- 0 002 00011 00015

Spindle thrust. ib: I 54

Depth cut. in 030 .0.060 0150

Cutting time, mm 12 ,21

Wear ratio (work to tool)- 1:! 80.1 100-i

lolerance. in i 0.001 C.001

Surface roughness
pir R. i 15 60 (est)

Remarks: i Hardest ceramic No ourrs o,. ttrough slots Low carbon steel too! for
_ __ engraving

10-62
 Ultrasonic Machining-USM 10.7
and Rotary Ultrasonic Machining-RUM

TABLE 10.7-2 i-Continued

1 7I
Work maternaI: Glass Sintered Tungsten Carbide

Workpiece
configuration.
00 8i
08 0i4n2 i
00-o 0 01
10 holes. 0.016 in dia. TSpline trepanninq

ALrasiveB0 C

grit size: 600 220

percent
concentration,
Poker supply
frequency, kHz- 20 I20

power, W.

amplitude, in: 0.0025

Spindle thrust, lb: 0 33 3.

Depth cut, in: 0 47 0 25

Cutting time, min: 0 0125 in/min 42

Wear ratio (work to tool) 9.1

Tolerance, in-

Surface roughness,
pin R :

Remarks. 0.01 4-inch OD, 0.007-inch ID Mild steel tool used.

stainless steel tube used
for tooi. j_____________

10-63
 PRECEDLNG PA(z BL NK.-NOT FILED

Water Jet Machining-WJM 10.8

PROCESS SUMMARY

lMultiple nozzle 71

Waste grease and od

Figure 10.8-1 WJM schemat6c.

Principles degreasg Some popashig actadties and preparations for

Water jet machining (WJM) is low pressure hydrodynamic pem npcinas aeue J.Pp lan n
machining Th pressure range for WJM is an order of mag- casting cleaning are good apphcatins.
nitude below that usedn HDM There are two versions of
tionsis tunneling
WJM one for mining, below
thatcio250JM
uses
psie
and Iin7anadhefis
presure
large pipe cleaning OP
that operates in the region from 250 to 100 psi 7v1to 6.9
MPal and one, for smaller parts and production shop sPtua-
tions that uses pressures below 250 psi 7 MPal The first [1
verstion, or high-pressure range, is chin acteinzed by use of a
pumped water supply with hoses arid nozzles that generally 2f
ihand-directed. In the second version, more produectn. _
oriented and controlled eq such as that shown n
ipment, Operating Parameters -A
figure 10.8-1, is involved In some instances, abrasives are :
added to the flird flow to promote rap-*d cutting Single- or
multiple-nozzle approachs to the workpiece depend on the TABLE 10.8-1 Typical Values for WJM Operating
size and number of parts per load. The principle is that Parameters ;
WJM is high volume-not high pressure
Pressure 30 to 250 psi [0 2 to 1.71 MPa] production
PracicalAppicat
ons250 to 1000 psi [1.7 to 6.9 MPa] civil engineering

Production applications for WJM include descaling, deburr- Fluid- Water

ng, surface cleaning, decorative finishing, nuclear deconta- Water plus grit additives
ruination, food utensil cleaning, internal deburring and

10-65
10.8 Water Jet Machining-WJM

Material Removal Rates and Tolerances Shake-out or cleaning of crevices in the workpiece is nec-
Low pressure WJM is -jot a mass material removal process. essary when grit loaded fluids are us,-d.
it is a finishing, cleaninj and del'urring process. The higher
pressure uses in civil engineering applications are outside
the scope of a machinability handbook. Equipment and Tooling
Production equipment is avadiable which offers adjustable
nozzles in a splash chamber, pumps. filters and associated
Surface Technology items in a single package. Portable equipment with flexible
A polished, scoured clean surface is typical. When abra- nozzles and lances also is commercially aviilable.
sives are used. a light peening texture may occur. Motion
in the workpiece o. the nozzle is desirable because dwelling
on one spot can result in grooving Oiling of iron bearing al- Machining Characteristics
loys is necessary to reduce rust formation after cleaning Suitable for cleaning large areas

10-66
 SECTION 11

ELECTRICAL NONTRADITIONAL
MACHINING OPERATIONS

11 1 Electrochemical Deburring-ECD ....... . . ........ ... ........ .. .... 11-3

11.2 Electrochemical Discharge Grinding-ECDG ................................. 11-5
11 1 Electrochemical Grinding-ECG ................................. .......... 11-9
11 4 Electrochemical Honing-ECH.. .............................. ........... 11-23
11.5 Electrochemical Machining-ECM .................................................. 11-25
11.6 Electrochem ical Polishing- ECP ...................................... ...................... ................... 11-63
11.7 Electrochemical Sharpening-ECS ...... ............ ................. ....... . 11-65
11.8 Electrochemical Turning-ECT...... ..... ........ ................... . 11-67
11.9 Electro-streamTM-ES ................................................. 11-69
11 10 Shaped Tube Electrolytic Machining-STEMTM ........................ ............ 11-71

11-1
 PRECEMDNG PAGE BLAAN-NOT FILVXD

Electrochemical Deburring-ECD 11.1

PROCESS SUMMARY

Fixture Pump

Insulation'

Heat - Electrolyte
protection h - supply

Figure 11.1-1 ECD schematic

Principles Operating Parameters

Electrochem.cal deburring (ECD) is a special version of
ECM (see figure 11-1/. ECD was dcveloped to remove
burrs and fins or to round sharp corners Anodic dissolution
occurs on the workpiece burrs in the presencc of a closely TABLE 11.1-1 Typical Values for ECD Operating
placed cathodic tool whose configuration matches the Parameters
burred edge. Normally, only a small portion of the cathode
is electrically exposed so a maximum concentration of the Power supply
electrolytic action is attained. The electrolyte flow usually type: Direct current
is arranged to carry away any burrs that may break loose voltage- 4 to 25 V
from the workpiece during the cycle Voltages are low, cur- current. 50 to 500 A (approximately 10 to 15 A per
rent densities are high. electrolyte fHow rate is modest, and linear inch of edge)
electrolyte types are similar to those used for ECM. The Gap 0.005 to 0.050 inch (generally 0.030 inch)
electrode (tool) is stationary, so equipment is simpler than [0.13 to 1.27mm-generally 0.76 mm]
that used for ECM Cycle time is short for deburring.
Longer cycle time produces a natural radiusing action Electrolyte
types.
frequently used: 1 to 2 lb/gal [120 to 240 g/L] NaCl
Practical Applications most used: 2 to 3 lb/gal [240 to 360 g/L] NaNO 3
rarely used- 2 to 4 lb/gal [240 to 480 g/L] NaNO 2
Almost any conductive material ca-' be deburred or pol- rarely used: 2 to 4 lb/gal [240 to 480 g/L] KCl
ished electrolytically. Most ECD is performed in seconds temperature: 900 to 110OF [320 to 42 0 C)
and is many times faster than hand deburring The cycle pressure: 15 to 50 psi [100 to 350 kPal
time is limited by the load and unload paits of the oper- flow. 1 to 4 gal/min [4 to 15 L/min per 100 A
ation Drilling-burr removal is routine and involves only
simple electrodes. Interior burrs, intersecting holes and ilters: 10 to 75 am (microns)
internal fins can be deburred using precisely located elec-
trodes Applications include automotive connecting rods. Electrode material: Brass or copper
gear teeth, blanking dies, valve parts, punch press blank-
ings and machined pipe fittings. One 20-second ECD oper-
ation on automotive pistons simultaneously deburrs two oil
ring slots, six piston wall oil holes, two piston pin oil holes Material Removal Rates and Tolerances
and al'weight bosses The absence of mechanical contact Most deburring occurs in 5 to 30 seconds, as shown in fig-
or residual stress effects permits the use of ECD on thin ures 11.1-2 and 11.1-3. The rate depends on work mate-
parts or sections without fear of distortion or damage. rial, voltage, electrolyte, flow rate and tool design. Longer
Shallow reliefs (up to 0 030-inch 10 76 mml deep) can also "on" times can produce a rounded corner in addition to de-
be produced. burring. Tolerances are in the range of 0 0007 to 0.002

11-3
11.1 Electrochemical Deburring-ECD
inch I 0.018 to 0 050 mniml The larger tolerances are as- hydroxides in the used electrolyte need to be filtered out be.
sociated with lower current densities and large operating fore the electrolyte is reused This action minimizes metal
gaps: however, the principal factor controlling accuracy is hydroxide deposition on the workpiece or tools and pro-
the "on" time. Automatic controls are needed to hold the motes more uniform material removal rates. Disposal of
best values. sludge from the used electrolyte should be carried out in an
environmentally sound manner.
Surface Technology
The highly focused electrolytic action produces smooth SELECTED DATA
radii and surface roughness in the range of 8 to 16 micro-
in'hes R, 10.2 to 0.4 pmal. With high current densities. sur-
f- , ess can be 2 microinches Ra 10.05 trol. Stray 0 020 in
.Nil; occur at some considerable distance from the [0 508 mini Average
- ng deburred. Shallow striations (less than
00oi irch 10.0025 mml) can occur where turbulent flow.
-ubbles or insulation discontinuities are present. Some
-. 0 015 in
ajiGs with large. distinct grains can exhibit selective etch- .0 (0381 I
0010 mm! Expected variation~l -
ing on a microscale. particularly in low current density "xpin vartie
ing0 in removal time
areas adjacent to the principal focal point of the electrode.
ECD is not stress-inducing ancd can remove some pre- 0010 in
viously strained surface layers. Alloys with nonconductive "10.254 mm
grains, for example, silicon grains in aluminums alloys, can
exhibit a pock-marked surface where these grains have o
fallen out.
a) 0 005,in ,.;o
< [0 127 mi_
Equipment and Tools
ECD equipment is smaller and less complex than that for
ECM because feed motion is not required. Plastic tables or
shallow tanks are arranged to accept the fixtures and to al-
low quick connections for electricity and electrolytes. 0 10 20 30 40
Stainless steel fixtures and fittings are used to resist the Deburring cycle time, seconds
corrosiveness of the electrolytes. Tooling and electrodes
are tailored to conform to the configuration of the work- Figure 11.1-2 Burr removal rates for aluminum al-
piece and the edLas to be deburred By properly insulating loys. Thickness of burr is measured at root of burr.
the cathode, effects on other exposed areas of the work- (D W Sickels, Electrochemical deburnng-some ca-
piece are reduced to negligible amounts. Power supplies pabilities and limitations, Technical paper MR76-133,
range from 100 to 500 amperes, with multiples available if Society of Manufacturing Engineers, Dearborn, Ml,
several parts are to be run concurrently Automatic con- 1976, p 10)
trols are desirable to secure repeatable results. particularly
with the very short machining cycles. Multiple workpiece
fixtures and automation of the ECD cycle are frequent. 0.020 in
The cycle begins witi, closure of the lid or splash guard and mm] 10.508
placement of the electrode in correct relation to the work-
piece. The cycle continues automatically from electrolyte-
on, to current-on. through the cutting time to current-off,
flushing. and opening of the lid. Hand-held tools for ECD
also are available (see discussion of ECS. section 11.7). .0381
o n
mmni
I
-
A,
r-..
Electrolyte supplies, pumps and filters are sized to handle 0 :
the flow rates. Flow rate depends on component size and Expected
fixtures, but usually ranges up to only a few hundred gal- = 0-010 in variation in. 1015-1
Ions because cycle times are so short. - [(0 254 mm] removal -
time
ECD equipment for the 20-second operation on automotive
pistons cited under "Practical Applications" was integrated > 0 005 in _._,. ___

into a transfer line that included cleaning, rinsing and < [0.127 mm! / --
oiling.

Machining Characteristics YAverage--

It is essential that burr size and location be consistent. 0 10 20 30 40
Burrs of excessive size or random location can cause shorts
in the electrical circuits unless they are knocked off before Deburring cycle time, seconds
the workpiece is placed in the close gaps with the elec-
trode. Uniform results are typical with the fixed electrode Figure 11.1-3 Burr removal rates for iron base al-
positions. Variations in material properties will sometimes loys. Thickness of burr is measured at root of burr.
be revealed by the more uniform ECD action. The metal (D. W. Sickels, p 9)

11-4
 Electrochemical Discharge Grinding-ECDG 11.2
PROCESS SUMMARY

Insulatedl /l Graphite~dl~tve

LgContct

power jSite of
random discharge

Figure 11.2-1 ECDG schematic

Principles and the wheel and to prevent boiling and possible severe
Electrochemical discharge grinding (ECDG) combines the arcing. Sometimes the process is called ECDM. electro-
teatures of both electrochemical and electrical discharge chemical discharge machining.
methods of material removal (see figure 11.2-1) ECDG
has the arrangement and electrolytes of electrochemical
grinding (ECG). but uses a graphite wheel without abras~ve Practical Applications
grains. The random spark discharge is generated through The workpiece must be an electrically conductive mate-
the insulating oxide film on the workpiece by the power ial. As with ECM. the hardness of the workpiece does not
generated in an alternating-currentsource or by a pulsating affect the material removal rates, e'nd almost any con-
direct-currcnt source The principal material removal ductive material can be cut Single-point carbide dis-
comes fron, the electrolytic action of the low levei direct- posable-insert grinding or resharpening is done by ECDG.
current vortages. The spark discharges erode the anodic Plunge, face and surface grinding are all performed. Thin
films to allow the electrolytic acton to continue. At in. or delicate profiles can be form ground. The electrolytic ac-
creased operating levels, electrical discnarge contributes to tion produces a burr-free surface. Circular forms that need
the material removal, as demonstrated i figure 11 2-2 to be stress free are g.od applcations, as is the machining
There is no mechanical contact between the wheel and the cf honeycomb materials. The low cost wheel and the ease
workpiec : however, there are separating forces developed with which it can be formed for intricate profile grinding
by the compression of the electrolyte in the space between are distinct advantages. Careful economic comptrisons be-
the wheel and the workpiece.
diec-cric:
Careful
ricialmaeia
ouceTh
electrolyte control
rmoal
,s tween
dctvemaera
ECG and ECG
cn
should
e- u
beSnl-nmade beforecabdeds
completing
required to assure its placement between th workpiec an applhcation study.

11-5
11.2 Electrochemical Discharge Grinding-ECDG
Operating Parameters

TABLE 11.2-1 Typical Valueb ftr ECDG Operating Parameters

Power supply
type. Pulsating dc ac
frequency: 120 Hz 60 Hz
vchage" 4 to 12 V (8 optimum) 8 to 12 V
current: 200 to 1000 A 200 to 500 A

Electrol :e
type. NaCl, l,,aNO 3 proprietary neutral salts
concentration: 1/i to 2 lb/gal (180 to 240 g/L;
temperature (inlet): 800 to 100 F (270 to 380C]

Wheel
type: Graphite, typically 300 mesh
speed: 4(O0 to 6000 fpm [1200 to 1800 m/mm]
(Lower speeds do not promote good
electrolyte flow and permit gas bubbles
to become too large, thus inhibiting
maximum current densities-see figure
11.2-3.)

Operating gap. 0.0005 to 0.0015 inch [0.013 to 0.038 mm]

(figure 11 2-4)
Pressure between wheel
and workpiece. 5 to 20 psi [35 to 140 kPa]

Current density for

carbides: 600 A/in 2 [1 A/mrm2] maximum
other metals. 800 A/in 2 [1 3 A/mm 2] maximum
stee. using pulsed dc: 1200 A/m (2.0 A/mm 2 maximum
(Excessive current density can overheat
workpiece and/or wheel)

Feed rates*
plunge grinding, carbide: 0.020 in/m [0 5 mm/mini]
plunge grinding, steel: 0.060 in/min [15 mm/mini
surface grinding, carbide. 0.15 in/mm [3.8 mm/min]
surface grinding, steel: 0.50 in/min [12.7 mm/mmin

Wheel wear ratios

ac power- 7:1 (carbide or steel)
dc power: 40:1 (steel)

'Fo, 575 A/in 2 [0.9 A/mm 2] on an 8-inch [200 mm] diameter wfleel
Surface grindng at 0 10 inch (2 5 mm] iepth of cut.

11-6
___ .
 Electrochemical Discharge Grinding-ECDG 11.2
Maierial Removal Rates and Tolerances The surfaces are sometimes pitted with miiiue craters
ECDG will remove about one cubic inch 110 cmil of tool from the electrical discharge if tie v ages used are too
stecl per hour-about 5 times faster than EDG while using high (Too-high voltage aiso deteriorates the wear ratioi
10 to 15 times as much current. Dimensional accuracy is Tie electrolytic dissolution promotes stress-free material
Dimesionl is removal action and burr-free edges
less than that from EDG and is typically =0.0005 inch
[::0.013 miml with close control and =0.001 inch 1 =0.025
mml for routine production. While a typical depth of cut is Equipment and Tools
one-half inch 112 5 mmI when machining at 200 amperes.
1
10
the1 cm
cubic'minl for carbide
inches workpieces
per minute and 0.015
metal enoval 10.25
rate cm-A/
is 0.006 peres is available
Comercial onlspecial
equipment in the engineering order
range from 20 Tooling
to 1000 am-
mini for steel workp'eces. Single-point carbide disposable involves the electrolyte flow control so as to obtain a
iniorset have een
been roundtoaSingepoith
inserts ground to a depth ofcfr0.010icpos0.2
0.010 inch 10.25 uniformly thick
Conforming film between
graphite thefilm
or plaotic workpiece
scrapersand
arethe wheel.
essential
minI at the rate of one insert per minute. Carbide thread Cnomiggaht rpai imsrpr r seta
chasers have been ground with a mean thread height deva- to tolerance and repeatability control. A sufficient flood of
tion of h0.0003 inch 1:0.008 mini and pitch deviatiov of filtered electrolte is essential to l-gh material removal
S0.00015 inch 0h mini
.004 The accuracy is primarily a rates and to the prevention of excessive temperatures. gas
function of the degree to which the electrolyte filmiS unr bubbles or :oiling in the working gap Fixtures should be
funcionof
egre t whch
he te eectolye flm.is nt- made of stainless steel. plastic. or materials compatible
form. Special scrapers are needed to control the electrolyte with the corrosiveness of the electrolyte
flow and to prevent air films.

Machining Characteristics
Surface Technology Wheel-to-workpiece wear ratios are dependent upon !he
Surface roughness values of 5 to 15 microinches R,,10.13 to type of power supply. the voltage, the grade of graphite and
0.38 .ml for carbide workpieces and 15 to 30 microinches the uniformity of electrolyte film. Figure 11.2-5 demon-
R. 10.38 to 0 76 pinl for steel workpieces can be expected. strates the relationship between wheel wear and voltage

SELECTED DATA

Electrode diameter 4 mm (0157

E:ectrolyte- 20qo NaCI in) I . .
0A- (0.031 n/s) Average voltage- 20 V 11
0.O6 Not enough sreed to get
EC" I electrzlyte into gap.

0.4
02 --

o0 CC"I
__ 0 __ _ _ _ __i..
0 200 400 600 800 0 1000 2000 3000
(5000A/mn') Z
Current density. A/cm2 Wheel speed, rpm

Figure 11.2-2 Feed rate versus current density in Figure 11.2 -3 ;-ielationship beiween current aen- -_
drillirg steel plate with ECDM. (M. Kubota. Metal re- s.tv and wheel speed. (W.G. Voorhees, Electro-
n.ovai in ECDM, ISEM-5 roceevings, International cn3inical discharge machining. Technical paper
Symposturr,tor Etectromachining.Zurich. Switzer iand, MR67-165. Socit!y r, Manuf"ctunng Engineers, Dear-
1977. p. 218) born, M, 9bl p.7)

11-7
11.2 Electrochemical Discharge Grinding-ECOG

~~ 12Vo

C 000010
C Vlt

0.00005-
0.

ness, 5 1 ~nd 5 20 5 kPal

Workpiece pressure, lb/in2

Figure 11.2-4 Relationship between gap thick-

aMech.. jGa-
-~_wear ;parking

< L

0 4 8 12 16

Voltaoe. V

Figure 11.2-5 Effect of gap voltage oo wheel

wear. (W G. Voorhees, p. 7)

11-8
 Electrochemical Grinding-ECG 11.3
PROCESS SUMMARY
Conductive bonding
~Abrasive wheel

Insulating protruding
abrasive grains Abrasi - Shp ring

Flter lElectrwr sEuppl I + F;crushes

Workpece the g g w

rc nductive,-
i - Worktable
Constant11.35)
feed

DC
Power supply +!

maeilisdsove y o i uation anIrsltn

Figure 11.3-1 ECG schematic.

Principles the grinding wheel wear of conventional grinding. It also

Electrochemical grinding (ECG) is a special form of elec- compares favorably with conventional millhng and grinding
trochemical machining in which the conductive workpiece (see table 11.3-5).
material is dissolved by anodic action. and any resulting
films are removed by a rotating . conductie. abrasive O e ai g P r mt r
wheel (see figure 11.3-1) The abrasive grains protruding Operating Parameters
from the wheel form the insulating electrical gap between TABLE 11.3-1 Typical Values for ECG Operating
the wheel and the workpiece. This gap must be filled with Parameters
the electrolyte at all times The conductive wheel uses con-
.rentional abrasives-aluminum oxide (because it is non- Power supply
conductive) or diamond (for intricate shapes)-but lasts type: Direct current
substantially longer than wheels used in conventional
grinding. The reason for this is that the bulk of the material volte 4 to 14 A
removal (95 to 98 percent) occurs by deplating. while only
a small amount (2 to 5 percent) occurs by abrasive mechan- Gap: 0.001 inch [0.025 mm] (about equal to
ical action Maximum wheel contact arc lengths are about protrusion of abrasive grains)
,3 -4 to 1 inch 119 to 25 mml to prevent overheating the elec-
trolyte. The fastest material removal is obtained by using Electrolyte
the highest attainable current densities without boiling the types:
electrolyte The corrosive salts used as electrolytes should frequently used: NaNO3, 1 to 2 lb/gal [120 to 240 g/L]
be filtered. and flow rate should be controlled for the best rarely used: KNO3, 1 to 2 lb/gal [180 to 240 gIl.]
process control. rarely used: NaCl. %to 1Y2lb/al [60 to 180 gIL]
temperature: 90' to 110'F [260 to 420C]
pressure: 2 to 10 psi [14 to 70 kPa]
Practical Applications filters: 50 to 100 micrometers
Face. plunge, cone or contour grinding are usual ECG ap- flow control- Close-fitting nozzle with air scraper
plications on high-strength. conductive materials, regard-
less of hardness. Almost any conductive material can be Abrasive wheel
ground electrochemically. Low wheel wear. infrequent type: Conductive
dressing. minimal forces on the workpiece and automatic" abrasive: A1203 or diamond grit
deburring are characteristic. Sharpening. shaping or re- speed: 4.000 to 7,000 fpm [1.200 to 2,100 m/min]
sharpening tungsten carbide tool bits. contouring fragile
honeycomb parts. ana cutting surgical needles and thin- Feed rate and depth
wall tubing are practical Grinding hard, tough materials cut, Figure 11.3-3
without heat checks or burrs is frequently done. Inner cor-
ner radii are limited to 0.010 tw 0.015 inch 10 25 to 0 38 Length of contact. Up toO 75 inch [i mm]. Limit length to
mml Precision and fine finishes are combined with more prevent boiling in electrolyte. See also
rapid cutting. freedom from burrs and absence of residual figure 11 2-3.
stress or distortion. ECG is performed with 1/7 or less of

11-9
11.3 Electrochemical Grinding-ECG
Material Removal Rates and Tolerances glas or equivalent dielectric material (see table 11.3-4).
The material removal rate is proportional to the current Workpiece fixtures should be made of copper. copper-base
density The cui rent density is limited by the anodic dis- alloys or 300-series stainless steel and should be con-
solution rate for a particular alloy-electrolyte system and structed such that all cathodic components remain elec-
the boiling point of the electrolyte A convenient value for trically insulated from anodic components during the ECG
most common materials is 0.010 cubic inch per minute operation. The wheels must have the correct abrasive qual-
10 16 cm , mini per 100 amperes of current A plunge grind- ities of the insulating grit (silicon carbide and some forms
ing feed rate of 0.050 inch per minute 11.27 mm/mini is at- of Borazon cannot be used because they are electrically
2
tained at 500 amperes per square inch 177.5 A/cm l. while conductive.)
.3urface grinding operates at 1.0 inch per minute 125.4 mm/
mini with a 0.010 incn 10.25 mml depth of cut at 1000 am-
peres per square inch 155 A/cmil Size control is typically Machining Characteristics and Precautions
=0.001 inch I = 0.025 mini and is attainable in a one-pass It is necessary to "condition" any ECG wheel to remove the
cut. Accuracies to =0.0002 inch 1=0.005 mini can be metal matrix and to allow the nonconductive abrasive par-
achieved with the final pass without electrolytic action. ticles to protrude (see table 11.3-4). To accommodate the
Outside corners usually have a radius about 0.001 inch usually longer runs between wheel dressings. truing of the
10 025 mini. Inside corners have a limit of 0.010- to 0.015- wheel should be more precise than that for conventional
inch 10 25 to 0 38 mini radius. Removal rates are 5 to 10 grinding-0.0002 to 0.0005 inch TIR 10.005 to 0.013 mml.
times those for conventional grinding on hard materials
(Rockwell C45 and up). Handling and storage of the electrolytes should be done
with care and strict attention to the cautions pertaining to
the particular chemicals (see table 11.5-6. ECM). A mod-
Surface Technology erate fire hazard exists when dry NaNO 3 is mixed with or-
Surface finishes improve with increasing current densities ganic materials. With their heavy metal and salt content.
and big. -r feed rates Roughness values of 8 to 32 micro- the disposal of the used electrolytes needs careful. envi-
inches R::0.2 to 0.8 pml are common. with 1 to 4 micro- ronmentally sound planning.
inches R. 10,025 to 0.1 ptml attainable. The surface texture
is similar to that obtained with a metallographic polish. Areas adjacent to the current gap are exposed to the con-
Workpiece hardness is not a factor: howvcver. the material ductive spray and may be slightly eroded or pitted by the
type can affect the range of roughness values. The surface low current densities present there. Appropriate insulation
is free from process-induced residual stress and there is no in the tooling is required to avoid bimetal electrolytic cor-
heat-affected zone Both of these effects contribute to the rosion. NaCI electrolytes are rarely used in ECG because
production of workpieces with high surface integrity, they have strong corrosive effects on machine components.
Citrates. tartrates or proprietary chemicals frequently are
added to the electrolytes and can aid machining while re-
Equipment and Tools ducing corrosiveness. A thorough washdown of the equip-
Grinding machine construction must be rigid enough to ment and tools at the end of each day or each period of use
maintain precision under the deflecting forces which can is a good preventive maintenance practice. Workpieces
reach 150 psi I1 MPal between the workpiece and the should also be well rinsed after ECG, and some materials
wheel. The spindle must be insulated and capable of con- should be checked for possible adverse metallurgical reac-
ducting the low-voltage, high-current d-c power to the tion to the electrolytes.
%%heel. Associated equipment is required to store. pressur-
ize. filter and withstand the corrosive electrolytes. Con- Spindle current for the a-c drive motor is a good indication
trols. fixtures and mechanicai and electrical systems must
be made of suitable material or coated so as to be capable
of the amount of mechanical grinding during ECG. An in-
crease in current to 125 percent of the no-load value for
4
of operating in the salt mist environment. Conversion kits roughing ECG or t- 1.5 -.- , .. nt of the no-load value for
to convert mechanical grinders are available. Wheels must finishing ECG is a :easonaaie ,.pper limit for the amount of
be conductive and must use an insulating grain. Electrolyte grinding The d-c operating current should be selected such
nozzles should be close fitting and should be made of Plexi- that resistive overheating does not occur in the workpiece.

11-10
 Electrochemical Grinding-ECG 11.3

SELECTED DATA
There are several valid techniques for selecting operating
parameters for ECG. The steps in table 11 3-2 are recom.
mended as one logical sequence Supporting data come
from the other figures and tables in accordance with the
terms as explained in figure 11 3-2.

I Feed

_I
d

SURFACE ECG

_ Fee
WN

FACE PLUNGE ECG

Figure 11.3-2 Parameter terminology for surface

and face plunge ECG.

11-11

. -

 11.3 Electrochemical Grinding-ECG
TABLE 11.3-2 Steps To Select ECG
Operating Parameters

ITEM SURFACE ECG FACE PLUNGE ECG

1 Select wheel type to suit work
Table 11 3-3
material Table 11 3
2 Select size of wheel Largest possible diameter for
particular part shape La:gest possible diameter for
3. Select wheel speed partcular part shape
4.000 to 7.000 fpm (1.200 to 2.100 m,
4.000 to 7,000 fpm 11 200 to 2.100
min]. Too low. electrolyte not
inserted as well: too high. no extra mnmini. Too low. electrolyte rot
inserted as well: too high. no extra
benefits
4 Select electrolyte. mix benefits.
Table 11.3-3
5. Select electrolyte specific gravity Table 11 3-3
Figures 11.5-10. 11.5-11, 11.5-12 in
test value and opera ng F;gures 115-10. 11 5-11, 1!.5-12 in
temperature ECM section
ECM secton
6 Select current density for Table 11.3-3 (or from trial or laboratory
particular material (A,inz) Table 11.3-3 (or from trial o laboratory
iA/cmJ testing) (or work from generalized
material removal rate-see item testing) (or work
13) The current density in the material removal from general zed
rate-see item
workpiece must be low enough to 13) The current density in the
workpiece must be low enough to
7. Determine depth of cut (d) prevent
Maximum to overheating.
suit part configuration and prevent overheating
Not applicable
8. Determine contact length (l
(maximum , to 1 inch f 19 to
wheel diameter
Figure 11.3-3
jigure 11.3-2
25 mmj electrolyte flow path) I
9 Calculate contact area
l times w (if siot and side cutting also.
then area on side of wheels must Itimes a
De inc!uded-see figure 11.3-8)
10 Calculate current required
11. Select voltage setting Current density times contact area
Set to attain required current during a I Current density times contact area
(4to 12 Vdc approx.) Set to attain required current during a
trial cut after full contact made. Do
not increase to point any sparking trial cut after full contact made. Do
occurs Final setting to be 1, volt not increase to point an) sparking
occurs Final setting to be volt
less than value that gives sparking
less than value that gives sparking
with the correct value of spindile
current, item 12. (See also figures with the correct value of spindle
11.3-6 and 11.3-7.) current. item 12. (See also figures
I 1.3-4 and 11.3-5.)
12. Check spindle current Full contact spindle current should be
only a little larger than the no-load Full contact spindle current should be
current so as to keep the only a little larger than the no-load
mechnicl
gndmglesstha 5%current so as to keep the
mechanical grinding less than 5% mechanical grinding iess than 5%
of the total metal removal rate. A
value of 115% for finishing ECG rr of the total metal removal rate. A
value of 115% for finishing ECG or
125% for roughing ECG is a
practical lim:. 125% for roughing ECG is a
13. Material removal rate (MRR) practical limit.
Use generalized value of 0.010
Use generalized value of 0.010
m)i;min/100 A 1164 mm3 'mni /1
Al as a starting point or refine as in aiin100 A (164 mm3 'min100
A, sa arting point or refine as in
ECM to specific alloy dissolution ECM to specific alloy dissolution
14 Volume metal to be removed, in3 rate and multiply by current, rate and multiply by current.
d times w times length cut
I times a times d
(mmi me
15. Time for :ut or per pass Volume divided by MRR
16 Feed rate Volume dv ed by MR
Figure 11 3-3 Il~
Volueddensity
Current dved times MAR
by MRR

11-12
 Electrochemical Grinding-ECG 11.3
TABLE 11.3-3 Recommended Parameters for ECG of Various Materials

WOPK WHEEL IELECTROLYTE"

1 MAXIMUM
CURRENT
MATERIAL TYPE DENSITY*

Base
Chemical lb/gal H20 g/L H20 A/in2 A/cm-

Straigfh'tI. rt
ca. Diamond KNO 3 1.5-1.7 180-200 500 78
Tantalun, ..
carbic, bedoes Diamond KN03 1 5-1.7 180-200 500 78
High speed steel Diamond NaNO 3 1.0-1.5 120-180 500 78
Tungsten Diamond KOH or NaOH 1.0-15 120-1 80, 500 78
Low carbon steel Aluminum oxide KNO3 (90%) + INO2 (10%1) 05-1.0 601-120 1000 155
High carbon steel IAluminum oxide NaNO 3 1 0-15 120-180 1000 15.,-
Stainless steel Aluminum oxide NaNO3 1 5-1 7 180 200 500 78
Silicon iron Aluminum oxide NaCI 1.0-1 5 120-180 500 78
ICopper '~loys Aluminum oxide NaNO 3 or KNO, r .7 180-ad0 1500 233
IAluminum alloys Aluminum oxide NaNOI 1 0-1.2 120-140 1500 233
Titanium alloys Aluminum oxide NaNO 3 1 0-1.2 120-140- 1000 155
A-286 Aluminum oxide NaNO 3 10-1.2 126-140 1 750 116
Hastelloy alloy X Aluminum oxide NaNO 3 1.0-1.2 120-140. 750 116
M252 Aluminum oxide NaNO 3 1 0-1.2 [~12a44f0 750 116
Udimet 500, 700 Aluminum oxide NaNO~ or NaCl" 0 9-1 0 110- 750 116
Waspaloy Aluminum oxide NaNO3 1 0-1 2 120-140.. 750 116
Inconel Aluminum oxide NaNO 3 1 0-12 1120-140, - 750 116
Rene 41 Aluminum oxide NaNO3 ',8-2.0 1 81133 500 78-
Rene 80 Aluminum oxide NaNO 3 1.5-1 9 12 1d;44'0 500 78
Nick~el alloys Aluminum oxide NaNO 3 1.0-1.2 120-140 750 116,
Cobalt alloys Aluminum oxide NaNO3 10-1.2 6080 500 78-
HS-31 (X40) i /Aiuminum oxide NaN4O 3 + NaCl* 0 5-0.7 60- 80- 500 78--
Zirconium alioys .Jumninuin oxide NaNO 3 1.0-1.5 120-180 750 16-
Stellite i Aluminum oxide NaNO 3 1 8-2.0 -210-240 50(0 ~ 787

*Thero are many prcprietary mnixtures~or additives to the base chemicals that nave deeirabte eftects on specific allovs and restrain the corrosion of equip.
me-nt These are recor imended for iniiial iOals. Note that NaCi isespecially corrosive
'0ensty may te limited by possibility of overheating workpiece

11--13

---- -- . . . .- ----- -
11.3 Electrochemical Grinding-ECG
TABLE 11.3-4 Recommended Procedures for Conditioning the Wheel, Maintaining the
Electrolyte, and Fitting the Nozzle in ECG Operations

EGG wheels require 'conditioning'" after dressing to remove copper binder and allow nonconductive part:cles
of aluminum oxide or diamond to protrude Attention to electrolyte co dition and flow nozzle on a regular basis
is also recommended
Wheel mounting procedure recommendations
1 After iemoving worn-out wheel, clean flanges and spindle with warm, clean water and dry thoroughly
Check for any burrs on bearinq surfaces of flanges
2 Clean bear;ng surfaces and holes of flanges w.,ri an abrasive fabric, then blow clean with air to remove
any abrasive oarticles This is important for proper electrical conductivity between flanges and
v. eel
3 Mount wheel At this point, only hand-tighten flange nut
4. Indicate wheel face to within 0 001 inch [0 025 mm] TIR (total indicated runout), this is accomplished by
trial and error Use piece of wood to tap wheel into position Tighten fianges w,h wrench and re-
check TIR. 'f wheel has moved repeat procedure
Conditioning cutting face of wheel
1 Set source voltage at 4 to 5 volts.
2 Set spark suppress at maximum setting (if such control exists on powei supply)
3 Start wheel rotation and full electrolyte flow
4 Plunge grind into a piece of scrap steel. Plunge into steel slowly until ampere eter stabilizes
5. Increase voltage and feed until sparking occurs
6 Continue until cutting face and wheel has a dul! gray or charcoal appearance
7 Wheel is now ready to use
8 Return spark control to normal setting
Electrolyte checks:
If machine is rot equ.pped with a coolant filter, electroly'e should be changel onre a week, or when
mounting a new whee' Check electrolyte nozzles to ens.ire proper flow on all areas )f wheel
For cutofi wheels, electrolyte should flow evenly under 1 l ava:lable pressure on each side of wheel
and on whel periphery
Nozzle fitting:
The fitting of the nozzle is very important since it will helo to confine and direct the electrolyte into the
working gap between the wheel and workpiece contact area A properly selected and fitted nozzle will
also help to reUce "stray machining" caused by a combination of excessive electrolyte spray and un-
controlled current flow
The point at which the wheel enters into the nozzle must L'e tghtly fitted against the O.D surface of the
wl-eel, This will break up the air curtain around the periphery of the "spinning" wheel. The air cuitain
would seriously restrict the current flow between the anode and cathode in the wCrking gap. The
wheel will pick up the electrolyte by traveling tnrojgh the supply line. it is a!srN good practice to relieve
the inside of the nozzle chamber to eliminate any possible wiping acti-n between wheel and nozzle

11-14
 Electrochemical Grinding-ECG 11.3
TABLE 11.3-5 Comparison of ECG to Precision Conventional Milling and Grinding

STOCK STOCK TOOLING PRODUCTION POTENTIAL QUALITY

REMOVAL REMOVAL COSTS & SIZE OF FRAGILE OF HEAT OFSURFACE PROBLEMS
MATERIAL (MILLING) (GRINDING) REPLACEMENT CONTROL PARTS DAMAGE FINISH WITH BURRS

Machinery steel - + = - +
Tool steel, soft = - + + - +
Tool steel, hard + + - + + +
Cast iron -- + = -
Copper - + + + +
Brass -4- -+ = =
Aluminum -- + - -
Tungsten - + + - + +
Tungsten carbide + + + + + + -
Beryllium -.... +
300 stainless - + + = + + + +
400 stainless - + + + + + +
Titanium - - - + + = +
A-236 - + + = + + -+
Waspaloy + + + = + + + +
Inconel 718 + + + = + + + +
Inconel X + + + = + + + +
Rene 41 + + + = + + + +
HS-21 + + + + + + = -
Hastelloy alloy X + + + = + + = +
PWA 1004 + + + + + +
PWA 689 + + + = + + = +
AMS 5668 - + + + + +
Udimet 500 + + = + + + +
Udlm3tO00 + + + = + + + +
Greek Ascoloy - = + = + + = +
PWA. SO + + + = + + + +

Legend - Processes about equal

- EGG inferior to conventional machining
+ ECG superior to conventional machining

SOURCE R R Bra -di, Basics of electrochemical grinding, American Machinist 118 (April 24, 1974), p 48
NOTE In gereral, ECG superiority ncr- ases with hardness or toughness of material

AI

11-165
11.3 Electrochemical Grinding-ECG

UlW/U' aILw pae-

O 00 000 0 0 0 00 (D fl (0'TC.
0 )O C(~( C\j0 000 0 C

- o

r7~

Iu 0c.' -

0O 0
cn 0 -
I- C
4 0

oO (D0

-0 E
0- (

0 0
2 0 C

0~6)

0 ,000 ) - 0C D O7C 0

Cl 0 0 0 00C O 00 0 0 00

Ii I Iejo U)q~u-

11-16
 Electrochemical Grinding-ECG 11.3
0 080 (2m/i]1000
1155 A/cm2]

<

S0075 e900
Ce

CUC

.10)
000800

L) E

0 06570
30 50 70 90 110
(758 kPa]
Work to wheel pressure, psi

Figure 11.3-4 Effects of work~ to wheel pressure in face ECG on M2 tool steel with aluminum oxide
wheel (J R Thompson, Operating parameters in eiectrochemical grinding with aluminum oxide wheels.
New Developments in Grinding, Pittsburgh. PA Carnegie Press, 1972. p 793-812)

0 080
!2mm/minII1
0070 1000
(155 A/cm2]
C

0060<
E .,o~&800

(D a)
0.000

600
:3 0.040E

0.030 400

0.020 ______
6 7 6 9 10 11
Voltage. V

Figure 1!~.3-5 E'ffects of voltage in face EGG on M2 tool cteel with aluminum oxide wheel. (J. R
Thompson. p.811)

11-17
11.3 Electrochemical Grinding-ECG

2.8
6
450 1 Constants
10 volts
Note Voltages are 0 5 10-inch diameter (254 mml
2.4 volt below level for 1/2-inch thick 1127 mml
2.2 initiation of sparking 400 A M-2 steel
20 .

1.6 - 35- i
E
14 11 VoltsQ
C 12- 10OVolts 0.El (
10 (25 4 mm/minI- 9 Volts- 0
08 8Volts
0.6
0 020 0.030 0040 0050 250
Doned n[1.27 mm] 0.6 10 1.4 1.8 22 2.F
Cutting rate. in/mmn (66 mm/mini

Figure 11.3-6 Maximum cutting rate as a function

of voltage and downfeed for surface ECG on M2 Figure 11.3-7 Family of operating curves and
tool steel with aluminum oxide wheel. (J R. Thomp- maximum cutting rates for surface EGG on M2 tool
son, p 812) steel with aluminum oxide wheels. (j R Thompson,
p. 812)

bDirection of wheel travel

Radi. is R

Wheel thickness T

Downfeed =F

Tc~tal area cf c- ntact zArea of peri.-hery contact + Area of side contact

TnrR (Rt i R.-F\- 2

Are .
V5- co R +2 18)rcs -. (-F) jrRF-F 1-

iarccos 13 in degrees, not radians)

Flguro ',1.3-6 CalC~daVOi Of co'itact area of wlcel and workpiece for surface ECG of slots (i R.
Thomoson. p 810)
 Electrochemical Grinding-ECG 11.3
24
225 4 mm)

20 7/8 Burr-free distortionless tubing cut off

18 -by ECG is easily accomplished for type
304 stainless steel The data also are
16. .. -3/4 applicable to many other alloys to
obtain rough production rates even
14 ~th,)ugh the electrolytic dissoluton
1 5/8 rates will vary slightly with
12 composition (see ECM section 1#5)
For well radiused cut ends, a spindle
E 10 1/2- dwell time of 2 to 5 seconds car be
uter diameter. I ____ added at the end of the charted cutting
8t time These cutting times are the
3/8 fastest burr-free rate without regard for
6 wheel wear
4 14

2
0
0 0.010 0.020 0.030 0 040 0 050 0.060 0.070
[1 8 mml
Tube wall thi,.kness, inch

Figure 11.3-9 ECG cutoff operation for type 304 stainless steel tubing. Maximum cutting rates for vari-
ous tube diameters and wall thicknesses. (Courtesy of Evente Machine Products Company)

00O8
KNO3

006_NaN_3_
_____ KNO3 Potassium nitrate
ENaNO 3Sodium nitrate
KNO KNO 2 Potassium nitrite
o NaNO 2 Sodium nitrite
E KOH Potassium hydroxide
.KOH K, CO, Potassium carbonate
NHF Ammonium Fluoride
UKCO- Na2 CO3 Sodium carbonate
0 Na.CO_

O 0.02

0 10 2.0 3.0 4.0 50 [0 6 kg/Li -

Electrolyte concentration, lb/gal

Figure 11.3-10 Conductivity versus concentration for ECG electrolytes (Courtesy of Anocut Engineer-
ing Company)

11-19
11.3 Electrochemical Grinding-ECG
0 030 IWheel 0 97-inch [25 mm) wide!
I 13 42-inch (341 mi dial
Aluminum oxide
~~ Consta-it spindle load
Voltage. 6 5 Vdc
002
- ~Electrolyte. Anocut 90
_ j ( Hardened steel
\.x 'L~Rockwoll'64

\%* \ --- 304 Stainless

0.010 -\ S

0 10 20 30 40 50
f1016 mm/mm]in
Table teed, 'n/mmn

Figure 11.3-11 Effect of wheel 3peed in ECG of two work materials. Note: Wheel speeds are some-
what higher than the typical 4000 to 7000 fom. (L A W-Illiams. 1ll. Electrochemica! grind-ng Technical pa-
per MR67-649 Society of Manufacturing Engineeis. Dearborn. Mi. 1967. p 17)

Current for 3300 rpm spindle, A

20.00 1900 18-30 I 1700
7 1600 1500
1000 900i 800 I 700 600 500
0.20 Current for 1760 rpm spindle A

IMateal T-i5 tool stee!

I! Wheel ~/2-inch [12 7 mm] wide
V - 13-inch 5,33G mm] ia
0 15
I
1 i
I
Alurrinu~r oxide
Constant, spindle load. 4A
\oltage*
V 6.5 V dc

o.0 (28 inm5 J i

617 8 9 1 119 1pm

(254 mm. mini

Tsble feed. in//rnn

Figure 11.3-12 Effect of wheel speed in EGG of T15 tc.ol steel. Note: Wheel speeds are somewhat
higher thpn the typical 4000 to 7000 fpm (L H Williams, ;11P 17)

11-20
 Electrochemical Grinding-ECG 11.3

SPECIFIC APPLICATIONS DATA

TABLE 11.3-6 Specific Applications Data for Electrochemical Grinding

Work materal Fully Annealed Low Carbon Tungsten Carbide Stellite Repair Weld on Waspaloy
Steel and Medium Carbon Steel
Hardened to 60 R,
WorKpiece
confiq.2ration

40blades

Relay frame & Face mll

armature cutters

Wheel AI Diamond A120 3

diameter, in. 14 8

speed. fprr.: i 6.400 4,000 to 6.000 6.000

Electrolyte
type IS.Cl KNOI NaNO3

cooventration,
lb/gal: 05 10 20

Type of cut. Face Face Contour

Depth cut. in 0.030 0010 0 030 to 0.050

Feed rate. in/mn 0.105 3 faces in 80 min 4 G

Voltage, V: 8 to 9 8

Current, A- 1,200 300 125

Wh,.el contact area. m2 0.25

Tolerance, finish. Three parts per load Eliminated rough grinding. Tolerance was 0.0005
t2nef-ts and 17-second cutting r.ycle One wheel per year in place
remarks: 50 wheei oscillations per of several per week.
minute. No ,eat cnecks-33- more
parts pet wheel dtp-ss;ng
Accuracy was m0.00025 incn
30 wheel oscillations per
_ minute

11-21

-- -~~~~~
. -- ---.-
 11.3 Electrochemical Grindng-ECG
TBLE 11. 3-6--Continued
Work material Inconel Alloy X High-Nickel Magnetic Stainless
orpeeLamination
WorkpieceI
configuration

0 020 i

1/4 1n-- 0 0008 - 00000 0 010 in 1 '2-inch dia x 0 015-inch

1/8-inch dia 1/64-inch wall tubing -0 0002 thick wall

Wheel
type. AIO2
A12 03
A120 3
diameter, in 5 8 10
speed. fpm: 1.900 6.000
Electrolyte
type: NaNOI NaNO3 NaNO3 + NaNO,
concentration,
ib,
ydI; 2.0 2.0 1.7
Type of cut- Surface I Contvur Surface cutoff
Depth cut. in: 10.25 0.0092
Feed rate, in,
min- 20 3.0 30
Voltage. v/ 4 6 8
CL:rent. A: 25 120 25

Wheel contact area. in

Tolerance. finish, Burr-free and no distortion No distortion. No burrs.

Lenefits and 120 pieces per hour in place No nicks.
remarks Less than 0.001-inch ruout.
of 100 pieces per day.
No wrinkles
0.007-inch radius at bottom
of slot
Tolerance
S0001oninch.
width was

11-22
 Electrochemical Honing-ECH 11.4
PROCESS SUMMARY

Mechanical

exchanger

-- Pump Fifter Hnn

(noriconductive)

Figure 11.4-1 ECH schematic.

Principles Operating Parameters

ElectrochemicJ honing (ECH) is the removal of material
by anodic dissolution combinied w-th mechbanical abrasion
t-oin a rotating and reciprocating abrasive stone (carried
on a spindle which is the cathode) separated from the
wrorkpiece by a rapidly fiow~ing electrolyte (see figure
hIm-i1
principal matet ial remov.i actioncmsfo TABLE 11.4-1 Typical Values for ECH Operating
the electroly-ic dissolution. The abrasive stones are used to Parameters
maintain size and to clean the surfaces to execose fresh
metal to the electrolytic action. The n'a!elects ical gap is Power supply
maintained by the nonconducting stoc-t s .-which are bonded type: *Jirec! current
to the expandable arbor with cemen-, The cement nust be vlae o3
compsatible with the electralyte and the low direct-current
voitage The mechanical hoig action uses materials, current. 100 to 3000 A 4
7
speeds and pressures typical of convenifn:al honing.curndest: 10o300A l.to45/m]

PracicalAppicatonsElectrolyte
PracicalAppicatonstypes and
The advantages of ECH are most prowounced when honing concentrations: NaNOi. 2 lb/gal [240 g/L]
hard metals. The workpiece must 'Le conductive The ab- NaCI. 1 lb/gal [120 g/L]
sence of heavy mechanical action keeps the workpiece cool ternperaur. 100 0 Ff38-C]
and free from heat distortion The electrolytii action in- pressure: 75 to 150 psi [500 to 1000 kPaj
troduces no stresses ard deburrs automiatically Blind holes flow: Up to 25 gal/min [95 L/min]
in cr'st tool Ntee[ components and pinion gears of 62 Rr gap- 0.003 to 0.010 inch [0.076 to 0.25 mm]
high alloy steels have been honed using ECH

11-2.3
 11.4 Electrochemical Honing-ECH
Material Removal Rates and Tolerances
Material is removed 3 to 5 times faster by
the combined matermal --nova) modes, Automatic sizi- gag-
ECH tha- by ing is sometimes w'Vc...rrated -rcs og for
conventional honing and 4 times faster thian cnizrol of the
1bv internal elec ivt l.ow Path aird for POjsit. ninig
griningRemval
f 0008inch10.0 mnI o stck rom shouid be labri-
the bore of 8620 steel in 30 seconds cated from stainless steels or plastics tnat
has bieen reported To)- are resisi.nt to
eranck-s up to =0 0001 inch I the,(coromie.
38-cos t hes1.(
=0 0025 mi are possible 15or~v
in if qipmiet
Product-on tolerances achieve =:0 with fower 3acksch to 600incheres.
0005 inch I =0 013 mm. ihpwr ak pt 30 mee jmiti dae
on, the diameter and 0 0002 inch
ness. 10 005 minI an straight-
Machinina Characteristics
Surface Technology The electrolyte se!ection arid control
ECM because of td:e cleaning action is not as critical as in?
of the stonies
Surface roughness of 8 to 32 microinches
is routine, arid roughness of 2 microinchesR, 10.2 to 0 8 arml
attainable For a controlled surface R,, 10.05 ,aml is
sometimes arc allowed to cut for a roughness, the stones H-one-Forming
few
curient has been turned off This sequenceseconds after the A reversed-polarity veiesion of EC-Il
cocnbines honing with
also will leave a plating. This "hone-form~ing" process
light, compressive residual stress uses plating solutions5
in the surface, For a in place of deplating electroltes and
stress-free surface, the last few seconds can achieve rapid. ac-
of action should be curate metal deposition,. This highly
pure electrolytic material removal, This focused plating has
practice is helpful achieved aeposition rates of 0.00
foi controlling surface integrity, ich per !rnn-ite
f0.0025 mm'rninl for copper. 0.0005
inch per minute o0i 3
mm, mini for nickel and 0.0001 inch
per
Equipment and Tooling mm/minI for chromium. The mechanical minute 10.0025
action prepares a clean surfa-~e for (abrasive) honing
Commercial ECH equzpment is made the plating and sizes the
to special engineer- bores to close tolerances The equipment
ing order only for internal cylindrical
suitable pumps. tanks, filt-..rs. power
honing. It comes with ECl- equipment, and sometimes the is quite smilar to
packs and controls for acronym ECF is
applied.

11-24
 Electrochemical Machining-ECM 11.5
PROCESS SUMMARY

Fan

Eleetrolytepo xusrant H
Pnie!s-de e mel osar roe
Peat excnanger inslation c
Ecr eic(Mi t Too older Is pnrtetto
2to3
IIP p;' r - d _l " Fixture
F.lter Sl~ 2 j DC

"" : -- :..' .. -=Tank

" f removal Fixture Cvercut

Figure 11.5-1 ECM schematic

Prinriples des. While metal ions are removed frm the workpiece sur-
the reinoval of elec-
El,.;ctrocheniica! machining (ECM) I-s face. hydrogen is generated at the electrode_ Adequate pro-
trically conductive material by anodic dissolution in a rap- vision is required to safel vent this hydrogen.
idly flow~ng electrolyte which separates the workptece
from a shaped electrode (see figuare 11.5-1). The filtered
erectro;yte is pumped ujider pressure and at controlled tern
perature to bring a controlle d-conductivity fluid into the Practical Applications
narrow gap of the cutting area. The shape imposed on le ECM is best suited for repetitive production of complex
workpiece is nearly a mrirror or conjugate image of the shapes in high st-ength. hard. or difficult-to-machine mate-
shape or the cathodic electrode. The electrode is advanced rials where high surface quality is needed. The work mate-
into the workpiece at a constant feed rate that exactly rial must be electricaliy conductive. Sma.l. odd shaped. dif-
matches the rate of dissolution of the work material The ficult or deep holes as small as I 8-inch 13.2 mini across
current density is the chief factor in setting feed rates and can be 'di.!ed" individually or in multiples. ELfrtrodes di,
in attaining sniocthness Higher curreiit densities and feed not wear: consequently. long tool life is possible. The
rates create better finishes and higher materiai removal stress-free material ,'er.nval eliminates dist.rtizo, from the
rates The hydraulic pressures and toolworkpiece separa- ECM operation (but not necessarily from prior stress-
ring forces increase with smaller gaps and can affect work- inducing operations)- Ccnc ntr.,tion of current density at
piece tolerances Fixtures i'ith epoxies or other sccurely the edges on the workpiece provide., automatic rounding
fastened olastics for insulation locate and control the elec- and the absence of burrs. Anodic dissolution general.v prt,-
trol-e flow so that it iscontinuous and uniformly tu. aulent ceeds independently of material hardness. so finish cuts in
M,.terials and design must accommodate the hieh currents the heat-treated state are practical.
without distortion or overheating. Fixtures must be com-
patible with the organic salts or acids that are used as elec- The characteristics of an application thai inake It a p;.-e
trolytes Metal dissolved by .r"electrolytes forms a sludge candidate for ECM are as follrws:
of considerable volume. and excess sludge must be re-
moved by filtratnon centrifuge or settling. Canductivity a Material is hard or toigh.
control of the electrolyte is maintaned by temperature con-
trol. usually cooling. and by Iperodit: Lhecks on chemical 9 Difficuh con-ours are ;nvolvie
composition. Both inlet and outet pressure cortro:.r pro-
vide flow control. The electrode design must ;-.,udr. coM- Machining without coid working is needed.
pensation or corrt-ction for the variable current density that
comes with variations in the shape of the work:,:ece and * Repetitive production is invo!ved (more than 30 pieces)
the metal content of the electro;yte. Exact control of all
critical parameters is needed to ensure the best results * Distort:uless. burr-free parts are req uired.
Catting action occurs on all exposed faces simultaneouslv.
and there is no mechanical contact or wear of the el -ctro- * High surface quality is requirxi.

11-25
11.5 Electrochemical Machining-ECM
Operating Parametert,

TABLE "1.5-1 Typical Vclues; for ECM Operating Parameters

Power suopiy
type- Direst current
voltage 5 to 30 V
current: 50 to 40.000 A
Current density: 50 to 3.000 A in2* [8 to 465 A cm2]

Electrolyte
tyoe and concentration:
mrost used NaCl at 1/t2 to 2 lb 'gal (60 to 240 g L]
frequently used: NaNO; at i to 4 lb gal [120 to 480 g L)
less frequently used: Proprietary mixtures
.ernperature. 90' to 125'F 1126' to 460C]
flow rate- 0 25 gal mnin., 100 A f0.95 L men 100 A]
velocity: 5.000 to 10 000 fpm [1.500 to 3.000 m 'me-.]
inlet pressure. 20 to 300 psi j-,37 to 2.060 kPal
outlet pressure: 0 to 45 psi [0 to 310 kPa)

F.'ontal wcrking gap 0.003 to 0.030 inch 10.076 to 0.76 mnm)

Side overcut* 0 005 to 0 04C. incni [0.127 to 1 mmi
Feed rate. 0 020 to 0.50 ;n. min [0.51 to 13 mm rin)
Electrode material: Brass. coper. bronze (table 11,5-'C'.

IToleranca
2-dimensional shapes: -0.001 it'dl: 0.025 mm]
3-dimensional shapef;: 0.002 inch f~z .051 mrm)
Surface roughness. R..
sa'.. 8 o 63 microinches [0 2 to 1.6 urn)

oveitetrperature inwo~kciece or eieztrotyie

LUried b~y

Material Removal Rates and Tolerances 0.8 tan.1 is normal Roughness values dect ease with the in-
Material removal rate is independent of material hardness crease ;n cutting rates that accomnpannies higher curr ~nt
and for most common metals is approxmaielv 0 10 cubic densities The :aster the cutting. the bctter the Finish. Mir-
inch per !timlte 11.64 cmnmirl per 1000 amp-cres The cu- ro3r finishes (8 microhliches R. i0.2 uii! or better) are easily
tisoccu7s sismnutarteously on all exposed surfaces. and th: obta;ned in frontal cuts or stainless steels or nickel allo>s
aids productivity. Accur.acy up to =oJ.004 inch' 1=0.1 ii Th, side-gap areas generally are much rougher because
is usual for contoured cavities, and accuracy up to cur.rent densiy is lower in these areas. incorrect electro-
-0 0010 inch I = 0.025 niril is conimon for frontal cuts or lvte. different work material heat treatment, low current
cuts made with refined tools ,These tul.-ice-s can be c'it density. or stray current can produce selective etching PUtS
in half with well-devcioped tools and experienced oper- or interCranular a-. at the grain boundaries. Th-e ab-
ators.i Deep cavities will h~ave a taper of up to 0.001 inch sence ef residual stiess (in contrast with the presence of
per inch 10 (01 mm.'mn 1 with 0 00- 'nch 10-13 min! overcut cornpicssive stresses from many mechanical process!es)
ga nless a spf-c-al tool design :s used internal radii of produces a reduced high cycle fatigute strength (by com
0 rj07 inch 10 18 mini and external radi: of 0.062 inch parison). but thtse values more nearly represent the true ar
10-051 minI are attainable T olerance capabilities are de- unaffzctled material values. Any physical blemish ie the tooli Z
pendent upon part geometry tool d&sign and narticular will I- ireprodtticed on the workpiece. and poor flow condi x
shop practices and renmii'e careful checking wit cxe tio-is can produce- striations in the surface. Hydrogen ewp
rienced people for patc-a plctosbrittlement is not a problem, because the hydrogen is ir
pplc'ionsated
par~c~ar at the elsckrode. (as a gas) and is catried away by the
Suflac Techologyflowing electrolye aus
shown in figuzre 11.5-2.
Stirlees roughness o: iv to 32 ricroin':hes R. 0O.4 -.0

11-26 -
 Electrochemical Machining-ECM 11.5

_ Electroite; _

4
Electrons
H2 0- EIElectrons 1

0 Fe - Fe" + 2e
2H + 2e HFe(OH)
Gas
4 000
00
2 Fe++ + 20H-- Fe(OH) 2
Precipitate
O0 0
IN ~~ 000 i~~ I
00
00

Cathode 000 Anode

(Electrode) 0 0 (Workpiece)
0 00
0 00
0000
Oo0O Dissolved
0 ' metal

Figure 11.5-2 Electrochemical reactions in the working gap during ECM.

Equipment and Tooling electrolyte to the 7.5-micrometer level or better is most de-
The available equipment ranges from small S0-ampere sirable. Placement of the filter immediately ahead of the
bench models to 40,000-ampere models with a five-foot- electrode is good practice. With salt solutions, the volume
cube working space. Power sources providing from 4 to 30 of metal hydroxide or metal hydrate can be 100 to 500
volts direct current are available with special, fast-acting, times the volume of.the metal removed, as noted in table
short-circuit protective devices. Ancillary equipment, such 11.5-13. Settling or filtration for removal of these "chips" is
as pumps, tanks, plastic piping, mixing vats and sludge- necessary, and disposal requires environmentally satisfac-
disposal devices, should be engineered as a complete sys- tory planning.
tem. Equipment and tools should be rigid enough to with-
stand the forces from the high hydraulic pressures. The
fixtures. the insulation and the tool material must be chem-
ically compatible with the electrolyte. Electrode materials Machining Charact: 3tlcs
are high-conductivity coppers, brasses or bronzes (see table Process contro! and the sequence of operating steps must
11.5-10). be exact and precisey repetitive for good productionm The
workpiece should be thoroughly cleaned and/or oiled after
Tooling trials and start-up costs should be carefully as- ECM to prevent corrosion. Periodic washdown of the
sessed and included in development plans. The electrode equipment can reduce maintenance expenses. Special
design- and correction during tryout may require several safety precautions should be instituted when the electrolyte
"cut and try" cycles for complex shapes. Filtration of the used is a chlorate or a nitrite (see table 11.5-).

11-27
11.5 Electrochemical Machining-ECM
SELECTED DATA
There are several valid techniques for selecting operating
parameters for ECM. The steps in table 11.5-2 are recom-
mended as one logical sequence. Supporting data come
from the other figures and tables in accordance with the
terms as explained in figure 11.5-3.

- I Electrode !-Feed, vi

Workplece
o 0 Se
- a)
- -Gap, Sc= Se sec 0 = ---
Overcut, S _ 4 W /a/,/ --. sina

11 approx.
Tip or lip -- "- Tip
-ientatior lip II 14
*_.' 0for - "'oo 0< 400
Cno. Orientation .

inclination angle 0o19

Se ang!e

H Projected frontal area, A,

Figure 11.5-3 ECM parameter terminology.

11-28
 Electrochemical Machining-ECM 11.5
TABLE 11.5-2 Steps To Select ECM Operating Parameters

ITEM DATA

1. Workpiece material From engineering drawings obtain material type, composition, and metallurgical state. Must be
electrically conductive material.

2. Material removal rate, A. For planning or rough estimating, good approximation can be had from the following values which
MRR, (at 100% 3fficiency) apply to most common conductive materials and alloys:
0.1 in33/min/1,000 A [1.64 cm 3/min/1,000 A]
1.0 in /min/10,000 A [16.4 cm 3/min/10,000 A]
B. For pure metals, removal rate depends on valence and the relationships established in Faraday's
second law:
specific removal rate = atomic weight 1 1
valence density 96.,494
where 96,494 is Faraday's constant representing the number of coulombs (or ampere-seconds) of
electricity required to remove one gram equivalent weight of material. Gram equivalent weight is
atomic weight divided by valence. Values in table 11.5-3 represent theoretical metal removal rates
assuming 100% current efficiency (all current goes to dissolving metal and none goes to gas
generation at the anode).
C. For alloys, rates of material removal can be calculated from alloy chemical composition using
Faraday's law (table 11.5-4).

3. Assume efficiency, h, of With complex tools, long electrolytic path, higher voltage or current density, valence variation or
electrochemical action chemical activity, and appreciable stray current or spray, the efficiency can decline to 80 to 90%. For
most estimatinr prior to a pilot run, 90% is a fair assumption.

4. Determine projected area. See figure 11.5-3

A,,. of electrode
perpendicular to feed
direction

5. Determine maximum Rated amperes of equipment + A.

current density available

6. Establish feed rate, A. material removal rate MRR times h

vf, that exactly projected area A.
matches rate of material poetdae ,
dissolution, Current B. See figure 11.5-7 and 11.5-8 for quick approximations. (Figure 11.5-9 for one specific alloy-
density and feed rate electrolyte combination.)
will be in balance. C. The current density that balances the feed rate is limited by (1)boiling of the electrolyte, see table
11.5-7, (2) overtemperature in the workpiece from resistive heating (and possible distortion or
dimensional inaccuracies), or (3) available power supply (item 5). See also table 11.5-9.

7. Electrolyte Selection Table 11.5-5 and 11.5-6. Many applications try simple NaCI first, then try more complex electrolytes
Composition only if necessary. Keep concentrations as low as compatible with productivity so as to reduce
Concentration accumulations of salt deposits on equipment and tooling.
Temperature Selection should be based upon compatibility with particular metallurgical state of alloy being
machined, feed rate, surface roughness (both frontal and side) and surface integrity.*
Temperature control should be within 1OF [ 1.80C] to attain consistent electrolyte conductivity at
the inlet to the electrode, see table 11.5-i, figures 11.5-14 and 11.5-15.

8. Electrolyte Testing
Select a measure for
electrolyte condition or
control
Specific Gravity Nomographs, figures 11.5-10 to 11.5-12.
Salim ter Table 11.5-8, figure 11.5-13.
Conductivity Figures 11.5-14 and 11.5-15.
Titration Standard analytic chemical test.

*For detail on Interrelationships, see J. A.Cross, ECM machinability data, Technical paper MR73-228. Society of Manufacturing Engineers, Dearborn, MI.
1973, or J. A.Cross and A.U.Jollis, Electrochemical machining (ECM), Technical report AFML-TR-72-188. General Electric Company. 1972.

~-.-----
---- -r~- --- 1-1-29
~7~-- . ~~ --- - -
 11.5 Electrochemical Machining-ECM
TABLE 11.5-2-Continued

ITEM DATA

9. Voltage A minimum voltage, AE, is required to initiato full electrochemical action, see figure 11.5-17 and table
11.5-9. The usual operating range is between 5 and 30 volts. The value is set to attain the desired
current density that matches the feed rate. Typical setting ranges are:
Steel alloys 5 to 10 volts dc
High strength alloys 10 to 20
Titanium alloys 15 to 25
Superalloys 10 to 25

10. Tool design, cutting gaps The equilibrium frontal gap is a compromise depending on tool design and prior parameter
and corrections selections, see figures 11.5-16 and 11.5-17. It is not independently adjustable. Electrode shape
Frontal gap, S. should he adjusted depending on orientation angle, see figure 11.5-18.
Side gap. S,
Orientation, A gap

11. Current Cannot be set independently-it is a result of equilibrium among prior parameters to just balanc3 feed
rate and MRR. Adjusted by setting feed rate. Note that current increases as starting gap reaches
operating or equilibrium gap during full engagement when selected current density (item 6) is
attained.

12. Electrolyte Pressures The tool design and operating gaps will determine pressures required to get rapid turbulent flow. Inlet
pressures range from 20 to 300 psi. Outlet pressures range from 0 to 45 psi (and sometimes to 75).
Adequate provision to contain the considerable hydraulic forces is needed in the plumbing, fixtures,
electrodes and machine if good accuracy is to be attained (figure 11.5-19).

13. Starting Gap and Depth These parameters can be set independently and are a function of the shape to be generated and the
of Feed shape of the raw material stock. Adequate cutting stock is required to permit penetration of electrode
to point of electrochemical equilibrium.

14. Thol Construction The insulation and tool materials must be compatible with the electrolyte being used. Typical
materials are listed on tables 11.5-10 to 11.5-12.

15. Sludge The "chips" from ECM are In the form of a sludge in the electrolyte composed of metal hydroxides or
hydrates. The volume of sludge is considerable with salt electrolytes, see table 11.5-13.

16. Trial cut The extensive interrelations among the ECM parameters make a trial cut highly desirable. If it is
performed on a sample of the workpiece in the metallurgical state equal to the production item, a
simple me' allographic section of the ECM surface can reveal possible surface integrity Imperfections.

13
Io .. 11-30

- . . - - ... . . S=... r. . ' _ . o _ - - .X . . - _ - -

-
 Electrochemical Mac hmning...EcM 1.
100
%Simple
... shapes
10.000 ampere ECM
-- Single-spindle milling

nermediate shapes
I~

Di ficull shapes

*%b

Aluminum Steel Titanium Stainless Steel Nickel

alloys 200 Bhn alloys steels 400 Bhn alloys
Decreasing mechanical machinability- .

Figure 11.5-4 Comparison of metal removal rates for 10,000

pere ECM and single-spindle NC conventional milling of am-
vestment cost. (Courtesy of Lockheed-Burbank) equal in-

00

C np

ECM

0 100 200 300 400 500 600

Work material hardness. Bhn

Figure 11.5-5 Relative penetration rates

and conventional drilling for increasing workof mate-
1ECM
nial hardness. (Courtesy of Cincinnati Milacron)

11-31
11 .5 Electrochemical Machining-ECM

U) UO

00
0
'N C
0
LUC) 0 C
C

00

C- 0 E
0
0 0
CE

10 U')
'0
cc
C.
C7

0~
L .0

u -k -- a:

a) 0 0
0 ID
0 0 2 0 C
2E t; E E
(D C 0 W
o 0
CD
0o -D Ca a
.C)
0 CL0

_~L 0 i
0&
I ii

TPA
to- 0

Cw V

N U,6C ci
113
cc~_
_ _ _ _
 Electrochemical Machining-ECM 11.5
TABLE 11.5-3 Material Removal Rates for ECM of Pure Metals Assuming 100 Percent
Current Efficiency

ATOMIC REMOVAL RATES

METAL WEIGHT VALENCE DENSITY AT 1000 AMPERES

g lb/in' Ib/hr in'/min fY ./tn

Aluminum 26.98 3 0.098 _._ 0.74 0.126 .

Antimony 121.75 3 0.239 66 , 3.33 0.23 51 S7
1 5 2.00 0.14

Arsenic 74.92 3 0.207 , 73[ 2.05 0.17 .,,

.

5 1.23 010 A. o;
Beryllium 9.012 2 0.067 0.37 0.092 2 14
Bismuth 20o.98 3 0.354 t 5.73 0.27 - '4-,
5 __ 3.44 0.16 Q
Cadmium 112.40 2 0.313 k 8,- 4.62 0.25 _ZI.t
.,i3+
Chromium 51.896 2 0.260 2.14 0.137
3 1.43 0.092 1ItIV
6 0.71 0.046 !
Cobalt 58.93 2 0.322 _ 2.42 0 125 r1
3 1.62 0.084
Columbium 92.906 3 0.310 2.55 0.132 A
(Niobium) 4 1.92 0.103 j -
5 1.53 0.08 ;-157-
Copper 63.546 1 0.324 5.22 0.265 I
2 2.61 0.134 17 2.'
Germanium 72.59 4 0.192 1.49 0.13 I
Gold 196.967 1 0.698 4 1622 0.39 Y.22, i
3~ ~ ~ 5.40 0.3 6*
Hafnium 178.49 4 0.473 , 3.68 0.13- -

Indium 114.82 1 0.264 +, 943 0.60 '+ "M+ i..

2 . 4.71 0.30
3 314 0.20 -

Iridium 192.20 3 0,813 5.27 0.11 j _i

4 3.96 0.08 ,
Iron 55.847 2 0.284 2.30 0.14
3 1.53 0.09 A
Lead 207.19 2 0.410 - +. 8.52 0.35

4 4.26 0.17
Magnesium 24.312 2 0.063 ' 1.00 0.27
Manganese 54.938 2 0.270 2.26 0.14

Molybdenum 95.94 3 0.369 2.653 0.12

Nickel 58.71 2 0.322 2.41 0.13

Osmium 109.20 2 0.815 7.82 0.16

5.2 01
3i z4

11-33
 11.5 Electrochemical Machining-ECM
TABLE 11.5-3-Continued
ATOMIC REMOVAL RATES
METAL WEIGHT VALENCE DENSITY AT 1000 AMP1ERES

9 lb/in' ~~9IarrA lb/hr in)/min ~/uj~~~wn

Palladium 106.40 2 0.434 12 4.38 0.17 ~SJ iI
4 2.19 0.08 A
6 1.46 0.06 T21OZ 9S
Platinum 195.09 2 0.775 8.02 0.17 6S
4 -- d 4.01 -0.09

Rheniumn 186.20 3 0.756 :~ 7.60 0.17 5 B- <2i$

4 3.82 0.08 -2111131 12
5 ~3.07 0.07 2i 1R
6 _ 2.55 0.06 3 ~ O
1 7 2.19 0.05
Rhodium 102.905 3 0.447 i2S 2.82 0.11 AW4
Silver 107.6 38 1 0.379 0630, 8.87 0.39

Tantalum 180.948 5 0.600 2.98 0.08

Thaliumn 204.37 1 0.428 160 0.65 1?.
3 5.60 0.22 -

Thorium 232.038 4 0.421 :. 47 .9~ 5II

Tin 118.69 2 0.264 - 4.88 0.31

Titanium 47.90 3 0.163 -~1.31 0.13

4 0.99 0.10 4
Tungsten 183.85 6 0.697 25 .6~
8 - 1.89 0.05
Uranium 238.03 4 0.6&M- 4.90 0.12
6 - 3.27 0.08
Vanadium 50.942 3 0.220 - 1.40 0.11 .

Zinc 65.37 2 0.258 - 2.69 0.17 Ad

Zirconium 91.22 4 0.234 - 1.87 0.13

TABLE 11.5-4 Material Removal Rates for ECM of Alloys

AssumIng 100 Percent Current Efficiency

ALLOY 1.00 AMPERES PER SQUARE INCH

4340 steel 0.133

17-4 PH012
A-2860.1
M2520.1
Rene 41 0.108
Udimet 500 .i
Udimet 700018
L6050.7

NOTE: Rates listed wers calculated using Farada law and valences a
foows:
Aluminum 3 Copper 2 Splkon 0
Carbon 0 Iron 2 TOtN=u 4
Coluimbium 3 Mangans 3 Tungsten 6
Cobalt 2 Molybdenumt 4 Vanadium 5 --

Chromium 3 Nickel 2

11-34

----------- ~- -- -
 Electrochemical Machinirag-ECM 11.5

1-
Feed rate II- Usual machining range
in/min Complex Symmetrical
shes sshaes
0.800

0.700 - - - - -----

- - - - ~ -- metals*

o.600

.50[12.7 mm/mm])
CY

20.400
a)

0.300

0.200 I_0000

* 0.100 2000 00 40 00 00 70

Current density, A/in2 [775 Afcm2]

FIgure 11.5-7 Feed rates versus current density for ECM of various materials. (Courtesy of Cincinnati
Milacron)

Z4 Tor
11.5 Electrochemical Machining-ECM

Machining area
2
in
200-
Feed
in/min
100- 1.0
80 0.8
60 0.6

40Z 0.4
Current
A

20- 5- -0.2

10- [64.5 cm 2] _ 10,000 -4 0.1 [2.5 mm/mini

8- -- 0.08
,
6 --- 4
2000 0.06

-2,000
4- 0.04
1.000

2- 400 -0.02
-- 200

1.0- -- 100 0.01

0.8-- 0.008
0.6- -40 0.006
0.4- -- 20 --
040.004 -
_-10

4.0
9.2- 4.0 -0.002
-- 20

0.1- - 1.0 L 0.001

Figure 11.5-8 Nomogram for appro.ximating ECM feed rates and currents. (Courtesy of Anocut Inc.)

773
 Electrochemical Machining-ECM 11.5

0.10 1
Slope of graph is metal removal constant. k
k= 9.4 x 10-lin'/A-min 0

0.08

Theoretical
rate from
table 11.5-4

CD

0.
0.04

0.02 0!

Material: Rene 41
Electrolyte: 2.15 ib/gal NaC!
Temperature: 85OF

Ul-3
0

0 200 400 600 800 1000 1200,

0..0
~Current density. A/in 2

= Figure11.5--9 Typical material removal rate data for a specific alloy-electrolyte combination with data
~points from ECM machinability data test ig. (G. Bellows, ECM machinability data and ratings, Technical
paper MR67-71 0, Society of Manufacturing Engineers, Dearborn, MI, 1967)
1
11.5 Electrochemical Machining-ECM

.2
7iga -615g

4C U Ca C r-

*
CL= 0 --
0 b.C0

C - L ;w

-52 0
.2 a C.8
(__ 13- -- - ;

0
*~~ -
Cg d .
' -ff
* -- -
00~~'0 00v, 0 C~

-~3-0

-~ 00
Anl An LO4 ) '

0 L 0 0

0) 400 0) 0 00 0)a 0 )m

-'0 00C
.0~~~~~~ .- a% 0 r
00r0 l -

'03

OZO
00 Z 000 to Z. 02 000 N 00 ZM 0F m Oft

U- U
CJ

C.J- 0- C

-,66 +0(5 (5 6

10 5C
0

Cb E
C00 0, 0

I- <.j -< go

3 2 3 3
U -j wO 0 0 Ca HP0

11-382
-~C. ,~ C- b- E~___
 Electrochemical Machining-ECMV 11.5

C
W 0
.2 -0

U) NS OR

t:(a E 0 (A~ '-.

a Z0
* 0 0 z
-~~ = n-
UV LO O
0~~0O: (D E 0C
Cu r E

OR , S 0 4) a

2 0 :2
) a
.0
0~
0
CL C

0 'I-& wIff- ) 00 0 CO 4,

-5 2

0~ 0

0 , '@ 0)UCO
z1 z~ C- 0 w S-0.
00 (DLuc3

000D0 00c 00U 00 0 cc 0 0 0 00 200.

0) O 0 CO
M0 coo 0) 0N 0 ) 0 D 0 0-0 .n
Or VC

r-1. .2

IS C0 C) -2!0 5 C
0 -D . 5 ccz

I w - k 0

00

0M-0

11-39
- N -O Ln Iwo------- r
43 -LQ--- -
11.5 Electrochemical Machining-ECMV

CO -0.
z 50 00 .C onoC
0) -O N 0 M
0 a.
cO w a0 cfQ
E, Z ' 0 U' E
(D -00020 ' a) 0)

0c4Ma) 2 t0(IT
U)
)

a CDOS

f 7- w
-S~ ~~~ ~N
-,,Ak~t
ft~~~IZ ____"- r

au -Ca
160 '-

R0

6
LO2
0!
- 0~ 0 - I
00 0

-6'v

AA - ,n-0- 0E
'AQW
-r 6
-
0
0
0D 0 .. f 0'
-0
F'O
06, ]1
=1 0 0 0 2
0 c
LO-
N ItN S C

iM -O 0 0 CC J to

0 +

11-40 '
 Electrochemical Machining-ECMV 11.5

Co -
Co
(0
C1.

EC
=OEC
Co CL0

0 0 17

0-R0

~ C~oEECM

~~ 0~

1 C

0,0

LL~ 0 Co
aN0 0 Co !?

- '0 0C 4

_ 4 eg - 4
4 ___ e C CL
40C Co

w~fo -z. a

- -r 80

r- C

S..

. O0 0' L COj
0 ;a
CM, CL CL

~<

_C..
qit-x

C0I
Ca

0 0

0C 4 C

4n 0

0U 0-1I0

02 o( 0.0 ID0
i-as!
0 O ,0

11-41
11.5 Electrochemical Machining-ECM

TABLE 11.5-6 Corrosiveness and Safety Considerations for ECM Electrolytes

COST
ELECTROLYTE RATIO* SAFETY CORROSIVENESS

Sodium chloride 1.0 Safe. Highly corrosive. Brass

(NaCI) or stainless steel
required for tooling.
Sodium nitrate 3.0# Safe in solution; moderate Noncorrosive-mild
(NaNO 3) fire hazard when dry and steel can be used for
mixed with organic tooling.
materials.
Sodium chlorate 7.5 Safe in solution; very Noncorrosive.
(NaC1O 3) highly combustible when
dry. Special precautions
required.
Sodium hydroxide 2.0 Caution-will cause Mildly corrosive on
(NaOH) severe burns, ferrous alloys and more
corrosive on aluminum,
zinc and cadmium.
Sodium fluoride 8.0 Poisonous and needs check Highly corrosive.
(NaF) of medical hazards.
Potassium chloride 2.3 Sate. Highly corrosive.
(KCI)
Sodium nitrite 6.7 Similar to NaNO 3, buf Noncorrosive.
(NaNO 2) less stable. Special fire
precautions advised.
Sodium sulphate 3.0 Safe. Highly corrosive.
(NaSO 4)
Potassium nitrate 8.0 Similar to NaNO 3, but Noncorrosive.
(KNO 3) less stable.

*Based on salt as 1.0 and market circa 1972.

fAs it takes twice as much NaNO3 for conductivity equivalent to NaCI. the cost ratio for equal conductivity Is 1:6.
Similar factors affect other electrolytes.

TABLE 11.5-7 Boiling Point of Water at Various Pressures E

GAUGE PRESSUQE ABSOLUTE PRESSURE BOILING TEMPERT

in Hg in Hg OF

29.5 0.5 58.8

29.0 1.0 79.0
20.0 10 161.5
10.0 20 192.4

psi psi

0 14.7 212.0
35.3 50 281.0
85.3 100 J27.8
135.3 150 358.4
185.3 200
11-42 36.1.8
 Electrochemical Machining-ECM 11.5
Specific gravity
-- 1.20

1.19

-- 1.18

Salt concentration 1.17

lb/gal
2.5 1.16

Temperature 1.15
OF

140 [60C] 1.14

2.0

.130 -- 1.13

-120 -- 1.12

.110 1.11
1.5
-- 100 -- 1.10

-- a- -1.09

80 1.0 -- 1.08
[119.8 g/1-]

70 [21C] '--1.07

-- 1.06

-- 1.05
0.5
-- 1.04

- 1.03

Figure 11.5-10 Nomogram to determine the specific gravity of sodium chloride solutions. Specific
gravity measured by 60 0 F/600 F hydrometer. (Courtesy of Anocut Engineering Company)

11-43
1135 Electrochemical Machining-ECM

Specific gravity
-1.40

-1.38

Temperature
Salt concentration 1.36
OF
lb/gal
140 [60-C]
5- -1.34

130
-1.32

- 120
-1.30

- 1 04
- 1.28
100
-1.26

90--1.24

- 80
3-1.22

70 f21 0C]
1.20

-1.18

- 1.164

1.12j

[119.8 gL

Figure 11.5-11 Nomogram to determine the specific gravity of sodium

tiftrate solutions. Specific grav-
ity measured by 60 0 F/600F hydrometer. (Courtesy of Anocut
Engineering Company)
 Electrochemical Machining-ECM 11.5
Electrolyte
concentration Temperature
lb/gal OF
3.000- Specific 50-
gravity [1000]

501.200 -- 55-

60-
2.500- -1.180
65-

220- -1.160 70-

2.000--7 -
-1.140
80-
1.750-
-1.120 85

1[4900

f 119.81-45
11.5 Electrochemical Machining-ECMV
TABLE 11.5-8 Sodium Chloride (NaCI) Electrolyte Concentration Conversion Chart
HYDROMETER READING CONCENTRATION/TEMPERATURE
Specific 100OF 110OFC1201105F @ 13011F
0
'Baume* Gravity Salimeter* lb/gal 9' lb/gal lb/gal gd lb/gal
ow,
8 1.06 30 0.7 ~ ~ 0.6 z 0.6 .06079 01pzl
9 1.07 34 0.8 95J 0.7 0.7 0.7
10 1.07 38 0.9 'r iD~q 0.8 . 0.8 ',Atj~08 95~
11 1.08 42 1.0 0.9
09W 0.9 VIM~.8 0.9 ~O
12 1.09 46 1.1 g13IZ 10 1. 1.0 0iiazs
13 1.10 50 12 143M 1.2 1.1 ~i~* 1.1 ~S
14 1.11 54 1.3 1.3 1.3 ~ 1
15 1.11 58 1.5 % 7 1.4 ~6 ~~~1.4 1.3 i7
16 1.12 63 1.6 ~1f~ 1.5 ~j ~~ 1.5 gzq 15 ~1
17 1.13 67 1.7 1.7 Wj 1.6~b & 1.6 ~
18 1.14 71 1.9 ~2T~ 1.8 I.:; 1.8 ~25'
19 11 76 2.0 ~ 0 1.9# 1
20 1.16 80 2.1 ~2L - 2.1 NMI~6 2.0 !L 20 22.0
211.17 842.3 2.2 22 1 .25*
22 1.18 88 2.5 24
2___ 2.4 2.3 ,.IVW7
23 1.19 93 2.6 1L 2.6-~1i 2.5 2. Arkes
24 1.0 I 97 2.8 hI~ 28 2.7 - 2.6
25 1.20 I 100 3.0 ~W ; 2.9 2.9 2.8 ~
SOURCE: Cincinnati Milacron. of salt by weight. A reading on the Salimeter scale represents the percent-
*Generally.a reading on the 8aume scale is approximately the percentage age of saturation in a sodium chloride solution.

lla-46
 Electrochemical Machining-ECM 11.5
Specific DegreesDers
gravity aierers
Dam
1.210 25 100er

1.200 2

1.190 -23 9
1.18090
1.18022

1.170 -21 85 -

1.160 -20 80
1.150 19575

1.140 -18 70 3
-174
1.13065;

1.120160
6
-15
1.110
-14 55
1.100 -13 50

1.090 1245

1.080 40
1.070 -03
-9
- -. 8 -30 -

1.050 25

-1.040 20

1.030 -4 15

1.020 -310
-2
1.010 1 5

1.000 0 0

*Degrees Salimeter =0.26395% salt by weight per degree satimeter.

Figure 11.5-13 Nomogram for salt concentration. Hydrometer scale comparison at 68 0F. (Courtesy of
International Salt Company)

11-47
11.5 Electrochemical Machining-ECM

ElectrolyteTeprte
Conductivity TepeFtr
concentration mohm-cm
lb/gal
2.000 0.340-13
0.320-12
1.750 0.300-12
120
0. 280W
1.500--,
0,260 115
0,240

1.250-
0.220

105
0.2001
0.181 (380-C]
(119.8 g/1_1:
- - - -100-
1.000

0.160- 95

90
0.140

0.750-
85--
0.120-

0.1001
75-

To convert to resistivity in ohm-

inches. multiply - by 0.3937

mb- 70-
0.500
(J. A. Cross
Figure 11.5-14 Nomogram to determine (ECM), the conductivity of sodium chloride electrolytes.
Vol. General
11, Elec-
Technical report AFML-TR-72-1 88,
and A. U. Jollis, Electrochenmical machining
tric Company, 1972. p. 83)

11-48
 Electrochemical Machining-ECM 1.

Electrolyte
concentration Conductivity Temperature
lb/gal mohm-cm OF

400 -0.280: 130-

0260- 125
3.500-
3.250- 0.240 120-
3.000-
2.750 -
2.500- 0.220115 1 r

2.250- Ile-

[240 gIL] 0.200

2.000- 0.1825

0.180= [38-0]
1.750- 100 -M.

0.160
95-

15 0 -0.1401
90 -

85-

1.250--0.120-

80-

0.100-7-7

To convert to resistivity in ohm-

1.000 inches, multiply mohm-cm93

Figure 11.5-15 Nomogram to determine the conductivity of sodium nitrate electrolytes. (J. A. Cross
and A. U. Jollis, p. 84)
115Electrochemical Machining-ECM
2 30
Current~ denSitY. A/in 0050
50 30
1500 20
100

6.00

27 .5
30.440
.0701 0D 0.40

000

Penetration rate, in/mir

"r bands represent
aneurat electrolyte at 120F and 15 volts. The
~M o stel n ECM. (Courtesy of0e1~ I~ n.
Flg~@ 1.5-6
expected in normal
the variability 4

11-50
 Electrochemical Machining-ECMV 11.5

4011
Material: Rene 41
Electrolyte: 2.15 lb/gal f258 g/LJ NaCl
Temperature: 850 F [29.40 C]

30 ______ ______

0.020-inch Gap

02

0.0

100

Minimum starting voltage (AE)= 2.6 V

0-1 I _ _ _ _ _ _ _ _ _ _

02040600 800 1000 1200

[155 A/cM2J
2
Current density. A/in

Figure 11.5-17 Specific gap selection data for specific alloy-electrolyte combination. (Note that figure
11.5-9 and 11.5-17 are the same data set.) (G.Bellows, ECM machinability data and ratings, Technical pa-
per MR67-71 0. Society of Manufacturing Engineers, Dearborn, Ml, 1967)
11.5 Electrochemical Machining-ECM

0.015

0.010

0.005

00 10 20 30 40 5 07
Orientation angle. 0 degrees

" ANGLE 0- 00 to 200 (ar = 700 to 90")

Use mirror or conjugate image of part and uniform
gap. Sc -=Se -
" ANGLED0 - 200 to 400 (a = 500 to 700)
Correct tool shape from uniform gap to
Sc = e sec0or Sc s.n -Se
c
" ANGLE 0 - greater than 400 (ar less than 500)
Develop toot shape by trial cuts and correction.

" An Approximation:
AGap Se (sec 0 - cos 0

Figure 11.5-18 Design of contour cutting electrodes in frontal ECM cutting under steady-state (equi-
librium) process conditions.

11-52
 Electrochemical Machining-ECM 11.5

TABLE 11.5-9 Typical Operating Conditions for ECM of Aerospace Alloys

ELECTROLYTE MINIMUM
WORKPIECE STARTING METAL REMOVAL
MATERIAL Type Concentration VOLTAGE (.AE) CONSTANT (k)*

in3/A-min
az/gal x 10-S

Inconel alloy 718, NaCI 16 -- 2-3.3 8.8

STA
AF 95, STA NaNO 3 1 36 %2W . 03
Ti-6AI-6V-2Sn, NaCI 16 ~ 2 ~ 321.
Annealed _

Ti-6A1-4V, NaCI 16 ~ki2~ 38 1.

Annealed ;01-
17-4 PH, STA NaNO 3 36 27 3.6 8.6
300M, Tempered Naki16 11 13
18%N1 Marage, STA NaCi 16 M52O.-A- 10 13.2
MA-M509, NaCI 1 1.2 9.6
As cast
AstrloyNaNO 3 32 ~i4 ~ 4.0 1

SOURCE J. A Cross and A U. Jallis, Electroc hemical machining (ECM), Technical report AFML-TR-72-188, General Electric Com-
pany. 1972
*Used for estimating current required In formula

k
I- current, amperes 2 2
A. - area being machined, in [cm l
vf = feed rate, an/mm[cm/mini
k -metal removal constant, an3/A-man [cmS/A-mln]
See also tagure 11.5-7 and table 115-3.
'Can also be cut satisfactorily with 16 az/gal NaCI.

11 -54
11.5 Electrochemical Machining-ECM

270

300 galmin
[1136 L/minj
24C

200 gal/min
1757 L/min]
210

180

a:T
150

2~10(827 kPa]

a. 100 gal/min
1379 L/min]
90

50 gal/min
[189 L/min]

60

30 __1

00 0.5 1.0 1.5 2.0 2.5 3.0

[0.076 mm] I-
Gap, thousandths inch

Figure 11.5-19 Theoretical pressure drop for an idealized cathode as a function of flow rate and gap
size. (Courtesy of Anocut Inc.)

* - 11 "54
 agg

Electrochemical Machining-EGM 1135

(1 0o 03 c
00 (1) r-
CLa)
E
cu~ E
~ E.N.2
cu E 0
0
z - g ajc6 a xi ic
2~~ 2 0 ~ Cf U) 2)090
0 0 .~ 550
Na =5 IDS.- 0 * a2 f.l W
.0 f E
'Co a)0) (D
0 4)0 -5 -T ( E 0 0S

~ 0 00 L
a.- 0 *-

00 0 0
04 0 0 00

LW0 0
0
0 0
0
0
0
0
20
0)
zi-
0
0
aL aL aL aC > ) CL

LIL 0 0 In U) 0 0 (0 NM 0

e CMr CO CO N~

CDN0) (7 r-oN1 C

0" 06 0l 0 0 0-CO C
C
00
o 'ajp E -

A.

25
U)u01-t)
CU) UK ui CD (6
-
I CD 0)
%
IQr
L.INS -- -

raZWI

EE0 .0

E 02 E .0E > 2 > . > .0 2

: 0
1 ,
0
- N
c-S c-
o
ow C)
S 0 0
aO (R cRa0
.0 4300 0 (

ZW -E0 0~

us
M a. O a?010
.
a. .W
2
E.
,r
Co
Ca -
0 -a)-
0) z0 E*a
M.
o~ z o 2!ii
_ O W 0_ 0 -0 -- -

11-55

7;t
11.5 Electrochemical Machining-ECM
TABLE 11.5-11 Insulating Materials for ECM

MATERIAL TYPICAL SOURCE METHOD OF APPLICATION

#260 Epoxy powder 3M Company Spray or fluid-bed dip

E-201 Epoxy powder Armstrong Resins Inc. Spray or fluid-bed dip
Microsol E-1003 Michigan Chrome & Chemical Liquid dip
Anocoat 6004 epoxy putty Anocut Inc. Knife
Anocoat 6005 Anocut Inc Brush
Arocoat 6006 Anocut Inc. Spray or fluid-bed dip
Plexiglass Various Fabricate (for short life
applications)
Epoxy-glass laminates Various Fabricate
Textolite 11558 General Electric Co. Fabricate
(NEMA G10, sometimes
called green glass)

TABLE 11.5-12 Organic Coatings to Protect Metals from Corrosion by ECM

Electrolytes

CHEMICAL RESISTANCE
Dilute RESISTANCE
COATING Hydrochloric Brine Dilute TO REMARKS
and Sulphuric Solution Alkalis ABRASION
Acids

Polyvinyl S S S Good
chloride
(PVC)
Polythene S S S Good Preferred to the low
(high density) density material or
electrical applications
Polythene S S S Fair
(low density) I
Nylon Limited S Limited Very good Very low water
absorption. Electrical
insulation excellent

PTFE Good, but difficult to obtain Poor

coatings free of pores
Chlorinated S S S Very good
polyether
(Penton)
Solvent-based Generally S, S As for Good Oven-drying preferred to
epoxy resin depending on acids air-drying
formulation
Solventless S S S Good Better performance
epoxy resin than solvent-based
compositions
Polyurethane S S S Said to be
similar to
vitreous
enamel
Chlorinated S S S Good
rubber
Neoprene Limited S S Very good

SOURCE: A. E. De Barr and D. A. Oliver, Electrochemical machining (New York: American -Elsevier, 1967),
p. 181.
NOTE: S - Satisfactory

11-56
 Electrochemical Machining-ECM 11.5

TABLE 11.5-13 Volume Ratio and Specific Gravity for

ECM Sludge
(Ratio of volume of sludge to volume of metal removed for
sodium chloride (NaCI) electrolytes)
VOLUME SPECIFIC
WORKPIECE MATERIAL RATIO GRAVITY

Nickel base alloy 250:1 1.3

Titanium base alloy 500:1 1.1
Iron base alloy 150:1 1.3

SOURCE: J. A. Cross and A U. Jollis, Electrochemical machining (ECM),

Technical report AFML-TR-72-188, General Electric Company, 1972.

14_

1157.

= =
11.5 Electrochemical Machining-ECM
SPECIFIC APPLICATIONS DATA

TABLE 11.5-14 Specific Applications Data for Llectrochemical Machining

Work material: SAE 1020 Steel, 60-75 RB 52100 Steel, 65 R, 715 Tool Steel

Workpiece rnd0

0
configuration:
F0i00-oh c032a 3312-inch dia

020000 in1.42
Vav82 in---,Broach
in
Valve S:ots 0 20-inch thick tool
0 250 O0010 in
0 090 -0010 in

Electrolyte
type: NaCI NaCI NaCl
concentration,
lb/gal: 1.25 1.7 1.0

inlet pressure, psi: 60 to 100 100 to 150 200

outlet pressure, psi: 0 0 0

flow rate, gal/min: 10 18 to 20

temperature, OF: 85 to 90 90 100

Voltage, dc volts: 20 13 13

Current, A
start: 650 1.500 200

end: 600 2,200 250

Feed rate, in/min: zero (static tools) 0.150 0.094

Depth of cut. in: 0.015 0.330 0.2

Tolerance, in: 0.005 0.007 0.005

Surface roughness,
pin R=: burr free 25 to 50 30

Electrode material, Brass electrode. 10 /m (micron) Brass electrode. 50 pm (micron) Two pieces cut simultaneously.
filtration, benefits filters. 5-second dwell time. filters. Piercing cut.
and remarks: 72 groves spaced at 50 Intervals for All8 kidney slots machined
3600 both sides. Groove width simultaneously.
0.040 inch; thickness 0.0693
inch 0.0035 inch. One side
machined at a time.

-4

11-58
 Electrochemical Machining-ECM 11.5

TABLE 11.5-14-Continued
Work material: A286, 25 R, Waspaloy Udimet 700, forged

Workpiece
configuration: Turbine blade Turbine blade T e engine bade
073-in
radius 0073-in radius111

0164
in4
30-
'~iF
0164
in
6in
IE
lI 2 7
0.700 in3 0.700 in
in 020-ch dia in
0 020-inch dia
blend blend

Electrolyte
type: NaNO3 NaCI HS0 4
concentration,
lb/gal: 2.2 1.7 10% solution
inlet pressure, psi: 130 to 200 130 to 200 15
outlet pressure, psi: 0 0 0
flow rate, gal/min: 2 2.5 0.6
temperature, OF: 110 90 95
Voltage, dc volts: 11 12 9 with periodic reversal

Current. A M
start: 100 100 3
end: 150 150 10
Feed rate, in/min: 0.300 0.325 0.050 4
Depth of cut, in: 7.0 7.0 3.0
Tolerance, in: 0.004 0.004 0.002

Surface roughness,
Ain R.: 15 to 25 10to20 63 to 120
Electrode meterial, Copper-tungsten electrode. 50 m Copper-tungsten electrodes.
filtration, benefits 50junr Insulated titanium tubes as
(micron) filters. (micron) filters.
and remarks: Constant section turbine blade. electrodes. 10 Am (micron)
Constant section turbine blade. filters.
6 holes of slightly different
"_
sizes machined simultaneously.
_ _ _ See also STEM process.

11-59

t---
11.5 Electrochemical Machining-ECM
TABLE 11.5-14-Continued
Work material: Inconel Alloy 718, STA Tungsten Uranium, 53-57 RA

Workpiece
configuration:
0 002 in
-- 0 54W2
T , 1 in
approx Tube 2 in
1n0 739x i
50 pO 025-inch fad

( j 0 070 0 005 in
Turbine disk pockets

0675.n-F-T

Electrolyte
type: NaCI NaCI NaOH NaCI

concentration,
lb/gal: 1.0 0.1 1.0 1.5 1.0
inlet pressure, psi: 225 to 275 100, start; 160, 50 150
end

outlet pressure, psi: 25 to 75 60, start; 40, end 0 0

flow rate, gal/min: 15 (est.) 290, start; 235, 3

end

temperature, OF: 105 5 100 80 110

Voltage, dc volts: 18 11 10 12.5

Current, A
start: 130 (est.) 2,800 to 3,500 450 400 (est.)

end: 630 16,000 to 18,000 450 800

Feed rate, in/min: 0.060 0.032 none 0.10

Depth of cut, in: 0.2 0.3 3.04 11

Tolerance, in: 0.003 0.003 0.002 0.010

Surface roughness,
pin R.: 30 to 40, front; 70 to 90 10
75 to 150, side

Electrode material, Copper electrodes. Brass electrodes Copper electrodes. 50 pan Copper tubing electrode.
filtration, benefits 75 pm (an assembly (micron) filter. Trepannede -inch hole through -
and remarks: (micron) of 54 separate Bore enlargement from 0.535 21-inch ingot. (Ingot turned
filter. replaceable to 0.542 inch. end for end after penetration
Single pocket per units). Similar to ECP. of the tool had reached one
stroke. All 54 pockets per half the length of ingot.)
stroke. Nine-
minute ma-
chining cycle.

11-60
- . " - --- --- - |
 Electrochemical Machining-ECM 11.5
TABLE 11.5-14-Continued
Work material: TI-6AI-4V HC250 Alloy Steel, 54 R.316 Stainless Steel
Workpiece
configuration.
Brickette 0#.400/in
roll 177 x 186
x 0555 in 4* -Nozzle
095in

j2i in
-3/8

0060-inch tad

00000 28 in Q)
2in-m 0 10in 0040J
1 27/32ii
0 075 in squaie L i
2 7 2 /32 Inc

Electrolyte
type: NaCI NaCI NaCl
concentration,
lb/gal. 1.0 1.0 1.0
inlet pressure, psi: 190 10 210 80
outlet pressure, psi: 10 (est.) reverse flow 150 0
flow rate, gal/min: 50 (est.)
2
temperature, *F: 115 to 125 100 80
Voltage, dc volts: 13~ 15 17

Current, A
start: 2.000 (est.) 3,000 20
end: 2.400 9,000 310
Feed rate, in/min: 0.050 0.060 0.230
Depth of cut, in: 0.925 0.555 1.74
Tolerance, in: ; 0.002
-- 0.015 40 taper

Surface roughness.
Ain R.: 22 to 28, bottom; 120 to 240, side 70 5 to 10
Electrode material. Copper-tungsten electrodes (side 7 pockets cut simultaneously.
filtration, benefits Copper electrode, so Lm (micron)
insulation). 630 pockets in 45 rows of 4
and remarks: 0.008-inch front gap. 0.030-inch side filters.
each. One indexing vertically
gap (overcut). 0.060-inch corner per row.
radii.

11-61
 11.5 Electrochemical Machining-ECM
TABLE 11. 5 -1 4 -Continued
Work material: 18% Ni Maraging Steel Inconel AlloyX750 4340 Steel
Workpiece
configuration:

This area ECM machined

A 14 holes

17 -442
0022 0-_l
00081 0.750 in-.
nj ban
Roller
3 495-inch dia A
cage

Electrolyte
type: NaCI NaCi + NaNO 3 NaCI NaCI
concentration,
lb/gal: 1.25 1.33 + 0.67 1.0 1.0
inlet pressure, psi: 60 to 100 80 (est.) 200 200
outlet pressure, ps: 0
20 (est.) 125 so
flow rate, gal/min: 17 10 (est.)
temperature, IF: 110 100 (est.) 100 100
Voltage, dc volts: 6.5 17 15 10.5
Current,
start:A 1,000 400 5,000 1,000
end: 2,600 1400 6,000 1,200
Feed rate, in/min: 0.076 0.080 0.195 0.400
Depth of cut, in: 0.090 1.250 0.50 0.50
Tolerance, in: *0.0003 on thickness 0.003 (est.) Trepanning Finish cut *0.002
roughing cut
Surface roughness,
tin R : 4 to 10 35 to 50
30 max.
Electrode material, Copper electrode. 100 Im (micron) Copper-tungsten
filtration, benefits filter. electrode. Five Parts cut simultaneously.
Through-hole slot. Trepanning roughing cut followed by
and remarks: Workpiece rotated at 125 rpm
(or ECT). One side machined fnsigct
finishing cut. 300mnt
minute
at a time. floor-to-floor time per part.
Waffle grid of pockets.

1142-
 Electrochemical Polishing-ECP 11.6
PROCESS SUMMARY

Feed Cathode Stationary

Insulation
Uninsulated E

Ilctrolyte

SWorkpiec /Workpiece -

Cutting Polishing

Figure 11.6-1 ECP schematic.

Principles sulation, only selected portions of the workpiece will re-

Electrochemical polishing (ECP) is a special form of elec- ceive the extra polishing. The rougher side walls on deep
trochemical machining (ECM) arranged for cutting or pol- ECM cavities can be smoothed by the use of an uninsulated
ishing a workpiece (see figure 11.6-1). Polishing parame- electrode.
ters are similar in range to those for cutting, but without
the feed motion. ECP generally uses a larger gap and a Operating Parameters
mod-
lower current density than does ECM. This requires
estly higher voltages. (In contrast, electropolishing (ELP) ECP operates in the same manner as does regular ECM;
uses still lower current densities, lower electrolyte flow and however, the values of the operating parameters are modi-
more remote electrodes.) fled slightly. For ECP, the working gap is larger, typically
0.020 inch 10.50 mml; the current density is much lower,
Sometimes, after ECM of a cavity, the ECM electrode is less than or equal to 25 percent of cutting level; and the
allowed to dwell at the end of the cut to accomplish a pol- voltage is higher, up to 50 percent. The electrolyte flow
ishing action. Dwelling must be performed under carefully rate is maintained at its usual high level.
selected conditions and timing to prevent a bulge in the cut.
Occasionally, the ECM electrode is retracted slightly (to Material Removal Rates, Tolerances and Suface
electro-
double or triple the cutting gap' to promote better
chemical polishing. An uninsulated electrode may also be Technology
inserted in place of the cutting electrode to polish the side ECP removes insignificant amounts of material-only ten-
walls of deep pockets. thousandths inch. The accuracy of the timing of the -onI
cycle controls the tolerances and the surface roughness. A
surface roughness of 12 microinches R. 10.3 pml can be at-
tained easily in stainless steels or nickel alloys.
Practical Applications
The special efforts and electrodes required for ECP can be
justified for high production or unusual applications on dif- Equipment and Tools
ficult-to-machine materials. Very fine finishes can be ECP requires modification of the electrodes and operating
achieved with only a few seconds exposure. With proper in- conditions of regular ECM equipment.

11-63
 RiECED1DJ FAh BLAN(-ZNOT PI1hZD

Electrochemical Sharpening-ECS 11.7

PROCESS SUMMARY Principles

Electrochemical sharpening (ECS) is a special form of
electrochemical machining arranged to accomplish sharp-
From power ening or polishing by hand (see figure 11.7-1). A portable
pack & power pack and electrolyte reservoir supply a finger-held
ele,.trolyte electrode with a small current and flow. The fixed gap in-
Supply corporated on the several styles of shaped electrodes con-
trols the flow rate. A suction tube picks up the used elertro-
oyte for recirculation after filtration.
ki
Suction line Practical Applications
to reservoir Rapid. localized finishing to low roughness levels can be
achieved on any conductive material. Spot removal of un-
Tray wanted recast layers or heat-affected areas is practical as
o c part of a finis '.,T bench operation.

Operating Parameters
For ECS. only 10 amperes or less are required for the
small electrodes and fractional gallon-per-minute flow
rates. The voltage range is similar to that for ECM. 8 to 18
volts.

0Material Removal Rates, Tolerances and Surface

Technology
ECS smooths without significant material removal. Rough-
ulatorsness levels of 30 microinches R 10.8 pl from an initial 63
microinches R. 11.6 panl are possible with a few seconds
application.

Workpiece \ Equipment and Tools

ECS equipment has been packaged into a portable set;
however, any small power pack, tray and pump ai range-
ment suitable for use with the salt electrolytes can be
Figure 11.7-1 ECS schematic. adapted for use for this process.

11-65
 9EC9014 PAGE BLAU -NOr FIIMD

Electrochemical Turning-ECT 11.8

PROCESS SUMMARY Principles
Electrochemical turning (ECT) is a special form of electro-
chemical machining designed to accommodate rotating
workpieces (see figure 11.8-1). The rotation provides addi-
tional accuracy but complicates the equipment with the
method of introducing the high currents to the rotating
part. Electrolyte control may also be complicated because
rotating seals are needed to properly direct the flow. Other-
wise, the parameters and considerations of electrochemical
machining apply equally to the turning mode.

Electrolyte Rotating Practical Applications

iconductive
workpiece Both peripheral and face cuts are practical on electrically
materials. Roughing of large disk
forgings is
practical with electrochemical turning. Some shops have
plunged a full-face electrode into the face of the rotating
Peripheral disk. Turning of inside diameters has also been accom-
plished. ECT can be used to finish parts such as bearing
races to close tolerances with surface roughness values bet-
ter than 5 microinches R. 10.1 pai.

Operating Parameters
The operating parameters and typical values are similar to
these for electrochemical machining, section 11.5.

Cathode ~Material Removal Rates, Tolerances and Surface

_ 4Wo~ atralRmoa RtsTleace ndSrfc
Technology

ECT attains the same values as those for electrochemical

ing machining.
Bru table

Fae Equipment and Tools

ECT equipment is available by special order for face, inter-
nal or peripheral turning. Capacities range up to 20,000
Figure 11.8-1 ECT schematic. amperes.

11-67
 14iECED1iO4 PJI Ba"1..NQ] FIU"

Electro-streamn'-ES 11.9

PROCESS SUMMARY

19-" EExhaust
Feee
P cwt re fan

Acid electrolytes eManifold

S Nozzle

creoo io of tControls

Acidfrhaieco.
supi wl

eaui sMotion control/

igre11e9u1 ES schematic.

Principles with a reject rate of 1-1/2 percent and an average drilling

Electro-stream - ti (ES) is a special version of electro- time of one minute per part. Up to 0.75-inch 119 min deep
chemical machining adapted for drilling very small holes holes can be drisled.
using high voltages and acid electrolytes (see figure
11.9-1). The voltages are a.more than 10 times those em-
ployed in ECM or STEMTM so special provisions for con- TABLE 1119-1 Some Materials that Have Seew Drilled
tainment and protection are required. The feed must be Using ES
controlled to match exactly the rate of dissolution of the
workpiece material. Temperature. pressure concentration With HC 70
and flow control are needed for the acid electrolyte. which Aluminum
is chosen to be chemically compatible with the workpiece IN-100
metallurgical state. For corrosion protection. both the feed T 060-4V .
and the motion mechanisms are in pressurized chambers. SEL 15
separated from the acid electrolyte. The actual drilling
takes place in a plastic chamber. suitably vented. with con- Wih HS10 n
trols for automatic rapid advance of the tool. close pro-t Con l
304 Stainless steel
gramming of feed. dwell at hole breakthrough if desired. 316 Stainless steel
and rapid retraction prior to indexing to the next location. 321 Sinaless steel
The tool is a drawn-glass nozzle one or two thousandths 8630 Alloy steel
inch smaller than the desired hole size. An electrode inside t
the nozzle or the manifold ensures electrical contact with Udimet 700
L
the acid. Multiple hole drilling predominates. Rene 41
Relo 77
Rene 80
Practical Applications Rene 100
Rene 120
Holes rangingerom 0.008- to 0.040-inch
ameter with depth-to-diameter ratios up10.2
to to
50:1 mln
can di-
be Rene 125
made in any conductive material. Table 11 .9-1 lists mate- IN-102
rials that have been drilled with ES. Holes can be drilled at
angles as shallow as 10 degrees. A principal application is Inconel alloy
Inconel 625
allay 718
the drilling of cooling holes in gas turbine components IN-738
which are usually fabricated from nickel and cobalt alloys- lnconel alloy X-750
Insertion of a nozzle with a formed tip permits right-angle Incooy alloy 825
drilling deep inside prior holes or cavities. Over 70 holes Hastlloy ally C
per machine stroke have been accomplished ou,multiple Hasteloy alloy X
parts: automatic indexing permits the drilling of several HS-31 (X.40)
hundred holes per part. One example is the drilling of 96 Haynes alloy 25 (1.605)
holes simultaneously in the leading edge of a superalloy gas Haynes alloy 188
turbine vane. Ovr, 100.000 such parts have been drilled

11-69

- -7
11.9 Electro-stream -ES
Operating Parameters electrolytic dissolution follows Faraday's laws (see section
11.5), and current density is limited by the boiling of the
electrolyte in the nozzle from the resistive heating. Diame-
TABLE 11.9-2 Typical Values for ES Operating ter tolerance is typically 0.001 inch 10.025 mm] or plus
Parameters or minus 5 percent for sizes above 0.020 inch 10.5 mini.
Straightness is 0.0005 inch per inch [0.0005 mm/minI.
Power supply
type' Direct current
voltage: 150 to 850 V Surface Technology
current: 20 to 200 milliamperes/hole Surface roughness in the holes ranges from 16 to 63 micro-
(not independently adjustable) inches R. [0.4 to 1.6 piml. There are no metallurgical
changes when the electrolyte and operating parameters are
Electrolyte compatib.- with the metallurgical state of the workpiece,
type (s): H2S04,HCI, or proprietary mixtures nor are there process-induced residuL' stresses in the sur-
concentration: 5 to 15% faces. Thermal damage is nonexistent. Surface imperfec-
temperature: 80- to 120F [270 to 490C] tions frequently are a reflection of material inhomogeneity
pressure: 20 to 100 psi [138 to 689 kPa] rtn roe s varalty.
contamination: 6 g/L max rather than process variability,

Feed rate: 0.030 to 0.180 in/min [0.76 to 4.6 mm/mini Equipment and Tools
Hole diameter: 0 008 to 0.040 inch [0.2 to 1 mm] ES equipment is available from the General Electric Com-
Hole depth: Up to 0.75 inch [19 mm]
Depth-to-diameter pany, Cincinnati, Ohio 45216. Equipment can be provided
ratio: Up to 50:1 with all the ancillary devices needed to operate the system.
Holes per stroke: Up to 100 Fixturing requires the careful selection of materials suit-
Drilling angle- 100 to 1700 able for the process environment. The nozzles are drawn
from special glasses and are designed for penetration either
Diameter tolerance: 0.001 inch [0.025 mm] or 5%of hole in the feed mode or in the stationary, "dwell" mode.
diameter
Surface roughness: 16 to 63 pin R (0.4 to 1.6 m] Machining Characteristics
The highly corrosive environment can shorten the life of
the equipment unless exceptionally good maintenance is
Material Removal Rates and Tolerances endered. Adjacent equipment must also be protected. Dis-

I
Penetration rates of 1 to 2 thousandths inch per second posal of the metal-ion-contaminated electrolyte, must be
10.025 to 0.050 mm/sl are typical for the superalloys. The carried out in an environmentally satisfactory manner.

!
I

i
417

11-70 _
 Shaped Tube Electrolytic Machining-STEMTM 11.10
PROCESS SUMMARY

Metal tube Dielectrc

electrodFigue coang
(cathode):-

Pricpes
tiaeteroConstant uieedpf -

\Ie Flowmeter I ;:

IIplate
Filter Supply ddsto
=.j .,.., -- (anode) :
-g Workpiece,'
Heater ,, T ni

Fixture ?

Figure 11.10-1 STEMTIAschematic.

Principles diameter ratios up to 300:1 and diameters ranging from

Shaped tube electrolytic machining (STEMT. 1) is a special- 0.020 to 0.250 inch 10.5 to 6.4 min). Special and oval
ized ECM technique for "drilling small, deep holes utiliz- shapes should have a minimum width of 0.020 inch 10.5
ing acid electrolytes (see figure 11.10-1). Acid is used so mm and a major-to-minor-axis ratio of 3:1. Over 100 holes
that the dissolved metal will go into the solution rather per machine stroke are practical. The same tooling can
than form a sludge, as is the case with the salt-type electro- produce different sizes of holes within a modest range by
lytes of ECM. The electrode is a carefully straightened, adjusting the feed, voltage, and other parameters (see fig-
acid-resistant, metal tube. The tube is coated with a film of ure 11.10-2). A typical case was the simultaneous drilling
enamel-type insulation. The acid is pressure fed through of sixteen 0.050-inch 11.27 mm] diameter holes in cast
the tuoe and returns via a narrow gap between the tube in- Udimet 700 nickel alloy. The holes were 9-inches 1229 mini
sulation and the hole wall. The feed, constant within plus deep in the center of 0.150-inch 13.8 mm) thick airfoil walls.
or minus one percent, advances the electrode into the The drilling rate was 0.001 inch per second 10.025 mm/s]
workpiece at a rate exactly equal to the rate at which the using a 10 percent sulfuric acid electrolyte.
workpiece material is dissolved. Multiple electrodes, even
of varying diameters or shapes, may be used simultane-
ously. A guide plate is used to direct the electrodes. A solu-
tion of sulfuric acid is frequently used as the electrolyte TABLE 11.10-1 Some Materials that Have Been Drilled
when machining the nickel alloys. The electrolyte is heated Using STEM Tm
and filtered, and flow monitors control the pressure. Tool-
ing is frequently made of plastics, ceramics or titanium al- 304 Stainless steel Incoloy alloy 825
loys to withstand the electrified, hot acid. The electrode 321 Stainless steel Rene 41
414 Stainless steel Rene 80
can be shaped to drill odd cross sections, and, within the 4130 Alloy steel Rene95
yield limits of the tooling material, divergent holes may be 4340 Alloy steel Rene 100
drilled simultaneously. The voltage used is modest and is M2 Tool steel Ti-6AI-4V
reversed periodically for a fraction of a second to remove DCM TI-6AI-2Sn-4Zr-2Mo
any film buildup on the electrode, but not long enough to Stellite TI-8AI-lMo-IV
remove substantial material that would change the elec- Udimet 500 Haynes alloy 25 (L605)
trode shap.,. Udlmet 700 Haynes alloy 188
Udlmet 710 HS-31 (X40)
Inconel alloy 718 Hastelloy alloy C
Practical Applications IN-lO Hastelloy alloy X
IN-102 Greek Ascoloy
STEMTM is used to drill round or shaped holes in difficult- Inconel alloy 625 SEL 15
to-machine conductive materials. Table 11.10-1 lists mate- IN-738 TZM Molybdenum
rials that have been drilled using STEMTAv-. Holes as deep Inconel alloy X-750
as 24 inches 1610 mml can be produced with length-to-

11-71

Wpm.
 11.10 Shaped Tube Electrolytic Machining-STEM
Operating Parameters per second 10.018 to 0.064 mm/sI. Several dozen holes
have been drilled simultaneously. with tooling or setup
costs being the practical limit Runout is typically 0.0015
inch per inch 10.0015 mm/mml: however, 0.001 inch per
TABLE 11.10-2 Typical Values for STEMTM Operating inch 10.001 mm/mml can be achieved. Diameter tolerance
Parametem is typically 0.0015 inch 10 038 mml for hole diameters
under 0.10 inch 12.5 mml and plus or minus 10 percent for
Power supply larger diameters. The material removal rates are governed
type: Direct current by Faraday's laws (see section 11.5) and are limited by the
voltage: 5 to 15 V
forward on time: 3to 20 s current-carrying capacity of the tube and the boiling point
reverse time: 0.2 to 0.4 s of the electrolyte.

Electrolyte
type: H 2SO 4 Surface Technology
concentration: 6 to 15% volume Surface roughness in the holes ranges from 32 to 125 mi-
temperature: 900 to 110OF [320 to 430C] croinches R. 10.8 to 3.2 pIml. There is no stress introduced
pressure- 10 to 45 psi [69 to 310 kPa] into the surface. The electrolyte must be compatible with
metal content* 8 oz/gal max. [6 g/L max I the netallurgical state of the workpiece to prevent inter-
flow rate: 1 2 to 9.1 in3/min (20 to 15C cm 3/min] granular attack or selective-etch pitting. The natural radi-
using action of electrolytic machining eliminates all burrs.
Feed rate: 0.030 to 0.080 in/mm [0.76 to 2.0 mm/mini Close control of the electrolyte flow and degree of metal-ion
Hole diameter: 0.02 to 0.25 inch [0.50 to 6.4 mm] contamination is required for quality assurance. Mon-
Bare electrode, OD. See figures 11.10-2 to 11.10-4 itoring the current during operation can provide an early
warning of size deviation.
Amperes per hole: 1 to 40 A
Holes per stroke: 1 to 100
Hole length: Up to 24 inches rup to 610 mm] Equipment and Tools

Hole length-to- The STEMTM process equipment is available from the

diameter ratio Up to 300.1 General Electric Company, Cincinnati, Ohio 45216. The
Hole tolerance equipment includes controls, tanks, pumps, and so on, and
on diameter: 5% enclosures, ventilation and plastic components to protect
Hole tolerance, the operator from the electrified and corrosive environ-
straightness: 0.0015 in/in [0.0015 mm/mm] ment. Several equipment sizes are available to accomplish
Surface roughness, multiple drilling up to 24-inches 1610 min) deep. The tubes
R,: 32 to 125 1tin [0.8 to 3.2 ,uml or "drills" are usually made from high quality titanium with
acid-resisting organic coatings to provide insulation. Car-
NOTES- Electrolyte concentration below 10% reduces attack on tube bide locators withstand the environment of machining.
insulation.
Hole size and roughness in,'reases with increasing electrolyte con-
tamination levels.
Reverse polarity is frequently at lower voltages (typically 4 to 5 V) than the Machining Characteristics
forNard voltages. Corrosion
- protection is required for equipment adjacent to
STEMT I installations. Speciai tooling is required for
through-hole drilling so that electrolyte pressure is not lost
Material Removal Rates and Tolerances upon breakthrough. Careful straightening of the tubes is
Drilling penetration rates are typically 0.001 inch per sec- essential, as is end preparation and adhesion of the
ond 10.025 mm/sl but can rnge from 0.0007 to 0.0025 inch insulation.

!1-72,

1--
+~
 mwI

Shaped Tube Electrolytic Machining-STEM TM 11.10

SELECTED DATA

cc
cc.

0
CTO

.1a
cmJ

CD

Q0
oC
Co CL

60

C5
oQ 0)

0*

0 C o,

43U,~~~~0 '()J4wlC10.:

11-Co
11.10 Shaped Tube Electrolytic Machining-STEM TM
0.160T

0.140 -f- - __ - - __-

0.120 [PmrI- - - -t---

0.10
- ___Tube O.D.
Tube I.D.

E 0.080 - ---
0.06

Applies to:
F- 0 nikel asealloys at
0.040 - -- 0.056 in/mmn
(1.42 mm/mini feed.
Current density in tube
0.020 - 2 -- - wall = 1750 A/in'
0-10 [271 A/cm2]
0 HII I I II
0 0.020 0.040 0.060 0.080 0.100 0.120 0.140 0.160 0.180 0.200
[4 mm]
Hole diameter. inch

FIgure 11.10-3 Tube diameter versus hole diameter for STEMTm drilling nickel base alloys. (C. Jackson
and R. 0. Olson. Shaped tube electrolytic machining, Technical paper MR69-1 09, Society of Manufacturing
Engineers, Dearborn, Mi. 1969. p. 10)

0.0100 - - - -- -

0.0080 -- -__

0.00W0 - ___ -

0.0040 - - -__

0.0020- - - ___

cc 0.0010 -

cc 0.0008

0.0004Applies to:
nickel base allays at
0.056 In/min
0.0002 - 1.42 mm/mm]) feed.
Current density in tube
wall =1750 A/in'
0.0001 -1 271 A/cm']
0.001 0.002 0.004 0.006 0.010 0.020 0.040
[0.065 cm']

Area of hole, In2

Figure 11.10-4 Tube wall area verreus hole area for STEMTMI drilling nickel base alloys. (C. Jackson and
R. 0. Olson, p. 10)

11-74
 Shaped Tube Electrolytic Machining-STEM TM 11.1l0

SPECIFIC APPLICATIONS DATA

TABLE 11.10-3 Specific Applications Data for STE MTM

WORK MATERIAL

OPERATING PARAMETER 304 Inconel L.605

stainless tidimet UdImet alloy Rene 95 TI-8A1Mo-1V (Haynes
steel 700 700 718 alloy 25)

Electrolyte
type H2S0
4 H2S04 H2S0 4 H2S04 H2S04 HCI H2SO4
concentration, % vol. 10 10 8 9-10 10 5.0 0.5 10
temperature, OF 90 100 2 95 100 2 100 100 =5 100
pressure, psi 10 40 10 est. 25 22 45 10
metal content, g/L 2 2 3.0-6.5 4 none
flow rate, cm3/min 100 60 115 5 330 20

Voltage, dc: volts 10 6 10 7.4-7.8 6.5 13.5 64w

Forward on time. s 8 7 8 10 10 10 3
Reverse time, s 0.3 0.1 0.3 0.3 0.3 0.3 0.3
Feed rate, in3/min 0.060 0.050 0.050 0.050 0.050 0.070 0.003 0.0042

Hole diameter, in 0.02 0.050 0.120 0.05 0.124 0.060 0.025 0.003
Bare electrode, OD, in 0.015 0.035 0.090 0.035 0.107 0.045 0.017
Amperes per hole, A 1 1 8 2 max. 7.5 4.3 0.5
Holes per stroke 1 16 8 6 1 3 30 41

Hole length, in 6 9 2.5 4.0 1 8 0.030 ;Af

Hole length-to-diameter ratio 300 180 21 80 20 134 1.2
Hole tolerance on diameter, in 0.002 0.0025 0.002 0.001
Hole straightness, in/in 0.001
Surface roughness, ttin R. 100-130 130-150

11-75 __________
 -RCEDIIOG PA(Z BLAC-NOT FILMD

SECTION 12
THERMAL NONTRADITIONAL
MACHINING OPERATIONS

12.1 Electron Beam Machining FBM ............................................................................................ 12-3

12.2 Electrical Discharge Grinding- EDG ....................................................................................... 12-11
12.3 Electrical Discharge Machining-EDM .................................................................................. 12-15
12.4 Electrical Discharge Sawing-EDS ....................................................................................... 12-47
12.5 Electrical Discharge W ire Cutting-EDW C ............................................................................. 12-49
12.6 Laser Beam Machining-LBM ............................................................................................... 12-55
12.7 Laser Beam Torch-LBT ............................................... 12-71
12.8 Plasma Beam Machining-PBM .............................................................................................. 12-97

1-
12-1
 - RECMAG PAGE BLANK-NOT FILMD

Electron Beam Machining-EBM 12.1

PROCESS SUMMARY also permits the production of unique designs. Figures

12.1-3 and 12.1-4 show perforation ranges and rates for
EBM of steels and nickel alloys. The absence of mechani-
cal contact and the suitability for automatic control en-
Electron Seam Gun hance the process capabilities, but the necessity to work in
High voltage cable a vacuum lengthens the floor-to-floor cycle time. One appli-
0cation placed 400,000 holes 80 microinches 12 p]i in diam-
eter in each square inch of a 0.001-inch 10.025 mini thick
Cathode grid A foil. Another application incorporates the drilling of holes
approximately 0.020 inch 10.50 mini in diameter in 0.250-
inch 16.4 mini thick material at speeds several times faster
than for EDM or ECM. Metering orifices, rough wire dies
Oicl .Electron stream and spinnerette holes are other applications.
viewing f agnetic lens

Vicwing .-..- Deflection coils

Vacuum chamber Workpiece Operating Parameters

pump TABLE 12.1-1 Typical Values for EBM Operating

Parameters
Figure 12.1-1 EBM schematic.
Accelerating voltage:
50 to 150 kV
Beam current: 100 to 1.000 pA
Power: 0.5 to 60 kW

Pulse time: 4 to 64,000 ps

Pulse frequency: 0.1 to 16,000 Hz
Vacuum: 10-2 to 10-4 mm Mercury
Principles
Beam spot size minimum: 0.0005 to 0.001 inch (0.013 to
Electron beam machining (EBM) removes material by 0.025 mm]
melting and vaporizing the workpiece at the point of in- Beam deflection range: 0.25-inch (6.4 mm] square
pingement of a focused stream of high-velocity electrons Beam intensity: 10 to 1010 W/in2 (1.55 x 105 to 1.55
(see figure 12.1-1). To eliminate scattering of the beam of x 109 W/cm]
electrons by contact with gas molecules, the work is done
in a high-vacuum chamber. Ele'-trons emanate from a Depth of cut: Up to 0.25 inch (6.4 mm]
triode electron beam gun and are accelerated to three- Narrowest cut: 0.001 inch in 0.001-inch thick
fourths the speed of light at the anode. The collision of the metal (0.025 mi in 0.025-mm
electrons with the workpiece immediately translates their thick metal]
kinetic energy into thermal energy. The low-inertia beam
can be simply controlled by electromagnetic fields. Mag- Hole range, diameter: 0.001 inch [0.025 mm] in 0.0007-
netic lenses focus the electron beam on the workpiece, inch [0.020 mm] thickness
where a 0.001-inch 10.025 mini diameter spot can attain an 0.040 inch [1 mm] in 0.20-inch (5
energy density of up to I09 watts per square inch 11.55 x mm] thickness
108 W/cm 2l to melt and vaporize any material. The ex- Hole taper: 10 to 2* typical
tremely fast response time of the beam is an excellent com- Hole angle to surface: 200 to 900
panion for three-dimensional computer control of beam de-
flection, beam focus, beam intensity and workpiece motion. Cutting speed: See tables 12.1-3 and 12.1-4
View ports and optical tracking systems help guide the Material removal rates: Up to 0.0024 inl/s [40 mml/sJ,
beam or the workpiece. Deflection coils permit magnetic see figure 12.1-5
control and programming of the beam to any desired pat- Penetration rates: Up to 0.010 in/s [0.25 mm/s]
tern over a small area-about 1/4-inch 16.4 mini square. Perforation rates: Up to 5.000 holes/second (if part
can be traversed rapidly)

Practical Applications Tolerances: *0.001 inch [0.025 mm] on 0.125-

The power densities available in EBM will vaporize any inch (3.2 mm] diameter, see
known material (see examples, table 12.1-2). This permits figure 12.1-6
a wide range of processing possibilities, as shown in figure E0.00005 inch [0.0013 mm] on
12.1-2. Micromachining of thin materials, engraving and 0.0005-inch 10.013 mm]
hole drilling are the principal applications for EBM. The diameter
hole depth-to-diameter ratio can reach 100:1 with multiple and
* 0.0002 inch [0.005 mm]
pulses. The capability for machining microholes and nar- attainable, 10% otherwise
row slots with high precision in a short time in any material

12-3
12.1 Electron Beam Machining-EBM
Material Removal Rates and Tolerances tural integrity of highly stressed components, and for such
The thermal properties of the work material and the power components, this material should be removed or modified.
level of the EBM unit dictate the material removal rates.
Tungsten can be machined at a rate of 0.92 x 10-4 cubic Equipment and Tools
inch per second 115 x 10-4 cm 3/sl with one kilowatt of
power, while aluminum can be machined at a rate of 0.24 x Machines for EBM are produced with capacities ranging
3 3 3
10- cubic inch per second 13.9 x 10- cm /sl with the same from a few hundred watts to 60,000 watts with vacuum
power level, as shown in figure 12.1-5. Typical tolerances chambers of nominal or special volume-up to 20-by-27-
are about 10 percent of the slot width or hole diameter, as foot 16 by 9 ml capacity. Special equipment can include
shown in figure 12.1-6. The taper present in slots and holes room-size chambers with electron beam guns traveling
limits the depth-to-width ratio. With computer control of over NC positioning tables. Optical scans and controls with
the pulsed beam and integrated workpiece motion, hole as much as 40:1 magnification are available to utilize the
drilling rates up to 5.000 holes per second can be attained precision capability of the small spot size, high beam power
in thin materials. including ceramics. densities
beam andandthelow beam inertia.
work motion is Simultaneous
common. Proper control of the
program-
ming of the deflection beam, "flying spot" scanners and
pulse controls can produce intricate geometric cuts in the
workpiece.
Surface Technology
Estimates of surface roughness for the small holes and cuts
are in the neighborhood of 40 microinches R. 11 pml. The Machining Characteristics
short bursts of the beam limit the extent of the heat- The "chips" from EBM are small dust particles or small
affected zone; however, there is always a thin layer of beads formed from the solidified, expulsed molten material.
recast or heat-affected material on the cut surface. Heat- Cleanliness efforts should be continuous. Cathode life de-
affected material up to 0.01 0-inch 10.25 mini thick has been clines at the higher power densities. Shielding of the sec-
observed. This material can be detrimental to the struc- ondary radiation is necessary for safety.

.4

12-4
 I

Electron Beam Machining-EBM 12.1

SELECTED DATA

Li..1
10"0

109
10I Metals
5 1 Hardening
E 43 2 Fusion-transformation
Joining
44 Perforation
0106' (6.5 x 101 Wlin2) -5 Drilling/Milling
CL 6 Engraving
lu 105 - 2 377Sublimation
1 Plastics
10' 8 Polymerization
F T10 9 Electro-resist
10- I9I 10 Plastic-perforation

0
103 -'

102 F
10'-

100ns 1 /s 10/gs 100/ps 1 ms 10 ms 100 ms is l0s

Energy input time

Figure 12.1-2 Application range of electron beams. Power density and time of impact are typical for
the various techniques. (J. Drew, Electron beam drilling, Influence of metallurgy on hole making operations,
Metals Park, OH: American Society for Metals, 1978, p. 115)

2.0

1.0

0.5
V04
E
E
Capability of EB perforation
E 0.1

0
0.05

0.01 0.05 0.1 0.5 1.0 5 10

(0.040 in)
Material thickness. mm

Flgure 12.1-3 Range of EB perforation for steel and nickel alloys. (J. Drew, p. 118)

12-5
12.1 Electron Beam Machining-EBM

50.000 - 40

1: hole dameters, mm 3.5

10.000 .

-0 2.5
C 1.000- _ -
______ 0.1 (0.004 in)

p0.15
I~~ ~ 2.0 - -~o~

Qi O 0.2

100 1 1.5

50
100.4
'~0.6

1o 008--.o 0.5
0.01 0.05 0.1 0.5 1.0 5.0 10
(0 040 in)
Material thickness. mm 0 0.001 0.002 0.003
0.005 0.006 0.004
(0.0004 in'/s)
Figure 12.1-4 EB perforation rate for steel and Metal removal rate. cm/s (
nickel alloys. (J. Drew, p. 119) Figure 12,1-5 Metal removal rates versus power,
assuming 15 percent cutting efficiency. (R. K.
Springborn, ed., Non-traditional machining processes,
Dearborn, MI: American Society of Tool and Manufac-
turing Engineers, 1967, p. 141)

2.00
Material thickness. mm

(C040 in)

0.5-
E 1 -
04.0 (0.157 in)

E 0.5
.! V 0.1 0.
0.3 I1

- 0.05

0,011 ... 1 1 fl
111l

1.0 5 10 100 200 50

(0.0008 in)
Tolerance of hole diameters,/Jm =Cn
Figure 12.1-6 Hole tolerances variation with hole
size and- material thickness. Generally, deeper
holes require wider tolerances. (J. Drew, Electron
beam tackles tough machining jobs, Machine Design
48 (February 26. 1976), p. 96)

12-6 -
 Electron Beam Machining-EBM 12.1
TABLE 12.1-2 Physical Thermal Properties of Various Materials

PROPERTY MATERIAL

Aluminum Titanium Molybdenum Tungsten Iron

Melting temperature. 0C 660 1,668 2.610 3,410 1,536

Boiling temperature, C 2,450 3,260 5,560 5,930 3,000
Specific heat. cal/g/OC 0.215 0.126 0.061 0.032 0.11
Heat of fusion, cal/g 94.6 36.7 70.0 44.0 65.0
Heat of vaporization,
cal/g 2,517.6 2,223.4 1.340 1,005.9 1,514.8
Specific energy to
vaporize, joules/cm3 3.54 x 104 5.07 x 104 7.46 x 10 1.0 x 105 6.28 x 10
Power to vaporize*
(ratio to aluminum) 100 150 220 290 180

*Relatve power to remove equal volumes inequal time.

TABLE 12.1-3 Holes Drilled by EBM in Various Materials _

AVERAGE
WORK WORKPIECE HOLE DRILLING ACCELERATING BEAM PULSE PULSE
MATERIAL THICKNESS DIAMETER SPEED VOLTAGE CURRENT WIDTH FREQUENCY
in P-w in s kV ILA 11s Hz

400 Series
stainless
Alumina A1203steel 0.010
0.030 0.0005
0.012 <1
30 130
125 60
60 4
80 3,000
so
Tungsten 0.010 0.001 <1 140 50 20 so

90-10 Tantalum-
tungsten 0.040 0.005 <1 140 100 80 50
90-10 Tantalum-
tungsten 0.080 0.005 10 140 100 80 50
90-10 Tantalum-
tungsten 0.100 0.005 10 140 100 80 50
Stainless steel 0.040 0.005 <1 140 100 80 50
Stainless steel 0.080 0.005 10 140 100 80 50
Stainless steel 0.100 0.005 10 140 100 80 50
Aluminum 0.100 0.005 10 140 100 80 50
Tungsten 0.016 0.003 <1 130 100 80 50
Ouartz 0.125 0.001 <1 140 10 12 50
SOU.CE: Adapted from R.K.Sprinjbom, ad.. p.143.
NOTE: The main control parameters for shaping the hole are the pulse width for the depth of the hole, the beam current for the diameter of the hole and the
power ditriution within the beam as we as the position of the focus with respect to the workpiece.-J. Drew. Farrel Company.

12-7
12.1 Electron Beam Machining-EBM
TABLE 12.1-4 Slots Cut by EBM In Various Materials ____________ ___ ___

ACCEL- PULSE
WORK WORKPIECE SLOT DESCRIPTION TIME OF CUT ERATING AVERAGE PULSE FRE-
MATERIAL THICKNESS AND/OR DIMENSIONS OR RATE VOLTAGE BEAM WIDTH QUENCY
in n
ij~ A~_MkV pA s Hz

Stainless steel 0.062 f.57 Recta n :lej i 140 120 80 50

0008 by

1a 0.072
Stainless steel 0.007 WO1Sl 0.004 wd2inmn130 50 80 9
Brass 0.010 OOwide
0.00 WO~M 2 in/min 130 50 to 50
Stainless steel 0.002 tOUOW 0.002wide 4 in/min 130 20 1 4 s0
Alumina A1203 0.30@ 2 0.004 wide - 24 in/min 15020 8 200

Tungsten 0.002 , -0 0.001 wide 7 in/min 150 1 30 80 50

SOURCE: Adapted from R.K.Springbom. ed .p.145.

12-8

_____ ___irk ______

 Electron Beam Machining-EBM 12.1
SPECIFIC APPLICATIONS DATA

TA13LE 12.1-5_Specific Applications Data for Electron Beam Machining

CUTTING AVERAGE
CONFIGURATION SPEED ACCELERATING BEAM PULSE PULSE
MATERIAL PRODUCED OR TIME VOLTAGE ICURRENT WIDM FREQUENCY
WV pA FS Hz
Aluminat
0.030-inch thick 0.012-inch dia. hole 30s 125 J 60 81) 50
Alumina wafersI
0.010-inch thick 0.003-inch dia. hole los 125 60 80 50
0.010-inch thick 0.004-inch wide slot 12 in/min 90 150 80 150
0.030-inch thick 0.004-inch wide slot 24 in/minm 150 j 200 80 200
Ferrite wafers
0.010-inch thick 0.001-inch dia. holes <Is- 140 25 5 50
Microdiodes
scribing Scribed to approx. 1 mil depth Approx. 110 7 12 so
________________________________60 nin/ _______I___

Myar tape
0.0015-inch thick Cut a 4.615 in/mmn 110 600 - Continuous
Ouart crystal
0.125-inch thick 0.001-inch exit dia. <is 140 10 12 50____
Sapphire crystal
0.026-inch thick 0.0025-inch dir, hole <:30 s 1020 950
0.026-inch thick 0.0015-inch dia. hole. hole <30 s 110 j 20 9 so
______________taper dpprox. 2*_______
Silicon wafers
0.01 0-inch thick Scribed to 0.002-inch depth 5 in/mmn 130 70 4 3.000
gold deposited ____________ ____ ______

Aluminum
0.100-inch thick 0.005-inch dia. hole los 140 100 80 50
1/16-inch and Slotting Manual 130 15 S00 300
1/8-inch thick _____________ ________

Copper (OFHC)
0.002-inch thick cut Approx. 130 50 2.5 25.00
tubveligd v _ 1_________
min__ (cner)j

tubaveligwvd msa
Brass
0.01 0-inch thick 0.004-inch wide slot 2 in/mmn 130 50 80 50
i
Brass, foil grid
0.004-inch thick Cut by fly.,ng spot scanner Approx- 120 50 4 3.000
____________________3 min_______ ___

Steel, hardened__ ___

0.125-inch thick Rectangle-0.018 by 0.072 inch 10 min 140 150 80 50
Steel, high speed
tool
0.1875-inch thick 0.008-inch entrance width. - 120 30.000 50.000 3.3
0.007-inch exit width, slot
Steel, drill 0.014-inch dia. hole Approx. 140 200 80 50
3min
Steel, plate
0.062-inch thick Cut 15 in/mmin 150 9,000 2.100 330
0.040-inch thick cut 30 in/mmn 150 9.000 2.100 330
Steel. 304 steinless Cut (reopening of welded I10 to 20 13C 5.000 5,300 35
'h4-inch thick container) Iin/min
Steel, stainless
(400 series)
0.010-inch thick 0.0005-Inch dia. hole <IS 130 I 60 4 3.000
Steel. 410 stainlessI
0.010-inch exitra widthlo0
__________thic

thick
0250-inh 0.03 0-inch enitra width 50 j ___ 7.000____3.
7.0o100t.

12-9
12.1 Electron Beam Machining-EBM

TABLE 12.1-5-Continued
I CUTTING AVERAGE
CONFIGURATION SPEED ACCELERATING BEAM PULSE PULSE
MATERIAL PRODUCED OR TIME VOLTAGE CURRENT WIDTH FREQUENCY
kV AA ps Hz
Steel, stainless
0 250-inch thick 0.020- to 0.040-inch 3 mm 145 4,000 2,100 12.5
dia. holes
0.040-inch thick 0.005-inch dia. hole <1 s 140 100 80 50
0.080-inch thick 0.005-inch dia. hole lOs 140 100 80 50
0.100-inch thick 0.005-inch dia. hole 10s 140 100 80 50
0.062-inch thick Rectangle-9.008 by 0.250 inch 5 min 140 120 80 50
0.00025 inch
0.007-inch thick 0.004-inch wide slot 2 in/min 130 50 80 50
0.002-inch thick 0 002-inch wide slot 4 in/min 130 20 4 50
Hastelloy 0.200-inch dia. hole in - 130 5,000 5,300 100
0.200-inch thick material
0.100-inch dia. hole hi 70s 130 5,000 5,300 100
0.450-inch thick material
Molybdenum, shim
0 010-inch thick Less than 0.002-inch dia. <1 s 140 20 20 50
_______ alloy holes on 0.003-inch centers
Tantalum alloy
(90Ta-10W)
0.040-inch thick 0.005-inch dia. hole <1 s 140 100 80 50
0 080-inch thick 0.005-inch dia. hole lOs 140 100 80 50
0.100-inch t" .k 0.005-inch dia. hole 10s 140 100 80 .50
Tantalum, 100A
thin film resistor Manual cut -- _100 20 9 1,000
Tungsten
0.010-inch thick 0.001 -inch dia. hole <1 s 140 50 20 50
0.016-inch thick 0.003-inch dia. hole <1s "30 100 80 50
0.002-inch thick 0.001-inch wice slot 7 in/min 150 30 80 50

I"
12-10
 Electrical Discharge Grinding-EDG 12.2
PROCESS SUMMARY

Rota ting
Insulated conductive
spride wheel

~supply A

FilterZ
servo

ismltEWeeteor afeed
sero c
gapFtuisontrol e T

pt ci iWorktable u

Figure 12.2-1 EDG schematic. a

iI

Principles Operating Parameters

Electrical discharge grding (EDG) is the removal of a
conductive material by rapid, repetitive spark discharges pr
between a rotating t o the workpiece,which are sepa-
and TABLE 12.2-1 Typical Values for EDG Operating
rated by a flowing lectric fluid (see figure 12.2-1). (EDG Parameters
D,
issimilar to EDM except the electrode isinthe form of a t 7
grinding wheel and the current isusually lower.) The spark Power supply.
gap is servecontrolled. The insulated wheel and work type: Direct current with pulse control
table are connected to the direct-current pulse generator. A voltage: 30 to 400 V
positive charge on the workpiece is"standard." Higher cur- frequency: 200 Hz to 500 kHz
and deeper current: 0.5 to 200 A
rents produce faster cutting, rougher finishes Wheel
heat-affected zones in the workpiece. Wheel wear depends
upon current density, work material, wheel material, die- type: Graphite or sometimes brass
lectric and sharpness of corner details speed: 100 to 600 fpm [30 to 180 m/min]
Dielectric: Filtered hydrocarbon oil
Practical Applications Spark gap: 0.0005 to 0.003 inch [0.013 to 0.076 mini
S EDG provides greater accuracy in cutting hard materials
such as carbide form tools, hardened gear racks or tung-
sten carbide throwaway bits, even though its cutting rates
are low. Lamination die grinding in the hardened state is a Material Removal Rates and Tolerances
frequent use of EDG. The absence of significant cutting Material removal rates range from 0.01 to 0.15 cubic inch
forces permits the grinding of fragile shapes or closely per hour 10.16 to 2.45 cm3/hri, with the higher figures ac-
spaced, thin slots in any conductive material. Cast irons companied by surface roughness in the 63- to 125-micro-
usually are not electrical -discharge-ground because the inch R. 11.6 to 3.2 pml] range. Corner radius depends upon
sand inclusions can damage the grinding wheel. overcut values used and ranges from 0.0005 to 0 005 inch

12-11
12.2 Electrical Discharge Grinding-EDG
(0.013 to 0.13 mm. Tolerances to 0 0002 inch [10.005 Equipment
mm are normal, witt 0 000050 inch 10.0013 mini Equipment for EDG is available in a range of sizes. Sys-
achievable. terns are equipped with variable speed drive, insulated
wheel spindles and a servomechanism to control the table
Surface Technology speed.
Surface roughness values decrease with an increase in
spark frequency and are typically 16 to 125 microinches Ra
10.4 to 3.2 ml. The melting, vape g and resolidification
of the surface of the workpiece I :, a heat-affected zone Machining Characteristics
that can be from a few tei, sandths- to a few
thousandths-itich deep Hardness .erations occur which Grinding action is nonexistent. Wheel wear occurs from the
also affect the material properties. Components intended spark discharge. The wear ratio ranges from 100:1 to 0.1:1
for high-stress applications should have these heat-affected with an average of 3:1
layers removed or modified to ensure the best surface
integrity.
volumetric volume of work removed
TABLE 12.2-2 EDG Material Removal Rates versus wear ratio volume of wheel consumed
Surface Roughness

MATERIAL REMOVAL RATE SURFACE ROUGHNESS, R, It is necessary to redress the wheel frequently if sharp radii
in3/hr j- n are desired. Sharp radii also contribute t, -nore rapid
0.05 :125 wheel wear than do round or flat shapes. Abj.,t one-half of
0.05 125 the wear ratio can be attributed to redressing. The dielec-
0.03 63 tric fluid must be inserted between the wheel and the work-
0002 16 piece; consequently, the contact area is usually submerged
in dielectric.

12-12
 Electrical Discharge Grinding-EDG 12.2
SPECIFIC APPLICATIONS DATA

J,! ) g
0 0
0 0 0 Uf)
~
C0

UD)
~ E~.E

C; 0 0

U) Cc C
(1)= E 1)

Laio 0 0 0

0. 0 C (0

r- o0

.0~ 00C

0 0 0 0 0

4)
.0
-5
0
'ro-
r4 cm CjV
-0.c.
.
V)
~ v CwC

o C

-~ 0 ~~~a o

.9 0 0; m Co C
Z U aI
9C
U > .V.
IM
. Q

00
0 0
00
) 00)

LJ o ;F3 E -- -- -

m *-- 6 a . 66 > 56 a.CC

C!o 'tf mo0f
oC . . . 6 CO.r
C50 60 ~ C U) l

00

0C.0N
0l o 0) ..

__
0 0

-C Cm Cv @(-C

0 a

_ _ _ _ 1213c
 MRE PAG
WING BLAM-N=T FIIMD

Electrical Discharge Machining-EDM 12.3

PROCESS SUMMARY

Servo controlled feed

4W Toolholder

41 Dielectric

EElectroe Failte

Spark Tank

dscharge ts l a oeist.t

generator

Figure 12.3-1 EDM schematic.

Principles and NC motion control all contribute to electrical dis-

Electrical discharge machining (EDM) removes elec- charge machining's versatility. Tool and die work is a fre-
trically conductive material by means of rapid, repetitive a ere applicationr eait. ms production ofdsmall
spark discharges from a pulsating direct-current power a
supply with dielectric flowing between
nce the workt and and/or shaped holes at shallow angles to the workpiece
the tool (see figure 12.3-1). The shaped tool (electrode) is surface is commonplace. Narrow slots (0.002- to 0.012-inch
fed into the workpiece under servo control. A spark dis- [0.050 to 0.30 mml wide), honeycomb cores and fragile
charge then breaks down the dielectric fluid. The fre- parts can be cut in high-strength and high-hardness mate-
quency and energy per spark are set and controlled with a rials.
direct-current the toolThe
power source.
constant gap between andservo control maintains
the workpiece a
while ad- OeaigPrmtr
vancing the electrode. The dielectric oil cools and flushes tn
material while reestab- See table 12.3-1. p
out
lishing thecondensed
vaporized inand
the insulation gap. Surface roughness decreases
with increased frequency and reduced current. Material re-
moval rate, surface roughness and overcut all increase with
a current increase or with a frequency decrease (or longer Material Removal Rates and Tolerances
"on" iecce) lcrd aeil rqetyue r Feed rates and material removal rates range from 0.00036
brass, copper, copper-tungsten, tungsten wire and graph- to 0.04 cubic inch per hour per ampere 10.0059 to 0.65
ite Small spark gaps are as'ociated with close- - tolerance cm 3 /hr/A. Corner radii to 1/64 inch 10.4 mml are com-
control and slower cutting rates. Erosion occurs on the tool mon. Production tolerance to 0.001 inch 10.025 mini is
as well as on the workpiece, with wear ratios depending on normal; tolerances of 0.0002 inch (0.005 mini are re-
spark wave-shape from the power source, electrode mate- peatable with careful selection or development of cutting
rial and workpiece material. A nearly "no wear" com- conditions. The recast layer can be controlled and is re-
bination of operating parameters can be found for electrical peatable to a few ten-thousandths inch.
discharge machining of some steels when using reverse po-
larity, as opposed to "standard" polarity (positive on the Material removal rates, surface roughness, recast layer
workpiece). and heat-affected zones all increase as spark intensity in-
creases, see table 12.3-3.

Practical Applications Electrode erosion is expressed as wear ratio as follows (see

EDM cuts any electrically conductive material regardless also figure 12.3-19):
of its hardness and is particularly adapted for machining ir-
regular slots or cavities. The scope of EDM applications volumetric _ volume of work removed
extends from 0.002-inch 10.050 mml diameter holes to 50 wear ratio volume of electrode consumed
ton [45 metric tons] automotive die cavities. Because there
is no physical contact, delicate structures can be cut suc-
cessfully. Cutting is three-dimensional as the shaped elec- or
trode is fed into the workpiece. Because the sparks focus
first on peaks and comers, burr-free cutting occurs. Mul- linear - depth of cut
tiple electrodes, automatic dressing, automatic positioners wear ratio length of electrode consumed

12-15 1
12.3 Electrical Discharge Machining-EDM
Corner radii are controlled by the spark length, while taper Surface Technology
is controlled by the amount of cutting debris in the arc gap The surface texture is a series of overlapping, small craters
or fluid. that increase in size with increasing spark energy and/or
lower spark frequency. Recast and heat-affected layers oc-
cur on all materials and range from 0.0001- to 0.005-inch
10.002 to 0.13 mini deep. These layers should be removed
or modified on critical or fatigue-sensitive surfaces. Surface
TABLE 12.3-1 Typical Values for EDM Operating roughness is typically in the 63- to 125-microinch Ra 11.6 to
Parameters 3.2 piml range. Surface roughness from rough cuts can
INDEPENDENTLY CONTROLLABLE PARAMETERS range up to 500 microinches Ra 112.5 pml, and more costly,
deluxe methods can attain 2 to 4 microinches Ra 10.05 to
0.1 iml. Surface residual stress is shallow (under 0.001
Open circuit voltage: 50 to 300 V inch 10.025 mml) but may be a high percent of tensile
Frequency. 50 Hz to 500 kHz or equivalent duty- strength. The fatigue strength of EDM surfaces without
cycle setting of on and off times post-treatment usually is severely reduced.
per pulse
Dielectric type: Hydrocarbon (petroleum) oils,
deionized water, kerosene, gas Equipment
(dry) (see table 12.3-10) EDM equipment is available in a wide range of sizes from a
Dielectric flow pressure. 28-inch 1711 mm] vacuum to 70 psi bench model with a few amperes capacity to 13-by-18-foot
[482 kPa] pressure 14 by 5.5 ml die sinkers with 5.000-ampere capacity (made
Electrode materials: Graphite,
steel, copper, brass, zinc-tin,
copper-tungsten, copper- up
u from multiple 500-ampere
rmmlil power packs). Automatic or
0-meepwrpcs.Atmtco
graphite, silver-tungsten, NC controls are common. Automatic feed, interchangeable
te tungsten electrode holders and rotary-turret electrode holders are

Servo drive gap sensitivity Gaps: 0.0005 to 0.005 inch 10.013 to available to aid electrode changing and automation of the
control: 0.13 mm] EDM process. Multiple electrodes and multi-lead power
Capacitance: (on some style machines) from trial supplies enhance the productivity of many equipment
cuts types. Integrated systems are the usual order: thus. EDM
Polarity: "Standard" is positive on machines can be placed almost anywhere in the normal
workpiece, negative on shop. Fume vents are recommended, and tooling should
electrode (see table 12.3-8) provide a means for venting the liberated gases. The pulse
power supply usually contains full control of "on and off'
times for each discharge, as well as full control of the dis-
DEPENDENT VARIABLES AND RESULTS charge energy.

Average current: 0.1 to 500 A (A few large machines The "grinding" mode of EDM is covered in section 12.2 on
use multiple 500 A power EDG. Section 12.5 on EDWC covers the wire cutting
packs, with separate leads.) EDM operations. Orbital or planetary erosion is a recent
Spark gap: 0.0005 to 0.005 inch [0.013 to 0.13 addition to EDM capabilities. This method makes possible
mm] the almost constant enlargement of a die cavity of geomet-
Overcut: 0.0002 to 0.020 inch/side [0.005 to rically difficult contour with simple electrodes. Electrode
0.50 mm] motions range from simple orbital movement to complex
Material removal rate: 0.003 to3 1.5 in3/hr [0.05 to 24.6 combinations of vertical, eccentric and orbital motions, as
cm /hr] shown in figure 12.3-2.
Wear ratio (ratio of
workpiece erosion to
electrode erosion): 0.5:1 to 100:1 (see table 12.3-12) Machining Characteristics
Surface roughness: 8 to 250 microinches Fl (0.2 to 6.3 High quality output depends upon rigid machine tools and
UmJ
Depth of recast plus 0.0001 to 0.005 inch [0.0025 to 0.13 fixturing for close gap control via the servomechanism
heat-affected zone: mm] which controls the electrode movement.
Corner radius: 0.001overcut
inch [0.025 mm] or equal to Good safety practice makes it desirable to operate with the
Taper 0.0005 to 0.005 inch/inch/side spark fully submerged in the dielectric. Gas and fumes gen-

[0.0005 to 0.005 mm/mim/ erated should be carefully vented. Good hygiene, thorough
side]. With proper tooling, washing by the machine operator and the use of a moistur-
taper can be eliminated. izing cream can eliminate skin irritations caused by the die-
lectric oils.

12-16
 Electrical Discharge Machining-EDM 12.3

0/

C '20
0

EmL 0

0 C)

0;

M0

x C/)
CL..~
U .c i ...
......

AC 0
a) 0

NL-0

0t
CL
UNu

00

0.

ii-1
12.3 Electrical Discharge Machining-EDM
I
SELECTED DATA frequently are measured under "standard" conditions. In
practical application, deviations from "standard" might re-
There are many combinations of EDM operating parame- suit from the use of different materials, dielectric fluids, or
ters that will remove material from conductive workpieces. product forms or from different levels of operator expe-
Experience with particular equipment and/or systems plus rience.
a limited number of test points on particular electrode-
material/workpiece-material combinations will provide the The steps in table 12.3-2 are recommended as one logical
operator with reference points for improved estimating and sequence for selecting EDM operating parameters. Sup-
operating efficiency. Most equipment manufacturers are porting data come from the other figures and tables in ac-
supplying approved data for their installations These data cordance with the terms as explained in figure 12.3-3.

'Swiss stadard 37550 and a Gen-mn reconunenxation V]DI 3400 arm in

exisence circA 197".

12-18
 Electrical Discharge Machining-EDM 12.3
Generalized Cavity Cut
Electrode Dielectric

0 Curen Tracesl

Electrodea

discarg
channelge I-okic
Sparlw

(Plasma) IN*

I *+j cycle

Vaor
I
:-
[o0+ b-i. I
/ I/Chips
/.~.-
~On
I time'
Off
time

t
Peak

Average
LiqidCrater --
E Arc
Recast energy_
Heat-affected zone
Wokiece
Time

Figure 12.3-3 EDM parameter terminology. (Drawing at top courtesy of Agietron Corporation)

12-19
12.3 Electrical Discharge Machining-EDM
TABLE 12.3-2 Steps to Select EDM Operating Parameters

ITEM DATA

1. Type material, metallurgical Engineering drawing and material specifications.

state and melting point
2. Surface roughness required Engineering drawing. (Consider recast and heat-affected zone removal only if
(finishing operation application function requires it and then only on the critically loaded areas or surfaces.
allowance-if any) Recommend removal of 2 times recast layer shown on micrograph of cross section of
trial cut.)
3. Volume of material to be removed From engineering drawing and raw stock shape, calculate in3 [cm 3] to be removed.
4. Material removal rate- Figures 12.3-4 to 12.3-6; tables 12.3-3 and 12.3-4.
preliminary
5. Cutting time estimate Material to be removed divided by material removal rate.
6. Select type electrode material Tables 12.3-5, 12.3-6 and 12.3-12.
7. Mak , trade-offs among machining Table 12.3-7. According to work complexity, electrode, cost, desired precision, and
parameters quantity, a choice between high removal rate or normal or lowest wear must be fixed.
8. Select operating polarity and Table 12.3-8
open circuit voltage
9. Select spe.,ific parameters: Figures 12.3-7 to 12.3-11 and table 12.3-9 are given for one specific electrode
On time-for roughing and (graphite) and material (steel) combination. Similar curves on other material-electrode
finishinc polarity combinations should be developed by the operator using his specific equipment,
Current controls and materials. Many EDM builders have data for their own equipment, figures
Capacitance 12.3-12 to 12.3-15. For "drilling." see table 12.3-15 and figure 12.3-22.
Material removal rate
Surface rc "ghness
End wear
Corner wear
10. Dielectric selection Table 12.3-10; figures 12.3-16 and 12.3-17.
11. Flushing and filtration Table' - 1. One of the most important parameters to secure high quality repeatability.
Must L )red to workpiece configuration, electrode shape and spark gap or overcuts.
Ccnsider use of orbiting electrodes, figure 12.3-2. Increasingly difficult flushing
conditions, figure 12.3-18, can increase the machining cycle time.
Filtration degree for recirculated dielectric should increase as the spark gap decreases
and the flushing becomes more difficult. Recommend 75 pm (micron) filtration maximum.
12. Check availability of selected Equipment ratings ard control points. (Circuit type may require selection of
parameters on equipment to be used capacitance.)
13. Cutting time-refined Based on revised material removal rate from !-.m 9 and material tz be removed item 3.
revised by excluding provision for flushing holes-i 'ny. On finish cuts, it is a good
approximation to assume unworn corners on electrodes when calculating material to be
removed. Allow a multiplying factor for flushing difficulties, figure 12.3-18.
14. Overcut-the side wear between Figures 12.3-12 to 12.3-15. Increases with increase in spark intensity and material
electrode and eroded removal rate and voltage senit,,. "--achworkpiece material-electrode material
workpiece-an allowance for combination has its own overcut, current, frequency charts.
electrode design
15. Wear-an ailowance for electrode Figure 12.3-19; table 12.3 -12. Corner wear is usually the most critical or limiting wear.
design, stroke setting and
accuracy of fine details
16. Number of elect:odes Use finishing electrode for fine details. It can frequently then serve as the -oughing

17. Voltage setting

electrode on subsequent parts. Number to use depends on wear rate and Jepth of cut.
Figure 12.3-20; table 12.3-8. For maximum efficiency, use minimum volts to achieve
average current.
I
18. Select electrode manufacturing Often the most costly element for EDM. Many fabrication/machining methods available.
method Choice depends on electrode material oroduction rate, shape and costs, tables 12.3-13
and 12.3-14.
19. Electrode design
20. Assess ext6nt of altered material
See items 2, 14, 15. 16 and 18.
Figure 12.3-21. Depth of HAZ below recast approximately equal to depth of recast.
i
zones on surface: recast. (Note: If EDM'd surface is highly stressed, subject to stress corrosion or otherwise
heat-affected zone (HAZ) critically loaded, steps should be taken to ameliorate these surface integrity effects.)
21. Trial cut Several test cuts are recommended in the workpiece material using the selected
conditions to check the resulting values for overcut, removal rate, surface roughness and
wear
for hisratio. Theseconditions.
data will, in time, provide the operator with his own machinability tables
particular

12-20
 Electrical Discharge Machining-EDm 123

(/2

0-

00

o .Co
ED
0

U)

CLC'

Co

o o w

0)0
CC
0) C

00

r-r
U'T ~t
12.3 Electrical Discharge Machining-EDM
TABLE 12.3-3 Relationship of Metal Removal Rate In EDM to Surface Roughness and Expected Recast W4
iterlal

EPCE EATMTRA
PROCESSING
LEVEL SURFACE ROUGHNESS, Ro METAL R~EMO VAL RATE Predominant Maximum

Gentle <63 h : Ijjl <0 003 ~ < 0.00022 o< 0.00054- j5414-g
__ ~~ 0.00060 f#5
Finishing 63-1 25 003008ffifPMW 0.00022- ~E- 0.001-
-2 a S - ~ 0.00028 0.03-A
Normal 125-250 0.018-0.42 0.00028- rO1 0.0022- ~.6
0.00043 0.0033 FO06

Roughing 250-500 0.2150.00043- AtJ- 0.0055- O4

0.0008 0.0090 Oi-
Abusive >500 >1.5 >0.00068 - ~~~to 0.014 *

TABLE 12.3-4 EDM Metal Removal Rates

TABL
omePhy~calProGrtishoiED
12~-5 ElectrodeMatetal Elctod

5030 cm C5DC
1 NU-1.

Coppr 1083 2,50 160 9. 651. 500 1.

NOTEr Apomonroh
esiaigguds10___r[64 m/r or2 mee

Sublimes
oribonlsmbeforesmeltinghathatmosrh apclpressure.

I CODC CON- -n -
 Electrical Discharge Machining-EDMV 12.3
40

20 _

100

6 A t
4

x
C

10
C

> .
0

E 0.8 _

0.

0.4 - 0 Workpiece-- - - - - -

- A Tool material -- _ _ - - - -

0.12-

00Sn-Bi Zn Al Cu-NiV MA2 L

5 -. C-ii4 J
100 200 400 600 1000 2000 4000

Melting point. OC

Figure 12.3-S Average metal removal rate versus melting point. (L. J. Quackenbush and W. N. Law-
rence, Electrical discharge machining for the 70's, Ann Arbor, Ml: University of Michigan. 1971, p. 19)

12-23
12.3 Electrical Discharge Machining-EDM
TABLE 12.3-6 Selection of EDM Electrode Material

MATERIAL LINES FORM

CORNER
RATIO IN
I END
RATIO IN COST
V ACHIN-
RATING
RECOM-
USES
USES NOT
MENDED
See Footnote FINISHING ROUGHING

Graphite 1 blocks, 5:1 to 100:1 low excellent tLsling

rod. tube.
bar
Copper 2 bar, rod, 1:1 2:1 medium good holes, slots high accuracy
sheet i and detail
wire, tube.
forgings.
stampings

Copper-graphite 3 blocks.
rods 2:1 4:1 medium fine general purpose I
I
Brass 4 same as 0.7:1 1:1 low good holes and high accuracy
copper cavity sinking
Zinc P.'loys 5 cast, die 0.7:1 2:1 low good forging die holes
casting cavities
Steel 6 all forms 1:1 2:1 low excellent through hols carbides
Copper-tungsten 7 bar, fiats. 3:1 8:1 medium fair slots. carbides large areas
shim stock.
rod, wire.
tube
Silver-tungsten 8 sintered 8:1 12:1 high fair small slots, large areas
I holes and
intricate
details
Tungsten 9 wire. rod. 5:1 10:1 high poor small hWles irregular
ribbon holes

NOTES: Can be pressure-cast ard coined to an existing cavity. Complex shapes

1. GRAPHITE permits fast EDM rates ard best wear ratio, is easy to ma- reproduced more readily than n-.achining Reusable by remelting. Not
chine, and offers excellent stability. Surface rcughness prtduced on recommended for fine detail. Usually has poor wear ratio.
the workpiece is related to graphite particle size and denuity. Rotating 6. STEEL gives slow stock removal rates. Applicable when doing parting-
graphite electrodes can produce roughness values less than 40 micro- line matching. Greater heat-affected zones. Readily machined. but
inches R. [1.0 .m]. A number of different grades are available. Easily wear ratio unsatisfactory for some types of steel.
attached to tool holder with conductive cement. Needs good dielectric 7. COPPER-TUNGSTEN has good wear and finish characteristics. Can be
fnow onditions. brazed and has good rigidit. Used for close tolerances, fine detail, and
2. COPPER produces fine finishes and is excellent for No-wear EDM. Eas- low wear. Used on carbide. Used in slotting operations. Metal removal
ily machined or coined. Low wear ratio, rates are lower than graphite, and the cost is hig-ler. Use positive polar-
3. COPPER-GRAPHITE has best characteristics of both materials-more sty on electrode when machining steels. Molded Cu-W electrodes are
conductivity and strength than graphite. Will work well under poor available for complex shapes or repetitive production.
flushing. 8. SILVER-TUNGSTEN resists corner wed. Good for accurate detail or
4. BRASS has a higher wear ratio than copper but can be economically thinecuts. Provides low wear and faster removal rates than copper- #
machined for many operations. Not recommended for EDM of tungsten tungsten. Is more expensive and generally limited to machining in-
carbide. tricate carbide dies.
5. ZINC-TIN ALLOYS are used for high productiot, where many identical 9. TUNGSTEN has high rigldty which makes it excellent for EDM of holes;
electrodes are needed because they are easily cast in metal molds, under 0.01 0inch [0.25 mm] diameter. High cost but good wear ratio.

I
I

12-24
 Electrical Discharge Machining-EDM 12.3
TABLE 12.3-7 Trade-off Conditions Among EDM
Parameters
SITUATION A SITUATION B

Hiyh material removal rates Low material removal rates

High surface roughness Low surface roughness
Low frequency (long cycle High frequency (short cycle
time time)
High arc energy (high amperes Low arc energy (low amperes
ard long on-time) and short on-time)
Large arc gap Small arc gap
High overcut Low overcut
Modest electroae wear Low electrode wear

TABLE 12.3-8 EDM POidrity and Ope' Circuit Voltage

Guidelines
ELECTRODE (TOOL) POLARITY*
ITEM
Negative Positive

Metal removal rate Medium to high Medium to low

Work-to-wear ratios Medium High to "no wear " t
Surface roughness
steels Gocd to rough Good to excellent
other materials Good (depends on Good (depend- on
other parameters) other parameters)
- I.

WORKPIECE ELECTRODE ELECTi"DE OPEN CIRCUIT

MATERIAL MATERIAL POLARITY* VOLTAGE

Steel Steel Positive Up to 270

Steel WCu Positive Up to 100
Steel Graphite Positive Up to 100
Steel Cu Positive Up to 150
Steel Cu Negat;ve Up tc 270
Copper WCu Prsitive Up to 100
Copper Cu Negatwe Up to 100
Carbides WCu Negative Up to 270
NOTE: These guidelines are subject to change depending upon power
pack characteristics and voltage needed to s tain des;red average cur-
r3nts and cutting rates.
* Normal or "standard" polarity isusually considered to be positive on the
workpiece and negative on the electeode tool However, since the advent
ofsolid state controls (circa 1970), some writings have reversed this, par-
ticularly for sr ne materials where better wear ratios have been expe-
rienced
t"No wear" EDM is the special combination of operating parameters that
on some workplece material-electrode material combinations yield wesir
ratios 100:1 or better, see table 12.3-12.

12-25
12.3 Electrical Discharge Machining-EDM

10 1 eoa
1_ihmta

0.80 t4High power

0.40

0 eMetal removal
E
0.10 (1 64 cm3/hr]
008
006- --

004-- -- -

0 -, - - - 200

0.0110
ow electrode wear 80 a

40)
0

204~

100~

- 0 Z0

8 "

.00 Appreciable electrode wear - ---- ~

... ~~~~~....................... ........ ........ 4

High frequency - JLow frequency - 2

~tiI si
I
-
1 11 j Rough finish2 IT
300: 200 100 50 40 30 20
Imnpulse frequency, kHz
-10
I15 43 2 1

50 100 150 200 250 300 350 400 450 500 550 600 650 700 750
(6 3 im] Surface roughness, pin rms

Figure 12.3-6 Interrelations of EOM process varlak:--a. (Courtesy of Poco Graphite, Inc.)

12-26
 Electrical Discharge Machining-EDM 12,3
1000 - I 1ii I
800 j - Example.
-- . - '-Convert 20 kHz at 75% duty cycle into pulse and pause times -
600 . -- , expressed in microseconds.
_ _Reading from the horizontal scale at the intersect point of 20
kHz (vertical scale), the total cycle time is shown to be 50 micro-
400 seconds at 75% duty cycle, pulse time = 50 x 75% = 37.5 micro- -
seconds, pause time 50 x 25% (the remainder) = 12 5 micro-
seconds.

200 '- I
100 --

80 - ----
N 60 ,-

o 40 i
U-

20 ................ ... ...........--

10 -

8 - ----- --- -

6 -
8\ -- - -"~--- - -

1~~ i__
2 4 6 8 10 20 40 60 80 100 200 400 600 8001000

Total cycle time,ps

Figure 12.3-7 Cycle time-frequency conversion. (Courtesy of Poco Graphite, Inc.)

12-27

- -i-- - -- -- .- - -~ ~ - -
12.3 Electrical Discharge Machining-EDM
Electrode Polarity: NEGATIVE Ip = Peak current
Electrode size. 1 in x 1 in x 4 in rms = Root mean square, /j in
Flushing- Thru elec., 1/4 inch Ohole -/- Pulse/pause time.p)s
1.5

10
3
16 4 cm /hrj- --
_ur1 rr
25/6
100/25 200,/50
080 12/6 - Power (p 25 A)
060 - -- -2 5/6o 0-
-414- 100/25- Power (Ip 12.5 A)
0.40 33 -/
3/2- 4/2 50/12

0.20 25/6 100/25 power (Ip 625 )

3/2 50/12 100/25

E 1 2/2 1l2/3 256 Power (Ip 3112 A)

0.08

o-006 4/2 1

00 2/2 1
002 -- - -- - -- - -- - -

0.01 100
80
8
60

. .- - --- - .0)
- 40

. - 20
3:c
C0

-10 x
}:z End wear 8

,-- 25 A-- 6
312.5 A- 0
" " 3" 2 A
3 1' 4 C.

-9 625 A
6 125A-2A
1. 3.12 A- 1 2
- Comer wear

50 100 150 200 250 300 350 400 450 500 550 600 650 700 750
[6 3pj ml
Surface roughness, p in rms

Figure 12.3-8 Data for Poco EDM-1 electrode (negative polarity) cutting tool steel. (Courtesy of Poco
Graphite, Inc.)

12-28

---,.~-w------- - ----
 Electrical Discharge Machining-EDM 12.3
Electrode Polarity: POSITIVE IP= Peak current
Electrode size- 1 in x 1 in x 4 in rms =Root mean square, min
15 Flushing: Thru elec, 1/4 inch Ohole I-Pulse/pause time. us

1.07

S 0.0 Power
- ( 0p623A

0.0 Powe 3.12 A)A Powp

0.012 25A2 25A0 2. 25

3/2
0.006/ 3. 2 /

14- 3 ' i ~ Iam jii, ii

0.622-I/
-6
50 10 61020 25 0050 50 50 5060 5 0 5

122-2

0.0 Powei~ = 3.12 A)- -lp

12.3 Electrical Discharge Machining-EDM
800 -

700 -

600 -

U1)
fc 400
000

a) 300

U) 200 1

100
50
25
1 2 3 45 10 50 100 500 1000
Arc duration, IIs

Figure 12.3-10 Surface roughness versus arc duration at various currents for EDM of steel with
graphite electrodes. (Courtesy of Hansvedt Engineering, Inc.)

201
18
< 16 Full (20 A) 00
5D 14

W 12 ______
0)
10
>, 10/2 __

E 8_ _

44

2 .,.......1 /20 _

0 10 20 30 40 50 60 70 80 90 100

On-time, %

Figure 12.3-11 Maximum average current versus percent age of on-time for EDM of steel with graph-
ite electrodes. (Courtesy of Hansvedt Engineering, Inc.)

12-30
 Electrical Discharge Machining-EDM 12.3
Graphite electrode 100V
MM nu NAL. j Steel workpiece +

012- 8 4

7
0 126 8 j0l3 -- -

01 -
016 - I

2-2- 3CurAen2
J
u6ac
-0b - 0-

10 20 so 100

330
tp(s mple uato. wtc p
V~ Rte o ersion rnm/"J
v~20 Vouerc6er
RmaxMaxPeakto-ally
Roghnss high. 6
GAP Spark gap.m
Undrsze m
M~~~

131
--

41 4q--:1 2
2.0,
 M A

12.3 Electrical Discharge Machining-EDM

Graphite electrode +
M 2GAP AGIE Riex0100
mm mnm jMSelwrpee
NORiMAL XF
=*~~
=.=* mSelwrklc
U. l
08- 500__
2 i

1 05-05QS

90 50L -9
g - 6

Q2-020 1 8
01 - 7 20-
01 1
008 , 006
7
6
6
5 2 -

iM r200 2

.e-O-~~2j Curren
500
iz 24- zz
S200ace

R.U

roughness t i

1
JT Current amplitude. Switch JT. JP- JR: 20 -

1JT =3A duain1wth0u ____%

tp(g~s) Impulse drto.Sic is51 _ 2

3
Vw Rate of erosion. mm /min
~v Volumetric wear. % 2-----
Rmax Max Peak-to-Valley Roughness height.m 1- - -- f-
GAP Spark gap. mm 02_
M Undersize. mm
Test conditions according to VSM 37550
0~
5
iz iz10 20 so
~
10
~
200 S00 V000 2000
t 9 1s

Figure 12.3-13 Parameter selection for EDM. (Courtesy of Agietron Corporation)

12-32
 Electrical Discharge Machining-EDM 12.3

Copper electrode +10

M 2GAP AGIE Rmax
pmn Steel workpiec_ JJ T11
mm mm NORMAL
#Li U LI U

~0 - O3 - - 10

- -9 10 10- 188 12 8 6
0 --02- 02 - 10
8 - -

9 50
3,_

5 10 20- 50 10 0 00 0

tp ;is
~~~~T~V
amltue Si0hJ. Currentn 04

GAP7
Sprkgp.m

200 _i0 5 10 20 50 00

4 4

.U12-33
12.3 Eiectrical Discharge Machining-EDM

Tungsten-copper electrode, 7 0%W +

M '2GAP AGE RI10
mm mm NORML.MSelWoklc r
='* = =#1.
0 6 06- 03-j - 1
U9 50-LU 60
03
05 05:1-5
04 04-
00404 40- 01

- 0 12 6

02- 01- 0

4
01 -

5 10 20 50 100 200 500

N--- Curren 20 -- 1

21%

30 33A

RateU ersin
K~ 2f 2m/mP

M Underize.mm
res cndtinsacordngtolSo355

F~gue 123-15Paraete'
:..ectin fo EOM (Cortes of gieton orortin

6m.
Current-34
 Electrical Discharge Machining-EDM 12.3
TABLE 12.3-9 Pulse/Pause Times versus Duty-Cycles: TABLE 12.3-10 EDM Dielectrics
Conversion Chart
Principal functions of the dielectric in EDM
UsTP s Insulate until required conditions are achieved.
Flush particles out of spark gap.

2 2 Cool machined particles, tool and workpiece.

3 3 2 Desired properties of the dielectric
4 4 2 Low viscosity.
126 6
12
3
6
2
2 High dielectric strength.
25 25 12 6 2 High flash point.
50 50 25 12 3 Freedom from acid, alkali and corrosion products
100 100 50 25 6 (particularly sulfur compounds when machining sulfur-free
200 200 100 50 12 steels).
400 400 200 100 25 Low toxicity (particularly chlorine compounds).
800
1,600 800 400 200 50
1.600 800 400 100 Dielectrics used in EDM
Hydrocarbon oils-the most widely used
dielectric. Select
APPROXIMATE DUTY CYCLE type and viscosity to suit type cut, gap size and surface
roughness (see figure 12.3-16). Generally cuts more
50% 66% 80% 95% smoothly after a few minutes use, or conditioning.
Water-distilled and deionized. Used principally for
SOURCE, Poco Graphite, Ic., Decatur. TX. micromachining and wire cutting machines (EDWC).
Kerosene-good for superfinishing, but infrequently used.
Deodorizing recommended and attention to safety
precautions. Useful with tungsten electrodes.
Silicone oils-infrequently used: more costly.
Ethylene glycol solutions-rarely used.
Gas-very specialized applications.

x 200
E
cc 100
E
: 50

C 20

10
o 52

O 2_4

0 1 2 3 4 5 6 7 8 9 10
=1 recommended
unfavorable
Viscosity. centistoke at 20 C

Figure 12.3-16 Recommended dielectric viscosity

for EDM as a functior of peak to valley, R,. surface
roughness. (Courtes of Agietron Corporation)

12-35
12.3 Electrical Discharge Machining-EDM

Metal Removal Rate vs Amps at 2,000 HIz

Metal Removal Rate vs Amps at 130,000 Hz

120> 040

072 -

048 -
01

0240.

0010 20 30 40 5 60
Current.A
0 5 10 15 20 25 30
Current. A
End Wear Ratio vs Amps at 2.000 Hz
End Wear Ratio vs; Amps at 130.000 Hz
7 7
6
6
5
2 5-
3

4 - -4
0
1

W 3

0
0
0 10 20 30 40 50 60 0 5 10 15 20 25 30
Curn.ACurrent.
Corner Wear Ratio vs Amps at 2.000 Hz AIat 130.000) Hz
Corner Wear Ratio vs Amps
35 - - - -3.5

30
30
25 - -~25
2

0 2
20 - -
.
1.0.5 3

Dielectric
01- 1 - 1
No 1l-- 100% Silicone oils 0
0 0 20 30 40 So No 2 -Dow Corning 1025-
Curn.AEDItfuid
Curent
ANo 0 5 10 15 20 25 30
3-Conventional 6DM Current. A

coo!anisI
Figure 12.3-17 Effect of dielectric on operating parameters. (Courtesy
of Dow Corning Co.)

12-36
 Electrical Discharge Machining-EDM 12.3

Very good
Factor 1

Good
Factor 2

Fair
Factor 3

Poor
Factor 4

Very poor
Factor 5

S Extremely poor

H more than 10 x D

Figure 12.3-18 Flushing evaluation chart. (L. Houman, How to

estimate 2DM time requirements, Metal
$tamp.ng, 1 (June 1977), p. 15)

12-37

-_ :~~= Z1------
12.3 Electrical Discharge Machining-EDM
TABLE 12.3-11 Flushing Techniques Used In EDM

" Flow aver workpiece cutting area*

* Submerge work in tank
* Pressure through electrode or workpiece
" Suction through electrode or workpiece-or both pressure
and suction
" Ram cycling
" Vibration on workpiece
" Invert cavity (workpiece on ram)

*Carefultire safety check recommended.

Electrode for square hole

Original
lengtht
-Cdre ear

Volumetric

Side wear AY1ioi wear

Original end shape Edwa

Roughing cut

Depth of cut
Workpie ce

Figure 12.3-19 Types of electrode wear in EDn.4. (Modified from H.W. Yankee, Manu-
facturing processes, Englewood Cliffs, NJ: Prentice-Hall. 1979. p.311)

12-38
 WIN

Electrical Discharge Machining-EDM 12.3

TABLE 12.3-12 Electrode Wear Ratio Chart
PART 1
ELECTRODE MATERIAL WORKPIECE MATERIAL POLARITY ON ELECTRODE WEAR RATIO*
percentage
Aluminum Steel Positive 700
Brass Brass Negative 50
Brass Carbide Negative 700
Brass Steel Negative 200
Brass Tungsten Negative 700
Carbide Carbide Negative 150
-' Copper Steel Negative 200
Copper-tungsten Carbide Negative 150
Copper-tungsten Copper-tungsten Negative 50
Copper-tungsten Steel Positive 30
Copper-tungsten Tungsten Negative 75
Zinc-tin Steel Negative 500
Graphite Steel Negative 50
Graphite Carbide - 150 (with caution)
Silver-tungsten Steel Negative 20
Steel Steel Positive 150
Graphite Steel Positive* <1
Copper Steel Positve' <1

PART 2
ELECTRODE MATERIAL WORKPIECE MATERIAL POLARITY ON ELECTRODE ELECTRODE CORNER WEARII
percentage

Graphite Steel Positive <1

Graphite Steel Negative 30
Graphite Incvqel alloy 718 Positive < 1-
Graphite Inconel alloy 718 Negative 35
Graphite Aluminum Positive <1 :nZ
Graphite AI.mnum Negative 15
Graphite Coppsr Negative 40
Copper-graphite Carbide Negative 62
Copper Carbide Negatiw, 50
Copper Steel Positive < 1
Copper Copper Negative 40
Copper Graphite Negative 40
Copper Aluminum Positive <1
Copper-tungsten Steel Positive 6
Copper-tungsten Graphite Negative 40
Copper-tungsten Copper Negative 36
Copper-tungsten Copper-tungsten Negative 80
Copper-tungsten Graphite Positive 70
Copper-tungsten Carbide Negative 40
Brass Steei Negative 100
Brass Carbide Negative 500
Steel Steel Positive or Negative 100

SOURCE: Pat 1, Hansvedt Engineering, Inc., Urbana, IL; Part 2, Elox Divi- *Low- ,ear (pulse mode).
Colt Industries, Dav!dson, NC 'Wear ratios are for 90 corner. Less than 1%electrode wear is achieve,
electrodo length 1wo0.decs enngth between 450on-time
croseconds -nd 50 wit
microseconds on-time vary
graphite. Settings with with
ropper, and 250
electrode to 35 ni-
material

inthis total wear ratio so figure provides length of electrode required for a
finished lengin (depth) of workpiece

12-39
 - 5-

12.3 Electrical Discharge Machining-EDM

26 r
24 -

22 - ___

20 ' '00

> 18

16 -

14

12
E 10

0 000
8 -10

0 11) 20 30 40 50 60 70 80 90 100
On-time. %

Figure 12.3-20 Voltage setting for FDM. 'Courtesy of Hansvedt Engineering, Inc.)

TABLE 12.3-13 Electrode Manufacturing Methods

" Conventional machining from solid block; mill, drill, turn, etc.
" Cut oft from bar stock, rounds, squares, shapes, extrusions !
" Tracer milling from plaster master
" Punching
* Total form machining (TFM, see section 10.6)
Electroforming
o Casting (die, investment, plaster)
* Rotating discs
" Molding (cold, powder metal)
" Pressing, forging, coining
" Extruding
" Electrical discharge wire cutting (EDWC, see section 12.5)

12-40
 r...

Electrical Discharge Machining-EDM 12.3

TABLE 12.3-14 Typical Equipment and Conditions for Machining Graphite
ECONOMICAL TOLERANCES* SURFACE MACHINE
(varying with size ROUGHNESS SETTINGS
EQUIPMENT and volume) RQ TOOL TYPE Tool Speed FEED RATE
in 4 JWm pinl j~f ft/mm n i

Band saw 0.06 to 0 19 15 350 to 600 8 tO5 0.5 inch [12 7 mm] 5,000 J.525 Feed by hand
blade width-
_7,.c 4 teeth/inch [6 3
mm/pitch]
36-grit 003 toO006 125- Thickness 7,000 2130 Feed by hand
silicon w gtlj -Aw 0.06in [1.5 mm]
wheel [1.5-mm]

Lathe 0.003 to 0 125 I 2 50 to 250 !iifto e. Radius tungsten- 850 0.008 to

s tipped..
carbide 0.018 inch
carbidels [0.2 to 0.5
AM mm]
Drill 0.003 to 0.016 2__Ub-X 1300 to 400 i010 Tungsten carbide 110 ;AM Feed by hand
Mill 0.003 to 0.06 120 to 300 tQ . Fly cutter with 2 1. F 9 to 60
tungsten-carbide : in/mm [0.2
bits, 6-inch to 1.5 m/min]
QW. [150 mm] diameter
Reamer 0.002 to 0.005 _9 135 to 65 Tungsten-carbide
reamer
80 1 0.01 in [0 25
mm] cut
Hone 0.001 to 0.003 -W ', 20 to 324 'a os=; 400 to 800 grit 200 Force

Pressure
psi _

Lapping 0001 to 0.003 15 to 30 .4 No.320 or higher 40 * Grind for 1

machine grit aluminum minute
oxide wheels - (variable)
SOURCE Airco Speer. St Marys. PA avoided if possible since these set up stress points that can cause
NOTE- Graphite is readily machinable and can be machined using normal cracking.
metalworking equipment Power requirement for machining graphite is *Finer tolerances can be maintained by carefully controlling operations
normally about half that required for steel Good dust collection equipment when only afew parts are being machined
is a "must" when machining graphite, since large quantities of abrasive 'Lower surface roughness values can be obtained by using finer-grit
dust that are generated will cause wear to the moving parts of machinery wheels
Graphite is a brittle maieral ano requires good-quality tools with sharp
cutting edges to maintain tolerances Sharp internal corners should be

TABLE 12.3-15 Optimum Machining Perameters Used To Compare Mini-Rod* Electrodes with Metallic
Electrodes
ELECTRODE ELECTPLDE PEAK PULSE/PAUSE1 GAP

MATERIAL POLARITY CURRENT TIME FREQUENCY DUTY CYCLE VOLTAGE

A is kHz percentage V
Poco Mirii-RodTM Negative 12.5 12/100 8.93 11 50
Brass Negative 25.0 200/800 1.00 20 50
Copper F itive 25.0 100/800 1.11 11 50
Copper-tungsten Positive 25.0 25/100 8.00 20 5
Tungsten Positive 25.0 50/1600 060 3 50
SOURCE' Poco Graphite, Inc, Decatur, TX.

12-41

- - r ----- --
------- '' ~ ~ -~ -
12.3 Electrical Discharge Machining-EDM
8
6__ _

4
00

2
*0

08

04

02

0005 0.01 002 0.05 01 02 05 1.0 2.0

Material removal rate, ins/hr (16 4 cm3/hrj

Figure 12.3-21 Depth of recast versus process intensity (material removal rate) for EDM of a variety of
materials. (Modified from G Bellows, p. 19)

50 Sixteen electrodes (0.018-inch dia by 12-inches long) 2.0

4 0 -cutting simultaneously, produced sixteen holes in 410
stainless steel 0 100-inch thick. The power supply was a
3 0 -single lead, solid state, variable pulse unit. -

20 Poco Mini-Rod Electrodes1.

0.7 E

CU 0.5
C 10 Copper 0
-0

C) I 0.3
05 - 0.2 O
0.4 - Tungsten
%Copper
03 -tungsten j0.1
0,2

2 3 4 5 10 20 30 40 50 100 200 300400 500

Pulse time. g:;

Figure 12.3-22 EDM drilling performance data for varicjs electrode materials. (Courtesy of Poco,
Graphite, Inc.)a

12-42
 Electrical Discharge Machining-EDM 12.3
SPECIFIC APPLICATIONS DATA

TABLE 12.3-16 Specific Applications Data for Electrical Discharge Machining

Work material: Rene 80, STA Hastelloy Alloy X A6 Steel, 56 R,

Workpiece
cofgrtin n 4 625 i-..58 airfoil slots with
5n,~ 2188-inch cord lengthK
through 0 090-inch watt

4t0 ~
8i
/
0250 in
117 in'

0060 in 150 in

I Fatigue test speciiien 34-inch dia cone 0020 in

Slot

Power supply: Elox HPR104 Elox HPR104 Ingersoll Special Hansvedt SM-150B Hansvecdi SM-150OB

Electrode material: copper copper copper punching (used once) graphite rotating graphite rotating
(rotating (rotating disc disc
wheel) wheel)

Dielectric
type- Texaco 499 Texaco 499 Eloxal 13 oil spray flushing spray flushing
Hansvedt Hansvedt -

SE-290 oil SE-290 oil

pressure, psi: 0 0 submerged

Operation type- roughing finishing roughing finishing

Capacitance, ILF: 2 0 130 0 0

Frequency, kHz: 16 250 18 10 (70% on) 250 (5%on)

Voltage (open circuit), V: 80 70 40 15

Average current, A: 14 to 5 1 25 to 30 14 2 ;I
Polarity on electrode- negative negative negative positive negative
Material removal rate,
in3/hr:

Cutting time, min:sec. 24:00 9:00

I
Su'rface rouighness.
pi R.: 1205 s0 no burrs 32
Tolerance, inch: -0.001 0.001 0O.002

Ovo~cut, ind /stde: 0.003 0.0005

Taper, inch/side:
Oviiner radii, inch/side.

Unear wear rafio

Pnd-. <1% 0.002
' ornier: 15:1 bf volume

INotes:[reciprocation. reciprocatior,. jAutomatic index

45 strokes/min 45 strokes/mmn 4 electrodes simultaneously.
U

12-43 1
 12.3 Electrical Discharge Machining-EDMV
TABLE l 2 .3-l6-Continuei
Work materna1 420 Stainless Steel (1ToStel

WorkpieceI
C~nigraio configrati0 563-
25-inh 05ic in dia
thick ~ 312 in

~II~it 0
563-inh dia: -.
-05 in
Through hole
i Ze l
HatO mold fortfitting

Elowe matrl-yrpit rs HanSvedt SM-150B Hansvedt SM-150B

El ecro
mtei 'gr p ieIr s copper zinc copper copper
Dielectric
type- I oil
oil oil oil Hansvedt Hansvedt
SE-290 oil SE-290 oil
pressure, psi.
Operation type
roughing finishing
Capacitance, fiF 24 24 24 16 0 0
Frequency. kHz: 16 16 16 16 2 (70% on)
Voltage (open circuit), V.
25 80
Average current, A: 25 25 25 15 10 1
Polarity on electrode: negative negative negative negative Positive positive
Material removal rate,
in3/hr: 10.40 0.34 0.38 0.21
Cutting time, min sec:
156:00 48:00
Surface roughness,
jin R.. 210 to 270 170 to 210 210 to 240 200 to 230 24
Tolerance, inch.
Overcut, inch/side: 0.002 0.003 0.0024 0.0034
'--per, inch/side:

Corner radii, inch/side:

Linear wear ratio

end: 5.45 2.08 3.556.5%
corner. 64
Notes:
Ram cycling and Ram cycling and
Pulse flush, pulse flush.
One electrode for One electrode for
both roughing both roughing
and finishing, and finishing.

12-44
 Electrical Discharge Machining-EDM 12.3
TABLE 12.3-16-Continued

Work material: Hastelloy Alloy X H13 Tool Steel, 76 RA

Workpiece
configuration 5 346 holes in 13 sizes
0
c 020 to 0 070-inch dia 0 375-inch thick
long
130-rich
_0
0\095
I In

0 030-inchn Through hole

thick section of
combustor liner

Power supply. Raycon solid state 40-ampere split Elox PS50 Elox PS50 Elox PS50 Elox PS50
lead with refeed control

Electrode material: copper-graphite and Poco EDMC-3 graphite graphite graphite graphite
I (Gentrode (Gentrode (Gentrode (Gentrode
1 10) 10) 10) 10)

Dielectric
type. Texaco 499 petroleum oil petroleum oil petroleum o;I petroleum oil
pressure, psi: surface flow 5 5 5 5

Operation type.

Capacitance, jIF: none 56 28 14 5

Frequency, kHz 10 (50 /is on-time; 50 ps off-time) 20 20 20 20

Voltage (open circuit), V-

Current, A- 3 38 38 15 5

Polarity on electrode negative negative negative negative negative

Material removal rate,
in3/hr. 0.11 in/mm (7 to 26 holes/pass) 1.98 1.84 0.70 0.16

Cutting time, min:sec: 0:50 1:40 1.50 4:45 19:40

Surface roughness,
pin R.- 150 (approx. 0.001-inch recast)

Tolerance, inch: =0.002

Overcut, inch/side. 0.002 0.0042 0.0040 0.0033 0.0019

Taper, inch/side: 0.0018 0.0016 0.0015 0.0012

Corner radii, inch/side: 0.013 0.010 0.007 0.005

Linear wear ratio

end. 15% 7.0 6.5 5.9 3.2
corner, 1.1: 1.1 1.1 1.2

Notes: Fully automatic multiple drilling -inch diameter -inch diameter -inch diameter -inch diameter
with 3-axis NC control and predrilled pI'edrilled predrilled precirilled
multiple slides for electrode hole for hole for hole for hole for
refeed cartridges, flushing. flushing. flushing. flushing.
11 holes average per pass.

12-45
12.3 Electrical Discharge Machining-EDMV
TABLE 12.3-16-Continued

Work material Low Carbon Steel C111

Carbide 7520 Heat-treated Steel

Workpiece
configuration. II0 062 in
5 sl~s dia 8 holes
00069-inch dia
-4- 0045 in x 0 75 in 0Ooo i n
005
0in045-inch wall

0 125-inch thick
I Fuel injector nozzle

Power supply-j Elox PT5 Raycon SH101

Electrode material- graphite tungsten wire jtungsten
Dielectric oimieaolIol
type. petroleumoimneaolol
pressure, psi- 10 0

Operation type:

Capacitance, AF: 0.25 0.90

Frequeri'y. kHz: 100

Voltage (open circuit), V- 40

Current, A: 2 o).2

Polarity on electrode: necaie

leative negative

Material removal rate,

in 3,'nr: 0.030 9 x 10-5 -
Cutting time, min:sec: 240:00 5:25 0.30 per hole

Surface roughness., -
pin R,, 50 J16 to 18, no burrs
Tolerance, inch: I 0 001 0.001

Overcut. inch/side: 0.0007 0007

Taper. inch /side: -0.001 0.0002 >0.00021

Corner. radii, inch/side,

Linear wear ratio

end:U

Notes: One slot per stroke. Electrode Automated flAture. a_

reground 3 times per slot.F0
Quill recycling used.

12-46
 II

Electrical Discharge Sawing-EDS 12.4

PROCESS SUMMARY

Ste, band r+l W~ ec

Disc
"r thickness Feed

Workpece

Insulated work table

fpn
Power feedKe

Workpiece

Figure 12.4-1 EDS schematic. Left, band saw: right, disc saw.

Principles significantly smaller kerf. The low cutting forces permit A

Electrical discharge sawing (EDS) is a variation of elec- slicing of fragile or cellular structures like honeycomb. and M
trical discharge machining (EDM) that combines the mo- because erosion rates are independent of vworkpiece hard-
tion of either a band saw or a circular disc saw with elec- ness. it easily cuts aluminum, stainless steel or titanium.
trical erosion of the workpiece (see figure 12.4-1). The No-burr cutting produces few or no roll-over edges on thin
rapid-moving. untoothed. thin. special steel band or disc is materials. Cuts up to 40-inches I1ml deep have been made
guided into the workpiece by carbide-faced inserts. A kerf on thin-walled heat exchanger tubular assemblies. The low
only 0.002- to 0.005-inch 10.050 to 0.13 mml wider than the forces involved result in few tracking problems. and the to-
blade or disc is formed as they are fed into the workpiecc. tal indicator runout (TIR) is low. Billet and bar cutoff is a
The feed can be (1) uniform with continuous arcing and natural application.
constant feed or (2)servo-controlled to maintain a positive
gap and arc control. The low-voltage. direct-current power Operating Parameters
supplies high currents to the gap, and water is used as a See table 12.4-1.
cooling quenchant for the tool. swarf and workpiece. Circu-
lar cutting is usually performed underwater, thereby reduc-
ing noise and fumes. While the work is power-fed into the
band (or the disc into the work), it is not subjected to ap- Material Removal Rates and Tolerances
pieciable forces because the arc does the cutting, so fix- Cutting rates are approximately proportional to the melt-
turing can be minimal. Precision adjustment of the feed ing point of the workpiece material. The rate is independ-
rate is made to be in exact balance with the arc erosion ent of material hardness, but the material must be elec-
rate. trically conductive. When cutting steels, band EDS
provides cutting rates of 5 to 20 square inches per minute
!32 to 129 cm2/mini, while circular EDS runs from 20 to
I
Practical Applications 300 square inches per minute 1129 to 1935 cm 2/minl (see
EDS will cut any electrically conductive material or. simul- table 12.4-2). Straightness runs from + 0.003 inch I + 0.076
taneously, a mixture of such materials. It will cut about mini TIR at the lower ff.;d rates to 0.016 inch 10.40
twice as fast as a conventional abrasive saw and has a mini TIR at the higher feed rates.

12-47
12.4 Electrical Discharge Sawing-EDS
TABLE 12.4-1 Typical Values for EDS Operating Parameters-Steel
Workpieces

OPERATING PARAMETER I SAND EDS I DISC EDS

Power supply
type: Direct current Direct current
voltage- 16 to 24 V 18 to 35 V
current (varies
with thickness): 400 to 1,500 A 1,000 to 15,000 A

Fluids
frequently i Water Water
sometimes: Air Air
rarely: Water glass (sodium I Water glass (sodium
silicate) silicate)
Fluid flow: 5 to 13 gal/min Submerged
[20 to 50 L/min]

Speed of band or disc: 5,000 to 6.000 fpm 6,000 to 8,000 fpm

1 [1.525 to 1,830 m/mini [1,830 to 2.440 m/min]
Thickness of band or 0.020 to 0.030 inch 0.025 to 0.20 inch
disc: 1 [0.50 to 0.76 mm] [0.64 to 5.1 mm]
Width of band or disc
diameter: {
10.5 to 1.25 inch
[12.7 to 31.8 mm]
Up to 50-inch dia.
[up to 1.25 m dia.]

Wear ratio,
workpiece-to-band or
workpiece-to-disc: Approx. 3:1 Approx. 10:1
Cutting rates: 5 to 20 in2/min 20 to 300 in2/min
[32 to 129 cm 2/min] [129 to 1,935 cm 2/min]

Surface roughness, R.
.oarse, high-ampere 400 to 500 Itin 400 to 500 !dn
cutting: 110 t.125 pm] , [10 to 12.5.urnj
fine, low-ampere 250 to 400 pin j250 to 400 pin
cutting: [6.3 to 10 apm] [6.3 to 10 pm]

TABLE 12.4-2 Circular Arc Saw Cutting Rates recast and heat-affected zone on the surface that is 0.001-to
0.005-inch 10.025 to 0.13 mini deep.
WORK MATERIAL CUTTING RATE
in2/min Equipment and Tools
Tooling consists of simple holding devices because only
Aluminum 775 low forces are involved. Good electrical contact is needed.
Tool steel 280 Z i Band arrangements are available with throats up to 48-
Stainless steel 263 1 inches 11.2 ml deep. Discs with 18- to 60-inch 10.5 to 1.5 ml
Nickel alloys 280 --- blades are typical. with blades up to 72-inches 11.8 ml di-
Cobalt alloys 280 ameter available on special order. Current capacities up to
15.000 amperes have been used.

Surface Technology Machining Characteristics

Surface roughness values for EDS are usually greater than Fast. narrow-kerf. s;ngle-plane cutting is available. Both
those for conventional band sawing or abrasive cutoff. Typ- noise and fume pollution can be reduced when EDS is car-
ically. values range from 400 to 500 microinches R. I10 to ried out underwater. Clean. easily recovered swarf aids
12.5 pml for high feed rates and 250 to 400 microinches R. recycling of expensive metals. Arc erosion also occurs on
16.3 to 10 fnl for low feed rates. The arc discharges leave a the blade or disc.

12-48
 Electrical Discharge Wire Cutting-EDWC 12.5
PROCESS SUMMARY

supplyuppl reel tr t
Dielecri
supply!damete-

Numerical -Spark gap

control X L

_.lotKerf)

Wire

guideS Take-up reel

Figure 12.5-1 EDWC schematic.

PrilncInPs regular practice. and operating time has extended to as

Electrical discharge wire cutting (EDWC) is a special form much as 50 hours of cutting with one reel of wire.
of electrical discharge machining wherein the electrode is a
continuously moving conductive wire (see figure 12.5-1).
EDWC is often called travzling-wire EDM. A small-diame-
ter. tensioned wire is guided to produce a straight. narrow- Operating Parameters
kerf cut. The slowly moving wire brings a fresh. constant-
diameter electrode to the cutting gap. thereby enhancing TABLE 12.5-1 Typicai Values for EDWC Operating
kerf size control. Usually. a programmed or numerically TAEters
controlled mot--n guides the cutting. while the width of the
kerf is maintained by the wire size and discharge controls.
The dielectric is oil or deionized water carried into the gap Power supply
by motion of the wire. The wire is inexpensive enough to be 55 to 60 V (open circuit volts to 300)
frequency: Pulse time controlled 1ito 100pjs in timL'
used only once. The cutting is basically a two-axis process. or 180
1 cto 300 tokHz
zwwith 3 kHz in
most
frequent
PNictical Applications current- Ito 32 A
EDWC acts like ar, electrical band saw with the wire re- Electrode wire
placing the band and the spark discharge. the teeth. A types: Brass, copper, tungsten, molybdenum
straight cut perpendicular to the major axis of (he work- diameter: 0.003 to 0.012 inch [0.076 to 0.30 mm];
piece has no flaring or bellmouth. and extremely tight cor most frequently used size is 0.008 inch
hers can be cut with almost no radius. Punches, dies and [0.2 mm]
stripper plates can be cut in any of the hardened. con- speed: 4.1 to 6 in/s [2.5 to 150 mm/s]
ductive tool materials. The same NC tape can be used re-
peatedly for short production runs. Mir-or-image profile Dielectric: Deionized water, oil, or rarely, air. gas
work and internal contours from a starting hole are fre- or plain water
quent. Stacking of sheets for multiple cutting is possible. Overcut
Conventional carbide dies can frequently be cut from a (working gap): 0.0008 to 0.0020 inch [0.02 to 0.05 mim]:
solid plate using EDWC. without the conventional seg- usually 0.001 inch [0.025 mm
menting and fitting. Operation without an attendant is a
4

12-49
12.5 Electrical Discharge Wire Cutting-EDWC
Material Removal Rates and Tolerances Die relief angle generators and offset controls are available
Cutting of 0.001- to 6-inch 10,25 to 150 mini thick materials on most machines along with kerf-width control via the gap
can be done at a rate of approximately I square inch per setting and wire-diameter selection. Equipment is also
hour 16 5 cm 2 /hri. which on thin parts can yield cutting at available with cam or other mechanical programming for
40 inches per minute 11 m/min (sce tables 12.5-2 and the wire motion as well as with standard EDM servo con-
12.5-3). Positioning accuracy up to =0.0001 inch trol for straight cutting.
I =0.0025 mml is normal in all metals. Workpiece accuracy
usually is =0.0005 inch I= 0 013 mini. with special in- Some machines have CNC or optically guided motion di-
stances of = 0.0002 inch I = 0.005 mml and = 0.0001 inch rect from an enlarged drawing. Table motions as much as
I =0.0025 mml in unique applications. 2 by 3 feet 10 6 by 1 ml have been made. with 1 by 1 foot
10.3 by 0.3 ml being more common. Workpiece thickness 3
to 6 inches 175 to 150 mini can be accommodated-
Surface Technology
Surface roughness is typically in the 30- to 50-microinch R. Forces are low, so simple holding fixtures are practical. A
10 8 to 1.3 aml range. and the surface has a matte or velvet- 5-pound 12.25 kgl reel of 0.008-inch 10.2 min diameter cop-
like texture. Special care and slower cutting can produce a p-r wire can provide 36 hours of cutting.
surface roughness of 15 microinches Ra 10.4 pml. The re-
cast and the heat-affected zor.e are very small and uniform
with the low spark energy levels that are typically used.
These layers should be removed or modified on critical or
fatigue-sensitive surfaces. Machining Characteristics
The machine motions are similar to those for a band or a
wire saw. Use of cutter offset control permits several sizes
Equipment to be cut from the same NC tape. The cutting accuracy is
Several manufacturers regularly build EDWC equipment high because the spark erosion emanates from a fresh, con-
with NC. tracer controls and all programming accessories. stant-size section of wire,

AN

-1-

12-50
 Electrical Discharge Wire Cutting-EDWC 12.5
SELECTED DATA

TABLE 12.5-2 Average Performance Data For EDWC with Brass Wire Electrode

WIRE WORK CUTTING SURFACE CO

WORKPIECE DIAMETER THICKNESS. H WIDTH.S ROUGRATEESS. . Vs
MATERIAL in
[min In
(mm
m ~m! In
(.,a
Rz (Ten-Point Height)
...
-
M

0004 008 to 080 0005 8 to 12 ( 309

[1 ,2,o201 f[130 "02o 03 0 0701

0106 008 to2 00078 14 020 00186

[0151 2 to 50 1981 i 35 to 0.5 [0 120]

0008 0 C8 to 3 0 00,02 14 tc 28 0 0388

[021 [2to 751 1259- [0 35 to 0 71] [02500

Steel carb~on
chrome

0010 041o50 00134 14 to 28 003o8

[0 251 [10:o 125) u0} [035 to071i 10201

0012 3.0 to 60 00149 14to20 00388

[03) I75 to 150) [3781 [0 35 to 0.5 (02501

000 008 to 6 00126 14to28 003 1

P0 25 i [2 to-401 [3201 . 03 to
to0 7 [0 194!

Copperx

SOuRCE Agmetron Corporat-on

NOTE ii- calcwate ctu g sPee drde reova rate (VsI by work IhiCkeSS IH)

__ __
12-51
______ 5
12.5 Electrical Discharge Wire Cutting-EDWC
TABLE 12.5-2 - Continued

WIRE WORK CUTTING SURFACE REMOVAL

WORKPIECE DIAMETER THICKNESS. H WIDTH. S ROUGHNESS. RATE. Vs
MATERIAL 'n R (Te-Point Height) ,r

0 004
0 j 0 08 :o0 .8
"2 000
n 7-S 6 :o9
:3 - :o 244; 035

0006 008 to 1 2 009 9 to 00n:

i015 i2 ,o 229 :C;2- ,- 0 28, 3 n71

Camlece ;1%
cofla,

0010 008"o20 -2 81o20 0019

0 2r 2:o501
0036.- E0 2!; 01221

I
0010 0 C8 to ,6 0011 39 14 " 24- 00186
255 22-c-4C, "0 '351. -03 !o 06- -0120,!

G~ao.hte Ij o35 C093

0010 008 to 1 6 0013-: 2i'zo 35 C093

10 251 2 to 401 0(0
13-0! 10 5 to 34 601

Alumnum 0i 5

SOURCE Ag**ron CotlaO n

NOTE To rca~lcat CurieO ,eved ova;
-e Vy
si work thf~cress aHa
"ave

12-52
 Electrical Discharge Wire Cutting-EDWC 12.5
TABLE 12.5-3 Average Performance Data for EDWC with Molybdenum Wire ,iectrode

WIRE WORK CUTTING SURFACE REMOVAL

WORKPIECE DIAMETER THICKNESS, H WIDTH, S ROUGHNESS. RATE, Vs
MATERIAL iR (Ten-Point Height) /mmin
[mm] [mm] [/jum] pinmi

0003 0.08 to 0.4 0004 14 to 22 00078

10081 [2 to 101 11051 [0 35 to 0 551 [0051

/ ST A
T
Steel. carbon
chrome 0004 0 08 to 0.4 00049 18 to 23 00109
[Oil [2 to 101 [125] [0.47 to 0 591 [007)

0.003 0 08 to 0.5 0004 3 to 9 00062

[0.08) [2 o 127) [105) [0 078 to 0 231 [004)

Carbide. 15%
cobalt 0004 0.08 to 0 5 0 0153 5 to 9 0.0093
[Oi [2 to 12 71 [135) [0 118 to 0 231 [006]

0N

SOURCE Agietron Corporation

NOTE To calculate cutting speed, divide removal rate (Vs) by work thickness (H)

12-53
 POMCIDING PAM BLAW(-NOT FILAMD

Laser Beam Machining-LBM 12.6

PROCESS SUMMARY
Elliptical reflecting cavity length

Total
reflecting ~ --- - ~ - .
mirror ---
- "e -
?Xsngi Material~o~- artial
-~-
Protective
ro
_ , 'n Le n s , t a pe

01 Power N cN
position control table

Figure 12.6-1 LBM schematic.

Principles Cutting, welding, scribing and heat treating can all be done
Laser beam machining (LBM) removes material by melt- with the same laser by varying the energy density and by
ing, ablating, and vaporizing the wcrkpiece at the point of appropriately adjusting the focus (spot size) and the pulse
impingement of a highly focused beam of coherent mon- duration Sharp, short, Gaussian-mode repetitive pulses
ochromatic light (see figure 12.6-1). Laser is an acronym are best for cutting because they have high energy den-
for "Light Amplification by Stimulated Emission of Radt- sities. Welding requires longer duration pulses and a broad
ation." The electromagnetic radiation operates at wave- spot. Welding energy densities are 105 to 107 watts per
lengths from the visible to the infrared (see table 12.6-3). square inch 11.55 x 104 to 1.55 x 106 W/cm 2 . Heat treating
The principal lasers used for material removal are the neo- operates at under 106 watts per square inch [1.55 x 105
dymium-glass, the Nd-YAG (neodymium-yttrium aluminum W/cm 2 l, and scribing requires very short cutting pulses (see
garnet), the ruby and the carbon dioxide (CO2 ). The last is figures 12.6-3 to 12.6-7). Heat treating and welding are
a gas laser (most frequently used as a torch with an assist- not covered in this process summary.
ing gas-see LBT, laser beam torch), while the others are
solid state lasing materials. During laser beam machining, the expulsed material forms
metal gases and vapors, which subsequently solidify to dust-4
For pulsed operation, the power supply produces short, or minute beads. In addition to protection for the lens from
intense bursts of electricity into the flash lamps, which con- molten particles or splatter, a "chip" removal system-fre-
centrate their light flux on the lasing material. The result- quently a vacuum cleaner type-is desirable to keep the op-
ing energy from the excited atoms is released at a charac- crating area clean and free from dust.
teristic, constant frequency. The monochromatic light is
amplified during successive reflections from the mirrors. Practical Applications'
The thoroughly collimated light exits through the partially
reflecting mirror to the lens, which focuses it on or just be-
low the surface of the workpiece. The small beam diver- LBM is not a mass material removal process-it is a fast,
gence, high peak power and single frequeucy provide excel- easily controlled process with a non-contact, non-wearing
lent, small-diameter spots of light with energy densities up tool that imparts minimal heat and thermal distortion with
to 3 x 10 l watts per square inch 14.6 x 109 W/cml which minimal demands upon fixturing. The high energy density
can sublime almost any material. Cutting requires energy in a well-focused beam will melt and vaporize any material.
densities of 101 to2 109 watts per square inch 11.55 x 106 to Contour cuts and slitting of thin steels, aluminum, titanium
1.55 x 10 W/cm 1, at which rate the thermal capacity of alloys, and other metals are done at rapid rates with nar-
most materials cannot conduct energy into the oody of the row kerfs; continuous-wave (CW) modes or high pulse rates
w;orkpieee fast enough to prevent melting and vapor- are used. Texturing and etching are performed at lower
ization. The initial or leading edge of the power spike is energy levels. Small hole drilling can be done at shallow
most important in CO 2 lasers to initiate vaporization in angles (15 degrees) to the surface. Multiple pulses permit
nonmetal drilling, which then promotes better absorption
of the energy. Workpiece surface reflectivity, absorption
coefficient, thermal conductivity, specific heat and heat of 'Laser technology isadvancinarso rapidly that current limitations frequently
vaporization are all important when considering a laser are removed by more recent developments. A check with active laser-
application, equipment buiders is recommended for
new applicat;'.q.

12-55
12.6 Laser Beam Machining-LBM
hole dri;ling to 40:1 depth-to-diameter ratios on 0.005-inch of the laser's speed and precision. Viable applications for
10.13 mm diameter holes, while larger holes, 0.050-inch LBM range from diamond wire draw dies to catheter drill-
11.27 mm diameter, can be drilled in 0.50-inch 112.7 mm ing to food sieves. The ability to direct and focus the laser
thick material. Trepanning is done for still larger holes us- beam into inaccessible locations permits unusual appli-
ing NC or a circle-generator attachment. Plastics, rubber, cations, such as balancing rotors dynamically while they
cloth and similar organic-base materials cut more easily are rotating.
than the metals. Ceramics, glasses and composites of many
types are drilled, scribed and diced. Microcircuit com- For additional applications, see Laser Beam Torch. sec-
ponents. resistor trimming or circuit "deburring" make use tion 12.7-particularly for slitting and for contour cutting

Operating Parameters

TABLE 12.6-1 Typical Values for LBM Operating Parameters and Process Capabilities

OPERATING PARAMETERS

Lasing material: Ruby Nd-YAG Nd-glass CO2

Type: Solid state, Solid state Solid state Gas,
smallest spot, high efficiency
high peak watts,
most easily
absorbed by
metals
Composition: 0.03 to 0.07% Cr 1%Nd Glass + CO, + He + N2
2 to 6%Nd
Wavelength, micrometers
(see figure 12.6-8): 0.69 1.064 1.064 10.6
Efficiency, %: Up to 1 2 2 10 to 15
Beam mode: Pulse Pulse or Pulse Pulse or
continuous continuous
Spot size at
focal point.
in: 0.0005 0.0005 0.001 0.003
[mm]: [0.013] [0.013] [0.025] (0.076]
Pulse repetition
rate, pps*
(normal mode
operation): 1 to 10 1 to 300 or 1 to 3 Continuous wave
continuous
wave
Beam output,
watts: 10 to 100 10 to 1.000 10 to 100 250 to 10,000
Peak power, kW
(see figure 12.6-9): 200 400 200 100
Beam divergence,
milliradians: 5 to 7 1to 5 5 to 7 0.1 to 10
Excitation sources: Krypton, xenon or tungsten-halogen lamps, electrical discharge

PROCESS CAPABILITIES,

Drilling diameter: 0.00002 to 0.050 inch [0.005 to 1.27 mm]

(larger with trepanning)
Drilling depth: Up to 0.70 inch [17 mm]
Drilling angle to surface: 15 to 90 degrees
Drilling taper: 5 to 20% of hole diameter
Drilling length-to-diameter ratio: Up to 50:1
Drilling length. trepanned: Up to 0.25 inch [6.4 mm]
Drilling tolerance: h5 to 20% of hole diameter
Minimum comer radius: 0.010 inch [0.25 mm]
O -- pulsts per second. 0-switched lasing can greatly increase all these repetition rates.
'See also table 12.6-3 and figures 12.6-10 to 12.6-14.

12-56
 I
Laser Beam Machining-LBM 12.6
Material Removal Rates and Tolerances concern. Removal or modification of such lasered surfaces
Material removal rates are slow. approximately 4 x 10
4
is recomr ended (see section 18.3).
3 3
cubic inches per hour 16.5 x 10- cm /hrl. Nevertheless. a
laser can drill or slot thin materials faster than a workpmece
can be repositioned by numerical control. Even if multiple Equipment and Tooling
laser pulses are necessary. each pulse typically takes only The principal equipment emphasis is the control of the po-
one-thousandth second. The removal rates are inversely sition of the workpiece under the focal point of the beam.
proportional to the material thickness. Even deeper holes Multiple-axis control is needed to allow the beam to follow
can be drilled rapidly. for example. 1 to 3 seconds for a undulations in: the workpiece. Computer or numerical con-
0.020-inch 10.50 mm diametri hole in 0.10-inch 12.5 mm trol makes use of the easy integration of the laser parame-
thick nickel alloy. Because flash lamps have a long life. ters-intensity. focus, pulse rate-with motion control or
costs :an be reduced to a few cents per slot. and for mul- automation. Beam deflecting, beam splitting for multiple
tiple arrays of holes, to tenths-of-a-cent per hole. Holes and machining sites, circle generators for trepanning. special
slots will have irregular surfaces or roundness and will con- lenses (toric, axicon). rotating mirrors, and time sharing
tain taper. yet location accuracies up to 0.001 inch are all employed in special laser systems. The absence of
10.025 mml are commonplace and limited primarily by mechanical contact, the low-inertia beam and the nearly
the accuracies available in the positioning devices for the forceless characteristics of the laser simplify the fixturing.
workpiece. Conventional. axicon or toric lenses are used to
attain better productivity in unusual applications.
Machining Characteristics
Surface Technology The ease with which the laser beam can be manipulated
Laser machined surfaces are usually rough and have a re- enhaaces its versatility. Adequate eye protection is needed
cast texture. The rapidity of the application of energy re- for bath direct and reflected laser light. The United States
duces the heat-affected zone and recast to less than that Bumeau of Radiological Health has issued requirements
from other thermal processes. The usual recast is about that laser manufacturers should follow to assure personnel
0.001 - to 0.002-inch 10.025 to 0.050 minI thick, with some safety. The CO:! laser wavelength is opaque to plastic, so
as much as 0.010 inch 10.25 mm, with a heat-affected zone shielding or enclosure is simplified. Dust control is neces-
below the recast. as shown in figure 12.6-13. In many ma- sary. and vacuum systems are the prevalent method for
terials, a hardness alteration will also occur below the sur- removing'the -chips." The gases released by some mate-
face. These surface effects can be detrimental to product rials during LBM should be checked with OSHA for safety
integrity if the surface is highly stressed or if fatigue life is a effects.

12-57
12.6 Laser Beam Machining-LBM

SELECTED DATA
There are several valid techniques for selecting operating
parameters for LBM. The steps in table 12.6-2 are recom-
mended as one logical sequence. Supporting data come
from the other figures and tables in accordance with the
terms as explained in figure 12.6-2.

TABLE 12.6-2 Steps To Select LBM Operating

Parameters

ITEM DATA

1. Workpiece material Engineering drawings, specifica-

and its thermal tions, handbooks
characteristics
2. Select type laser, Tables 12.6-3 to 12.6-5 and figures
wavelength, and mode 12.6-3 to 12.6-9.
of operation
3. Type optics Small spot size, easier with shorter
wavelengths; better quality optics
required with longer wavelengths
4. Lens selection Depth of focus (d), focal length (f),
and spot size (s)determined on
application need and configuration
of workpiece
5. Workpiece motion CNC, DNC, or NC depending on
control complexity of workpiece and
volume of production
6. Safety shields Determined by material handling
needs*

*See also D.Sliney, Health hazards from laser material processing. Tech-
nical paper MR75-581, Society of Manufacturing Engineers. Dearborn, Mi.
1975. A

M
I

12-58
 Laser Beam Machining-LBM 12.6
Flash lamps
Workpiece

okic
Divergence angle
' Lens spot s--
...:---
.. --
.-=..
: ..size
. . ... .,

Vaporization

Full Stimulation Partial Monochromatic

mirror mirror coherent
light Focal length

dH

*Distance within which the spot size (s) is no more than 40% larger than at focus. Depth of focus'

Figure 12.6-2 LBM parameter terminology.

TABLE 12.6-3 Commercial Lasers Suitable for Materials Processing_____

LASER MODE OF PULSE PULSE

TYPE WAVELENGTH OPERATION POWER REP.RATE LENGTH APPUCATION COMMENTS -:

A.lM W pps

Argon 0.4880 Repetitively 20 peak; 60 50 ps Scribing thin Power low

0.5145 pulsed 0.005 films
average
Ruby 0.6943 Normal pulse 2 x 105 Low 0.2 to 7 ms Large material Often un-
peak (5 to 10) removal in one economical
pulse, drilling
diamond dies,
spot welding
Nd-Glass 1.06 Normal pulse 2 x 106 Low 0.5 to 10 ms Large material Often un-
peak (0.2) removal in one economical
pulse
Nd-YAG* 1.06 Continuous 1,000 Welding Compact;
economical at
low powers
Nd-YAG 1.06 Repetitively 3 x 10s 1to 24.000 50 to 250 ns Resistor trimming, Compact and
0-switched peak; 300 50 nis electronic circuit economical _
30 average fabrication
Nd-YAG 1.06 Normal 400 300 0.5 to 7 ms Spot weld,
pulsed drill
Coil 10.6 Continuous 15,000 - - Cutting organic Very bulky at
materials, oxygen- hgh powers
assisted metal
cutting
CO 2 10.6 Repetitively 75.000 400 50 to Resistor trimming Bulky but
0-switched peak 200 ns economical
1.5 average
COz 10.6 Superpulsed 100 100 10 0 1pS Welding, hole
cutting Bulky but
economical
average and up production,

SOURCE: Modified from J. F.Ready. Selecting a laser for material working. Laser Focus (March 1970). p.40.
*Neodymium-yttrium aluminum garnet. I
* COl plus He plus N,mixture.

12-59
12.6 Laser Beam Machining-LBM

Drilling Welding
intensity >1 O"W/cm' intensity <1 05W/cm'
Vapor -i - - ------
~u-suf -Surfade
-t rmeraiur eriraire-
*0~~ur- miraeSbsiae-
cciii ~ dmfa.~gr%.

Melt- ice s -
yt wd
0._::- I emea

F- cc -srto/
Room
Time

Figure 12.6-3 Difference in energy and absorption between laser drilling and laser welding. (S. R.
Bolin, Pulsed-laser metalworking, American Machinist 120 (October 1976) p. 124)

Gaussian Mode (or TEM~c)' Ideally suited for Mixed Mode (approximately 50% each of
high quality cutting. Power densities up to 109 TEMQ0 and TEMo,). Flat topped distributionI
watts/inch2 [1.55 x 101 W/cm?]. Mode quality is makes this model ideal for welding and heat
maintained throughout the pov -r range. treating.

*TEM - transverse excitation mode

Figure 12.6-4 Laser excitation modes for cuffing versus welding. (Courtesy of GTE-Sylvania)

12-60
 Laser Beam Machining-LBM 12.6

1 5 __________________ 2 x continuous wave

.10 gsContinuous wave

Optimizedga
3:mixture 0
0.
05 '~ 0 5 rStandard gas
mixture

0
0 02 04 06 08 1.0 0 1.0 2.0 3.0 4.0 5.0
Pulse length. ms Pulse length. ms

Figure 12.6-5 Pulse configurations for C02 lasers. Left, short pulse length (less than 100 ps to peak);
right, long pulse length. (Courtesy of Coherent, Inc.)

20

15

7)
CL

a; 10
C. Maximum pulse rate
0)

0 20 40 60 80 100
Pulse rate. pps

Figure 12.6-6 Operating range of a flash-lamp pulsed Nd-YAG laser. (Courtesy of Coherent, Inc.)

12-61
12.6 Laser Beam Machining-LBM
500 ________ 1_______1___ 250 TABLE 12.6-5 Selecting a Laser Type for Machining
% Continuous wave power. W
%APPLICATION LASER TYPE
400 ---- 4-200
% % NLarge holes (to 0.060-inch
Average [1.52 mm] diameter) Ruby, Nd glass. Nd-YAG
_____power 150 3: Larger holes (trepan ned) Nd-YAG, C02
~300 %1
o Small holes (>0.010-inch
[0.25 mm] diameter) Ruby, Nd glass. Nd-YAG
~ 20 0 ___0_ Drilling (punching or percussion) Nd-YAG, Ruby
20 -i- 100
% Thick cutting 002 + gas assist*
%< Thin slitting metals Nd-YAG
100 ---- 50 Thin slitting plastics C02
Peak%
power -=---Plastics C02

0 ____ 0 Metals Nd-YAG, Ruby. Nd glass

0 6 12 18 24 Organics. nonmetals Pulsed 002
Repetition frequency. pps x 103eaic usd00,N-A
*See also gas-assisted cutting under LET. section 12.7.
Figure 12.6-7 Relationship of peak power and av-
erage power with variation in repetition frequency
(YAG laser). (Courtesy of Holobeam Laser Company)

TABLE 12.6-4 Relative Power To Vaporize Equal

Volumes In Equal Time

Aluminum 1.0
Titanium 1.5
Iron 1.8 0
Molybdenum 2.2Ri
Tungsten 2.9

SOURCE: Metals Handbook. Vol. 3-Machning Metals Park. 011: Ameni-

can Society for Metals. 1967. p.254.

12-62
 Laser Beam Machining-LBM 12.6

This nomograph provides fast, convenient conversions among the 40

various ways of describing light waves in energy, frequency and
wavelength -30
As an example, the left side of the nomograph shows that the 532- 1
nanometer wavelength of a frequency-doubled neodymium-yag Af ( (X,
laser corresponds to an optical carrier frequency of 5 6 x 10"-hertz. Hz cm-" -20

and a photon energy of 2 3 electronvolts or 18.800 wavenumbers (cm* )
The right side of the nomograph shows that the laser's spectral
width of 0.5 cm-" is equivalent to a width of 15 gigahertz or 0.14 3- 1000
angstrom. -10
-500 -
-
10' - 7
Energy Frequency Energy Wavelength- 200
eV Hz cm-, nm 5- -5

1.5 5 200 -100 -

6

5 4 -50
10,2_
-2
1 10's 300 20
5
3
8 10
-3 400 1

1- -10.7
(L 6 2 500_
5-2
< 5- 5 -050

2 -------4-
5
5 05 03
-1.5 800 1
-02
0.2
3 1 "10' 1000 5---72-
."0.1
7-
-- -8 --- - - .1
0.9 -0.05 -

0.8 2 - - - 6 - --- .07

010'.
-- 0.0

0.7 510'02 .05

1.5 5 2000L 0.01 -

-0.03

.02

-0.01

0.005

Figure 12.6-8 Energy nomograph. (Courtesy of Photonetics Associates; reprinted from 1979 Laser Focus
Buyers' Guide)

12-63
12.6 Laser Beam Machining-IBM
This nomograph relates the energy and power of a laser beam to its temporal
Average characteristics. In the example. the right side of the nomograph shows that a Peak
power 50 nanosecond
kilowatts. the leftpulse
side containing
shows that,20formillijoules
the 20 mJhas a peak
pulse, power
a pulse of 400
repetition power

1 jj frequency of 10 hertz corresponds to an arverage power of 200 milliwatts. I1W

Pulse
energy

10 PW 100 J l0w

ioopw 101 100 W

1mW1 Pulse 1 kW
duration
Pulse
repetition 100p
frequency

10 RIW0.Hz10mlol10k

100 mW 10k

10 kHz 1 100 ps

low100kHZ 10 nsJ

1w1 kHz 1ip1rs;IM

10W10MkHz 105*Js

100 MHz

1kW
I 1 GHz 1 1GW

lO~nJ 10GW

Figure 12.6-9 Pulse energy and power nomograph. (Courtesy of Photonetics Associates; reprinted from
1979 Laser Focus Buyers' Guide)

12-64
 Laser Beamr Machining-LBM 12.6

0 150 Multiple pulses

0/0
cC

0.

0 0010 0.020 0.030 0 040 0.050 0.06 0.070

1? 5 mmI
Hole diameter, in

Figure 12.6-10 Capabilities for laser drilling of superalloys.

1.0

0.5

CL 0.1 12.5 mm]

0
Y- 0.05

0.0001 0.001 0.01 0.1

Hole diameter (2.5 min]

Figure 12.6-11 Typical depth and diameter values for pulsed-laser drilling in ferrous alloys. (Adapted
from S. R.Bolin. p. 126.)

12-65
12.6 Laser Bpqm Machining-LBM
60

50

c40

20

10 [254 mm/si

[0.76 mm]
0
0 0.015 0.020 0.025 0 030 0.035

Cloth thickness, in

Figure 12.6-12 C02-laser cloth cutting (250 watts TEM~o). (Courtesy of Coherent, Inc.)

0.010
[0.25 mm]

C:
0
N

E 0.005 Ha

Z0 Predominate afetdon

0 0.05 0.10 0.50.20 0.25

[6.4 mm]
Material thickness, in

Figure 12.6-13 Surface effects from LBM, circa 1978.

12-66
 Laser Beam Machining-LBM 12.6
TABLE 12.6-6 C0 2-Laser Drilling of Plastics____
HOLE DIAMETER
PULSE POWER
MATERIAL THICKNESS Top Bottom LENGTH LEVEL

inin w'IW& in ms
S

PVC 0.025 0.010 5.0 50.0

PVC 0.025 e6 ~ 0.030 7z 40 50
PVC 0.020 0.012 0.010 RNA5~ 10 50
Pvc0.2 0.020 30
Acrylic 0.060 0.007 Ql 0.005 ggg 3 10 50
Polyethylene 0.006 0 .0014 4.5 150
Polyethylene 0,020 0.015 20 50
0010 205 50
Polystyrene 0.01301050
Polystyrene 0.011 Ni 0.040 OE 40 50
ABS
plasticO0300.0010 5
ABS plastic I 0.030 0.040 100 50
ABS lasti 0.005 0.015 ~ 0. 506
Acylic 0.005 0.4 2.617
Alcr t 0.035 0.0165 10 175
Nylon 0.035 - 0.011 '~ ~10.0 175.0

SOURCE: Coherent Inc.A

0.010-inch center-to-center spacing

0.016

.2 0.012

_CD

0.008

0.004

024 6810 12

Linear speed. in/s

Figure 12.6-14 Ceramic scribing chart-penetration depth versus speed using 185-watt continuous-
wave 002 laser. Shaded area reflects operating domain expected In production environment with a 1.5-
t ~Inch focal length lens. (Courtesy of Coherent, Inc.)

12-67
12.6 Laser Beam Machining-LBM

SPECIFIC APPLICATIONS DATA

TABLE 12.6-7 Specific Applications Data for Laser Beam Machining

Work material: ABS Plastic Strip Cloth, Single Ply Brass Caps

Workpiece
configuration:

0.030-inch thick 11-inch di.

Laser equipment
type: C02 CO2 Nd-glass Ruby

wavelength, /m: 10.6 10.6 1.06 0.69

power, W: 250 500

Operating conditions
power level: 50W 40J

beam mode: Pulsed CW TEM~o Pulsed Pulsed

pulses per second: 1 1

cycle time: <1 s Up to 40 in/s 50 caps/min

pulse length, ms: 20 0.150 0.60

Tolerance, in: 0.0003

Remarks: Drilled while strip moving. Computer controlled nesting Vibratory bowl feed for
Laser deflection used to and cutting. workpieces.
reduce relative motion. Seals edge so no fraying.

12-68
 Laser Beam Machining-LBM 12.6

TABLE 12.6-7-Continued

Work material. Stainlecs Steel Surgical Quartz Tubing, Cutoff Rene 80

Needle

Workpiece
corigur"on. 0 0,3-i:ct, dia

"
0 110 in 15

f-U~~~~~~~ *
Lm-'
~ .. inIlIul 10i

0 006-inch dia LO 125 in

x 0 n60-inch deep 0 007-ich dia

Laser equipment
type, Ruby COl Ruby

wavelength, pm. 0.69 10.6 0.6v

power, W. 150 J 500 25 J

Operating conditions
power level" 3J 250 W 14.5 J

beam mode: Pulsed CW Pulsed

pulses per second: 1 1

cycle time: 10 s 4s One pulse

pulse length, ms: 1 1

Tolerance, in

Remarks. No cracks and ends smoothed. 35:1 = length to diameter

Room temperature cutting with ratio.
tube rotating at 60 rpm. 0.002-inch recast.

12-69

S~ -- - -
12.6 Laser Beam Machining-LBM
TABLE 12.6-7-Continued

Work materiai: Kapton Insulated Wire Rubber Plastic

Stripping (No. 26 to 1/0 Wire)

Workpiece
configuration:

\ / 0~~0135.tnch dia- -.- , 04

Insulated wire 015i

Laser equipment
type: C02 Ruby Ruby
wavelength. jf : 10.6 0.6 0.69

oe~wer, W: 250 50 J 50 J

Operating conditions
power Ievel: 4W 27 J 25 J

beam mode: OW Multi Multi

pulses per second: 1 1

cycle time: 15 s for 18 wire 30 shots 3 shots

pulse length, ins: 5 6

Tolerance, in: No action on metal wire.

Remarks: Laser beam rotated around

wire.
Spot size 0.005-inch dia.
and IOs W/in2.

1
4

12-70 _
 Laser Beam Torch-LBT 12.7
PROCESS SUMMARY

_________________Plane mrirror

Focused beam f

Gas jet nozzle

Workoiec.
Workpiece motion

Figure 12.7-1 LBT schematic.

Principles contact lenses are all practical LBT applications. While

Laser beam torch (LBT) is a process in which material is most cutting is done on stock less than 0.10-inch 12.5 mrr
removed by the simultaneous focusing of a laser beam and thick, carbon steel up to 0.50-inch 112.7 mini thick has
a gas strcprm on the workpiece (see figure 12.7-1). A con- been cut at 30 inches per minute 1760 mm/minl with higher
tinuous-wave (CW) laser or a pulsed laser with more than power lasers. The narrow heat-affected zone minimizes
100 pulses per second is focused on or slightly below the trimming and post-cutting cleanup operations. Before se-
surface of the workpiece, and the absorbed energy causes lecting laser as a cutting process, a comparison with other
localized melting. An oxygen gas stream promotes an exo- processes is desirable. Table 1..7-4 and figure !2.7-4 con-
thermic reaction and purges the molten material from the tain comparative data. The rapidity of the change in the
cut. Argon or nitrogen gas is sometimes used to purge the state of the art of LBT makes it desirable to check with
molten material while also protecting the workpiece. Ar- laser builders for the latest process capabilities.
gon or nitrogen gas is often used when organic or ceramic
materials are being cut. Close control of the spot size and
the focus on the workpiece surface is required for uniform Operating Parameters
cutting. The type of gas used has only a modest effect on See table 12.7-1. !
laser penetrating ability (see table 12.7-3 and figure
12.7-19). Typically, short laser pulses with high peak
power are used for vaporizing materials (drilling and scrib-
ing) while long pulses are used for cutting and welding, as Material Removal Rates and Tolerances
shown in figure 12.7-3. The C0 2 laser is the laser most of- The cutting rates depend upon the thermal properties of
ten used for cutting. the material (table 12.7-5), the material thickness and the
power density in the focal spot (figure 12.7-3). A 0.002-inch
10.05 mm) diameter spot can attain a density of 7 x 109
Practical Applications watts per square inch 11.1 x 10 9 W/mm2 l, which is suf-
The LBT cut is characterized by a narrow, tapered kerf ficient to vaporize any material. Cutting rates range from
and a shallow heat-affected zone. For a given power level, 30 inches per minute 1750 mm/min) on 1/16-inch 11.6 mm)
the highest cutting speed yields the best quality of cut and thick tool steel, to 240 inches per minute 16,100 mm/minl
the minimum heat-affected zone. The assisting gas im- on 0.020-inch 10.5 mini thick tinplate, to 500 inches per
proves the quality and decreases the kerf. Complex con- minute 112,700 mm/mini on 0.030-inch 10.75 mini thick
tours can be cut in hard materials like silicon carbide, Lexan with a 1/2-kW continuous-wave CO 2 gas laser. This
friable materials like glass, or sticky materials like con- laser will cut 1/4-inch 16.4 mm) thick aluminum at 3 inches
fections. Thin materials are cut at high rates, with 1/8- to per minute 175 mm/mini or 1/4-inch 16.4 mml thick tita-
3/8-inch 3.2 to 9.5 min thickness a practical limit. Me- nium at 140 inches per minute 13,500 mm/minl.
chanical, optical or numerical control of cuts is usual.
Trimming of high strength alloy sheet products with LBT Accuracies up to 0.004 inch I 0.1 mmi are attainable
has reduced previous trimming costs as much as 50 per- and depend upon the accuracies in the workpiece motion
cent. Plywood die-board slotting for steel-rule dies, con- control. Taper is present in most kerfs, as shown in figure
tour-cut titanium plates for aircraft fabrications, stacks of 12.7-20, and too high cutting speeds will impart a curved
cloth for suits, stripping of wire insulation, and drilling of lay pattern in the cut.

12-71
12.7 Laser Beam Torch-LBT
TABLE 12.7-1 Typical Values for LBT Operating Parameters

Laser types: Continuous wave Nd-YAG (cutting)

Continuous wave C02 (cutting)
0-switch or pulsed ND-YAG (drilling)
Power: 0.25 to 16 kW

Gas
types: Oxygen, nitrogen, argon, air, helium
pressure: 20 to 120 psi [140 to 825 kPa]
nozzle diameter: 0.020 to 0.040 inch [0.5 to 1 mm]
nozzle gap: 0,020 .+.0.010 inch [0.5 0.25 mm]

Focus
spot size: 0.002 inch [0.05 mm] smallest diameter
0.003 to 0.010 inch [0.07 to 0.25 mm] usual
depth of focus*: 0.030 to 0.33 inch [0.76 to 8.4 mm]
focal length: 1.5 to 5 inches [40 to 130 mm]
foca! pcint: Surface vi biii1y 6310w

Trim/cleanup setback: 0.5 to 3 times stock thickness

Kerf: 0.004 to 0.080 inch (0.1 to 2 mm]
(see table 12.7-7 and figures 12.7-20
to 12.7-24)
Heat-affected zone (HAZ): 0.001 to 0.010 inch [0.025 to 0.25 mm]

Cutting rates (feed rate): 10 to 300 in/min [250 to 7,500 mm/mia]

(see table 12.7-7 and figures 12.7-6
to 12.7-19)

Cut thickness capability for

nonferrous alloys: Up to 0.040 inch [1 mit.]
ferrous and titanium alloys: Up to 0.200 inch [5 mm]
nonmetals: Up to 0.1C inch (2.5 mm]
ni-kel alloys: Up to 0.60 inch [1.5 mm]
plastics: Up to 0.20 inch [5 mm]
Minimum outside trim
radius: 0.50 inch [12.7 mm]

*Distance between which spot size is no more than 40 percent largerthan at focus.

Sura., Technology been built. Laser cutting forces are almost nonexistent so
A heat-affected zone (HAZ) is present in all laser cuts but fixturing is less complicated. Rotating mechanisms for the
the rapidity of the metal removal can leave less HAZ than lens (or mirrors) are employed when trepanning larger-size
competing processes (see table 12.7-7 and LBM section, holes.
figure 12.6-13). Surface roughness is high-125 to 250 mi-
croinches R, 13.2 to 6.3 pai being typical. The amount of
stock removal needed to clean up the roughness or HAZ is
minimal and ranges from one-fourth to three times the Machining Characteristics
stock thickness. Dross attached to the underside of the cut It is essential to keep the laser beam focused accurately on
usually is zasy to remove, the workpiece. Optical and mechanical contour followers
are availabl, to adjust the torch focus when workiS on
sheets with undulations. Adequate fume and sight pro-
Equipment and Tools tection are needed for LBT.
LBT equipment is --iailable in 1/4- to 16-kW sizes in
worktable sizes up to 4 by 6 feet 11.3 by 2 mi. NC, optically The noncontacting tool in LBT increases tool life almost
or mechanically guided torches or workpieces are available indefinitely. The choice of gas used can be influenced by
to cut straight or intricate contours. Multiple torch com- the need for protection of the workpiece material (see table
binations and LBT combined with punch presses have 12.7-6).

12-72
 Laser Beam Torch-LBT 12.7
SELECTED DATA 1o -.

There are several valid techniques for selecting operating N. Drilling

parameters for LBT. The steps in table 12.7-2 are recom- ..

mended as one logical sequence. Supporting data come 10;' N- - - .

from the other figures and tables in accordance with the E I Cutting
terms as explained in figure 12.7-2. , " -
Ir--- --
" 106 - Welding
it Alloying
LaserI LaserIl 1 Cladding
Lens I .
7!'

a- jos
~aCr,atio; .1

10' I , I I
Focal 10-.' 10"6 10"5 10-' 10
3
10"2 10-'
Gas Cutdance

material thickness
ri Figure 12.7-3 Laser material
processing appli-
Gap/ ,.../
/ ( cations in terms of power density and interaction
zv&piece; time. (A. Schachrai and M. Castellani-Longo, Appli-
cation of high power lasers in manufacturing, Annals
Heat-affected zone of the CIRP. Vol. 28/2, 1979, p. 466)
Kerr

0-- Trim allowance

Figure 12.7-2 LBT parameter terminology.

TABLE 12.7-2 Steps to Select LBT Operating TABLE 12.7-3 Penetration of CO2 Laser In Perspex
Parameters (Boxboard) with Various Gases
ITEM DATA GAS PENETRATION

1. Workpiece material _
_
_
_
_
_
_
_
_
in
I.
characteristics Engineering drawing and Helium 0.93 -
table 12.7-5 Nitrogen 0.94
2.Applicability of LBT Comparison of saw, nibble, Oxygen 0.89 i
plasma- arc, oxyacetylene, Air 0.96
etc., with laser, table 12.7-4 Argon 1.00
and figures 12.7-3 and 12.7-4 Carbon dioxide 0.87
3. Select assisting gas Tables 12.7-3 and 12.7-6 and Argon/hydrogen, 75/25 0.91
figure 12.7-19
4. Material thickness SOURCE: F.W. Lunau, Boc-Murex Welding Research and Development
(cut depth) Engineering drawing Laboratories, London.
5. Select power level
and cutting rate Figures 12.7-5 to 12.7-25
Table 12.7-7
6. Estimate kerf and
heat-affected zone (HAZ) Table 12.7-7 and figures
12.7-20 to 12.7-25
7. Template design with trim
allowance Figure 12.7-20 and item 6
8. Cutting gap setting Trial cut to verify parameters
and edge finish

12-73
12.7 Laser Beam Torch-LBT

200

A Laser-oxygen jet

9 Plasma-arc
160 160 Oxygen-fuel gas

c120 z

80

40

(1.020 m/mini II -t

40

0 1.0 2.0 3.0

176 mm]
Work thickness. in

Figure 12.7-4 Comparative cutting speeds of

laser beam torch, plasma-arc torch and oxyacety-
lene torch for titanium alloys. (Courtesy of I. Slater,
The Boeing Company)

1I

12-74
 Laser Beam Torch-LBT 12.7
TABLE 12.7-4 Comparison of Cutting Rates Among Competing Processes ______

TYPE WORK
II PRESS BAND OXYACETYLENE PLASMA-ARC
LASER TORCH
250 W plus
MATERIAL OF CUT THICKNESS NIBBLER SAW TORCH TOCH2 gas assist

Cutting Speed
____ in ,ii~ in/min __-W in/min __ in/mm in in/min IiN~ in/mm i ii
Titanium alloy Contour 0.020 8.5 0 22: - 200 N
Ct~ntour 0.062 5_ 160
Cnor0.125 ri~ 20 0S 44 'O 6 60 120
Straight 0.250 ~j ~23 ~O 100 ~24~ 167 ~A2~ 200 ~
Contour 0.250 30 075 50 --t.25tg 60 5
Contour 0.50 2 120 35 ~ 40
Contour 1 25 ~ 5 ~ 4 0 2i~ i~~
Contour 2 10~ ~16 0 22 0S' 5 01
Steel Contour 0.020 6j5 8 w8
Contour -q-~5. 40
Contour 10125 34.4 20 j _A5jQ
4130 Alloy steel Contour 0.100 30
3025! 20 Y 30 30 05 65 7
4340 Alloy steel Contour 0.375 8i2 14 J6 80 Z: n 88 2~ 35
Contour 0.75 ~1 ~ ~10 $2 50 .3 60 15-
Stainless steel Contour 0.050 i~~30 ~7~ 25 10 i~2~ 10 jO2518 0
16 kw lasert

TABLE 12.7-5 Properties of Metals and Alloys Important for Oxygen-Laser Cutting ______

ELECTRICAL THERMAL OXIDE

RESISTIVITY CONDUCTIVITY THERMAL MELTING HEAT OF
MATERIAL at 68OF at 212OF DIFFUSIVITY OXIDE POINT COMBUSTION
ohm-cm BTU/hr/ftt/ft/*F ff2/hr *F kcaI/cm3 metal

Ti-6AI4V 176 4.3 0.12 TiO2 3,360 12.9

Titanium 55 9.8 0.29 TiO2 3,360 12.9
4340 Alloy steel 22 0.43 F 82 0 3 2,840 14.1
C1 020 Carbon steel 14.3 27 0.52 Fe 2O 3 2,840 14.14
Zircaloy-2 74 8.1 0.29 ZrO2 4,930 16.3
321 Stainless steel 72 9.3 0.13 Cr 2O 4 4.130 14.4 ;N
6061 Aluminum alloy 3.8 99 2.5 A120 3 3,720 20.2w
Copper ETP 1.71 226 4.4 CU 2O 2,260 2.8

TABLE 12.7-6 Gas Selection for LBT

MATERIAL CLASS BEST OPTIONAL

Steels Air 02. N2

Titanium Helium Helium/argon. CO 2
Nonferrous alloys 02 Air
Nickel alloys 02 Air, 02
Nonmetals 02 Air
Composites 02 N2. argon
Plastics 02 Air, argon
Wood products N, Air, 02

12-75
 12.7 Laser Beam Torch-LBT

U.

C-

-! OW -,04-2 -

A R.

M 0a

00
0*

Wl c 0a 000 00 0 0 0 0 0 0 0(0oo 000 U 00 0 000 00 0010 0

l) 0 0 aIOW) C)0 0 0 : 0 0 (D 0(0f)CD0 0( 000 (00(0D 0 0(t)0 0 0,C
0 ,- M I.--.-c
a.o
-=- a-. ~ ~~--=----C
-==-~= ~
.- E

Go - C~
C)I- Q
(CID
rlV D qc0
CM-r 01j 0
C -J0 t
v )1
~
( A
M0IT0 ~ aOC 00(
( ' IDQa00)
Di)C -04
of (0D 00 .U)
VI 0
.000f)
C C Q)i~ 0 g -

- CO -II
99) IT M @#_:t C-=

0 C)) M C0D. 0 01 01 (0C% o 0- CD m 011) 0) (0 W co0( O0(to- 01&01co (0

cm
qq RR. CM*OCR S 000 0 000 000 000.- -- - '- - - C ow~
000 000 00 0 0 0 0 000 000 000 odd 66666 66o C 6
Ci CSI

0 C
MN0 01 x 1- 3:
01
CL 0) 0oc)

____
___;__ ___ 127N_ _ _ _ _

- - - - -)
 Laser Beam Torch-LBT 12.7

-
z 0z

- CI

o 0 I 0
I LIr -

IL I ~~-~-- - ~'-

1 ~ 1', 16550-O

0 3:

w 00
t 00M0 0 0 0) 0Y 000 00 0- 0. 0l 00 0 0 0 00 00 000n
000 7 0 0q 0 0f 000 00 0 0 ' uc. O ) ) -000 00
C0 OIM O (D wU
u)
0N'j
C\
OV
0' 0EU n ~ Y
IlDf 00
N~
W U )
102
100 N UC( )0D u(u ~CJ
o c
I I.
1w -RE:J
0N ) CMJ 0D 0 M0 00Vit L 'C) V) C) C- O rito c0)
a) 0 00 .- 0- 00
~~oE' S 10(t
.-.- ~ )~ C N (1)1 0 V9.-
N N
N-
N C) U)C (0 0( I ) ,~O 9 (00
R
?

Cv

C ~~ 0 ~
0 ~ ~ N ( . 00~
O C
- 10 - - - -0 t; '

0 . 0 00

L IC 2O 000 10
foO r
P 0 CO

12-77
12.7 Laser Beam Torch-LBT

IllwI
E Coo C~C-co Fj

_5
-. oMV O0
00 000 000 6_ 00 __ _5 _i __ II

a0 000 000 0 0 o0
00 -0 000

Oo0 000 000 0a0 0 000 0001 0 0

00(Dn 000 000 00C)0 000 000 0 0

aa

000 0w 0C

'A 000
coo 000 0 0 0 0 00 W0 W U0 000 0 0 0 0 Ct) C D
OqUct qq qqq0 qDI~
C!W R~C o~D 0 0 f0
0-.- 0 (0 O D 9-C~ U) C UJ

ME C4

Ct ('CiC0
0C C.CJ tCU) Ifl flt0 0WO D U) ) U) 90 0 CD -:U0 c0
0
CD C

CI - - - -

10r f 0 C~ t

4D 0

12-=7t
---- ~ -- :
 Laser Beam Torch-LBT 12.7

.oz -

I'0
C) Nt 4

00 0
0 0
0 0 0~~~~-
,0 0 0 0 000 -

ito)COL
) CD
"'
C5o e. c i *
0
0 0c
S ;

0>
00 0 00 01!q
C5 6 ;C 0 C S 0 00

C~ C=-i =~ CD aDU-m 3, C - r)0

~LD
COL)
oM CO
C
00
05 05 05 000o 00 001 0--0 0 0 C 5( 00(
0, 0l 00 0 0 0Q 0 0 0 j l03 0 03,
0 0 0 0 00 0 0
cc~
CY ~ ~Clci0
~ M-
0c uC )V )U)t D ) ,C ,C

, 000 0 c 0 00 000 0a 0
CO co 00 c 00 000 0 00
23 n 0) 0 P -3to c a C COC. CO I O 0 U - CJ

CY ~~~~~ o oi cot ~* CoU)t

X~~ ~ CT~ to~b cS) CYcmc 00 onWCc'. ) oa 000o

q 0------------ 0 to to in t&Dmo

00
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12-79
12.7 Laser Beam Torch-LBT

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12-80

-- ~ ).-~- - - - *~ - ~ 4~I ~ 14-

 Laser Beam Torch-LBT 12.7

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12-81
12.7 Laser Beam Torch-LBT

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Cl 000 0 0

0f 00f ( 4 I

cv cm'
m
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MU6

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(0c c

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 Laser Beam Torch-LBT 12.7

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c-, e

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c
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I- 0 t ql

a 000.

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Nf.: 0
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W,0
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0 0U a o
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CL
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aL.. CL C? CoCoO -coo w)

(I-> 83. 3-
(a___ co 1 .

12-83
 12.7 Laser Beam Torch-LBT

LU -1

Uww
XLL N
U.

Fi i
2 _M3

o ~h*3M
II it

(M Mcm cvO t-OV)Cl

rD 00 N

0 C 00 0 0 0 0 3

w 000 0D0C 00 0 0000CC 0 00 OLf 0 00 0 0 0 00 0

LL Lf Lfo )W 0 U)LDv) u)
(am ~l f~l O~j
Cl l cm cj
)L
Cl 0
A
Cl 0
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a
(Dc
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to
c'lj
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I-('.~ C')..
,-C~C~ 0 0 0 0 0 OU)C'J 0O)0 c0 i -t 'CJ

I:
c%1a0~~~(A ccJq U 00a0' 0 cci 0 It ccOU

!:icr&0
M0 00 '-0Ir 00000 0 L)00 >0 00 0
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*.l) N~ _) (D ?!
0-
co 03JI
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z4

-- -w- Q -CO~
 Laser Beam Torch-LBT 12.7

14 100 Hz ___ _________0.7

300 Hz ___ ______

1.2 400 Hz _ _ - - _ _ _ __ _ 0.6

500 Hz_____ __

10

00 0 .80 0.
C',0

:2 0 .8 .

o go

C1C

- 0.4 0 0.2

0 00.20. 0.C08.

2ength
Hzso Puls
~lgue 127-5
ulsepowe capbiliies f 0 watcniuu-wv O)02lse.(oreyo
Coernt Inc.)

VN

120
12.7 Laser Beam Torch-LBT

240
Machinability Rating

02 Assisted Laser Cutting

220 Good Titanium alloys
Zirconium alloys
Plain carbon and
low alloy steels
200 Intermediate Stainless steel
Nickel alloys
Poor Aluminum
180 Copper

160

.S
C
"" 140

COm 120 2
-- T

100
80
-[2.54 m/min]

60

40 80
Plain carbon and Titanium and alloys
20low alloy steels O

100 [25.4 mm]

0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6

Material thickness, in

Figure 12.7-6 Cutting rates for 325 waft C02 laser with 02 assist in slainless steel, carbon and low al-
loy steel, and titanium alloys. (Courtesy of Coherent, Inc.)
-
, : lo alo steelsl

12-86
 Laser Beam Torch-LBT 12.7
800 ('-- -600

(2 /mn 500 '[12 7 rn/minj

c 400 -

600-
9 300 -

200

S
40-- -- --
400100
- 6250W Power=1000W
Poer =1250 watts0
E
__
Z:5O 5W
:E0 005 010 015 020 025
E
20 - - (6.4 mm]
200 Thickness, in

Figure 12.7-9 LBT cutting of low carbon steel us-

0 - ..... -ing a 002 laser with 02 assist. (W.Hanson and
0 0.04 0.08 0.12 0 16 0 20 0.24 0 28 P. Lawryk, Laser machining is now, Modern Machine
Thickness, in (6.1 mm] Shop 50 (June 1977), p. 97)

Figure 12.7-7 Maximum material removal rate ver-

sus workpiece thickness for 002 laser cutting 302Z
stainless steel at 1250 watts with 02 assist. Rate in-
versely proportional to thickness. (Courtesy of GTE-
Sylvania)

0.280 [7.11 mm]

0.240-

2 0,200 - -- __

U,

0,16

0,12

0.080 -

0040 - 650 watts-

200 watts g
0 L --

0 40 80 120 160 200 240 280 320

[8.12 rnmm]n
Cutting speed. in/mmn

Figure 12.7-8 Maximum material removal rate versus thickness for CW Nd-YAG laser cutting carbon
steel with 02 assist. (Courtesy of Holobeamn Laser Inc.)

12-87_______ ___
 12.7 Laser Beam Torch-LBT
150
1600
125 3 2 m/mm E
lO a, 1200
100

E
25 -
0

0 000.060 004 008 0.12 0.16 *020 024

0.125 Thickness. in [6.1 mm)
[3 2 mm]
Thickness, in
Figure 12.7-12 002 laser cutting rate for Ti-6Ai-
4V alloy. TEMOO mode cutting at 1000 watts
Figure 12.7-10 LBT cutting of titanium using a with no
assisting gas. (Courtesy of GTE-Sylvania)
002 laser with argon gas assist. (W. Hanson and
P. Lawryk, p. 97)

80080
[20 rn/mmn) Thic ness in2
[20 in/mm] hc n ss 61 rm
600
E 600
S

2 400
D)
c400

E20
Power 1000W
200 E 200
0ower fir M
00
0 004 008 0.12 0.16 0.20 0 0.02 004
CO asrwiharo
gsasit.(. aso n
0.06 0.08 0.10
Thcnssn[5.08 mm)
thicknes i [2.54 mm]
Figure12.7-11 C02 laser cutting rate for 1018
low Figure 12.7-13 C02 laser cutting rate for 6061
carbon steel. TEM 0 mode cutting at 1000 watts
with no assisting gas. (Courtesy of GTE-Sylvania) Aluminum alloy. TEMo mode cutting with 02 assist.
(Courtesy of GTE-Sylvania)

12-88
 Laser Beam Torch-LBT 12.7
500 12 '
500 watts CW

400 110 m/mm]5 10

c (1254 min/s]
2300
Power 100OW

200 I 006200 '" 6 wwatts

o I \
lOO_ 0W - t\ 1: 71
100 4

02 1
0 0.025 0.050 0.075 0,100
12.54 mm
Thickness. in 0
0 0.100 0.200 0.300 0.400
(10 mmJ
Figure 12.7-14 C02 laser cutting rate for Hastel- Thickness. in
Ioy alloy X. TEMoo mode cutting with 02 assist.
(Courtesy of GTE-Sylvania) Figure 12.7-16 Acrylic cutting rates with C02
laser with air assist. (R. J. Saunders and M. Pasturel,
C02 laser beam machining of plastic and glass, Tech-
nical paper MR74-958, Society of Manufacturing Engi-
neers, Dearborn, MI 1974, p. 8)

7 Inconel alloy 718 L 6.0

0.8 mm (0.031 in) ...--
6 -700 W _
" 5 "[1. [15in/mm]
m/mini Douglas-fir
. plywood
(exterior grade)
Ti-6A-4V E 4.0
Q

V/
4 (13.1 fpm)--
,
1.3 mm (0.051 in)
700W
Air r_,.-T
-- 4
5.0 \
0 3 3.0-

.) 2
AISI 1045
.- I- 6.2 mm (.24 in) 2.0 -rapel
1
_
I? -1 10
0 0.5 1 1.5 2 2.5 3 35
[304 kPaJ 0 _

0 0.2 0.4 0.6 0.8 1.0 1.2

Gas pressure. atm Thickness, in (25.4 mm]

Figure 12.7-15 Cutting speed asa function of gas Figure 12.7-17 LBT cutting of plywood and lum-
pressure in cutting Inconel alloy 718, Ti-6AI-4V al- ber with 250 watt CO 2 laser with 50 psi N2 gas as-
loy and AISI 1045 steel. (A. Schachrai and sist. (C. C. Peters and H. L. Marshall, Cutting wood
M. Castellani-Longo, p. 466) materials by laser, FPL report 250, Forest Products
Laboratory, 1975)

12-89
12.7 Laser Beam Torch-LBT
0 044 30

f1 mm; 0W 1t
I E 20
0 036S

'g 0032 22__ C

( 10 (0 39 in)
20 waItts
0028

04 328

0024 1___0

0 2 4 6 8 10 0 50 100 150 200

(254
Cutting speed. in/min mm/minI Laser power. WV

Figure 12.7-18 LIST cutting of parallel-sided slots Figure 12.7-19 Penetration Of 002 laser in box-
in 3/4-inch thick plywood for steel rule die manu- board (Perspex) at 200 mm (7.87 in) focal length
facture with C02 laser using inert gas assist. (Cour- and 130 mm/mmni (5.1 in/mmn) cutting speed, (Cour-
tesy of Coherent, Inc.) tesy of F.W. Lunau, BOC-Murex Welding Research
and Development Laboratories, London)

TABLE 12.7-8 TsIe Requirements for Drilling 0.004- to 0.005-Inch [0.1 to 0.13 mm] Diameter Holes with Nd-YAG Laser 7

I WORK
ILAMP
DRILL TIME REQUIREMENT CURRENT
AVERAGE LASER
POWER OF 1.O6sm
MAXIMUM
THICKNESS
WORK
MATERIAL THICKNESS min USED WAVELENGTH DRILLIED
Oxygen Argon
in ass Ist Air assist A W in -

304 Stainless steel 0.120 sr1M.1.46 1.33* 3.69 34 31 0.190

Beryllium 0.049 I2 4.63 3.41 0.56' 32 24 0.198
3003 Aluminum alloy 0.065 very 0.99 0.28' 34 31 0.122
~~ long_
Tungsten 0.033 lb a 0.32 0.27' 134 34 31 0.100
Tantalum 0.051 0.44 0.35* 1 8. 1 35 42 0.l0o
Copper 0.100 -S 1.63 I1.01'Ilong
very 34 31 0.125 F

AZ 31 Magnesium
alloy 0.123 -. 1~ very 12.50 0.36' 35 42 0.123
Slong

Uranium 0.053 ~ ~ 0.20* 0.22 10.43 1 35 42 0.125__

SOURCE: C.A.Pippin, Metal machining with neodymium laser. Man ufacturing Engineering 76 (January 1976). p.39. _

*Optimum gas for drilling.

12-90 A
 Laser Beam Torch-LBT 12.7
30-60 Taper-..-.\
3' Tper--= nc
R =0.030
/

F-'a"1 inch
[0.76 rmm]

0.400 in [10.2 mini laser

0.500 in [12.7 mm] plasma
and oxygen fuel

Start of cut
OXYGEN CUTTING PLASMA - ARC

Width of cut
(Kerf)
Max HAZ

Extent of HAZ - -

OXYGEN CUTTING PLASMA

ARC
Lse Fuel Gas

in 0.010 to 0.030 0.250 0.100

HAZ -

in 0.035 to 0.055 0.080 0.312

Kerr
'a'

EMA~x
in 0.050 0.375 0 200
-

HAZ = Heat Affected Zone

EMA = Edge Machining Allowance

Figure
Inc.)
12.7-20 Comparison of kerfs produced by torch cutting techniques. (Courtesy of Coherent.

12-91
12.7 Laser Beam Torch-LBT

0. Matcriat Fe 3-mfm (0120 in) 260W 30

Focus.ng tlls GaAs, 64-mm
(25 onl)
-T.~ W flocal fer.u'n
0.6 2 Gas assist 0 '42 ]kPa .(20Ps') 200 W

0.4 (0 015 in)- 8o----W

Cut depth: 4 mm (0.157 in)

Gas pressure: 250 lkPa (36 psi)
Focal length- 95 mm (3.75 in)
0f I_
0 0.5 1 15 204
(40 in/min) 0 1 25 50 100 200 500 1000 2000
Cutting speed. rn/mmn (40 inl~nin)
Cutting speed. mm/mmn
Figure 12.7-21 Kerf width as a function of cufti-E;
speed in cutting AISI '161- stainless s!so; wanf 002' Figure 12.7-23 Relationship between cutting
laser torch with 0, assist. (A. Schachrai and speed and kerf depth with C02 laser. (A. Kobayashi,
M.Catel'tL~ 1 yp. 466) S. Shimakawa and Y. Nagano, Cutting of metals with a
300W 002 laser, Annals of the CIRP, Vol. 24 /1. 1975,
p. 122)

1(0 040;n Nozzle Pressure 40 psi 1276 kPaJ

Gap OO010to0O30 in 1025 toO076 rm
Fo~cus, On surface

E (5mml
12

:9 t.5 -- + E 0075

Cut dlepth,: 4 mm (0.157 in)

Focal length: 95 mm (3.75 in) 0050 0100 0150 0200 0250 0300 0350 -
Cutting speed, 0.5 rn/min (20 in/mmn) 050 MM
Gas pressure: 250 kPa (36 psi)
0 - I I Imaterial
I thickness, in
200 400 600 800 1300 1200
Beam power. W Figure 12.7-24 Maximum kern width versus mate-
rial thickness when cutting a variety of metals with
Figure 12.7-22 Kerf Width as a function of beam
250 watt C02 !aser. (S.Trink, Laser cutting of aero-
space materials. Technical paper EM73-214. Society
I
power in cutinig AISI 1045 steel wth 0? laser of Manufacwuring Engineers, Dearborn, Ml, 1973,
torch with 02 assist. (A.Schachrai and M.Castellani- p.18)I

14

12-92
 Laser Beam Torch-LBT 12.7

00 E

0 o c

c-

a LL
I\ c~0

00

CC

-,a Z
0

E C?
ICx -, CD

~.c .5
(*)0 E

C:

o. cE E
E E

oo

0 0 c 0 0
0 00 0 L 0Lo 0o 0
o 0 o 0;
U! ~
WnWT~ & C~ o U! V f Wx

czV

029
12.7 Laser Beam Torch-LBT

SPECIFIC APPLICATIONS DATA

TABLE 12.7-9 Specific Applications Data for Laser Beam Torch

Work material: Polyethylene Tubing (bi-wall) Glass Contact Lens TI-6AI-6V-2Sn

Workpiece
configuration: - [0 020-inch dia

0 180 inch
-5 panel--
0.004-inch pa e
diameter holes -

Hole spacing on

6-to 24-inch centers

Laser equipment

type: CO2 C02 CO2

wavelength, pm 10.6 10.6 10.6

power: 250 W 50 W 250 W

gas. 02

gas pressure, psr 40

Operating conditions
power level: 250 W

beam mode: CW CW CW

pulse length, ms: 5 to 15

cycle time- 1.5 s/lens

feed rate, in/min. 140

Tolerance, in:

Remarks: Drill during extrusion using 5 to 15 holes. Good saving by nesting parts.
optical tracking. NC controlled
Extrusion up to 300 fpm.
No deburring.
No
Wallresidue.
thicknesses range from
0.010 to 0.040 inch. Pulse
length depends on hole in
outer wall; some holes
through both walls.

12-.94
 Laser Beam Torch-LBT 12.7 I

TABLE 12.7-9-Continied
Work material: Aluminum Honeycomb Fired Ceramic Alumina Stainless Steel
Heat Exchanger Component
Workpiece
configuration:
36 in
0.25 in

14in 24 in
12 in 0.025-inch thick
0.062-inch thick

Laser equipment
type: CO2 C02 CO
wavelength, jpm: 10.6 10.6 10.6
powei: 1,000 W 50W 2,500 W
gas: Oi N2 02
gas pressure, psi: 40

Operating conditions
power level: 1,000 W 50W 1,000 W
beam mode: CW Pulsed CW
pulse length, ms:
0.5
cycle time:
feed rate, in/mm: 90 2 to 4 in/s 450
Tolerance, in:
No HAZ
Remarks: In contour cuts, no burrs or Scribing with closely spaced LBT substitute for large
bent combs, holes, 0.003-inch dia. by blanking dies.
0.008-inch deep. Vacuum-chuck worktable
with NC motion.

12-95

A
&
 J~ iI i ~ Z_ II
-

12.7 Laser Beam Torch-LBT

TABLE 12 .7-9-Ce ltinued

Work material- SAE 1008 Steel Carbon Steel Steel

Workpiece
configuraion'

Z 0.118 in 1 070
0035 in

0 055 in-- h
I-*-J

Laser equipment
type. YAG YAG YAG
wavelength, sin: 1.06 1.06 1.06
power. 70 J 200 W 600 W
gas: 02 yes 02

gas pressure, psi:

Operating conditions
power level- 55 J 200 W 600 W
'eam mode. Pulsed multi CW multi Multi
pulse length, ms: 1
cycle time: 10 shots at 1 pps
feed rate, in, min
50 50
Tole! ance, in.

Remarks:
Slitting Slitting

-4

12-96
 Plasma Beam Machining-PBM 12.8

PROCESS SUMMARY Practical Applications

_igh cutting speed and the ability to cut exotic metals are
ie greatest operational advantages of PBM Profile cut-
ting of metals, particularly of stainless steel and aluminum,
has been the most prominent commercial application; how-
ever, raiild steel, alloy steel, titanium, bronze and most met-
als can be cut cleanly and rapidly. Multiple-torch cuts are
possible on programmed or tracer-controlled cutting tables
on plates up to 6-inches 1150 mml thick in stainless steel.
Smoothness of cut with freedom from contaminants is an
advantage. Well-attached dross on the underside of the cut
Coolant can be a problem. The transfer arc is used for the thick
cuts in metals. Applications for surface heat treatment ex-
body Tungsten ist, and the plasma arc is widely used for metal joining. The
b~y-1I/I electrode plasma torch also is used for "punching" holes, as an assist
Shield to turning, or for grooving. Plasma cutting has become
cup Plasma popular as a maintenance tool since the development of
Tip (prgmary) LO'AMPTM portable plasma cutting equipment.

l SConstrcted
I arc Operating Parameters

I Plasma
Standoff TABLE 12.8-1 Typical Values for PBM Operating
%- Shield gas
(secondary)r
supply
Workpiece type: Direct current
wattage: Up to 200 kW
current: 50 to 1,000 A
Kerf --
Plasma let Primary gas
(Molten metal removed) type: Argon-nitrogen (80%-20%), hydrogen
flow: 15 to 20( ft3/hr [0.42 to 5 66 m3/hr]
Figure 12.8-1 PBM schematic Shielding gas
type: Nitrogen, oxygen, water, compressed air, C02
flow: Up to 400 ft3/hr [11.3 m3/hr]
Principles Water(inshield
place flow
of
Plasma beam machining (PBM) removes materi-r' by utiliz- shielding
ing a superheated stream of electrically ionized gas (see fig- gas): Up to 15 gal/hr [56.8 L/hr]
ure 12.8-1). The 20,000' to 50,000F 111,000* to 28,,t'0 C
plasma is created inside a water-cooled nozzle by elec- Plasma
trically ionizing a suitable gas such as nitrogen, hydrogen, temperature: 20,0000 to 50,000F [11,100' to 27,800C]
argon, or mixtures of these gases. Since the process does Cutting speed: 2 to 240 in/min [50 to 6,100 mm/min]
not rely on the heat of combustion between the gas and the Standoff distance: 0.25 to 3 inches [6.4 to 9.5 mm]
workpiece material, it can be used on almost any con- Nozzle orifice size: 0 062- to 0.25-inch [1.59 to 6.35 mm]
ductive metal. Generally, the arc is transferred to the diameter (figure 12.8-2)
workpiece which is made electrically positive. The
plasma-a mixture of free electrons, positively-charged ions Kerr width: 0.060- o 0.090-inch [1.52 to 2.29 mm] thin
and neutral atoms-is initiated in a confined, gas-filled plate
chamber by a high-frequency spark. The high-voltage di- 0.188 inch [4.76] for 1-inch [25.4 mm]
rect-current power sustains the arc, which exits from the plate
nozzle at near sonic velocity. The high-velocity gases blow 0.75 inch [19 mm] for 6-inch [152 mm]
plate
away the molten metal "chips." Dual-flow torches use a sec-
ondary gas or water shield to assist in blowing the molten ral
normal: 20 to 70
metal out of the kerf, giving a cleaner cut. Water shield or
arc,
special: 1 to 20
special:_1_*_to_20
injection is sometimes used to assist in confining the
blasting away the scale and reducing smoke. Greater
nozzle life and faster cutting speeds accompany use of wa- Accuracy: -0.031 inch [0.81 mm] on 0.25- to 1.375-
ter-injection-type torches. Control of nozzle standoff from inch[32 mm] on 6-to 8-inch [152
the workpiece is important. One electrode size can be used to 203 mm] plate
to machine a wide range of materials and thicknesses by Corner radii: 0.156 inch [3.9 mm] minimum (increases
suitable adjustments to the power level, gas type, gas flow with increasing cutting speeds to 1.50
late, traverse speed and flame angle. PBM is sometimes inches [38 mm] at 240 in/min (6,100
called plasma arc machining (PAM) or plasma arc cutting mm/min]
(PAC).

12-97
12.8 Plasma Beam Machining-PBM
Material Removal Rates and Tolerances for the functional purpose; however, an allowance of 1/16
Profile cutting can be done at 30 inches per minute 1760 inch I1 6 mml for finishing is typical for PBM.
mm/mini on 1-inch 125.4 mini thick aluminum plate, while
1/4-inch 16.4 mini thick carbon steel can be cut at 160 Equipment and Tools
inches per minute 14,060 mm/mini The use of water in- Hand-held plasma torches and small portable equipment
jection can increase the carbon steel cutting rates to 240 are available, as are NC or CNC programmable motion-
inches per minute 16,100 mm/min for 3/16-inch 14.76 mml controlled, multiple-torch arrangements. Optical followers
thick plate. Tables 12.8-2 and 12.8-5 through 12.8-7 show and table sizes up to 44 by 82 feet 113.4 by 25 ml are used,
the range of cutting speeds for PBM of various materials with cutting speeds controllable from 2 to 240 inches per
and thicknesses. Table 12.8-9 and figure 12.8-4 contain minute 150 to 6,100 mm/mini. Advanced systems with wa-
feed and speed data for plasma arc turning, ter injection, water shielding or water beds to catch the
dross are available. In addition to flat contour cutting, at-
The taper on the sides of the cut raxiges from 2 to 7 degrees tachments for lathe turning, grooving or gouging are made
with the straight side determined by the direction of the (see TAM).
cut. With special selection and controls, the taper can be
held to 1 to 2 degrees. The kerf width usually is 3/32 to Some advanced plasma cutting systems are designed for
3/16 inch 12.38 to 4.76 mm) for metals less than 1-inch mounting on large NC shape-cutting machines and are
125.4 mini thick and 3/8 to 3/4 inch 19.5 to 19 mml for met- equipped with torch standoff controls that automatically
als up to 6-inches 1150 mini thick. Corner radius is a min- find and maintain the correct torch standoff from the plate.
imum of 5/32 inch [3.97 mml on thinner plates. Tolerances
for slots and holes ordinarily range from 1/32 inch Tooling is simple because there is little load reaction from
10.81 minI on 1/4-to 1-3/8-inch 16.4 to 35 mini thick the torch.
plates to 1/8 inch 13.18 mini on 6-inch [152 mml thick
plates.

Surface Technology Machining Characteristics

Grooving is not as severe as in gas torch cutting, and sur- Eye shielding, and noise and fume control are needed to
face roughness can be as good as 32 microinches R. 10.8 meet workplace environmental requirements. High-flow
paml. The usual roughness is 63 to 125 microinches Ra [1.6 water shield (sometimes called a water muffler) may be
to 3.2 pinl. A heat-affected zone can range from 1/32- to used to recirculate cutting table water at a high flow rate
3/16-inch 10.81 to 4.76 mml deep, depending on the work- (1,000 gallons per hour 13,780 L/hrl) through a ring
piece thermal properties, the work speed and the depth of mounted around the torch head. This provides a shield or
cut. Sometimes an increase in hardness will accompany the curtain which reduces most of the light, smoke and noise
heat-affected zone and will require an edge-finishing oper- created by the plasma cutting operation. Introduction of a
ation. In many applications, the cut edge may be adequate dye into the water can reduce the glare of the arc.

12-98
 Plasma Beam Machining-PBM 12.8

SELECTED DATA

6I

5 0- .6.......... N2 Plasma gas +02 dual-flow

;E 4

N2 + 20% H2 Plasma gas

-a 3N 2 + 30% H-2Pl1asma gas

0 N2 + 10% H2 Plasma gas
E

2, N, Plasma gds with 0? injection

N2 Plasma gas

61 iCA2

0 0.01 0 02 0 03 0.04 0 05 [0.32 cm')

Nozzle orifice area, in'

Figure 12.8-2 Material removal rates for PBM with various gases and nozzle orifice sizes. (R. K.
Springborn, ed., Non-traditional machining processes, Dearborn, Ml: American Society of Tool and Manufac-
turing Engineers, 1967, p. 163) Zi

TABLE 12.8-2 Plasma Cutting Guide for Common Steel, Stainless Steel and Aluminum
POWER SELECTION
THICKNESS SPEED Amperage, A
in OE inm (steel Stainless steel Aluminum

70150 105
100 200140
10210 135

430 550

0.50 0 170135
40__ .190 120
70 260 25 180_

135 50027
15 1,00040
210100
280 1,000

SOURCE: J.A Bagley, Plasma arc cutting. Technical paper MR69-578. Society of Manufacturing Engineers. Dearborn,
Ml, 1969. p.23.

12-99
12.8 Plasma Beam Machining-PBM
TAB3LE 12.8-2-Continued
POWER SELECTION
WORKPIECE CUTTING
THICKNESS SPEED Amperage, A

in in/min mlim Steel Stainless steel Aluminum

07K 10180 130

V620 51 - 2201510

40 3302235530
70 9004227
800 87562040
1 10 Mm-4 i! 201515
11 M 701004

300 210 140

400 75035

20 850 610 390

40 1000 50 60
710 1t70000

125 105 1 58
30410 235
20 4-$$ 20 47
10

10 6590 65 385
20 .0 1800 585
350 50
1,1479 320

120 __6 _f 1,10

8010 64

10 59 400 20
40__ 2 87
00

70~ 1 100055

100 750
 Plasma Beam Machining-PBM 12.8
TABLE 12.8-3 Nozzle Size and Gas Flow Selection

REQUIRED GAS FLOW*

AMPERE MAXIMUM
RANGE NOZZLE SIZE N2 H2 AMPERAGE'

A in tV/hr
fU~ __ ft'/hr WIN=r~ A

0to 200 0.125 f@ 100 SEE 225

200 to 275 0.140 110 MOOR~ 10 ~ '- 0
275 to 300 0.1901 120 ~ 2400
350 to 400 0.187 .~-7~ 150 425< 15 550
1:0to 650 0.218 54 180 18 700
over 650 0.*250 3 225 20 =~9t>~ 1,100

SOURCSE J. A Bagley. p.23.

*Gas mix of N2 and H2 measured at 70 psi [480 kPaJ input to 25 feet [7.6 m] of 3/8-inch [9.5 mm] diameter hose.
'Do not exceed this amperage for each nozzle size. To estimate power consumption multiply amperes by 200.

TABLE 12.8-4 Plasma Arc Gouging Power and Speed In 5086 Aluminum Alloy
(Constant 1/8-inch [3.2 mm) standoff, torch angle of1450, and nitrogen gas)

- 3.10 -

37. 0.5;3 tI- 0.16 435

42. 0.560 0.19 4.601
70UCE lsaacguigo
0.4 imnm.VWsgoml5Nvme
0.. 96 5-70
3.a.J.

80 0.442- 013.1
12.8 Plasma Beam Machining-PBM
TAB3LE 12.8-5 Cuffing Speeds for Plasma Beam Machining
CUTTING SPEED
MACHINING MATERIAL ____ _ in/min
CONDITIONS THICKNESS _A_ _ _

Carbon Steel Stainless Steel Aluminum

in_____________Best Max. Best Max. Best Max.

100 ampere* 0,25 40 80 50 100 60 120

0.50 16 25 20 30 28 43
Primary gas: N 2 0.75 NR NR 12 15 15 19
at 55cfh 1.00 NR NR 9 11 10 12
30 psi _________ - -Y_

Secondary gas
at 210 cfh10
002 witis 4 ~~QK
40 psi

200 amperes' 0.25 50 100 65 135 75 155

0.50 30 40 50 70 60 85
Primary gas: N2 0.75 20 30 35 50 40 5
at 70cfh 1.0 j 15 20 20 26 26 35

30 psi 1.5 NR NR 12 16 18 24

at 210 cfh tVU-zR rE ___

40 psi W-5 0~

-6 t AxI
400 amperes'i054 57 2 011
1.0 30 40 40 55 50 7
Primary gas: N2 1.203258350
at 50 cfh2.142178285
20 psi2.101121160
Secondary gas: 002, -
at 210 cfh
40 psi

SOURCE- Data courtesy of Thermal-Dynamics Corp.

NOTES- NR - Not recommended.
*Minimum speed = 20 in/min [0 51 rn/mim] on 0.2-inch [6.4 mm] thick nmatenial.4
Maximum thickness for piercing applications isO0375 inch [10 mm).
'Maximum thickness for piercing applications isO05 inch [13 mm)
tm
Maximum thickness for piercing applications is 0.75 inch [19 mm).

12-102
 Plasma Beam Machining-PIBM 12.8
TABLE 12.8-6 Cutting Speeds with Water-injection PBM

CUTTING SPEED
MACHINING MATERIAL in/min
CONDITIONS THICKNESS S V
Carbon Steel Stainless Steel Aluminum
in
______ ~Best Max. Best Max. Best Max.

306 amperes* 0.25 60 110 75 130 85 145

0.50 40 60 50 70 55 80
Primary gas: N2 0.75 30 40 40 55 55 75
at75 cfh 1.00 20 25 25 35 40 60
30 psi 1.25 12 15 19 23 24 29
1.50 12 , 15 15 18 20 25
Water injection ~ ~
at 8 to 15 gal/hr A3 i

SOURCE: Data courtesy of Thermal-Dynamics Corp

*Maxcimum thickness for piercing applications isO0
625 inch [16 mm]

TABLE 12.8-7 Cutting Speeds for PBM of Sheet Metals

MACHINING MATERIAL
CONDITIONS THCNS idSelStainless Steel

50 to 100 amperes 0.062 275 280 -&

Primary gas: Nz 0.188 80 85 Z
at 15cfh R
35 to 40 psi 0.250 SL~ 65 *-70 __

0.375 50 S- ~ 55 ~ -

Secondary gas: C02 0.500 40 __35_4

at 150 cfh __W

45 to 50 psi -

SOURCE: Data courtesy of W.A.Whitney Co

TABLE 12.8-8 Tolerances for PBM Hole Piercing21

(For 0.156-inch [4 mm]. 9-gage steel)2
HOLE DIAMETER INCLUDED ANGLE DIAMETER TOLERANCE OUT-OF-ROUND

in~ degreesinn

0.188 10 t-i00
0.250 22 .100
0.312 2 .0 00

0.375 40000
4
0.437 4 0.02 0.1

12-103
12.8 Plasma Beam Mlachining-PBM
TABLE 12.8-9 Plasma Arc Turning Parameters

TYPE CURRENT ARC ROTATING FEED PER METAL

MATERIAL OF CUT DCSP VOLTAGE SPEED REVOLUTION REMOVAL RATE POWER

A V fpm m in m->in'/min Wmlnnhp/mn/min kW/cWM'/ii

Inconel Rough 300 100 40 1~010-.~~40 .8690 _.1

Smooth 170 1 90 75 23-0.050 ~4-- 1. 24 15.0 M,

Rene 41 Rough 325 95 52 62 0.160 1 5.0 8190

Smooth 240 90 10-3 0.080 .0 2.0 3.5

Hastelloy Rough 200 100 30 010 54< 7 P2

alloy C Smooth 140 130 60 ~1~~0.050 1.5 26 15.0

Precipitation- Rough 300 90 50 ~1~0.160 41 4.5 -~3 . 8.0 03

hardening Smooth 170 92 200 ~ ~0.040 1G'2.0 ~2 15.009
stainless -

steels__

Rotating workpiece

Metal removal

SOURCE: J A.Bagley. p.25.

Continues to 60 min at 0 500 in

7.60 40- 1 A
665 - 35 --- t

13 Time to cut 100 it (33 m)j using

25.-5---25 100 A with Nit;ogeni gas and CO. shield gas
o .C- 011 150 A with Nitrogen gas and a CO. shield gas
- c.,250 A with compressed air gas
28 - E5
0 1.-90 - 10 - --- -

0 0.125 0.250 0.375 0.500 0.625 0.750 0.875 1.00 f25.4 mm]
0.062 0.188

Stock thickness, in

Figure 12.8-3 Cost and time versus thickness in cuffing mild steel with plasma arc. Icost includes gas.
perishable parts and electricity, at prevailing rates in 1978, but does not include labor cost for time in-
dicated. (Courtesy of W. A. Whitney Company)

12-104
 Plasma Beam Machining-PBM 12.8
Feed per revolution, in

279 500in 0 01 0.02 0 03 0.04 0 05 0Ob 08 0 10 [2 54 mm]

400 tS o 012
210

001
zg 3.18
CL

105 a~ 20~

52 10

0 10 20 30 40 50f127m'min)
Carriage speed. in/mi

Figure 12.8-4 Interrelationship among some of the factors involved in plasma arc turning. (R. K.
Springborn, p. 165)

Workpiece thickness. in
001 1/8 114 4 24

Oxy-fuel-
Mild steel 7
Medium alloy sleel

Plasma arc-
Mild steel
Medium alloy seel
Stainless steel___
Aluminum - -

Laser
Mild steel
Medium alloy steel
Stainless steel

025 326.4 102 610

Workpiece thickness. mm

Figure 12.8-5 Comparison of plasma arc, oxy-fuel and laser processe-i in cutting metals.

12-105

-77 7=-___
 SECTION 13
CHEMICAL NONTRADITIONAL
MACHINING OPERATIONS

.3.1 Chemical Machining-CHM.......................................................................... 13-3

13.2 Electropolishing-ELP ............................................................................ 13-17
13.3 Photochemical Machining-POM ....... .. .................................................. 13-19
13.4 Thermochemical Machining-TCM or Thermal Energy Method-TEM...-.. ................. 13-25

IS

13.-1
 IECEM14 PAGE ULAD-NOT FILD'--Z

Chemical Machining-CHM 13.1

PROCESS SUMMARY Workpiece size is limited only by tank dimensions: alumi-

num wing spars have been chemically machined in 3-bv-8-
by-50-foot 11 by 2.5 by 15 ml tanks. Surfa,:e contours.
scratches and Ulaviness will be reproduced as CHM pro-
ceeds. Porous castings are poor candidates for CHM. and
Hanger" welds or welded areas are difficult to cut uniformly.
The iiaximum pra :tical depth of cut varies with the mate-
ank rial form as follows:
Sheets and plates.0.50 inch 112.7 minI
0.25 inch 16.4 minI
Forgings and castings:
orkpiece Extrusions: 0.15 inch 13.8 miI
eating See Photochemical Machining. section 13.3. for informa-

, " : _ 7 ... '- ' "Cooling tion or, chemical machining of thin or smali parts.

Operating Parameters
Figure 13.1-1 CHM schematic.

TABLE 13.1-1 Typical Values for CHM Operating

Parameters

Etchant
Principles Cheicl
"M types:
concentration: Aikalines. 13.1-3 proprietary mixtures
See table acids,
Chemical machining (CHM) is the controlled dissolution of oeratin
operating
a workpiece matei -a] ky contact with a strong chemical temperature: 70D to200'F [21 to 93*C]
ieagent (see figure 13.1-1). The thoroughly cleaned work- te eat ue R b r PVC. polet neprn
piece is covered with a strippahle. chemically resistant Maskana: Rubbers. PVC, polyethylene, neoprene
mask. Areas where chemical action is desired are outlined and similar plastics or elastomers
on the workpiece with the use of a teempiate and then (tables13.1-6 and131-7)
stripped of the mask. The werkpiece is then submerged in
the chemical reagent to remove material simultaneously Etching rate: 0.0002 to 0.0025 in/min [0.005 to 0.064
from all exposed surfaccs. The solution shoulu be stirred or mm/mi,) typical. 0.001 in/min
the workpiece should be agitated for more tffective and 10.025 mmimin]
more uniform action. Increasing the temperatures will also Etch factor. 1:1 usual: up to 1:3 (table 13.1-3)
expedite the action. The machined workpiece is then (ratio of undercut to depth of cut)
washed and rinsed, and the .emaining mask is removed. Metal ion content: A little is desirable but too much can
Multiple parts can be machined simultaneously ii' the same stop etching. Uncontrolled etching
tank. begins at about 75 grams per liter
f o oz/gall.
Contour machining is accomplished by successively strip-
ping masks and resubmerging the workpiece ;n the chem- Tolerance: Approximately =10% of cut depth
ical bath. Etching of the workpiece proceeds radially from (iables 13.1-8 and 13.1-9. figures
the openings i'i the masK. Thi- results in an undercut as 13.1-7 to 13.1-13)
well as a depth of cut. The ratio of distance etched beneath
the mask to the distance etched into the workpiece (the
etching factor) is typically 1:1 (figure 13.1-6). A controlled
rate of immerqion r withdrawal from the bath v' ll preduce
tapered sections. It is preferred that the workpiece be ori- Material RemToval Rates and Tolerances
ented such that the grain is in the direction of the longest The material removal rate is deteimined by the solution
cut. type. concentration and temperature. all of which are se-
lected to be compatible with the particular metallurgical
statt. of the work material (tables 13.1-3. 13.1-4. and
Practical Applications 13.1-5). While the removal rate is low. about 0.001 inch
Nearly all materials car 'e chemicallv machined: however, per minute 10.025 mm/mini. cutting occurs simultaneously
the depth of cu" has a practical limit of 0.25 to 0.5 inch 16.4 on all exposed surfaces. The depth of cut is .-antrolled by
to 12.7 mini. Large. shallow areas are especially suitable the time of immersion.
for CHM since removal is uniform and simultane( ;. No
burrs are produ( J d,,d ro workpiece surface stresses are Uniform;ty of removal rates depends upnn the chemical
ge,erated by CHM. Short-run. quick-change. low-cost tool- and metallurgical uniformity af the workpiece and the uni-
ing offers process flexibility. Thin sheets. formed sheets formity of the solution temperatwte. concentration and
and delicate cuts are particularly suitable for CHM. Sharp metal ion content (figures 13.1-2 to 13.1-51. Solution or
radii canr-t be produced in the cutting direction. workpiece agitation aids application of the etchant to the

13-3
 Or
--

13.1 Chemical Machning-C!;M

exposed surface Too violent agitation or fluid directional Equipment and Tooling
constraint can lead to uneven cut times or grooving. With Equipment runs from small bench-top devices to outdoor
good time, temperature and solution control, accuracies up tanks, 6 by 12 by 60 feet 118 by 3.7 by 18 ml Both sub-
to 0.0005 inch I0.0127 mini can be achieved for shal- merged and spray etching are used. Automation of se-
low depths of cut. Deep cuts yield tolerances up to 0.005 quence of wash and etchant immersion is commonplace.
inch I0 13 mini Minimum width of cut or land between Agitation by air or by mechanical motion is frequently built
cuts should be twice the depth of cut plus the etch factor. into the material handling fixtures. Excessive air agitation
can lead to excessive fuming. Multiple part handling racks
Scribe-and-peel masks can produce 0.007-inch I 0.18 are commonly used.
mini lateral tolerance per edge Screen masks can produce
0.003-inch I 0.076 mini lateral tolerance per edge, and Masking, mask scribing and templates for scribing are of
photoresist masks can produce a tolerance of 0.0005 many types and shapes (see tables 13.1-6 and 13 1-7). The
inch I0 013 minI. (See tables 13 1-8 and 13.1-9 and fig- mask must be inert to the chemical reagent and the heat
ures 13 1-7 to 13.1-13.) during etching Adherence and ease of stripping are neces-
sary to withstand handling. Dip-cut-and-peel masks ar -
common, and silk-screen-applied resists and photoresisis
Surface Technology are used for higher production rates. Lateral accuracy, fig-
The chemical machining process does not introduce stress ures 13 1-9 and 13.1-10. is affected by type of mask:
into the workpiece. The gentle chemical uction of remov-
ing material by molecule-by-molecule dis'olution results in Cut-and-peel mask: 0.007 inch[ 0.18 minI
surfaces free from residual stresses Screen resists: 0 003 inch I 0.076 mml
Photoresists: 0.0005 inch I: 0 013 mini
CHM surface rough .3ss values are influenced by the
roughness present in the initial workpiece surface and the
degree of adherence to the preplanned operating condi- Machining Characteristics
tions Typically, very smooth surfaces (32 microinches Ra Chemically resistant floors, plumbing, ventilation and solu-
10.8 /Aml or less) are slightly roughened, while rough sur- tion controls are required. Special environmental and
faces (125 microinches Ra [3.2 tml or more) are slightly safety precautions are required to meet local limitations
smoothed; see figure 13.1-14 and table 13.1-10 Surface Automatic monitoring of the chemicals is commonplace.
roughness values increase as the metal ion concentration Chemical etchants, by their very nature, are very corrosive.
increases in the etchtant. Extreme care in handling is required to avoid spillage and
splashing. Vigilance nmust be maintained at all times. The
Hydrogen embrittlement and intergranular attack can oc- fumes are corrosive and may be toxic with health risks and
cur and can have detrimental effects on material properties risks to nearby equipment or building structures, see table
unless post-treatment corrective action is taken. 13.1-11.

NO

13-4
 Chemical Machining-CHM 13.1
SELECTED DATA
There are several valid techniques for selecting operating
parameters for CHM. The steps in table 13.1-2 are recom-
mended as one logical sequ,-'iu.e. Supporting data come
from the other figures and tables.

TABLE 13.1-2 Steps To Select CHM Operating

Parameters

ITEM DATA

1. Workpiece material: Engineering drawings

type
heat treatment
grain size
metallurgical
state
rolling direction
2. Select compatible Tables 13.1-3,13.1-4 and
etchant: 13.1-5; figures 13.1--2 to
type 13.1-5
concentration
temperature
3. Estimate etching Tables 13.1-1,13 1-3,13.1-4
rate: and 13.1-12; figures
13 1-2 !o 13.1-5
4. Calculate time of Drawing dimension divided by
immersion from estimated etching rate
depth of cut:
5. Run test specimen to Laboratory tests on specimen
check estimates and with exactly same finish
establish final value and metallurgical state as
for operating the production workpiece
parameters:
6 Check surface Specimens from item 5 using
roughness final operating parameters
attained:
7 Quality control: Deviations from surface
roughness or etching rate
during a production run
signal the need for
4
corrective changes in the
etching bath conditions
8. Tooling,
maskant type Tables 13.1-6 and 13.1-7
template design
and undercut
allowances Table 13.1-3; figures 13.1-6,
13.1-8,13.1-9 and
13.1-10
9. Safety precautions: Local safety practices, OSHA
handling
ventilationi guidelines, EPA guidelines

effluents

15

13-5
13.1 Chemical Machining-CHM
TABLE 13.1-3 Etchant Characterlstivs and General Applications____________ ______

METAL THAT
ETCHANT
[ CTCHANT
ETCHANT
CONCENTRATION
1
I
OPERATING
TEMPERATURE
ETCH RATE WITH
FRESH SOLUTION FACTOR*
ETCH
WILL ATTACK Fi/mwlrn

Alformol FeCds 420 Be"l 120 '49

_______HNO
3:HCI H 2 0 1-12 100 tol120 '36to 40

Aluminum Fedj 12 to 18* 120 ',9 0001 + _0025 1.5:1 to 2:1

alloys HCI:HNO03 H2 0 10-1:9 120 49 0.001 to 0.002 005o00 2:1 (variable)
Cold rolled FbC1 3 421 Be 120 49 - 0.001 0052:1
steels HNO, l0 tol15. Ci.) 120 '49. 0.001 0125 tto 2:1
dapper and FeCI 3 420 Be' 120 ,49, 0.002 000 -'~ 2.5 to3:1
its alloys (NH 4 )2S20 8 2.2 lb/gal [263g/LI H,0 90 to 120 -'32 to 49 0.001 O2 2 to 3:1
Chromic acid commercially available 120 4 00015 0.3: 2
Cudl 2 350 Be' (regenerated) 130 -54 000055 3 2. to 3:1
Germanium HF or HF:HNO 3 various-- -

Glass HF or HF:HNO 3 various-

Gold HCI:HNO 3 3-1 90 to 100 3to8 0.001 toO0.02 (I 025 0 -
Hardened tc~l HN0 3 10 to 15% (Vol) 100 to 120 0005 to 0.001
03O f0 1ot 1:1 to 2:1
steel -.jCZ nt~A
Inconel FeC13 420 Be' 130 5J-
Inconel alloy X FeCds 420 Be' 130 ~ 4
Kovar IChromic acid commercially available 120 0.001 22to 2.5:1
FeC13 400 Be' 120 000 , ~ -0 .
Lead Fedl) 420 Be' 130 ~ 4~
Magnesium HNO, 12 to 15% (vol.) 90Oto 120 11ZIo4pj 0 001 toO005o05
00 2
Moly pernialloy Fedl 3 42' Be' 130 .4, ~ ~ ~ "

Molybdenum H2S04 :HNOj H20 1:1:1 to 5 130 -54.~ 0.001 at 13O F .0021*5
-~~_ varies With temp.v~Utn~
HN0 3:HCI.H 20 1:11lto2-
Nickel FeCI 3 420 Be' 120 .0005O toO0.00 1:1 to 3:1
Nickel-iron alloys, FeCI3 420 Be' 120 CjO49
'ti 0.0005 to 0.001 1OOM10l l5 1:1 to 3:11

Nickel-silver FedI 3 A20 Be' 130 5 44z ___

alloys Chromic acid commercially available 120 t494i,- . -

(NH4)2S20 8 2 2 lb/gal [263g/LJ H20 90 to 120 -

Phospor-brnze
Crarni acid commercially available cold (90) 2 ~ 005 ~ ~ ~ ~ K 2
(N 4) 2S208
____________ 2.2 lb/gal [263g/L] H0 cold (0 00 0~
Silicon HNO3 :HF:H20 various 100 to 120 :j" PA, slow
Silicon steel Fed13 420 Be' 130 0001 O 2 ' 1.5 to 2:1
Silver HN0 3:H2O 50 to 90% (vol.) 100 to 120 005t 001
.il~8
FeNOI 360 Be' 120 0.00080
Stainless steel FeCI 3 420 Be' 130 I E-0.0008 1.5 to 2:1

Tin FeCl 3 42c Be' 130 4

Titanium HF 10 to 50% (Vol.) 100 to 120 49-
HF:HNO3:H 2 0 various 100 to 10 4
___________NH
4 HF2:HCI:H2O various 100 to 120 _WS4 - -

Zinc HN 3 10 to 15% (Vol) 100 to 120 ~ 001_

*Theratio ot depth of undercut to depth of cut.
'Baumie specific gravity scale (Be').

13-6
 Chemical Machining-CHM 13.1
TABLE 13.1-4 Comparison of Data and Characteristics of Systems for Chemical Milling Titanium, Steel, Aluminum, and
Nickel- and Cobalt-Base Alloys

PRINCIPAL OPTIMUM ETCHANT AVERAGE SURFACE

METAL ETCHANT fETCH RATE ETCH DEPTH TEMPERATURE ROUGHNESS, R.

nifilf mmmmmfin-i_
. in mIT OF ! , piin

Titanium Hydrofluoric acid 0.0006 toO0O002 0Gf.03 .125 3 115 45 lto

16~2 100 ~~5
alloys-

Steels Hydrochloric acid- 0.0006 toO0 0012 0.15t60:031] 0.125 _32j 145 5 L~3*27 30Oto 120 8o3
nircacid 7-

Aluminum Sodium hydroxide 0 0008 to 0.0012 002. o 3 0.125 ~. ~15+59~2780 to 12 3.

_2.Oto
alloysZ

Nickel- and Niric acid- 0.0004 to 0.0015 '0.U014o .03d- 0.125 ~32'140 45 .8 2740 to 15010to38
cobalt- hydrochloric acid- -''

base ferric chloride .

alloys .+

35 300
I Unsatisfactory results.
+ metal may not
30 __ +even etch

E v
13u 200
Co _ r

0)

2-5 - 100

2.0 0 1-

02045 50 1002030

Nitrate concentration, normality NO- Chloride content. gIL Ci-

Figure 13.1-2 Suitable working ranges for the Figure 13.1-3 Relationship between metal and
free acid and nitrate concentrations of an aqua- chloride content for an aqua-regia-type etchant
regia-type etchant for 18/8 stainless steels. (W. T. (W. T. Harris, p. 238)
Harris, Chemical milling, Oxford. Clarendon Press,
1976,p 239)

13-7
13.1 Chemical Machining-CHM
2.5 2.0

2.0 15

E E

d" 1.5 a 1.0

10 05

0.5 , 0 _
2 3 4 5 6 0 10 15 20 25 30
Nitric acid, percentage by volume Sulfuric acid, percentage by volume

Figure 13.1-4 The effect on etch rate of increas- Figure 13.1-5 The effect on etch rate of increas-
ing the nitric acid concentration in an etchant con- ing the sulfuric acid concentration in an etchant
0 0 0
taining 25 percent sulfuric acid at 700C (158 F). containing 5 percent nitric acid at 70 C (158 F).
(W T Harris, p. 234) (W. T. Harris, p. 234)

TABLE 13.1-5 Etchants for Steel, Nickel and Cobalt Alloys -

METAL ALLOY H+(N) NOr(N) PO-(N) F-(N) METAL ION

g/L

Mild steel 2.0 to 3.5 0.2 to 4.1 1.5 to 3.0 100 to 250
Stainless steel 2.0 to 3.5 0.2 to 4.1 1.5 to 3.0 100 to 250
Nickel alloys 2.0 to 3 5 0.2 to 4.1 1.5 to 3.0 100 to 250
Cobalt alloys 2.0 to 5.5 0.2 to 2.0 0 to 3.0 0.5 to 1.0 125 to 250

SOURCE: W. T. Harris. p. 235.

13-8
 Chemical Machining-CHM 13.1
TABLE 13.1-6 Typical Maskants for Various Metals

METAL ETCHANT TEMPERATURE MASKANTS

C

Aluminum Alkaline 91 Acrylonitrile rubber,

outyl rubber, neoprene
rubber

Ferrous metals Acid 54 Polyvinyl chloride,

polyethylene, butyl
rubber

Magnesium Acid <38 Polymers

Titanium Acid 21 to 35 Translucent chlorinated
polymers

Titanium Acid 54 Vinyl polymers.

elastomers

Beryllium Acid 21 to 54 Vinyl, neoprene, butyl-

based materials
Nickel Acid 45 to 50 Neoprene

TABLE 13.1-7 Properties of Maskant Materials Widely Used in Chemical Milling

MASKANT MATERIAL
Exposure to Oxidizing Acids -
PROPERTY r-Exposure to Acids or Alkalis s-

Polyvinyl Acrylonitrile Neoprene -M

chloride Polyethylene Butyl rubber rubber rubber

Ease of manufacture Good Good Fair Fair Good

Shelf life, months 6 to 12 6 to 12 4 to 6 3 to 6 6 to 8
Solids, % 25 to 55 60 to 100 20 to 25 15 to 25 25 to 35

Ease of application:
dipping Good to fair Poor to fair Good Good Good
flow coating Good to fair Poor to fair Good Good Good
air spraying Good Good Poor Poor Fair

Type of cure Air or heat Heat Heat Air or heat Air or heat
Tensile strength, MN/m2
air-dried (24 hr) - - - 7 max. 14 max.
heat cured 7 to 17.5 6 to 11 6 to 11 11 to 17.5 11 to 21

Resistance to etchant:
deterioration Good to Very good Very good Very good Very good
excellent
permeability Fair to good Very good Excellent Very good Very good
Heat llriit OF* 160 140 300 250 200

*Maximum useful temperature for intermittent exposure-also curing temperature.

13-9
13.1 Chemical Machining-CHM
12 f
Position of template edge for B'. mm 1
first step ---- (04 in) 1 32
second step 10
third step4
/5

EE
838

A A;,.mm

Harris
p 26-9

TABL 131-8Typcal
urfce imesionl Tlernce

0.02
.05 .00 .00 .00 2iI ~4S 8--U 10 12

coppre alloys 0.0004ce 0.00

Uneru 0he002a
A, ste 0ll0an4 milig
0f00 is adjacen step B

so -Ec.eCautic oton . Staphtoceicl. achnntefco sdfndasteivrerto .(.T

Harri, p 28-69

TABL 131-8Typcal
urfce imesionl Tle-nce

_ kRZO
 Chemical Machining-CHM 13.4
TABLE 13.1-9 Tolerance on Depth of Cut
TOLERANCE, in

MATERIAL Depth of cut, in -0

0-0.050 0.051-0.100 0.101-0.250 0.251-0.500 ~12 .3t

General 0.002 0.003 0.004 0.006 O5 .Os~

Z 75~ O.~
Aluminum and 0.001 0.0015 0.002 0.003 OS XDI2
I
magnesium
alloys ~~-
Stainless steels. 0.002 0.003 0.004 0.006 ~ ~ ~
ferrous and ~
nickel allays -

Titanium and 0003 0.004 0.006 0.010 uizu

o~?~ ~ 4 i~
beryllium alloys

10 0.5m]TitaniUm alloys

9 100.25 mm] _ _

G 10

0 ___ Ferrous alloys U

- Nickel alloys 6
C C 6

U --

0Aluminum alloys

2 -2
L) * v Best gidin
0L
0~ ~ ~ 00.0.03
a0010 03 0.4 0.5 1 m
DethofCu,
n [12.7 min) Depth of cut, in

Figure 13.1-7 CHM depth-of-cut tolerance for Figure 13.1-8 Depth-of-cut tolerance capability of
sheet materials. CHM.

______________ ~13-11__________1-
13.1 Chemical Machining-CHM

0.6115 mm]

Land 0 030 in .____ _

0.060 in---" 0 060 in (076 mmn 0.5 -. /
[1.5 mm] [1.5m]

0.060 in "___:t__,_ "

[1.5 mm] E 03 0/
: E/
.2
0.2
Figure 13.1-9 Nominal lateral tolerance.
0.1

0
0 0.1 02 0.3
(7.6 mm]
Depth of cut. n

Figure 13.1-10 Recommended minimum widths

of cut and land for CHM.

0.18- 0.18

0.16 016 - Approximate sheet sizes

0.100 - 300 mm x 450 mm

0 - 014 -(12 in x 18 ir)

-- -200 mm x 250 mm
012 0.12 - (8 in x 10 in)
E E
(0,004 i) _ E / - - 50 mmx 50 mm
(2 inx2in)
010 in),, -. 0.10

o Iof

o
Io
00
004
003 -/ /
/
-
I-/
0/..oo
6,
0'3"o
0.06 - "
/
-

004 004 1 --

02 r0 Oo I
0 02 G4 06 0.8 10 0 02 04 06 0.8 1.0
Thickness. mm (0 040 in) Thickness. mm (0.040 in)
(a) (b)

Figure 13.1-11 Practical tolerances on etched dimensions, for a range of flat sheet sizes and material
thickness. (a) For prototype and short runs; (b) for production runs. (W. T. Harris, p. 192)

13-12
 Chemical Machining-CHM 13.1

Alumi numn alloys

0.14 - Y 1 - -

E Steel anidE
(0.004in) __magnetic afloys-

A- maximum transition zone 0- m-Iing cut edge

IB - depth of cut E- web thickness
A0.0 C- point wh'~re normal thickness

00e -
"Copper alloys Materials Maximumn Transition Zone
I IAluminum al)z4xdpho u
0T0 - ,agre-.um adtoys 6 x depth of cut
Ferrouss alloys 10 x depth of cut
0 vNui(ol and Cobalt alloys 10 x depth of cut
o~o -- ~ ~ .Tiniurn alloys 10 x deph 0f cut 0. ...5 inch 112 7 mm)
/ Nicel ato~'(whi,-he ,er isgreater)

0 0 1 0.2 0.3 04 0.t) 0.6 07 Figure 13.1-13 Transition zones of CHM.

(0014 in'
Thickness. mm

Figure 13.1 -12 Normally attained dimensionlal tol-

erances for a range of materials. (W.T. Harris,

3.0 (2pn

w A

0 0.1 0.2 0.3 0.4 05

(0.015 in)
Depth of cut. rmJ

Figure 13.1-14 the relationship between surface

finish and a6pth of cut for chemidcal milling 7075
aluminum sheet. (W. T.Halrris, p. 1 Q2)

13-13
13.1 Chemical Machining-CHM
TABLE 13.1-10 Surface Roughness Achieved by Chemical Milling

T
MATERAL
MATERAL
OR
FRM
SURFACE ROUGHNESS
(.0AFToR 0.15 in) REMOVEm
(.0AFtER 0.215 Ino0.40Vmm
jiqi~o
-pin R,

Aluminum alloys Sheet ":Oi38~- 80to150

Casting i~.~o..~150 to 300
Forging 100 to 250
Magnesium alloys Casting 0 75 1 ;-Qg_ 30 to 55
Forging
Steel alloys Sheet 05 1430 to 60
Forging
Nickes alloys Sheet 3to
30 40
Titanium alloys Sheet 8 to 32
Casting 15 ~ 30 to 60
Forging 81fD ito
15 40
Tungsten Bar 20 to 40
Beryllium Bar 150 to 250
Tantalum Sheet 10 to 20
Columbium Bar 40 to 60
Niobium (Columbium) Sheet 40 to 60
Molybdenum Sheet 60 to 130

SOURCE: W T Harris. p.114.

TABLE 13.1-11 Summary of Health Risk Arising from the Commonly Used Etchants

MAEIA iN ETCHANT(S

AuiuSoimSplashes
ETCHANT RISK(S)

on to
FUME RISK(S) j
alloys hydroxide J skin, mouth, or
Fume rnot dangerous
but hydrogen gas is
eyes explosiee
Magnesium Sulphuric ISplashes on to skin. Corrosive acidic fume.
alloys acid mouth, or eyes. Hydrogen gas is
Additicris may explosive
cause spatteringj
Steel/nickel Hydrochloric. Highly corrosive Corrosive and
alloys nitric, splashes on to suffocating turri is
sulphuric and skin, mouth, or also toxic
phosphoric acids eyes
Titanium Hydroluoric Highly corrosive Corrosive and
aloys acid with splashes on to skin, suffocating fume is
nitric or mouth. or eyes. also toxic
chromic acid Hydrotluoric acid is
particularly dangerous
Copper Ferric ICorrosive Wpashles Corrosive and
alloys chlrid&e on to skin, mouth, suffocating fume

SOURCE: W.T.Harrs. p107or

13-14
 Chemical Machining-CHM 13.1

LU0

a:
_0 7 1 -1 -1IA

00 0- 00Das0

00E- k-0

C.J jc c I

00u 00 00) 01 M
00
5 C; II II C5 -1 d

I 0 I
f- 0 0 I

1 C

(LZ
zI LaILM( C
,:E iWT 0 w*UM D
0 00i E

I-- E UC Ur
0w 0t- lo 0 CU. 0- 00 - - 0

o) Co 4 CIO L,-,~j~

I x

CL *1

Z
I-
0~
> ~ --

- w0M 10 o -
00 CUOC
-
0M .90
;v
00 N1
1~z.F00
-- Z0 Co) CDM CM tor rnn -

X. -) X__ - z_ z z
-M -.- -,; -; 0 .
0O E 00 0n .
0i 0.
C -c .CO zZff z -
Z
Z ~ j 6 o0 .z~

o E.

us cE = 0 0 aC

30 0
0
0 0M ~~~I~ou E
0. U 0 O JO

13-15
13.1 Chemical Machining-CHM

ju w

0
dr-*- y __t=

- 00

000

0ii 00~ 0 OI I
0 0. '0 0D 0

so 03 0

x4 00 t

C I

* .502 .5 L2 .0 j

r -&4 -:z=

zz

xr

00 0 0 0 0 Nr* NN
uflO
I ___________________________________
_________________ f ________________
_________________ _________________

I-* IP CRICq A DwC

W I 0 0

tI M1 qo .) c) C.) C) rC iI 1 cCY l
OD -o - . r-

C a m y0 I
r J5 (5 M 0
Wg! C5
13o; X: 0
B Z. z
5
.8
1 : :
I 2
x5 0 3 0 4rzC
z~~ If (a
IL 2 *x 0 )o z za z
x__x : ~ x2 xP2_IX
IUD2 C ~ j

13-16

- 7-7777 7 e
 Electropollshing-ELP 13.2

PROCESS SUMMARY On some alloys, for example. 17-4 PH. elcropolishing is

successful in removing tightly adhering scale after forging
and as a preliminary process to passivation

Operating Parameters
e Stirrer
Hanger TABLE 13.2-1 Typical Values for ELP Operating
i~ ~ ~----
-~ ~ ank parameters

-types: Acid mixtures, sodium hydroxide and

pieck proprietary solutions (see table 13.2-2)
temperature: 700 to 200OF [210 to 93*Cj
~& ~ eatng Current density: 50 to several hundred amperes per square
-0foot[0.05 to sevoraltimnes.1 A/cm2]
-_____________ Cooling

Figure 13.2-1 ELP schematic.

Material Removal Rates and Tolerances

The removal rates are very slow. on the order of 0.0005 to
0.0015 inch per minute 10.013 to 0.038 mm-Thinl: however.
it usually requires only a few minutes exposure to achieve
!he desired surface improvement. The current density in
the electrolyte concentrates around the surface asperities;
Princplesconsequently. erosion of the asperities takes place at a
(LP isa secalied om of chemical
Eletroalshig faster rate than erosion in the declivities. The surface.
Elecroplishng
EL? is spcialzedfo~therefore. can :& smoothed without considerable material
machining which uses an. delctrical, deplating action to en-
hance the chemnical action isee figure 13.2-1). The chem- removal.
;cal action from the concentrazed heavy acids does most of
th6 work. white the electrical action smooths or polishes
the irregularities. A metal cathode is connected to a low-
voltage. low-ampere, direct-current power source and is ir~- Surface Technology
stalled in the chemical bath near the workniece. Usually ufc ognssdpnsuo h ruheso h i
the cathode is not shaped or conformed to the surface being ta ufc n h ieo meso.Tetpclruh _

polished. The cutting action takes place, o.er the entire ex- ilsraeadtetm f meso.Tetpclruh
posed surface, thstreivire. a good flow of heated. fresh chcm- xezs values range from 4 to 32 microinches R. 10.1 to 0.3
eede in
icaiheisvuingareato scureunifrm fn- ~ with i to 2 microinches R~. 10.025 to 0.05 pail aichiev-
icss Theed cting ation wdill crao cre foro n-s able. WZen noniconductirg masks are used, an additional M
finsdshes corners.g action cocnrto
i sw lal thast usedurrth depth of cutting is experienced adjacent to the mask. ELP
fisan prevent ctng Mi unw- a trcat usd it prudcce.- a sazrface that is free from residual stress and es-
*b.ireofca ~letri~t
enanc tse thrwin poer sentially unblemished. The uniformity of surface conditions35
haeo"an flcr pwr also is enhanced.
of the. direct current to ralish re-cesses and speed the ctit- 7:
ting ac,eur. Almost any eleciricali- conductivec material
can be polished by this process.
Equipment andl Toolsle
Pacica Applications Commercial plating 3r chemical machining equipment ca~n
Electropolishirgs geitle removal action produces a work- be readily adapted f(-. ELP ts-,.
piece surface of high quafit,- and introduces no stresses. ItZi
is trctiuently used as a finishing process for appearance or
smoothne-s3, or t~or applications where the absence of proc- _

ess-in-duced residual strc sses it: the workpiece is desirable.

Antifriction surfaces can be mobre consister.nt. anud =a-rosion Machining Characteiostics
resistance can be improved. The pure or uralte-red mer. C-aution in handling the strong chunicals is essential. Suit-
cl'.anical propett-izs of a vorkpiece material remain after able venting for fumes and environmentally proper disposal
finishing with ELP. of speirt U&id ate necessary.

13-17
13.2 Electropolishing-ELP
SELECTED DATA

TABLE 13.2-2 Eiectropollshing Parameters for High Strength Alloys

MATERIAL TYPE BATH CURRENT DENSITY BATH TEMPERATURE

300 series stainless steel Phosphoric acid 10 ~ 122

300 & 400 series stainless steel Phosphoric-Sulffuric acid 30Wk -~~ 0t 8
300 & 400 series stainless steel Phosphoric-Chromic acid 100 to 1,000 &R 80to15
Waspaloy and Nimonic 80 Phosphoric-Sulfuric8acid 86
S-81 6 Phosphoric-Sulfuric-Chromic acid 500 200 to 260
AMS 5615 Phosphoric-ufrcai 400 20 Z~~
Beryllium (rapid agitation Perchloric-Ethanol-Butyl Cellosolve 700 to 840 ;Wv~9) <95
needed) Phosphoric-Sulfuric-Glycerol-Ethano 1,900 to 3,700 68
Titanium Chromic-Hydrctluoric acid 200 to 500 60 to 7
10% Sulfamic acid in formamide
(no water) 6.5 to 8.1 tot5O
39IVR17 7 7
Phosphoric-Hydrot luoric-Metnanol 500 to 1,000 IM~ 60 to 80

IRene
Tungsten
41
Molybdenum
Sodium Hydroxide
Phosphoric-Sulfuric acid
Ortho Phosphoric acid-Sulfuric acid-
30 to 1;0
400
3.to516
_U,TU 68
70

Motybdic Anhydride-Water 3. o5I 6

13-18
 Photochemical Machining-PCM 13.3
PROCESS SUMMARY

M Clean workpiece
Photo resist coat

Start Negatives

- - Both sides exposed

Developed

Et
ched

Finish qMask removed

Figure 13.3-1 PCM schematic.

Principles Practical Applications

Photochemical machining (PCM) is a variation of CHM Photochemical blanking is burr free and is capable of pro-
where the chemically resistant mask is applied to the work- ducing intricate designs. A wide range of materials can be
piece by a photographic technique (see figure 13.3-1). A etched; brittle materials can be "blanked" since there is no
photographic negative, often a reduced image of an over- mechanical strain. Small lot sizes can be produced at lower
size master print, is applied to the workpiece and devel- cost than with conventional mechanical presses, and there
oped. Precise registry of duplicate negatives on each side of is a short cycle time from design to finished part. Cost of
the sheet is essential for accurately blanked parts. Immer- tooling is low and design changes can be quickly effected.
sion or spray etching is used to remove the exposed mate- Flat, thin-gauge, small complex parts ranging in thickness
rial The chemicals used must be active on the workpiece, from 0.001 to 0.020 inch 10.025 to 0.50 mini are most easily
but inactive against the photoresist mask There will be produced by PCM. Table 13.3-1 contains a list of work
some undercutting behind the mask, however, which limits materials that can be processed with PCM.
the use of PCM to thin materials-up to 3/32 inch 12.4 mml
(see figure 13.3-2).
Operating Parameters
Scribed edge Operating parameters and typical values are sirilar to
Undercut-. 1 A o mask those for CHM; however, some metals that can te chem-
Mask of ically machined do not easily respond to PCM because the
s . .photoresist masks are more fragile (for example, Waspaloy
B and Rene 41).

Depth of cut
Material Removal Rates and Tolerances
Cutting rates range from 0.0004 to 0.0020 inch per minute
10.01 to 0.05 mm/minl, depending on the material and its
Depth of cut B metallurgical stat. (see tables in section 13.1). Tolerance
Etch factor Undercut =AB increases with material
13.3-2 to 13.3-6 and figurethickness,
13.3-3. Onassurface
shown in tables
dimensions,
the typical tolerance is 15 percent of the material thick-
Figure 13.3-2 Etch factor in photochemical ma- ,,tss; however, any one dimension can be held to 10 per-
chining. (Note: Inverse of that used in chemical cent when other dimensions are allowed to vary by 25
machining.) percent of the material thickness.

13-19

- - - - --
-_- _ -_
13.3 Photochemical Machining-PCM
TABLE 13.3-1 Materials that Can Be Photochemically 0 08
Machined

METALS
Aluminum N'icoseal 3 06 .
Aluminum anodized Therlo E- W7_ .
Brass Sealmet 29-17 E
Cold rolled steel Therlo 2
Coldhrolled steel ASTM F-30 Alloy
Chromium Gls eln 2o0) 0
Copper,
Copper, oxygen
rolled free Glass Seal
142 Alloy ng 42 0 0.0d .- , g -
& n MY; -
Copper, rol Glass Sealing 46 44
Copper, electrolyt!ic14Alo
Copper, beryllium lAso
Sealing 4_ OWoI
Copper (OFHC)
Elinvar Extra Glass
4750 Seang 49 0.02 . .
Einvary Extra Glass Sealing 52 _

Gold 152 Alloy __ -

Havdr ASTM F-31 Alloy 0____ -

Inconel Glass Sealing 42-6 0 50 100 150 200 250
Lead Sylvania No. 4 Alloy
Maqnesium Sealmet No. 4 Center-to-center dimension, mm
Manganese
Molybdenum
Molybdenum, cold rolled SOFT MAGNETIC ALLOYS Figure 13.3-3 Practical tolerances on center-to-
Molybdenum, arccast 44-50% Ni Fe Balance center dimensions using photochemical milling.
Monel High Permeability 49 (W T Harris, Chemical milling, Oxford Clarendon
Nickel 4750 Alloy Press, 1976, p. 191)
Nickel silver Hipernik
Nichrome High Permeability 45
Ni Span C High Permeability Alloys Surface Technology
Permanickel Hymu 80
Phospor bronze 4-79 Permalloy Similar to that for CHM.
Rehnium Hipernom
Silver Mumetal
Steels Hymu 800 Equipment and Tooling
Stainless steel Supermalloy Batch and automatic equipment are available for both dip
PH300 series
15-7 Steel 5-79 Permalloy Bthadatmtceupetaeaalbefrbt i
and spray etching of strips up to 2-feet 10.6 ml wide. Some

PH 17-7 Steel ELECTRICAL SILICON installations include an electrical assist to the light, low-
Custom 455 IRONS concentration chemicals in order to obtain a straighter cut.
Spring steel Direct-current power, with low current density, is required.
Tungsten Orthosil Photoreducing and photoreproducing equipment are read-
Udimet CONTROLLED EXPANSION ily available and can be integrated into continuous blank-
Vanadium ALLOYS ing lines.
Zinc
Zirconium Invar 36
90-10 Copper nickel OTHERS Machining Characteristics
GLASS TO METAL Plastics Safety considerations in handling the corrosive chemicals
AND Polyesters and fumes are similar to those for CHM.
CERIUM TO METAL Polymides
ASTM F-1 5 Alloy Epoxy resins
GlassThethfco The etch factor fcr photochemical machining and the cir
,rpoohmclmcingadhei- W
Kovar Ceramics cuit board industry, figure 13.3-2, has been defined as the
Rodar inverse of the ratio used in the chemical machining in-
dustry. The tool designer must exercise care to be sure
SOURCE Photo Chemical Machining Institute, Evanston, IL which is applicable in his case.

13-20
 Photochemical Machining-PCM 13.3
SELECTED DATA

TABLE 13.3-2 Standard PCM Tolerances for Common Materials

TOLERANCE, inch

WCRKPIECE MATERIAL Workpiece Thickness, inch

0.001 0.002 0.005 0.010 0.015 0.020

Copper, copper alloys
and glass sealing alloys
(Nicoseal*) 0.0002 :0.0005 0.001 0.0015 0.0025 0.0035
Nickel-silver 00005 0.001 0 001 0.0015 0.0025 0 0035
Magnetic Ni-Fe alloys
(HyMu 80*) 0.0005 0.001 0.001 0.0015 0.0025 0 0035
Steel 0.0005 0.001 0.0015 0 0015 - -
Nickel and
stainless steel 0.0005 0.001 0.0015 0.002 0 003 -
Aluminum and magnesium 0.001 -0 0015 0.0025 - - -

Plastics
(Mylart, Kapton') 0.001 0.0015 0.0025 0.005
Molybdenum, titanium
and exotics 0.0005 0 001 0.002 -

WORKPIECE MATERIAL WE

Copper, copper alloys M M_

and glass sealing alloys 0.0 N-

Nickel-silver a WOW
Magnetic Ni-Fe alloys vp 5.. .. .
(Hy[Au 80*) ~ wfl__9-- ;jflh.-.
Steel i R 4W
Nickel and ANE N5
stainless steel , 4 # f
Aluminum and magnesium '_U& FS
(lasticsrl,
Kapton)
W
Molybdenum, titanium
and exotics 9

SOURCE: Chem Par Corporation, Montgomeryville, PA.

*Registered Trademark-Carpenter Technology Corpcation.
Registered Trademark-lE. I duPont deNemours and Co. Inc

_ _ _
13-21

_ _ __ _FlH i
13.3 Photochemical Machining-PCM
TABLE 13.3-3 Practical Tolerances Attainable for Prototype and Short PCM Runs
APPROXIMATE TOLERANCE, inch
FLAT SIZE
Thickness, inch

in 0.001 0.002 0.005 0.010 0.015 0.020 0.040

2 x2 Empirical 0.0005 0.0007 =0.0010 0.0015 0.0020 00040

8X 10 Empirical 0.0007 x 0.0010 -t0.0015 0.0020 0 0030 0.0050
12 x 18 Empirical -0.0010 =0.0015 0.0020 0.0030 -*0 0040 0.0060

-AC0 TidcK s m~jm MOM

mm ~ -V$~
Oi5O ~ 3~ *. 2 ~o ~

SOURCE* Data courtesy of Photo Chemical Machining Institute.

TABLE 13.34 Practical Tolerances Attainable for PCM Production Runs

APPROXIMATE TOLERANCE, inch
FLAT SIZE
Thickness, inch

in 0.001 0.002 0.005 0.010 0.015 0.020 0.040

2 x2 Empirical 0.0010 0.0010 t0.0015 0.0020 0.0030 0.0050

8x10 Emprica
0.015 00010
0.020 0.005 .004 0006
82x 10 Empirical 0.0010 0.0015 0.0020 0.0025 0.0040 0.0060

NOW=

_*iMt___ 'M R -- '-

SOURCE Data courtesy of Photo Chemical Machining Institute.

13-22
 Photochemical Machining-PCM 13.3
TABLE 13.3-5 Practical Tolerances for Center-to-Center
Dimensions in PCM

CENTER TO CENTER
DIMENSIONS TOLERANCES

in 2 n
i~T lft

1 0 or less 25rls' 0.0005 .* 1

1.0 to 3.05to7 0.0010 005
3 0to6.0 5o15> -0.0020 O0
60to 100 j5t20 0.0030

SOURCE Data courtesy of Photo Chemicat Machining Institute

TABLE 13.3-6 Practical Tolerances for Holes Made by

PCM

MATERIAL PRACTICAL TOLERANCES

THICKNESS HOLE DIAMETER ATTAINABLE

0.0005 003Empirical EmpiriW! Empirical Xmplut

0.0010 005Empirical jEM#mp miia
0.0020 005 .0030 vg&0? 6 --M 0.001 O02
0.0050 -0.13- 0.0060 ~05~ 0D0015 03
0.0070 0, 0I0080 M:2-39 .0 0015 *~8
00100 025 .0120 -'053M -0'002 00f
0.000 ZO 0.0260 D8...0.003 EO8,

SOURCE Data courtesy of Photo Chemical Machiing Institute.

TABLE 13.3-7 Guidelines for Smallest Hole Sizes by PCM

METAL THICKNESS
ZakSMALLEST HOLE DIAMETER

less than 0.001 us 1be dletermirted by test run

0.00 1 to 0.005 At least metal thickiess
0.005 or over iZ 3~& At least 110% metal thickness

SOtURCE: Dat& coustesy of Photo Chemical Machini~ng Irstilute.

13-23
 ! -~~
PAOT BiG
pj~iBpA(Z FIUED

Thermochemical Machining-TCM 13.4

or Thermal Energy Method-TEM
PROCESS SUMMARY

Oxygen D

Igniter Charging
Vent cylinder
Mixing

Workpece

.. .. .. .
. xplosio n

~chamber , ~Gas line

Figure 13.4-1 TCM schematic.

Principles Operating Parameters

Thermochemnieal machining (TCM) removes workpiece
material-usually only burrs and fins-by exposure of the
workpiece to hot, corrosive gases (see figure 13.4-1). The TABLE 13.4-1 Typical Values for TC.M Operating
process is sometimes called combustion machining, ther- Parameters
mal deburring. or thermal energy method (TEM). The Gas
workpiece is exposed for a very short time to extremely hot type: Natural gas and oxygen or
gases. which are formed by detonating an explosive mix- hydrogen and oxygen
ture. The ignition of the explosive-usually hydrogen or mixture: 4:1 to 9:1 (oxygen:gas)
natural gas and oxygen-creates a transient thermal wave pressure (initial): 10 to 370 psi [69 to 255 kPa]
that vaporizes the burrs and fins. The main body of the (see table 13.4-2)
workpiece remains unaffected and relatively cool because Thermal wave A
of its low surface-to-mass ratio and the brevity of the expo- temperature: Estimated 6.000F [3,315 0 1C]
sure to high temperatures. time: 1 to 2 microseconds: Mach 8

Practical Applications
TCM will remove burrs or fins from a wide range of mate- Material Removal Rates and Tolerances
rials. but it is particularly effective with materials of low Burrs are removed in a few milliseconds and the total cycle
thermal conductivity. It will deburr thermosetting plas- time is typically 15 to 50 seconds. Handling time is the
tics-but not thermoplastic materials. Any modest size principal manufacturing rate determinant. Rifle bolts that
workpiece requiring manual deburring or flash removal formerly took 5 minutes each to deburr by hand are being
should be considered a candidate for thermal deburring. processed with more consistent results at the rate of 2
Die castings, gears, valves, rifle bolts and similar small pieces in 8 seconds in a batch processing setup. The bulk of
parts are deburred readily. including blind, internal and in- the workpiece is generally not affected in TCM. With the
tersecting holes in inaccessible locations. Carburetor parts application of extra energy, radii can be formed. Radiusing
are processed in automated equipment. Thin sections of is limited by the conductivity of the workpiece material, for
fragile parts or those made from highly oxidation-resistant example:
materials may be difficult for TCM. As a rule of thumb, the radii in steel 0.002 to 0.030 inch
maximum burr thickness should be less than one-fifteenth 10.05 to 0.76 mini
of the thinnest feature on the workpiece. Uniformity of re- radii in aluminum
suits and greater quality assurance over hand deburring is and brass 0.001 to 0.005 inch
a special advantage of TCM. 10.025 to 0.13 mml

13-25
13.4 Thermochemical Machining-TCM
or Thermal Energy Method-TEM
Surface Technology processing chamber. Delicate parts may require holding"
Other than the deburring or radiusing action, there is little fixtures to withstand buffeting during the thermal shock
effect of TCM on the surface of the workpiece. Thermal wave Bulk loading baskets are used for handling small
distortion is no- a problem unless extremely close toler- parts in lots up to hundreds per load
ances are involved. There can be a thin recast layer below
thick burrs or fins. A thin oxide film is deposited on most Machining Characteristics
parts. These films are easily removed with commercial sol-
vents or washes. Surface stains may result if the workpiece is not clean, dry
and free of oil before TCM. The equipment has a stout
chamber to contain the detonation. Preplanned handling of
Equipment and Tools the pressurized gases is needed. Noise can range from a
Automatic equipment is commercially available with cham- gentle "ping- to the sharp report like a 22-caliber rifle
bers up to 11 inches 1280 minI diameter and 9 inches 1229 when the higher pressure settings are used. Even at full
mml high. A cycle time of 15 seconds is possible with this load. the average sound emission level generally remains
equiment. Fixturing is primarily oriented toward sim- below 85 decibels. Cleaning of the operating chamber is re-
plifying the movement of workpieces into and out of the quired at regular intervals.

SELECTED DATA

TABLE 13.4-2 Thermal Energy Deburring Parameters

INITIAL PRESSURE
MATERIAL MIXTURE 02 TO NATURAL GAS M
psi _ _

Thermplastic 9 to 1 10 to 25
Zinc 4.5 to 1 30 to 70 . -O1 -U
Cast iron 4.5 to 1 50 to 175 104[S.4J6
Aluminum 4.5 to 1 50 to 125 S
Brass 4.5 to 1 200 to 240 E .
Steel 4.5 to 1 100 to 220 4 I
Stainless steel 4.5 to 1 175 to 370 1 W
SOURCE: SURF/TRAN Company. Madison Heights, Mi.
NOTE: The pressure or amount of energy required for deburring increases with the heat conductnty of the ma-
terial to be deburred.

13-26
 SECTION 14
TOOL MATERIALS

14.1 General Guidelines for Selection of Tool Materials ................ .................. ... . ... 14-3
14.2 High Speed Steels ........................... ...........--............................. ......... 14-4
14.3 CastAlloys .......... . ............ ............................. . ....................... ........ 14-6
14.4 Carbides ................................................... ..... ....... ......................... .14-7
14.5 Microgramn Carbides .......................... e ................................
. .. ................ 14-15
14.6 Coated Carbides ............................................. ................... .... ........ .... 14-16
14.7 Oeramic Tool Materials ............................ ...................................... ...... <.14-17
14.8 Diamond Tools ................................................. ................. ........... 14-18

14-1
 B14 M -N T iTi l ll
. . . . . .G . ...

TOOL MATERIALS 14
1.4,1 General Guidelines for 2 Cast alloy cuttiag tool materials are selected as an inter-
meaiate between high speed steel and carbide tool ma-
Selection of Tool Materials terials. The high cobalt high speed steels also serve as
intermed;ates, and there appears to be a trend for them
Selecting the optimum tool material is a major factor in to supersede the cast alloy tools.
realizing the full potential of a particular machine tool.
While only one type of tool material is specified for some
materials and operations in sections 1 through 7. there are
a number of cases for which two or three material types are I Carbide tools are generally applicable when one or
recommended. The following supplemental guidelines are more of the following conditions exist:
offered as an approach for the logical selection of the best
tool materials for machining a specific work material. * Rigidity of the machine tool. tooling, and workpiece
is acceptable.
1. High speed steel tools are generall, used for the
following: * Machine tool power is adequate for higher metal re-
moval rates,
" High volume, low cutting speed operations (for ex-
ample. in screw machines) e Workpiece configuration and machining operation

* Complex tool forms such as form tools, drills, cutoff permit higher cutting speeds.
tools, etc. * High production rates are required.

* All sizes of end mills, drills. reamers. taps and gear

cutters

" Certain machining operations on problem materials. 4. Ceramic tools, high strength carbides. diamond tools.
such as nickel base high temperature alloys and the cast alloy tools referred to previously have
rather specific application in contrast with the wide us-
" High positive rake requirements age of high speed steel and carbide tools.

14-3
14 TOOL MATERIALS
As a general rule. the tungsten grades such as T1. T2. etc..
14.2 High Speed Steels are not quite as tough as the molybdenum grades but are
much simpler to heat treat The molybdenum high speed
The high speed steels can be classified into three genera; steels such as Mi. M2. M3. M7 and MIO are much more
types as follows: widely used than the tungsten grades. Both the tungsten
and the molybdenum high speed steels can be hardened to
1. Tungsten high speed steels 64 to 66 Re and are recommended for the machining of
2. Molybdenum high speed steels easy-to-machine materials. These include steels having a
3. High speed steels contari1g cobalt hardness up to 350 Bhn. While high speed steel types 1 and
2 can be used in machining steels having a higher hardness.
The chemical compositions of the AISI and the ISO high the type 3 high speed steels containing cobalt are recom-
speed steels are listed in tables 14-1 and 14-2. respec- mended. It should be noted that several of the high speed
tively. Note that the type numbers and designations listed steels such as M3 and M4 contain more vanadium, thus
in table 14-2 are tentative, having been taken from the pro- providing increased wear resistance. but at the same time
posed draft international standard ISO/DIS 4957. making the grinding of the tools more difficult,

TABLE 14-1 Compositions and Applications of AISI-Type High Speed Tool Steels

TYPE NOMINAL COMPOSITION, percentage APPUCATION

C W Mo Cr V Co
1. Tungsten High Speed Steels

Ti 0.75 18.00 - .60 1.00 - General purpose

T2 0.80 1800 - 4.00 2.00 j - General purpose-Higher strength

2. Molybdenum High Speed Steels

Mi 0.80 1.50 8.00 4.00 1.00 - General purpose

M2 0.85 6.00 5.00 4.00 2.00 - General purpose
M3 Class 1 1.05 6.00 5.00 4.00 2.40 - Fine edge tools
M3 Class 2 1.20 j 6.00 5.00 4.00 3.00 - Fine edge tools
M4 1.30 5.50 4.50 4.00 4.00 - Abrasion resistant
M7
M10 1.00
0.85 I 1.75
- 8.75
8.00 4.00
4.00 2.00
2.00 -- Fine edgepurpose-High
General tools-Abrasion resistant
strength;

3. High Speed Steels Containing Cobalt

M6 0.80 4.00 5.00 4.00 1.50 12.00 Heavy cuts-Abrasion resistant

M30 0.80 2.00 8.00 4.00 1.25 5.00 Heavy cuts-Abrasion resistant
M33 0.90 1.50 9.50 4.00 1.15 8.00 Heavy cuts-Abrasion resistant
M34 0.90 2.00 8.00 4.00 2.00 8.00 Heavy cuts-Abrasion resistant
M36 0.80 6.00 5.00 I 4.00 2.00 8.00 Heavy cuts--Abrasion resistant
M41 1.10 6.75 3.75 4.25 2.00 5.00 Heavy cuts-Abrasion resistant
M42 1.10 1.50 9.50 3.75 1.15 8.00 Heavy cuts-Abrasion resistant
M43 1.20 2.75 8.00 3.75 1.60 8.25 Heavy cuts--Abrasion resistant
M44 1.15 5.25 5.25 4.25 2.25 12.00 Heavy cut.-Abrasion resistant
M46 1.25 2.00 8.25 4.00 320 3.25 Heavy cuts-Abrasion resistant
M47 1.10 1.50 9.50 3.75 1.25 5.00 Heavy cuts-Arasion resistant
T4 0.75 18.00 - 4.00 1.00 5.00 Heavy cuts
T5 0.80 18.00 4.00 2.00 8.0,) Heavy cuts--Abrasion resistant
T6 0.80 20.00 4.50 1.50 12.00 Heavy cuts-Hard material
T8 0.75 14.00 - 4.00 2.00 5.00 General purpose-Hard material
T15 1.50 12.00 - 4.00 5.00 5.00 Extreme abrasion resistant

14-4

- - -- r __- -
 TOOL MATERIALS 14
The high speed steels with cobait. type 3. contain 5 to 12 High speed steel cutters are widely used for the following
percent cobalt. The addition of cobalt provides greater hot machining operations:
hardness and wear resistance but results in a somewhat
lower toughness. In general. it has been found that these Operations using form tools
grades are not particularly advantageous in tie machining Screw machine operations
of the readily machinable materials. Tttev are. however. End milling
most beneficial for machining steels having a hardness Drilling
level above 350 Bhn and for the more difficult-to-machine Reaming (carbide-tipped reamers are also widely used)
metals. such as titanium and nickel base high temperature Topping (nitrided taps are often used for difficult-to-
alloys. The TIS grade also has a higher percentage of machine alloys)
vanadium: consequently. it is more difficult and more costly Broaching
to grind than the other high speed steels containing cobalt. Gear cutting

In general. the high speed steels containing cobalt can be A recent development in high speed steels is the .avail-
heat treated to a hardness level of 65 to 67 Re. While the ability of indexable inserts made by the powder metal proc-
M40 series can be hardened to a level of 70 R-.the hard- ess. The sizes and shapes of the inserts correspond to those
ness range usually recommended is 66 to 68 Re.Above 68 of some of the more popular carbide inserts. The current
R-. high speed steel tools tend to be too brittle for most grade selection is limited, but in the future. selection is
applications. likely to expand.

TABLE 14-2 Identification and Type Classification of High Speed Tool Steels

(Per ISO/DIS 4957)

TYPE OF STEEL CHEMICAL COMPOSITION. percentage

ISO AISI
Group No.* No., DesignationOt C Co= Cr Mo0 V W
Si T 'II I
S1 TI HS18-0-1 0.73 to 0.83 - 3.50 to4.50 I - 0.90to1.20 17.2 to 18.7
Basictypes S2 M7 HS2-9-2 0.95 to 1.05 - 350 to 4.50 8 20 to 9.20 1.70 to 2.20 1.50 to 2.10
S3 M HS 1-8-1 0,77 to 0.87 - 3.50 to 4.50 18.00 to 9.00 0.90 to 1.40 1.40 to 2.00
S4 M2 HS 6-5-2 0.82 to 0.92 - 3.50to4.50 14.60to 5.30 1.70 to 2.20 5.70 to 6.70
Increased I
5 M3 HS6-5-3 1.15to 1.30 3350!a4.50 4.60to 5.30 2.70 to 3.20 5.70 to 6.70
C + V-content

S6 use T5 HS 18-0-1-10 0.75to0.85 9.50to 10.5 3.50 to 4.50 - t.30to 1.80 17.2 to 1.7
With Co-content S7 use T4 HS 18-1-1-5 0.75 to 085 4.70 to 5.20 3.50 to 4.50 0.70 to 1.00 1.10 to 1.60 17.2 to 18.7
S8 M35 HS 6-5-2-5 0.85 to 0.95 4.70 tu 5.20 3.50 to 4.50 4.60 to 5.30 1.70 to 2.20 5.70 to 6.70

Increased C + V
content + Co
S9 T15
S10 - HS 10-4-3-10 1.20 to 1.35 9.50 to 10.5 13.50
HS 12-1-5-5 1.45 to 1.60 4.70 to 5.20 3.50 to 4.50 0.70 to 1.00 14.75 to 5.55 11.5 to 13.0
to 4.50 3.20 to 3.9013.00to3.50 -.00to10.0

Increased C-content S11 M42 HS 2-9-1-8 1.05 to 1.20 7.50 to 8.50 3.50 to 4.50 9.00 to 10.0 0.90 to 1.40 1.30 to 1.90
+ Co S12 M41 HS 7-4-2-5 1.05 to 1.20 4.70 to 5.20 3.50 to 4.50 3.50to 4.2011.70to2.20 6.40 to 7.40
I_1________ ____I I ____
*The type numbers and designations are tentative and will be subject to alteration when the reevan international Standards have been established.
'Approximate AISI egurvalent-See table 14-1.
'Successively W-Mo-V-Co.
'For all steels,
Silicon < 0.50%. Manganese < 0 40%. Phosphorus < 0.030%. and Sulphur < 0.030%.
'A dash in these columns indicates that these alloying elements 3hould no! De intentionally added to the heat and. that in the case of cobat, the content of
the cast should not exceed 1.00% and. in the case of moybede' um. it should not exceed 0.70%.

14-5
14 TOOL MATERIALS

14.3 Cast Alloys Cast alloy materials are not widely used. However. they
find limited use as a compromise since they perform wc;l at
higher surface speeds than conve:nticnal high speed steel.
Cast alloys have been available for many years. These ma- and are more resistint to chipping than standard carbide
terials are generally cobalt-chrome-tungsten ailoys with grades. A number of cast alloy tool materials and their
carbon and other alloy additions. They are not heat treat- compositions are shown in table 14-3.
able. and the maximum hardness (55 to 65 Re)occurs near
the cast surface. As a result, cast alloy tools must be tsed
as-cast with as little grinding as possible.

TABLE 14-3 Cast Alloy Tool Materials

NOMINAL COMPOSITION
TRADE NAME percentage HARDNESS, R. MANUFACTURER

Co Cr W C OTHERS

Blackalloy 525 440 24.0 20.0 2.0 61 to 63 Blackalloy Company of America, Inc.
Paterson, NJ
Blackalloy T.X. 90 42.0 24.0 22.0 2.0 63 to 65

Haynes Stellite R 98M2 alloy 38.0 30.0 185 2.0 1 2%boron, 63 Co-Bo Cast Tool Co. Inc.
4%V. 4% nickel Kokomo. IN
Haynes Stellite R Star J metal 43.0 32.5 17.5 2.5 61
Haynes Stellite R alloy No. 3 50.0 31.0 12.5 2.4 59
Haynes Stellite R alloy No. 19 53.0 31.0 10.5 1.8 55

Tantung G 47.0 30.0 15.0 3.0 5% Ta or Cb 60 to 63 Fansteel. VR/Wesson Division

Waukegan, IL
Tantung 144 45.0 28.0 1'.0 3.0 6% Ta or Cb 62 to 64.5

NOTES: The procedure used for making cast alloy tools is to met the particular analysis in an electric furnace and then cast the tools to shape with small
stock allowance for finish grinding. The tools are at maximum hardness when removed from the molds and cannot be hot or cold worked and do not respond
to heat treatment
"'HaynesStellte" is a registered trademark of Cabot Corporation.
This chart isnot to be considered an endorsement of any manufacturer's product or an approved list of any manufacturer's products.

ZE
______I.

-~ -

14-6
 TOOL MATERIALS 14
i4.4 Carbides Char.)14-4 Carbide Manulacturers (Carbide Grade
TABLE

Each tool manufacturer listed in table 14-4 has a wide va- CARBIDE MANUFACTURER
riety of carbide grades, so that a specific grade can be se- -
lected for a given material and operation. Although most 'if
the carbide grades are listed under the industry code (C-i. Adamas ADAMAS CARBIDE CORPORATION.
C-2. etc.) in table 14-5. this does not necessarily imply that Kenilworth. NJ
the various manufacturers' grades under a specific code are Atrax ATRAX RESEAIRCH &DEVELOPMENT
equivalent. CENTER. Wallace-Murray
Corporation. Tuscaloosa. AL
The C-1 through C-4 grades are straight tungsten carbide Carboloy CARBOLOY SYSTEMS DEPARTMENT.
bonded with cobalt and vary chiefly in cobalt content and General Electric Company. Detroit.
MI
grain size. They are widely "sedfor machining cast irons.
high temperature alloys, work hardening stainless steels. CmT o A Memb&
abrasive nonmetallic materials and nonferrous metals Industries. Madison Heights. MI
including titanium. Toughness decreases and hardness in- DoAll DOALL COMPANY. Des Plaines. IL
creases proceeding from C-1 to C-4. The C-2 grades pro- Duramet DURAMET CORPORATION. Warren. MI
vide a good compromise in properties and may be cate- Ex-CeIIO EXCELL-O CORPORATION. Detroit MI
gorized as "general purpose" for the aforementioned Ex-nea- X
materials. Greenleaf GREENLEAF CORPORATION.
Saegertown. PA
The C-5 through C-8 grades include those which contain GTE (Walmet) GTE SYLVANIA INCORPORATED.
various combinations of tungsten carbide, tantalum car- Walmet Division. Royal Oak, PA
bide and titanium carbide bonded with cobalt. The C-8 cat- Iscar ISCAR METALS. INC.. Edison, NJ
egory now also includes tools of straight titanium carb:de Kennametal KENNAMETAL INC.. Latrobe. PA
bonded with molybdenum (or molybdenum carbide) and Newbide NEWCOMER PRODUCTS. INC..
nickel. Other straight titanium carbide grades with proper- Latrobe. PA
ties in the C-5 through C-7 range are also availal-e. Grades Sandvik (Coromant) SANDfVIK, INC.. Fair Lawn. NJ
C-5 through C-8 are generally recommended for machining Seco SECO TOOLS INC.. Northbrook. IL
steels because they provide better crater resistance than Talide METAL CARBIDES CORPORA7ION.
the C-I to C-4 grades. Toughness decreases and the hard- Youngstown. OH
ness increases in going from C-S to C-8 The C-6 grades are Teledyne (Firthite) TELEDYNE FIRTH STERLING,
for general-purpose use. Pittsburgh. PA
TRW Wendt-Sonis WENDT-SONIS DIVISION. TRW Inc..
For work materials such as highly alloyed cast irons, alloy Rogers. AR
steels over 50 Re. ferritic or martensitic stainless steels and Tungsten Alloy TUNGSTEN ALLOY MANUFACTURING
some high temperature alloys, the preferred carbide grades CO.. INC.. Harrison. NJ
may come from either the C-1 to C-4 or the C-S to C-8 Ultra-Met ULTRA-MET MANUFACTURING
group. COMPANY. Farmington. MI
Valenite THE VALERON CORPORATION. Oak
Table 14-6 has been used in classifying carbides according Park. MI
to use as specified by the International Organization for VR/Wesson FANSTEEL. VR/Wesson Division.
Standardization (ISO). Recommended grades produced by Waukegan, IL
various manufacturers are listed according to ISO classifi-
cations in table 14-7.

14-7

- - - - -- t--
14 TOOL MATERIALS
TABLE 14-3 Carbide Grade Chart, C Grade

TRADE
NAME C1C-2 C-3
INDUSTRY CODE
C-4 C-5 C-6 C-7 ] C-8
Adamnas B A PWX 1GU-2 499 ACT-51 548 490
AM ACT-21 434 AG-5' ACT-71 ACT-71
ACT-21 ACT-51 495 Fitan 80* Titan 80*
IAG-5* Titan 60* Titan 1001
474
_______ _______I ________ _________ Titan 50* __________

Atrax M-22 A6 1A7 A7 T3 1T50 T63 T8

T50 iT64 T76
T56 T65 T78
Carbloy 18'
570' 545'210T50C I_____ T76C 10
Caboo 5850 55 20518' 570' 545#'10
44A 515, 570' 545' 370 5151 570' 320
320 I523' 515' 999 375 516t 515'
I883 523' 5709 390 350 516'
895 518 350
__________ _________370

Carmet CA-12 CA-31 0 OA-7 OA-8 CA-61 0 CA-606 CA-711 CA-704

CA-3 OA-4 . CA-84431 R-03* CA-740 CA-720 CA-971 1 R-03*
CA-443 CA-94A"O CA-721 CA-9720a

DoAII DO-i
_______
CA-84431
CA-9443
DO-2
R-03*
______

rO-3
___

E:04
CA-9740a
CA-9721
DO-15 DO-16
t 00-1 7 00-18
D0-30 DO-20 IDO-80 DO-35 D0-36 DO-34 00-80
00D-46' I______ 00-44' 00-401 D0-421 _____

Duramet DUl DU2 DU3 DU4 IDU5 DU6 DU7 01.38

____ D_U22 _____ ______{DU55 ______ U78 ___

Ex-Cell-o E-8 E-6 E-5 E-3 10A 8A I6AX 509

XLO-28 XL-2021' 8A I606 IXLO-61 XL-88*
XL-20211 XL-85*
IL-2 L62 X6 X.86
Greenleaf G-01 G-02 G-30 G-1 G-50 X-602" G-/GI T-
G-10 G-20/G-30
G-1
G-i G-40 G-53 IG-60 Ti-6 GA-6/G-1
Ti-2 G-52 IG-54 G-70/G-25 G-80/G-88
Ti-2 GA-S

G.T.E. WA-i110 IWA-2 WA-3 WIA-4 WA-54 WA-47 WA-7 WA-8

(Wamet) WA-i P-2- P-3 P-49 P-4 P-47 WA-73
WA-59 WA-35 WA-S P-471
WA-69 P-59
WA-63 WA-57

Isa -108- C2 IC020 10 4 10 50 IC 50M C070 1C so8

IC020 IC0424 IOS50M IC070 :C078 I
IC024 IC 54 IC0656 IC 60T
IC0424 10 656 IC757 IC080T

Kennametal K1
KC02501
_______

____
_______

K(6
1K68
K(8735
KC210'
F K68
______

1C210ti0
KC0910'
--
________

(1 1
KC9O
K(420
I 0850"
IC 757

t K420
K21
28
1(88
IC 757

K4H
K45
C11
K810
KC8501I
1K7H
______

1 K,65*
C1O

KC02501 KC0850"1 K091j#

Newb:~ N-10 N-22
N-2IN
N3
T-2 INT25
N-40 N-50/N-52
NT-S
N-00
NT55
N-70/N-72
NT-6
-N-80
N-93/N-95
_____N25 ____ N21)__ _ _____jN55 NT6 NT55 NT6
CAST IRON, 1'.ONFERROUS AND
NONMETALLIC MATERIALS STEEL AND STEEL ALLOYS
C-1 Roughing C-S Roughint,
0-2 General Purpose 0-6 General Purpose
0-3 Finishing 0-7 Finishing
C-4 Precision Finishing 0-8 Precision Finishing_______
NOTE~: Littings do oot necessarily imply equivalency of various manufac- iA1
203 coated.
turers' grade4 This cha~rt is not to be considered an endorsement of or an *TriPhase titanium nitride coated
approvad list of any manufacturer's products **AI 2 01 and T. coated.
*Cot, a more than 50% titanium carbide "'Coated.
'Ti(. coas . $'iTrIple-coatedl, TI-C + TI (C. N) + 41~, 3
'TIN over TIC coated.

14-8
 TOOL MATERIALS 14
Table 14-5-Continiued

TRADE INDUSTRY CODE

NAME C.1 C21 C-3 C-4 C-5 C-6 C-7 -

Sandv!k
(Coromarit)
420
HML
GC15l
G0315+
G0015v*
GC31 51
GCol5**
H05
S6
SM30
IG01025'
IGC015**
GC10251
GC015**
GC015**
SIP
GC10250 GC10251 HIP G01351 GC1351 SIP IF02-
HiP I P Hi0 S6/S4 S4 S2 G01025'
H20 H10 GC310** GC10251 SM SMI GC120'
HM FIM S35 SM30 SM30
HML GC30* S35 G0135*
GC310** GC320** GC120 GC120V
GC320** GC135'

IRB _ _ _ _ _ _ _ I__ _ _ _ __ _ _ _

Seco HX ISU41 H13 TX10V G27 S2 S 25M SIG

1 P15 TX10*" TP15$t S4 SU41 jSlOM TPl5ts
s SIJ41 T15M$* S6 S25M SiF
T15M"f HX S60M S1OM TP15",
TP15t TP351 TP25' TP251
ITi 5vsM" S25M TP35t

Talide

Teledyne
(Firthite)
0-89

IHi7
1-1
K1IATOi" ,

H
-93
0-1
0~-936_
0-95

HN +
S-880

T-04
T4
__
S-901

HN+*
TC"
S 92

HN+ t
T-25
_
-94
IT--1
N+"
H-6 HA KN +"1 HF HN + 4'1 TXH ITC+ 11 SD-3*
IHN+ 1 TO + SD-3* To + 4", T-22 'SD-3*
~T " SD-30 HN + 11
TRW iTW-167$ tTRW-027t TRW-237$ NTA37
Y-2 TR- $ TW74t TW71
22
CQdtSnjG-221V CO-23T, CQ-23T' CY-16* U225' U2271 CY-31T'
C0-22
C0-12
00-2
CQ0-23
CQ-23
O-3
00-4
G-0-23
CY-1i71
U225
CY-16
JTi8*
ICY-14 CY-31
Ti8*
I TRW-7156'

CY-1 2 ____
6B_______________

Tungsten A684B 38 11T lOT 8T 5S

Ultra-Met Z-1
Z-1 0
Z-2
IZ-20
1Z-20
Z-3
Z-4 Z-5
Z-52
1
Z-50
Z-6
Z-7
Z-70
Z-8
Z-80'

Valenite
Z-25_Z_51___60
Z-29___
V-iN"1 V-01** V-0~
4___
V-01**
Z-50
V-88, V-0~
___
Z-7
Z-8_
Vfi V-01*0
_ _

VC-1 V-9i1 '191+ '0-3 VN-81 V-99',0 VC-63*

VC11 VNe8l V-88, VC-23 V-991 V-90, -8 VC-8
VO- 101 V-t VN-6$ VN-5"t V-881 N8
VI-J-21 VN-."1 V-1i4" VN-8* N-1
V-i N" VC-3 VC- VN-5 VO-7
VC-2 VC-29 VC-55:6" VC-76
VR/W
sVCn-242 VC-56
0C-28 '/0-125

V/mn2A3
I2A68
2A5
VR-82
IVR-82
630'
2A7
630'
1650
660'
650'
660'
660'
670'
VR-651
VR-71
VR-54 630' 2A7 VR-65* VR-77 VR-75 VR-73 670'
_______Ramet-1 Ramet-1 j_____________1_____ VR-77 ______ _____

CAST IRON, NONFERROUS AND_

NONMETALLIC MATERIALS STEEL AND STEEL ALLOYS
C-i Roughing C-5 Roughing
C-2 General Purpose C-6 General Purpose
C-3 Finishing C-7 Finishing
0-4 Precision Finishing C-8 Precision Finishing
*'on'ains more ti-an 50% titafl~um carbide, 'Tri-Phase titai~um nide coated.
'TiC coated * IA1201 and TIC coated
IT.Nover TIC coated. "Coated.
'A120, coa'ed "$Triple-coated. T-C + Ti (C. N) + A1201

14-9
14 TOOL MATERIALS

0 0
- 0 T 9 0

(D OC 0) 1 C

0) - C 00 C

U) 0)
C.-
0 3 ~
0 U) m

'a C CD E) : -0 = o0w
o~' U)C
a) P
a. o
.D
;c
~ g 0)
~: EEQ
w 204)c
cc~-
0
-d
0)~
0)w Im V) ~- 0 U) ) ( 0z Cc a2 o) CU
ZC C 0 ) U0, a) a) 03
0 Q,( 2U 4)' 10a a)_0
0) .0 C-D :3 -0 C CL 0
0) E Z E- 0 00D 0

0 U a.) .C Cc Sac - ) n0-

CC aU C0 2: ) 0 U) CU
C~ ~ E
Us 03
a o (D= 0~ 0
> mz 0(
C U 5. c a
Z:6 0 E- C- CUV OCU UU) C 0 CU .
cU E 0 U)C Ea 0 Ot
C0n CO E
Ca CEoo . ) CU >
=S ~ E,> ~ *- -u)
C) .2
CU.S
E ~ 3:~ 0 Or

a.-oo ~~0C
CDE~
-5
g~CL)aC
0) 4)) E
1 S~~(U)0 ) 0)~

0 0 0. 0~ CEQ. E( (DU Cb 60

-a 0 L'-sEC
vE ) E
u..i- 6-2 E
0i 0 0
(I) C (D C C - 0 C
- . Q, E D CL ca ZU a) c
0 S :EU = a ic 02
U)E

U) o U)> U) ca 0. E E 0
0) )C C E~ m ) 0E ) CF 'A0
0) CL (
mC
0) )20 C)~4
0) U)cz~
42~~~. 0 00Ur C* > ~ U
- U) 420 *)0W
0_-
0 .2-
:s C mC a '
*( C a E ca c C ~
0
U) .00) LD-. C o)
C.) 0) 0) 0 )C zI. E0 2 Cm
E E2 S > c

u. cc) 0) W0 c

0 '

)..)
(D0 D c,

14-1
 TOOL MATERIALS 14

Woo o 0r
5

00
C
0

C C

,C.- o o i

0 o 00 c.a

4C C CC CDU

"U 6): _.=- 6:s

C,~~C CCDC)()1 ~ 00
CL

0
o~~~t ~ C* C)C
c
>~-

- o .-- o-- o"= =

14-110 ' o 0
E C

0 t xC

C- -a 0

0 o

uIE I
0 0
7E ca0i 0-a ( :

0 --UP a - CD .- - - - - - a-- 'a-- . - - - - - - - -

14 TOOL MATERIALS

cu
,K Ax - --- c

t- x

cci
I L--___.__ __

UU C., 3 1

cc~co -tic
<- 0

00
.
2i __ [Iccr.cc.
- -, c_ c

C D

cc~~ cooc

I K. ._- '--__
- _ - - ..= _
IcL t

14-12
 TOOL MATERIALS 14

r ICYt
ZUt
CL a,
0_ _Ch_ _ _ F -

21!~ L:g
~ ~ 2 t"'
-- /
~Rn

a.3i
a.H

Hil I

02

I -

14-13
14 TOOL MATERIALS

A I~oo
TT I

S> > > --

La -==. l -s I """ i2>

! - 7- I

' _ _ _ _ _ i " I1

m =++ . ?

t I

. -

+- ~ I

i;Ic.
:E
ICD~a
-
=
,..-',,, = -a ,
_

>>>
__

_>>>__
_ _

1
I u

++

a.4 M

I L =~--

14-1

u, =0 04

co
US_
j z? ?

Li >

14-14
 p

TOOL MATERIALS 14
mal strength levels would chip or break. The major use of
14.5 Microgran Carbides micrograin carbides at present is in cutoff and form tools.
replacing high speed steel in low-surface-speed, high-pro
A relatively new group of high strength carbides intended duction operations on screw machines and similar equip-
for machining applications is now available. These tung- ment. Some application is also being found for micrograin
sten carbide-cobalt base materials are characterized by carbide tools in the machining of problem materials such as
strength levels previously found onl) in impact and rock bit the high temperature alloys and for making punch and die
grades. coupled with much higher levels of hardness. as sets intended for extended use.
shown in figure 14-1. Their properties are achieved by var-
ious proprietary processes and depend in part on achieving The high edge-strength of micrograin carbides allows the
and maintaining a very fine carbide grain size. use of high speed steel tool geometry and. when necessary.
speeds as low as those used with high speed steels. Con-
Manufacturers recommend these materials for improving versely. operation at normal carbide speeds may not be
metal removal rates and tool life over those possible with practical because the high cobalt binder level in these ma-
high speed steels fc- conditions where carbides with nor- terials significantly reduces their resistance to cratering.

Mechanical Shock Resistance Abrasion Resistance Crater Resistance

(Transverse Rupture (Hardness. Rockwell A) (Arbitrary Scale)
Strength. ksi)

High Speed Steel 500 - 700 81.0(w - 70 Rc) PO

Cast Alloy 300-350 81- (60 -65 Rc)

846

Micrograin 400 -540 91.5 -92.0

Carbide

C-1 and C-2 240 -325 90.0 -92.0 FAIR

Carbide

C-3 and C-4 175-260 92.0 -93.0

Carbide

C- ad
-6 200 -300 90.0 - 92.5-- GOOD
Carbide

C-7 and C-8 100-250 92.0-95.0 .1

Carbide

Ceramic 801093.5-940 I 111 II_

Pr~lvcrystal line 10-0 6500 - 8000 Knoop ] EXCELLENT

Diamond

Figure 14-1 Comparative properties of tool materials derived from published data for available grades.
Crater resistance refers to ferrous metals.

I1
14-15J
14 TOOL MATERIALS

vapor r; cc,:verted to fine namtitanvmm crystals The

1 -4.6 Coated Carbides process continues until the coating is about 0.0002-inch 15
jiml thirk. Other coat:ngs such as TiN. HfN. HfC. and
Perhaps the most important advance in cutting tool tech- AI-,( 3 are produced using t' same technology with other
nology during the past decade has been the develcpment of gaseous components.
coated carbide irnsert. The impact of this inprovemew
can be measured in terms of the major be-efits of inLreased
metal removal rate and too' life that have been found in The improved machining performance of coated carbide in-
turning and face milling of cast irons and steeL, These two serts resum, from r.-duced frition. increased sur'aL- hard-
general types f work materials still represent th' bulk of ness and. most important of alI. chencal inertness. The
the work material being machined in t-e United States. thin layer of coa.ing provides a cobalt-free diffusion barrier
The application of these tool materials overlaps much of between the workp;ece and the it -it. The reduction or
the entire C-1 through C-8 range. The coatings are usually. elimination of di'tusion results in an appropriate reducton
but not necessarily, deposited on conventional carbide in- ofcratering and flank wear. For many applications, this re-
serts. Speciai 3ubstrates are being developed which defi- suits in either a longer tool life or a higher metal removal
nitely are not sumtab!e as metal cutting tools without the rate when compared to uncoatt' carbide-. An exception to
coatings. this advantage would probably occur in highly abrasive.
lower cutting speed ope *ons.Newer grades are being de-
Titanium carbide coatings are produced by reactive depes- veloped to succe-sfully perform heavy roughing and inter-
ition from the gaseous phase. where titanium tetrachloride rupted cuts.

1I
|I

Ia
i
j

14-16
 TOOL MATERIALS 14
ling and for machining materials of very high hardness (60
14.7 Ceramic Tool Materials to 68 Re).
There are two main types of ceramic cutting tools, the pure
alumina tools and the alloyed cermets (see table 14-8)_ The Presently. the main uses for ceramic tool materials are in
cermets are also aluminum-oxide-base materials containing finish and semifinish turning. Typical applications are bor-
various amounts of titanium carbide or other alloying in- ing and facing of cast irons for the automotive industry.
gredients The alumina tools are white in appearance. Al- turning of steels for ordnance applications, and finish turn-
though these tools may be either hot pressed or cold ing and facing of chilled iron and of hardened steel rolls.
pressed. ;.hey are usually cold pressed. The alumina inserts Where high rigidity has been designed into the machine
are norrrally applied in lighter-duty cuts. such as noninter- tool and the tooling, roughing of cast iron and steel may be
rupted turning and boring, performed with ceramic materials.

In addition to the introduction of hot-pressed cermets.

three recent developments in the preparation of ceramic in-
TABLE 14-8 Ceramic Inserts serts have expanded the usage of these tools. Those devcl-
opments are as follows:
IDENTIFICATION MANUFACTURER I The grinding of K-lands on the cutting edges
2. The use of thicker inserts
TRW-138 TRW Wendt-Sonis. Rogers, AR 3. The use of larger nose radii
TRW-1322
VR-97 Fansteel, VR/Wesson Div., Waukegan, IL The primary failure mode of ceramic inserts has always
VR-IO0 * been either edge chipping or insert breakage. These three
Ceratip 30 Ceratip-Division of Kyocera International improvements have all helped reduce those problems.
Ceratip 42. Inc., San Diego, CA
Cermet 61* A "K-land" is a precision-ground flat that removes the sharp
C1 NTK Division of NGK Spark Plug Co. Ltd. cutting edge where the top and side faces of the insert inter-
Harbor City, CA sect. The width of the flat varies from 0.002 to 0.012 inch
GEM9 Greenleaf Corporation. Saegertown, PA 10.05 to 0.30 mml. The angl- of the bevel may vary from 30
GEMI to 45 degrees with respect to the top face.
GEM2*
GEM3*
K 0900 j Kennametal Inc., Latrobe, PA A thicker insert will be less likely to break under the in-
K 060 j creased cutting forces produced by a chipped cutting edge.
V-32* Valenite Div., Valeron Corp., Detroit. MI This increases insert life by preserving unused corners
V-34 which would normally be lost if the insert cracks.
G-10* Babcock & Wilcox, Rochester, MI
G-20 A larger nose radius will naturally present a stronger cor-
j
CA-W
CA-B* J Carmet Company, Madison Heights, MI ner than will a smaller radius. This also helps to reduce
edge chipping and nose breakage.

NOTE Listings do not necessarily imply equivalency of various manufac- Even with the improved technology of adding K-lands and
turers graotz: This chart is not to be considered an endorsement of o. an using thicker inserts, more care must be exercised in apply-
approved list of any 'nufactiirPr'nodicts. ing ceramic tools than is : mally used in applying high
SCermet speed steel or carbide inserts. In particular, it is necessary
to avoid mechanical shock where possible and thermal
shock at all times. Ceramic tools are rarely, if ever, used
The cermet tools are hot pressed. These tools are much with cutting fluids. Their application in turning, boring or
tougher than the alumina inserts and are therefore appli- milling is always dry. Negative rake inserts are used al-
cable for roughing, for interrupted cuts. for some face mil- most exclusively.

14-17
14 TOOL MATERIALS
14.8 Diamond Tools Tools
TABLE 14-9 Producers of Polycrystalline Diamond

Diamond tools are most generally used for machining non- Carboloy Division of General Electric Company
ferrous alloys and abrasive materials, such as presintered Detroit, MI
carbides and ceramics. graphite. fiberglass. rubber and Kennametal Inc.
high-silicon aluminum alloys. Man-madc polycrystalline di- Latrobe. PA
amonds that are sintered under very high temperatures and
pressures are now available as cutting tool inserts of vari- Megadiamond industries
ous sizes and shapes. Manufacturers of these tools are Chicago. IL
listed in table 14-9. Polycrystalline diamond tools have
proved to I e. in most cases, greatly superior to natural
mined diamonds in normal machining operations on the
work materials listed above. However. even though the In general, diamond tools should be treated with the same
polycrystalline diamonds are much tougher and able to care as would be used with any very hard. brittle tool mate-
withstand a great deal more abuse than natural mined dia- rial. However. even light interrupted cuts are possible with
monds. it is still good practice to observe as much care in the stronger polycrystalline diamonds. Diamond tools are
handling the tools as possible. If natural mined diamonds generally used with positive-rake tool geometry in order to
are desired for use as the cutting tool material, then the fol- reduce the forces on the tool. but th. re are other appli-
lowing guidelines should be observed: cations of negative-rake geometries that have proved suc-
cessful. The new strei.gth and reduced cost of poly-
Diamond tools are purchased from suppliers who are crystalline diamond have opened up many new fields of
expert in the art of cutting and orienting diamonds and machining, and new applications continue to be found.
should be returned to them for resharpening. In-house
grinding or reshaping should not be attempted. The di- The use of a cutting fluid will usually ncrease the tool life
amond tool should be resharpened as soon as it be- of the diamond, but where this is not practical. a stream of
comcs dull to minimize breakage. thereby increasing air can be used to cool the tool and keep the cutting edge
the number of possible resharpenings. free from chips.

Mi

___ _ _ __ _ _ _
1j
- -- ~-~-

14-18
 SECTION 15

TOOL GEOMETRY

TOOL GEOMETRY GUIDELINES

The following table-s show the range of standard tool geo- "Modified" standard tools for specific materialz are of-
metries that are ised for various work materials. Negative fered by many tool manufacturers at costs considerably
rake is shown wherever applicable because it provides a less than for special tools.
stronger cutting edge and usually better tool life on rough-
ing operations. Special tools may be justified for high-production appli-
cations or for the machining of complex parts or difficult-
Standard "off-the-shelf" tools are satisfactory for most to-machine alloys.
applications.

SECTION CONTENTS
15.1 Turning and Boring Tools, Single Point .............................................................................. 15-2
15.2 Threading Tools, Single Point ............................... ............................................................ 15-4
15.3 Die Threading Tools, Thread Chasers .........................................................-........................ 15-6
15.4 Face M ills ..............................................................-............................. .................................. 15-8
15.5 Side and Slot Mills-Arbor Mounted ...................................................................................... 15-10
15.6 End Mills-Peripheral and Slotting, High Speed Steel ........................................................... 15-12
15.7 Drills, High Speed Steel Twist ...................-.........-................................................................. 15-14
15.8 Oil-Hole or Pressurized-Coolant Drills, High Speed Steel ...................................................... 15-16
15.9 Spade Drills, High Speed Steel ......................................................... .................................... 15-16 3
15.10 G un Drills. Carbide . ..................................... ........................................................................ 15-18
15.11 Ream ers, High Sp. d Steel .............. ............ ...................................................... .................. 15-19
15.12 Ream ers, Carbide ............. .-.............. 1....................................................................
15-20
15.13 Boring Tools, Carbide ............................................................................................................ 15-21
15.14 Taps, High Speed Steel ................................... ...................................................................... 15-23

15.15 Planing Tools .........................................- ............................................................................. 15-25

15.16 Broaches, High Speed Steel .................................................................................................. 15-27
15.17 Tool and Cutter Angles-Approximate Equivalents ............................................................... 15-28

15-1
15.1 Turiing ard Boring Tooth, Single Point
TOOL GEOMETRY

Side rake
angle
Side fA/
relie End cutting edge angle*
angle / 1/eg

Nose radius' Side unang'

Back rake angle

Note: All rake and relief ang!es are
Em' relief angle -measured in normal dire.-tion.
1 "Use the largest nose radius and the
largest side cutting edge angle or end
cutting edge angle that are consist-
ent with part requirements.

7 IG SPEED SEEEL
1__ I CAPBIDE

a BRAZED I "DEXALE

Side End Side Side 'I Bm

IRakeBakIRake
ATAIARNESSI Angle I IRelief Relief Rake Rake
_l Angle
Relief
Ang*
Rake Rake
I Agee I Angie
Sid,
j
Relief
Angles

_
hn degrees degrees Ideee deg rees degrees degrees degrees degreeses 6egrees
Free Machining Carbon Steels- - 5-25 10 12 5 5 0 6 .7 5 5
Wrought 1225-325 8 1101 1 5 6 7 0 5
Carbon Steels-Wrought and - ]
Cast
Free Machining Alloy Steels-
Wrought
1

I
325-52R
52R, 58R
0
-
j
io ~5 6 7
5
.5
5
5_
I
Alnoy Steelis-Wrought and
cast
High Strength Stel-
Wrought eels-I
Maraging Steeis-Wrouqht
I
1 i
Tool SteelsWrought
Nitiding Steels-Wrought
Armcr Plate-Wrought
Structural Steels-Wrought _-_ o
Free Machin"ngStane-t 135-275. 5 a. 1545 10 6 7 -5 5 5
SteelsWrought 1 275-425 0 5~ 5 0 6 7- -5 __

StainlessSleels.Ferritic- 135-185 5 8 5 5 0 6 7I 0 5

Wrought and Cast

Stalnless Steels, Austenitlc-
-
135-275 0
___
10
...........
5 5 0 6
I____
7
-____
0 .5 5

StainlessSkeelsMadensic- 1'35-325 i( 10 5 1 0 6 7 1 I s
Wrought and Cast 325-425 5 j
48,5R 0 5 5 0 6 1 7-55

-i

15-2

- - . - - r- -.. -rF
 Turning and Boring Tools, Single Point 15.1
TOOL GEOMETRY

, HIGH SPEED STEEl. CARBIDE

BRAZED [ INDEXABLE
Back I Side End Side Back S Back Sie
Rake IRake Rc'ief i Relief Rake Rakt- Relief IRake Rake ReiW
MATERIALHAMESS
IAngle Angle Ang. Angle A -gte 1Angle Angles Angle Angle Angles
oha1 degfees jdegres degrees j deg ses degret. d-grees 1 degrees degrees degrees degree
; - - ____ ___ ___

Precipitation Hardening
Stainless Steels-Wrought 5 0 ;
and Cast 150-50" 0 10 5 5 0 6 7 -5 -5

Gray Cast Irons t 10 51 : 'IJ

6 7 5 -5
Ductile Cast irons G-200 5 10 5 5 -

Malleable Cast Irons 1 5 5 -5

C.'omoacted Grephite Cast 200300 5 . 5 5 C 5
IS
Irons3f040
WheCast Irons i_
I I _
5
i
i
1 j i -7
- - :1I7
5
-5 -5 5

Aluminum Alloys-Wrought 30-150 I I I i

a1Cas, 500kg i 20 15 12 5 770 0 5
'
Magnesium AlotysWrought 40.90 i :'i
and Cast 5 gi20 15 12 3 15 7 0 s S
5 -

Titanium Aiiois-Wrough
and Cast
I I V-"05

0
5

.- 0 6 7J-5
t 5 -

Copper Allojs-Wrought and 40-200 r

Cast SOkg
0 5 101 s a 1 7 9 * 5 5

Nickel Alloys-Wrought and

t
Ch'rone-tk AIloys
f 8D.360 8 10 12 112 0 6
If
7 -5 -5 1 5
Beryitm-Niciel Alloys

Nitinol Alloys-Wrought 210-34C I

High Temperature Alloyz- 143Ri 52!

Wr and Cast
,,t I 14075 10 5 5 65 0
_ _ _.__ _ _ _ _-
_,._._ !-
ClmlmA170-2-!to0 20 5 5 0 20
oys-lirought,
Coumlum I 5O
cast ,PM
Molybdenum
Cast, P/ U Alloys-Wrought, I

Tantalum Alloys-Wrought. i a a
Cast. P/M "

Tungsten Alnoys-Wrougat, 8 I

ZiCAlloys-Cast 8-100 10 1 12 - i 5 5 a
11 i ; I .a L
tk.aium Ai-Wrooot 19-210 I - , -5 7

Zlrconium Aioy-W Vht 14-280 15110 10 1 ____115

Theimopaltics i Ad C 0 20 to30:15 to 20 0 0 '201c30 r 2

Thermong Flastlcs I AiU 0 0 2 0 3 0 ' ;
Magnetic Alloys. Nickel- and 1 i8

POb Cotole Exiom

alf-oe1520 1 i o
isk
8 o0
__ _ _a
Paldo Ira,
oe All I 1 8 61 1 71 0

M3f~ oeIo 8-4 __

Ai
5 30 A 8
a a
20__6
0 7 1515 5
Carbonand GphJe All '0 0120 '20 0 0 0 11 0' 0115

_ _I I . _
Machinable Glass Cera _ic 50 ___oop

o : ,I s 5 5 1 o , 7 o o 5
,3!;

15-3

_ _
15.2 Threading Tools, Single Point
TOOL GEOMETRY

00 Rake / 00 Rake

.2\ - 50 Relief 50 Relief

Typical Carbide Threading Tools

30K

Less than 300 . -

(on trailing edge)- Side rake angle .
~Back rake angleM3
-> End relief
angle

Typical High Speed Steel Threading Tool A-

15i
15-4
 Threading Tools, Single Point 15.2
TOOL GEOMETRY

HIGH SPEED STEEL

Back Side End
Rake Rake Relief
MATERIAL HARDNESS Angle Angle Angle
Bhn degrees degrees degrees

Free Machining Carbon Steels-Wrought 80-225 10 to 15 10 to 15 5 to 10

Carbon Steels-Wrought and Cast
Free Machining Alloy Steels-Wrought 225-325 8 to 12 8 to 12 5 to 10
Alloy Steels-Wrought and Cast
High Strength Steels-Wrought 325-425 0 to 5 5 to 10 5 to 10
Maraging Steels-Wrought
Tool Steels-Wrought
Nitriding Steels-Wrought
Armor Plate-Wrought
Structural Steels-Wrought

Free Machining Stainless Steels-Wrought 135-275 5 to 10 5 to 8 5 to 10

275-425 0 to 5 10 to 15 5 to 10
Stainless Steels, Ferritic-Wrought and Cast 135-185 5 to 10 5 to 8 5 to 10

Stainless Steels, Austenitic-Wrought and 135-275 0 to 5 10 to 15 5 to 10

Cast

Stainless Steels, Martensitic and

Precipitation Hardening-Wrought and 135-425 0 to 5 10 to 15 3 to 10
Cast
100-200 5 to 8 8 to 12 5 to 10
Gray, Ductile and Malleable Cast Irons 0to
Compacted Graphite Cast Irons 200-400 . 0 to 5 5 to 10 5 to 10

Aluminum Alloys-Wrought and Cast 30-150

500 kg 20 to 30 10 to 15 5 to 10
Magnesium Alloys-Wrought and Cast 40-90
500 kg 20 to 30 10 to 15 5 to 10
Titanium Alloys-Wrought and Cast 110-440 0 0 to 5 5 to 15

Copper Alloys-Wrought and 40-200

Cast* Group I 500 kg 0 5 to 10 5 to 10

40-200
Group2 500 kg 3 to 7 5 to 10 5 to 10

40-200
Group 3
500 kg 7 to 15 5 to 10 5 to 10

Nickel Alloys-Wrought and Cast 80-360 6 to 9 9 to 12 2 to 12

High Temperature Alloys-Wrought and Cast 140-475 0 to 10 10 to 15 5 to 12

*Copper alloy groups.

Group I Group 2 Group 3

314 356 377 842 858 935 953 226 442 467 821 872 915 948 102 172 614 803 818 863 917
330 360 385 844 864 937 954 230 443 651 833 874 922 952 110 175 706 805 820 902 962
332 365 485 848 867 938 956 240 444 655 853 875 923 955 113 210 715 807 822 907 963
335 366 544 852 879 939 973 200 445 675 861 876 925 957 114 220 745 809 824 909 964
340 367 834 854 928 943 974 268 464 687 862 878 926 958 115 505 752 811 825 910 966
342 368 836 855 932 944 976 270 465 770 865 903 927 116 510 754 813 826 911
353 370 838 857 934 945 978 280 466 817 868 905 947 122 521 757 814 827 913
170 524 801 815 828 916

15-5
15,3 Die Threading Tools, Die Chasers
TOOL GEOMETRY

Chamfer or throat
angle Rake
Hook angle angle

aneFiace
angle
Milged
CIRCULAR
Milled

Chamfer or throat
angle Hook aF7

a Chamfer or throat
angle

Rake
angle

Hobbed or Tapped
RADIAL
TANGENT

I
I
I
I
I
I
f+
15--6

~ -
 Die Threading Tools, Thread Chasers 15.3
TOOL GEOMETRY

HIGH SPEED STEEL CARBIDE

CIRCULAR TANGENT RADIAL FtADIAL
TAPPED MILLED
Rake Face Rake Rake Rake Rake
MATERIAL HARDNESS Angle Angle Angle Angle Angle Angle
Bhn degrees degrees degrees degrees degrees degrees

Free Machining Carbon Steels-Wrought 100-330 20 1-1/2 15'o25 10to 15 10to 15 5 to 10

Carbon Steels-Wrought and Cast
Free Machining Alloy Steels-Wrought 85-225 20 1-1/2 25 to 35 8 to 15 8 to 15 5 to 10
Alloy Steels-Wrought and Cast
High Strength Steels-Wrought 225-330 20 1-1/2 18 to 22 5 to 7 5 to 7 0 to 5
Maraging Steels-Wrought
Tool Steels-Wrought
Nltriding Steels-Wrought
Armor Plate-Wrought
Structural Steels-Wrought

Free Machining Stainless Steels-Wrought 135-330 15 to 25 1-1/2 10 to 20 7 to 10 7 to 10 5 to 10

Stainless Steels, Ferritic-Wrought and Cast 135-185 20 to 25 1-1/2 20 to 28 10 to 15 10 to 12 5 to 10

Stainless Steels, Austenitic-Wrought and Cast 135-275 25 to 30 1-1/2 15 to 20 10 to 12 10 to 15 5 to 10

135-200 15to20 1-1/2 20to28 10to12 7to10 5t100

Stainless Steels, Martensitic-Wrought and Cast
200-325 15to20 1-1/2 15to20 10to12 7to10 5t100

Gray Cast Irons

Compacted Graphite Cast Irons 110-330 10 2 15to25 0to5 0to5 0to5

Ductile and Malleable Cast Irons 110-330 10 1-1/2 18 7 to 10 7 to 10 5 to 10

Aluminum Alloys-Wrought and Cast 30-150

500kg 20 to 25 2 20 to 35 15 to25 15 to25 10to 15

Magnesium Alloys-Wrought and Cast 40-90

500 kg 20to25 2 20 to 35 15 15 10

Titanium Alloys-Wrought and Cast 110-340 5 to 20 0 to1 5 to 20 0 to 10 0 to 10 5 to 10

Copper Alloys-Wrought and CasP Group 1 40-200J
______
40-200
500 kg -51to5 0 010o10 0Oto-l0 01to-10 010o5
Cl po e sAW o g t a d C s * Gro u p 1 5 0 0O
kg -t o 20 0
to0 to 1 0 0 to 10 0 to 1 0 0 to 5

Group 2 40-200
500 kg 10 to 20 110o2 2010o25 010o10 10o10 0Oto 5

Group53 00kg 15to35 2to3 30 to35 12 to30 12 to30 5to15

Nickel Alloys-Wrought and Cast 80-240 15 to 25 1 to 2 20 to 25 20 to 30 20 to 30 5 to 15

240-320 10 to20 1 to2 15 to 20 8to15 8to15 5t100

High Temperature Alloys-Wrought and Cast 180-230 15 to 20 1 to 2 20 to 25 15 to 25 15 to 25 10 to 15

230-320 5to15 lto2 15to20 10to15 10to15 10

Zinc Alloys-Cast 80-100 15 to20 1102 5 10 to 15 1Oto 15 10

Thermoplastics 31R-103RM 5 to 10 0 5 to 10 0to 5 0 to5 5

*See section 15.2 for copper alloy groups.

15-7

- -+
. -- - S "
- ,+ += -4 -. . .. . . _ _+ _ a *- + _= - -. . - . , _...
15.4 Face Mills
TOOL GEOMETRY

End cutting edge angle

Corner angle (lead angle) Radial relief angle

Radial rake angle

(neg.)
7- t-
Axial r,-ke angle
(pos.) Axial relief angle

HIGH SPEED INDEXABLE BRAZED

STEEL CARBIDE CARBIDE END
Axial Radial Axial Radial Axial Radial CUTING AXIAL RADIAL
Rake Rake Rake Rake Rake Rake CORNER EDGE REUIEF RELIEF
MATERIAL HARDNESS Angle Angie Angie Angle Angie Angie ANGLE ANGLE ANGLE ANGLE
Bhn degrees degrees degrees degrees degrees degrees degrees degrees degrees degrees

Free Machining Carbon 85-270 10 tol1510to 15 5 to7 -5to-14 0Oto -7 0 to -7 30 5 tol 10 5to 7 3 to 7
Steels and Carbon Steels- - - - ___ ______
Wrought and Cast 270-325 10 tol1510to 15 -4 to -8 -3 to -11 0 to -7 0 to -7 30 5to 10 5 to7 3 to 7
Free Machining Alloy
Steels and Aloy Steels- 325-425 10 to12 10 to12 -4 to -8 -3 to -11 0 to -10 0to -10 30 5 tol10 5 to7 3 to 7
Wrought and Cast
Maraging Steels-Wrought 43R,-50R, 5 to 105tol10 -4 to-8 -3 to -11 -5 to -15 -5 to-15 45 4 to 7 5to7 31o7
Tool Steels- Wrought - - - ___ __
Structural Steels- 50Re-56R, -4 to-8 -3 to -11 -5 to -15 -5 to-15 45 4 to 7 8 8
Wrought I___ I______________
High Strength Steels- 225-425 5 tob10 tolO -4 to -8 -3 to -11 -5 to -15 -5 to -15 45 4 to 7 5 to 7 3 to 7
Wrought- - ______ ______

___________ 45R,-58R, -4 to -8 -3 to -11 -5to-15 -5to-15 45 4 to 7 8 8

Nflirdlng Steels-Wrought 200-350 5Stol 105tol10 -4to-8 -3 to -11 Oto-lO -5to -15 45 5 to 10 5 to7 3to5
Armor Plate-Wrought 250-320 0 to 5 Oto5 -4to-S -3to-11, 0to -10O -5to -15 45 41*7 5 to 7 3to5
Free Machining Stainless 135-275 10 tol1510tol12 Stall I-5ta-l1 0 0 to 5 45 5 8 to1 8 to 1O
Steels-WroughtI I
__________ 275-425 5 tol105tol 105to11 1-5to -l1 0 Oto-5 1 45 _5 8to 10 8 tao

15-8
 Face Mills 15.4
TOOL GEOMETRY

HIGH SPEED INDEXABLE BRAZED

STEEL CARBIDE CARBIDE END
Axial Radial Axial Radial Axial Radial CUTTING AXIAL RADIAL
Rake Rake Rake Rake Rake Rake CORNER EDGE RELIEF RELIEF
MATERIAL HARDNESS Angle Angle Angle Angle Angle Angle ANGLE ANGLE ANGLE ANGLE
Bhn degrees degre. degrees degrees degrees degrees degrees degrees degrees degrees

Stainless Steels, Ferritic

and Austenitic-Wrought 135-275 10to15 10to12 5to11 -5to-11 0 to 5 0 to -5 45 5 8 to 10 8 to 10
and Cast

Stainless Steels,
Martenstic-Wrought 135-425 5 to 10 5 to 10 5 to 11 -5 to -11 0 0 to -5 45 5 8 to 10 8 to 10
and Cast

Precipitation Hardening
StainlessSteels-Wrought 150-450 5to10 5to10 5to7 0to5 0 0 45 5 8to10 8to10
and Cast

Gray Cast Irons

Ductile Cast Irons
Malleable Cast lrons 100-400 20to30 -5to-10 5toll -5to-11 5to10 5to-10 45 5to10 4to7 4to7 z
Compacted Graphite Cast
Irons
White Cast Irons
Aluminum Alloys-Wrought 30-150
andCast 500kg 20to35 20to35 5to7 0to5 10to20 l0to20 45 7to12 3to5 10to12

Magnesium Alloys- 40-90

Wrought and Cast 500kg 20to35 20to35 5to7 0to5 10to20 10to20 45 7to12 3to5 10to12
Titanium Alloys-Wrought
and Cast 110440 5 5 0to-5 0to-5 0to-5 -10 45 6to12 10to12 10to12
Copper Alloys-Wrought 40-200
and Cast 500kg 12to25 10to12 5to7 Oto5 3to10 3to10 45 7to12 3to5 5t1010

Nickel Alloys, Chrome- -

Nickel & Beryllium-Nickel 80-360 7 15 5 to 11 -5 to -14 5 to 10 0 to -5 45 5 7 to 9 7 to 9
Alloys-Wrought & Cast

210-340
Ntinol Alloys-Wrought 48R-60R - - 5 to 7 0 to 5 0 0 45 10 12 12 2

High Temperature Alloys- 200475 slo 51010 0105 0to-5 0105 0to-5 45 5 7tolO 7t010
Wrought and Cast

Columblum Alloys- 170-225 0 20 5 to 7 0 to 5 0 10 45 5 to 10 10 10

Wrought, CastPIM 11

Molybdenum Alloys-
Wrought, Cast, P/M 220-290 0 20 5to7 0to5 0 0 45 5 to 10 10 10

Tantalum Alloys-
Wrought, Cast, P/M 200-250 0 20 5 to 7 0 to 5 0 0 45 5 to 10 10 10

Tungsten Alloys- 180-320 -4to-8 -3 to-li -15 0 45 51010 15 15

Wrought, Cast, P/M
ZincAlloys-Cast 80-100 10to15 10to15 5to7 0to5 10to12 101012 45 7to12 10 110to12

15-9
15.5 Side and Slot Mills-Arbor Mounted
TOOL GEOMETRY

Concavity Radial rake angle Land

Radial relief
angle Radial clearance
angle

Axial
rake t x ial relief angle
angle

15-10
 Side and Slot Mills-Arbor Mounted 15.5
TOOL GEOMETRY

HIGH SPEED STEEL CARBIDE

Axial Radial Axial Radial Axial Radial Axial Radial
Rake Rake Relief Relief Rake Rake Relief Relief
MATERIAL HARDNESS Angle Angle Angle Angle Angle Angle Angle Angle
Bhn degrees degrees degrees degrees degrees degrees degrees degrees

Free Machining Carbon Steels-Wrought 85-325 10 to 15 10 to 15 3 to 5 4 to 8 0 to -5 -5 to 5 2 to 4 5 to 8

Ca-bon Steels-Wrought and Cast .... ..
Free Machining Alloy Steels-Wrought 325-425 10to 12 5 to 12 3to5 4 to 8 0 to-5 -5 to 5 2 to 4 Sto8

45R,-52R, 101o12 5to12 2to4 31o7 -5to-10 0to-10 2to4 51o8

Alloy Steels-Wrought and Cast 125-425 10 to 12 5 to 12 ,. to 5 4 to 8 -5 to -10 0 to-10 2 to5 5 to 8

45Rc-52Rc 10to12 5to12 2to4 3to7 -5to-10 0to-10 2to4 3to6

High Strength Steels, Maraging Steels and 100-52Rc 10to 12 5to 12 21o4 3to 7 -5to-10 0to-10 2to4 5to8
Tool Steels-Wrought

Nitriding Steels-Wrought 200-350 10 to 12 5 to 12 2to4 3 to 7 -5 to -10 0 to -10 2 to 4 3 to 6

Armor Plate-Wrought 250-320 0 to 5 0 to 5 2 to 4 3 to 7 -5 to-10 -5 to -10 2 to4 3 to 6

Structural Steels-Wrought 100-50R, 10 to 12 5 to 12 3 to 5 4 to 8 0 to -5 0 to -10 2 to 4 5 to 8

Free Machining Stainless Steels-Wrought 135-425 101o 12 51o12 3to5 4to8 0to5 -5to5 2to4 5to8

Stainless Steels, Ferritic-Wrought and

Cast 135-52Rc 10to 12 5to12 3to5 4to8 0to5 -5to5 2to4 5to8
Stainless Steels, Austenitic-Wrought and
Cast
Stainless Steels, Martensitic-Wrought 135-52Rc 10 to 12 5 to 12 2 to 4 3 to 7 -5 to -10 0 to -10 2 to 4 5 to 8
and Cast

Precipitation Hardening Stainless Steels- 150-450 10 to 12 5 to 12 2 to 4 41o8 0 to -5 0 to -10 2 to 4 5 to 8

Wrought and Cast

Gray Cast Irons

Ductile Cast Irons 100-400 10 to 12 10 to 12 2 to 4 3 to 7 0 to -10 5 to -10 3 to 5 5 to 8
Malleable Cast Irons

Aluminum Alloys-Wrought and Cast 30-150

500kg 12to25 10to20 5to7 5to 10 to20 5to15 5to7 7t100
Magnesium Alloys-Wrought and Cast 40-90
500kg 12to25 10to20 5to7 51o11 10to20 5to15 51o7 7t100

Titanium Alloys-Wrought 110-440 10 to 15 5 to 10 5 to 7 51011 0 to -10 0 to -10 5 to 7 5 to 8

Copper Alloys-Wrought and Cast 40-200

500kg 12to25 10to20 5to7 5to11 10to20 5to10 4to7 5to8
Nickel Alloys-Wrought and Cast 80-360 10 to 20 10 to 15 3 to 5 4 to 8 -5 to -10 0 to -10 3 to 5 5 to 8

High Temperature AlIoys-Wrought and 140-300 10to15 10to15 1 to5 5to10 -5to-10 0to-10 3to5 51o8
Cast
300475 101o12 5to12 1105 4to8 -5to-10 0to-10 3to5 5108

Columbium, Molybdenum Alloys-Wrought, 170-290 0 15 to 20 3 to 5 5 to 10 0 5 to 15 7 to 10 7 to 10

Cast, P/M I I
Tantalum Alloys-Wrought, Cast, P/M 200-250 0 15 to 20 3to5 5 to 10 0 5 to 15 7 to 10 7 to 10

TungstenAlloys-Wrought,Cast,P/M 180-320 - -10to-15 51o15 10tol 110to15

ZincAlloys-Cast 80-100 10to20 10to20 51o7 8to11 101o15 101015 71o10 7to10

15-11
t
15.6 End Mills-Peripheral and Slotting, High Speed Steel
TOOL GEOMETRY

Radial clearance angle

Corner radius or Radial relief
corner angle angle

Helix angle

rY Axial relief
angle

End cutting edge Radial rake an

concavity angle (pos.)

15-12

o= =~~-
 End Mills-Peripheral and Slotting, High Speed Steel 15.6
TOOL GEOMETRY

GENERAL PURPOSE-30 0 to 350 HELIX

Steels, Cast Irons, Copper Alloys, 130t 5 EI
Titanium Alloys, Nickel Alloys, 30t 5 EI
High Temperature Alloys and Zinc Alloys Aluminum and Magnesium Alloys

NOMINAL I
Radial
Primary Primary
j Radial
Secondary
Radial
Primary Primary
Radial
Secondary
CUTTER I Relief Land Clearance Relief Land Clearance
DIAMETER Angle Width Angle Angle Width Angle
in degrees in degrees degree. in degrees

1/16 20 to 21 0.007-0.0 10 I 30to35 20 to22 0.007-0.010 30 to 35

1/8 12 to 13 0.010-0.015 I 22 to28 14 to 18 0.010-0.015 25 to 30
3/16 12 to 13 0.010-0.020 J 20to25 14 to 18 0.010-0.020 25 to 30
1/4 10 tol11 0.C1O0-0.20 20 to 25 12 to 15 0.010-0.020 22 to28
5/16 10 to 11 I0.015-0.025 20 to 25 j 12 to 14 0.015-0.025 21 to 28
3/8 10 tol11 0.015-0.025 17 to 20 12 to 14 0.015-0.025 19 to 26
7/16 9 to 10 0.020-0.030 17 to 20 11 tol13 0.020-0.030 18 to25
1/2 9 to 10 0.020-0.030 17 to 20 11 tol13 0.020-0.030 18 to25
5/8 9 tol10 0025-0.035 17 to 20 11 tol13 0.025-0.035 18 to 25
3/4 8to 9 0.030-0.040 15toiB 10 tol12 0.030-0.040 17 to 24
7/8 88to 9 0.030-0.040 I 15 to18 10 to 12 0.030-0.040 17 to 24
1 B to 9 0.035-0.050 15 to 18 10 tol12 0.035-0.050 16 to 23
1-1/1A 7 to 8 0.040-C060 13 to 18 9 tol11 0.040-0.060 14 to 22
1-1/2 7 to 8 0.040-0060 , 11 to 17 9 tol11 0.040-0.060 13 to21
1-3/4 7 to 8 0.040-0.060 ltol16
10 8 to 10 0.040-0.060 12to20
2 6 to 7 0.040-0.060 9 to 15 8tol10 0.040-0.060 12 to 20

0* o2-- -c-

IMb -5 ----- O- -- 22

'2j f - 7-; 42%Mgrq~-

"A A. _62

_m o -ao- -- 7- e

ffl-4114-~
Ex

3,S~ I

d :Mzj-I
_M_
Uv_ -1M-1V_'
15.7 Drills, High Speed Steel Twist
TOOL GEOMETRY

Margin 4 ___Chisel edge /'Point angle

angle

Land 7 Helix angle

Lip relief
V Web thickness
angle q

"

Standard Point Crankshaft Point

DRILL UP RELI
MATERIAL HARDNESS TYPE POINTANGLEO ANGLESI HEUX ANGLE POINT GRIND
Shn degrees degres
Fre._ Machining Carbon Steels-Wrought General
Carbon Steels-Wrought, Cast and P/U 85-225 Purpose 118 A Standard Standard
Free Machining Alloy Steels-Wrought
Alloy Steels-Wrought, Cost and P/N General
Maraging Steels-Wrought an .225-325 Purpose 118 A Standard Standard
Niftriding Stees-roughtGera
Armor PlaGeneralh
Structural Steels-Wrought 325-425 Purpose 118 to 135 B Standard Crankshft
Heavy 1t15Cakhf

45R,-52R,~ Web 11Bo 3 Standard Cakhf

Nog Strength Steels-Wrought 175-325 Heavy 118 A Standard
325-52Rc Web 118 to 135 B Standard Crankshaft

Austenltic Manganese StesCast 150-220 rill 135 B LOWspi

Free Machinting Stainless Steels General
Wrought 135-425 Purpose 118 A Standard Crankshaft
Stainless Steels, Ferdlic-Wrought and General
cast 135-200 *Purpose 118 to 135 A Standard Standard
Stainles Steels, Austenitic-Wrought.
Cost a"i PiN General
Stainless Steels. MairleraIIc-WroullKt 200-325 Purpose 118 to 135 A Standard Crankshaft
Cost and P/M ____

325-25 Heavy
Wrougot 8; Hadn.gStlesStes
P7cptto 0 ast 48Rc-52Rc Web 118 to 135 B Standard Crankshaft

Gray CasthIons General

Duciloe stIon 110-220 Purpose 118 ___ A Standard Standard
malleable Cast IronsA
Compacted Graht Cast Iron Heavy8
White Cast Iron 1220-400 jWeb 118 j A Standard Standard
NOTE: Use stub-length dnills whenever possible on high strengtih materials.
-Chisel edge angle: 115- to. 133
:See chart at end of table on next page.

15-14
 Drills, High Speed Steel Twist 15.7
TOOL GEOMETRY

MATERIAL HARDNESS ITYPE POtNT ANGLE' ANGLE- HELIX ANGLE POINTGRN

Bhn' degrees J degrees j_____
aneium Alloys-Wrought and Cast
Magnesium~50
AlosWguh anFatI9(
500 kg
40-950
Flutes
Polished
ose
90 to 118

70 to118
i

' C
C
I HighSadr

High
~Sadr
IStandard

Titanium Alloys-Wrought and Cast Genera

110-275 Purpose 118 to 135 B Standard Crankshaft
Heavy I
2z7z-44t
0 Web 118 to 135 t B Sanard Crankshaft
500
kg IFlutes 118 CLwSadr
__ __ __ __I
Nike lly-WoK
at n PMGeneral
Chromium-Nickel Alloys-Cast 80-360
__

jPurpose_
___

118
I B
_ __

Standard
J

!Crankshaft
ttnol Alloys-Wrought 210-360 General
48Rc-52Fl. Purpose 118 j B Standard Crankshaft
High Temperature Allys-Wrought HeavyL
enldCat 140-475 Web li8to 135 a Standard Crankshaft
n 170-2u90lyxlnun
General 11BStnadtnar
Tantalum Alloys-Wrought. Cast, P 10-9 Purpose 18aStnrdtnad
Tungsten Alloys (Anvil"o)' General
29"-20 Purpose 118 8 Standard Standard
Zinc Alloys-Cast General
80-100 Purpose 118 C Standard Standard
Uranim Alloys-Wroughti Special 1-5* Land on
190-210 Carbide 118 5-8 20-- DrilliLip
Zirconium Alloys-Wrought General
140-280 Purpose 118 A Standard Crankshaft
Thermoplastics and Thermosettig Speia
All Plishe 60 to 90 C Low Standard
Magnetic Core Iron General
185-240 Purpose loo to 118 A High Standard
Controlled Eipalon AlloysGera
125-250 Purpose 118 A Standard Crankshaft
Magnetic Alloys (HI Perm 49, HyMu 80) GeneralI
185-240 Purpose 118 A Standard Crankshaft
Carbon and Graphite 8-100 General
Shore Purpose 90 to 118 C Standard Crankshaft
Machinable Carbide (Ferro-Tic) General
40Rc-51 Rc Purpose 118 8 Standard Crankshaft

NOTE: Use stub-length drills whenever posseble on high strength materials.

*Chiseledge angle: 115* to 135*
*For both hss and carbide drifts.
IFor carbde drills.
:See followin chart.

Lip Relief
Angles al
JDrill Size
Periphery =8t==--0o4 =4tIo 406 t%*o icu
A j 24- 21- Is# W 141 12- 10. a.
8 K) 18!1 16- 14 1210 t* 8. 7
C 1 26- 24- 22* 2 18. 18' 14# 12*

15-15
15.8 Oil-Hole or Pres.murized-Coolant Drills, High Speed Steel
TOOL GEOMETRY
Drill geometry as shown in section 15.7 (HIGH SPEED
STEEL TWIST DRILLS) may be used for Oil-Hole or DRILL DIAMETER
Pressurized-Coolant Drilling. . inches WEB
op- - Upto 1/4
1 12%
Drills used for Oil-Hole or Pressurized-Coolant Drilling
erations, however, have heavy or semi-heavy webs which Over 1/4 to 1/2 10%
require thinning of the point. Instructions for thinning are Over 1/2 to 3/4 8%
shown below. Over 3/4 to 1 8%
Over 1 to 1-1 /4 7%
Over 1-1/4 to 1-1/2 7%

NOTCH THINr4INC OF HEAVY WEB OIL-HOLE DRILLS

oJ.P - Relation of grinding

. \15 t , wheel to drill

0
Web, shown as %
of drill diameter

Side View Front View

15.9 Spade Drills, High Speed Steel

140

-Chip breaker 70 to 80
Primary "B"
grooves relief Rad.
angleI
C
Point 0"A" WebRadius
angle 0 offset
00

1300 00A
20 to 30
70 to 100 "D"
Circular
land

15-16

EN 00-R.M-
 Spade Drills, High Speed Steel 15.9
TOOL GEOMETRY

MATERIAL*
D

M STE-LS, STEELS,
E Wrought Wrought ALUMINUM
N and Cast and Cast STEELS, and
S and CAST and CAST Wrought STAINLESS MAGNESIUM TITANIUM COPPER
DRILL I IRONS IRONS and Cast STEELS, ALLOYS, ALLOYS, ALLOYS,
SIZE I 100 to 175to 330 Bhn Wrought Wrought Wrought Wrought
RANGE S 175 Bhn 330 Bhn to 52R, and Cast and Cast and Cast and Cast
inches inch inch inch inch inch inch inch

A 1 1/16 5/64 5/64 1/16 5/64 1/16 5/64

!-1/32 to1-1/4 B 3/16 1/4 1/4 3/16 3/16 1/64 and 100 Rake 5/32
____,___

C 0to 1/32 0to 1/32 0tol/32 3/64 3/64 1/32 5/64

D 1/16 1/16 1/16 3/64 1/16 1/16 1/16

A 5/64 3/32 5/64 5/64 3/32 5/64 3/32

1-9/32 to 1-1/2- B 7/32 9/32 1/4 7/32 1/4 1/64 and 100 Rake 5/32

C 0to 1/32 0tol/32 0to 1/32 3/64 1/16 1/32 5/64

D 5/64 5/64 5/64 3/64 1/16 5/64 5/64

A 3/32 7/64 3/32 5/64 3/32 3/32 7/64

t.7
B 1/4 5/16 5/16 114 5/16 1/64 and 10- Rake 3/16
1-9/16 to 2 _____

C 0to 1/32 0to 1/32 0 to 1/32 1/16 5/64 1/32 1/16

D 5/64 5/64 5/64 1/16 1/16 1/16 5/64

A 7/64 1/8 7/64 7/64 7/64 7/64 9/64

B 9/32 __ 11/32 3/8 9/32 3/8 1/64 and 100 Rake 7/32
2-1/16 to 2-1/2 -..... ____

C 0 to 1/32 0to 1/32 0to 1/32 1/16 5/32 1/16 7/64

D 5/64 3/32 5/64 1/16 5/64 5/64 5/64

A 1/8 9/64 1/8 1/8 7/32 5/32 11/64

B 9/32 3/8, 3/8 5/16 1/2 1/64 and 101 Rake 1/4
2-9/16to 3 - _
C 0to 1/32 0 to 1/32 0 to 1/32 5/64 9/32 1/8 7/64

D 3/32 3/32 3/32 5/64 3/32 3/32 3/32

A 5/32 11/64 5/32 5/32 - - 13/64

3-1/16 to 3-1/2 B
-_____
5/16 3/8 3/8 11/32 - - 9/32
_____

C 0to 1/32 0to 1/32 Oto 1/32 3/32 - - 1/16

D 7/64 7/64 7/64 5/64 - - 7/64

, 11/.4 3165 I 11/64 11/64 - - 15/64

B 5/16 7/16 3/8 3/8 - - 5/16

3-9/16 to4 -4___________

C 0tol/32 0to 1/32 0to 1/32 7/64 - - 1/16

D 1/8 1/8 1/8 3/32 - - 1/8

A 3/16 7/32 3/16 3/16 - - -

I
B 3/8 1/2 1/2 7/16 --
B 112 7/..
4-1/16 to 5
C 0to 1/32 0to 1/32 . to 1/32 1/8 -

D 5/32 j 5/32 5/32 3/32 - ..

*For other alloys use recommendations for steel as starting geometry.

15-17
15.10 Gun Drills, Carbide
TOOL GEOMETRY

Slash or General Purpose Grind

Backtape:

.0096/.0010 inch per linear inch , angle (200 to 400)

Outer
Margin
diametric taper .
diameter
\

Point location 4daetr

% L ' l ointloCuttn 1750 Bearing
Flute
ng fluid

Shoulder

Cattagefluid
Inner angle (200)
Wear pads

Stack Grind

(This grind is for difficult to machine alloys and stacked applications) I

Outer angle (200 to 450)

Point location (diameter)

Inner angle (150 to 50)

15-18
 Reamers, High Speed Steel 15.11
TOOL GEOMETRY

Chamfer angle
Radial rake angle
1
I- Chamfer length
,.

g -Margin width
" 1 \ Land width
Chamfer relief Ld t
angle

Helix angle

Secondary- Primary
relief angle relief angle

PRIMARY
RADIAL CHAMFER
REUEF CHAMFER RELIEF
DIAMETER MARGIN WIDTH ANGLE ANGLE ANGLE
inches inch degrees degrees degrees
Under 1/8 0.004-0.006 20 to 25 45 7 to 12

1/8 to 1/4 0.006-0.008 15 to 20 45 7 to 12

1/4 to 1/2 0.008-0.010 11 to 14 45 7 to 12

1/2 to 3/4 0.010-0.015 8 to 12 45 7 to 12

3/4 to 1 0,012-0.017 7 to 10 45 7 to 12
I to 1-1/2 0.014-0.018 5 to 8 45 7 to 12

1-1/2 to 2 0.016-0.022 5 to 8 45 7 to 12
Over2 0.018-0.025 5 to 8 45 7 to 12

Reamer Selection Guidelines

STRAIGHT FLUTE RIGHT HAND HEMX LEFT HAND HEMX

For general purpose use. - Freer cutting. * Reduces chatter on nonrigid setups.
0
* Improves finish. * Use 3 0 0 to 45 helix for splines and
keyways.
- Reduces chatter.
* Requires rigid setups with no backlash. * Requires more thrust.

15-19

7- -- 2[.$4
15.12 Reamers, Carbide
TOOL GEOMETRY

Chamfer angle Radial rake angle

(pos.)

Lead angle length -1 Lead angle Primary relief angle

Secondary
clearance angle

Heli" angle

MARGIN PRIMARY CHAMFER CHAMFER

OR RADIAL SECONDARY LENGTH PRIMARY SECONDARY
CIRCULAR RELIEF CLEARANCE OF RELIEF CLEARANCE
DIAMETER LAND ANGLE ANGLE CHAMFER ANGLE ANGLE
inches inch degrees degrees inch degrees degrees

1/4 0.005-0.007 12 to 15 28 to 3k 0.020-0.030 10 to 12 25 to 28

3/8 0.005-0.008 12 to 15 28 to 32 0.020-0.030 10 to 12 22 to 24

1/2 0.008-0.010 11 to 13 26 to 28 0.030-0.040 9 to 11 20 to 22

5/8 0.009-0.012 10 to 12 22to26 0.040-0.050 8 to 10 18 to 20

3/4 0.010-0.015 9 to 10 20 to 22 0.040-0.050 7 to 9 14 to18

?/8 0.010-0.015 9 to 10 18 to 20 0.040-0.050 7 to 9 14 to 18

1 0.012-0.015 8 to 10 18 to 20 0.050-0.060 7 to 9 14 to 18

1-!/2 0.014-0.016 7 to 8 16 to 18 0.050-0.060 6 to 8 12 to 16

2 0.018-0.023 7 to 8 16 to 18- 0.050-0.060 6 to 8 12 to 16 _

15-20

-- - ~ i
 Boring Tools, Carbide 15.13
TOOL GEOMETRY

Side relief

E I.Side or axial rake

Lead angle or-Back or radial rake

End clearance - -.....- . End or peripheral relief

Mounting
angle
Note: All rake and relief
angles are measured
in normal direction.

BACK SIDE END

OR OR OR
RADIAL AXIAL PERIPHERAL SIDE
RAKE RAKE RELIEF RELIEF
MATERIAL HARDNESS ANGLE* ANGLE ANGLE' ANGLE
Bhn degrees degrees degrees degrees

Free Machining Carbon Steels-Wrought 100-425 -3 to -10 0 to 15 5 to 10 2 to 3

Carbon Steels-Wrought and Cast 85-425 -3 to -10 0 to 15 5 to 10 2 to 3

Free Machining Alloy Steels-Wrought 150-425
45Rc-56Rc -3 to-10 0to15 5to10 2to3
Alloy Steels-Wrought and Cast 125-425
45R-56R 0 to -6 -3 to -8 5 to 10 2 to 3
High Strength Steels and Maraging 175-375
Steels-Wrought 43Rc-56Rc 0 to -6 -3 to -8 5 to 10 2 to3

Tool Steels-Wrought 100-375

48R.-56Rc Oto-6 -3 to -8 5 to 10 2to3

Ntrlding Steels-Wrought 200-350 Oto -6 -3 to-8 5 to 10 2 to 3

Armor Plate-Wrought 250-320 -5to -35 15 to 35 5 tol1 2to3
NOTE: The lead angle and end clearance are In many cases dictated by part shape ahd tool holder mounting angles. When a choice is
possible, a larger lead angle and a smaller end clearance will usually decrease surface roughness and reduce the tendency to chatter.
.These values are based on boring tool being set on centerline. If tool Is set above centerline the radial rake angle should be In-
creased and the end relief angle should be decreased by a value of , - arc tan H/R; where H - height above centerline and R =
radius of bored hole.
'These end relief angles apply to bores 1/2 Inch and larger. Smaller bores require greater relief angles.

15-21
15.13 Boring Tools, Carbide
TOOL GEOMETRY

BACK SIDE END

OR OR OR
RADIAL AXIAL PERIPHERAL SIDE
RAKE RAKE RELIEF REUEF
MATERIAL HARDNESS ANGLE* ANGLE ANGLE* ANGLE
Bhn degrees degrees degrees degrees

Structural Steels-Wrought 100-350 -3 to -10 0 to 15 5 to 10 2 to 3

350-500 0 to -6 -3 to -8 5 to 10 2 to 3
Free Machining Stainless Steels-Wrought 135-425 3 to 10 0 to 15 5 to 10 2 to 3

Stainless Steels, Ferritic-Wrought and 135-185 3 to 10 0 to 15 5 to 10 2 to 3

Cast I
Stainless Steels, Austenitlc-Wrought 135-275 3 to 10 0 to 15 5 to 10 2 to 3
and Cast
S!-!n! as G'eei,, iiariensitic-Wrought 135425 3 to 10 0 to 15 5 to 10 2 to 3
and Cast I
Precipitation Hardening Stainless Steels- 150-440 3 to 10 0 to 15 5 to 10 2 to 3
Wrought and Cast
Carbon and Alloy Steels-Cast 120-400 0 to -6 -3 to -8 5 to 10 2 to 3

Gray Cast Irons 110-320 0 0 5 to 10 5 to 8

Ductile Cast Irons 140-400 0 0 5 to 10 5 to 8

Malleable Cast Irons 110-280 0 0 5 to 10 5 to 8

Aluminum Alloys-Wrought and Cast 30-150

500kg 0to15 5to15 8to13 5to8

Magnesium Alloys-Wrought and Cast 40-90

500kg 0to15 5to15 8to13 5to8
Titanium Alloys-Wrought 110-440 -3 to -10 -3 to -8 8 to 12 3 to 5
Copper Alloys-Wrought and Cast 40-200
500kg 0to10 5to20 8to13 5to8

Nickel Alloys-Wrought and C..& 80-360 3 to 10 0 to 15 5 to 10 2 to 3

High Temperature Alloys-Wrought and 140-475 3 to 10 0 to 15 5 to 10 2 to 5
Cast
Columblum, Molybdenum and Tantalum 170-290 0 20 8 to 12 3 to 5
Alloys-Wrought, Cast, P/M
Tungsten Alloys-Wrought, Cast, P/M 180-320 -15 0 5 5

Zinc Alloys-Cast 80-100 0to15 5to10 8to13 5to8

NOTE: The lead -ngle and end clearance are in many cases dictated by part shape and tool holder mounting angle. When a choice is
possible, a larger lead angle and a smaller end clearance will usually decrease surface roughness and reduce the tendency to chatter.
*These values are based on boring tool being set on centerline. Iftool is set above centerline the radial rake angle should be in-
creased and the end relief angle should be decreased by a value of ,= arc tan H/R; where H - height above centerline and R -
radius of bored hole.
'These end relief angles apply to bores 1/2 inch and larger. Smaller oores require greater relief angles.

15-22
 Taps, High Speed Steel 15.14
TOOL GEOMETRY

Land Chamfer
Ch-mfer angle relief Rake Hook

I
angle Rake Tangential

Cutting angle ho angle

edgeg .. hook angle
Cuttig
face

Heel
Flute I

L Chordal hook
angle

HOOK OR CHAMFER
RAKE RELIEF TYPEOFTAP
MATERIAL HARDNESS ANGLE ANGLE
Bhn degrees degrees Thru Hole Blind Hole

Steels-Wrought, Cast & P/M Spiral Fast Spiral

85-200 7 to 10 8 Point Flute

Spiral Fast Spiral

200-300 0 to 8 8 Point Flute

Modified
300-375 0 6 4 Flute Hand Tap
Modified
375-425 -3 to -6 6 4 Flute Hand Tap

Modified
48R,-52R, -5 to -10 4 to 6 4 Flute Hand Tap,

Stainless Steels, Ferritic, Heavy Duty Heavy Duty

Martensitic & Precipitation 135-275 8 to 12 8 Spiral Point Spiral Flute
Hardening-Wrought, Cast &
P/M Heavy Duty Heavy Duty
275-325 0 to 5 8 Spiral Point Spiral Flute

Modified
325-425 0 6 to 8 4 Flute Hand Tap

Stainless Steels, Austenitic- Heavy Duty Heavy Duty

Wrought, Cast & P/M 135-275 15 to 20 10 Spiral Point Spiral Flute

Gray Cast Irons 4 Flute 4 Flute

Ductile Cast Irons 120-260 5 1o8 6 Hand Tap
H Hand Tap
Malleable Cast Irons
Modified
260-330 0 to 3 6 4 Flute Hand Tap

Aluminum and Magnesium Spiral Point Fast Spiral

Alloys-Wrought, Cast & P/M All 10 to 20 12 High Helix Flute

*Specialtaps for these alloys are offered by some tap manufacturers.

15-23

K- _
15.14 Taps, High Speed Steel
TOOL GEOMETRY

HOOK OR CHAMFER TYPE OF TAP

RAKE RELIEF
MATERIAL HARDNESS ANGLE ANGLE
Bhn degrees degrees Thru Hole Blind Hole

Titanium Alloys- Modified Modified

Wrought and Cast 110-275 10 to 15 12 Spiral Point 4 Flute
Hand Tap
Modified Modified
275-440 6 to 10 12 Spiral Point 4 Flute
Hand Tap
Copper Alloys- Groups Spiral Spiral
Wrought, Cast & P/M' 1 &2 All 0 to 8 10 Point Flute

Group Spiral Fast Spiral

3 All 9 to 18 12 Point
Nickel Alloys, Magnetic Alloys, Spiral Spiral
Controlled Expansion Alloys- 80-170 9 to 12 6to Point Flute
Wrought, Cast & P/M 8-79t16toPinFu
High Temperature Alloys 3 Flute
-Wrought and Cast 2 Flute Hand Tap*
140-425 0 to 10 4 to 6 Spiral Point* Interrupted
Thread

Columblum, Molybdenum & 2 Flute 4 Flute

Tantalum Alloys-Wrought, 170-290 10 to 12 6 to 8 Spiral Point' Hand Tap*
Cast & P/M
Magnetic Core Iron 2 Flute Spiral
185-240 12 to 15 6 to 8 Spiral Point Flute

Zinc Alloys-Die Cast Spiral Point Fast Spiral

80-100 12 to 15 12 High Hook Flute

Thermoplastics Spiral Point Fast Spiral

All 5 to 8 12 High Hook Flute

Thermoset Plastics Modified

All 0Oto 3 12 4 Flute Hand rap
*See section 15.2 for copper alloy groups. A
'Special taps for these alloys are offered by some tap manufacturers.

15-24
 Planing Tools 15.15
TOOL GEOMETRY

Side rake
angle
Side
relief
angle End cutting edge angle

Nose radius /
LSide cutting edge angle

Back rake angle

End relief angle

Note: All rake and relief angles are

measured in normal direction.

1 5-25
15.15 Planing Tools
TOOL GEOMETRY

HIGH SPEED STEEL CARBIDE

End fEnd
Back Side End Side Cutting Back Side End Side Cutting
Rake Rake Relief Relief Edge Rake Rake Relief Relief Edge

{
MATERIAL HARDNESS Angie Angie Angie Angle Angie Angie Angle Angie Angie Angie
Bhn degrees degrees degrees degrees degrees degrees degrees degrees degrees degrees
Free Machining Carbon 85 - - - _
Steels-Wrought to 5 to10 61to10 101015 6to10 5tolS 0Oto -5 15to-15 3t05 3105 4 tol15
Carbon Steels-Wrought 375
andCast
Free Machining Alloy
Steels-Wrought
Alloy Steels-Wrought and
Cast
High Strength Steels-
Wrought
Maraging Steels-Wrought
Tooi Steels-Wrought
Nitriding Steels-Wrought
Armor Plate-Wrought
Struciuiz: Ste-is-Wrought
Free Mahining Stainles 135
StelsWrougZ to I51010 610o10 101015 61010 5Stol 010Ot-5 5to-15) 41o6 4 to 6 41to15
Sies Steels, Ferritic-
Wrought and Cast32
Stainless Steels, Austenitic-
Wrought and Cast
Stainless Steels,
Martensitic-Wrought and
cast
Precipitation Hardening
Stainless Steels-Wrought
and Cast _______

Gray Cast Irons 100

Ductile Cast Irons to 31to8 5 to 10 2to5 210o5 8 to 15 8 to-5 15to-3 4106 410o6 810101
Malleable Cast Irons 330 _ ____

Aluminum Alloys-Wrought 30
and Cast to 1t2 0oO 8o5 8o5 7o
150 112 000 805 805 70
500 kg__________
Magnesium Alloys-Wrought 401
and Cast to
101o20 301040 t1o15 810o15 710
to 9
90
500 kg ___ ______ __

Copper Alloys-Wrought and 40

Cast to 510o10 51to10 810o12 8to 12 51o15 - - - -
200
500 kg ___ __

Nickel Alloys-Wrought and 80

cast to 0105 51to10 41010 41010 1010o15 - - - -

____________ 320[j

NOTE: For all materials and for both high speed steel tools and carbide tools, use a 0*-30' side cutting edge angle. For best chip flow when planing mild and
medium hard steels. try a 230 side culling edge angle.

1&-26
nk
 Broaches, High Speed Steel 15.16
TOOL GEOMETRY

Face or
hook angle Pitch Land
Backoff or
clearance angle

Tooth depth

Root radius

MATERIAL HARDNESS HOOK ANGLE CLEARANCE ANGLE

Shn degrees degrees
Free Machining Carbon Steels-Wrought 100-375 15 to 20 2 to 3
Alloy Steels-Wrought and Cast
Carbon Steels-Wrought 85-375 15 to 20 1 to 2

Carbon Steels-Cast 120-375 8 to 15 1lto 3

Alloy SteelsWrought and Cast
High Strength Steels-Wrought
Maraging Steels-Wrought

Tool Steels-Wrought 100-375 8 to 12 i to 2

Armor Plate-Wrought

Nitriding Steels-Wrought 200-350 8 to 15 i to 2

Free Machining Stainless SteelsWrought 135-425 810o12 11to2

Stainless Steels, Martensitic-Wrought and Cast
Stainless Steels, Ferritc-Wrought and Cast 135-1 85 12 to 18 2 to 3

Stainless Steels, Austenltic-Wrought and Cast 135-275 12 to 18 1/2 to 2

Precipitation Hardening Stainless Steels-Wrought 150-440 10 to 15 2

and Cast

Gray Cast Irons 110-320 6 to 8 2to3

Ductile and Malleable Cast troy 110-400 Bto15 2to 3

Aluminum Alloys-Wrought and Cast 30-1 50

500 kg 10 to15 110o3

Magnesium Alloys-Wrought and Cast 40-90

500 kg 10 to15 1 t03

Titanium Alloys-Wrought 110-440 8 to 20 20o8

Copper Alloys-Wrought and Cast* Group 1 40-200
500 kg -5to 51to2

Group 2 40-200
500 kg 0 tol 0102
Group 3 40-200
500 kg 10 to15 2 to 3
Nickel Alloys-Wrought and Cast 80 to 360 12 to 18 112 to 2

High Temnperature Alloys-Wrought and Cast 140-475 j 15 to 20 210o8

Zinc Alloys-Cast 80-100 10 to 15 21o5

*Seesection 15.2 for copper alloy groups.

15-27
15.17 Tool and Cutter Angles-Approximate Equivalents
TOOL GEOMETRY
r
LATHE AND PLANER MILLING CUTTER DRILL BROACH

Back Rake Angle '.xial Rake Angle Helix Angle Hook Angle
Side Rake Angle Radial Rake Angle Radial Rake Angle Sid: Rake Angle
Side Cutting Edge Angle Corner Angle 1/2 Point Angle -
End Cutting Edge Angle End Cutting Edge Concavity Angle -
Side Relief Angle Radial Relief Angle - Clearance Angle
End Relief Angle Axial Relief Angle Lip Relief Angle Clearance Angle

I
I
1I

I
15-28
 SECTION 16

CUTTING FLUIDS

16.1 Cutting Fluid Selection and Use ....................................................................................... 16-3

Introduction ...................................................................................................................... 16-3
Functions of Cutting Fluids ........................................... 16-3
Types of Cutting and Grinding Fluids...................................... 16-3
Cuttin3 Oils..................................................................................................... ........ 16-3
Water-M iscible (W ater-Soluble) Fluids ...................................................................... 16-4
Gases ........................................................................................................................ l -7
Paste and Solid Lubricants ........................................................................................ 16-7
Selection of a Cutting Fluid .............................................................................................. 16-7
M achinability ............................................................................................................. 16-7
Other Considerations ................................................................................................ 16-8
Application of Cutting Fluids ............................................................................................ 16-9
M anual Application .................................................................................................... 16-10
Flood Application ..................................................................................................... 16-10
High-Pressure Application ........................................................................................ 16-12
Mist Systems.............................................................................................................. 16-12
Special Application M ethods ..................................................................................... 16-12
M aintenance of Cutting Fluids ......................................................................................... 16-12
Cutting Oils................................................................................................................ 16-12
Em ulsifiable Oils ........................................................................................................ 16-13
Occupational Derm atitis ............................................................................................ 16-13
M achine Cleaning Practice ....................................................................................... 16-14
Disposal of Cutting Fluids .......................................................................................... 16-!4
Recycling Cutting Fluids .......................................................................................... 16-14
Central Fluid System ........................................................................................................ 16-14
Econom ic Considerations ................................................................................................ 16-15

16.2 Cutting Fluid Recom m endations ............................................................................................. 16-17

16.3 Cutting Fluid Key ..................................................................................................................... 16-65

16-1
 - - -; _m-7-

PRECEDING PAE BLANK-NYP FILMED

Cutting Fluid Selection and Use 16.1

INTRODUCTION Water-miscible (water-soluble) flu;-,
When properly applied, cutting fluids can increase produc- 0 emulsifiable oils (soluble oils)
tivity and reduce costs by making possible the use of higher
cutting speeds. higher feed rates and greater depths of cut. 0 chemical (synthptir' f.,;Ad-
Effective application of cutting fluids can also lengthen tool
life, decrease surface roughness. increase dimensional ac- * semichemical (semisynthetic) fluids
curacy and decrease the amount of power that is consumed
when cutting dry. Knowledge of cutting fluid functions. Gases
types, physical limitations and compositions plays an im-
portant role in the selection and application of the proper Paste and solid lubricants
fluid for a specific machining situation. Cutting fluid recom-
mendations for various machining operations and work The cutting oils and the water-miscible fluids arm the types
materials are given in section 1o.2. most commonly used. Each of t e_ has distinctive advan-
tages over the other, depending on the type of machining
operation and the material being machined. Cooling is best
FUNCTIONS OF CUTTING FLUIDS accomplished by water-miscible fluids, while oil-base fluids
provide better lubrication.
Depending upon the machining operation being performed,
a cutting fluid has one or more of the following functions:
Cutting Oils
" Cooling the tool, workpiece. and chip Cutting oils have a mineral oil base and may be used
straight (uncompounded) or compounded (combined with
" Lubricting (reducing friction and minimizing erosion on polar additives and/or chemically active or inactive addi-
the tool) tives or compound.,). They have excellent lubrication prop-
erties, good rust control and long life, but they do not cool
" Contolling built-up edge (BUE) on the tool as well as water-miscible fluids. Oils may be classified as
inactive or active.
Flushing away chips
Inactive Cutting Oils
Protecting the workpiece from corrosion Inactive cutting oils (compounded with chemically inactive
The relative importance of each function depends upon thdhe anti-weldinghave
additives), relatively high lubricity but low or no
properties. They have nonstaining properties
work material, the cutting tool, the cutting conditions and which prevent discoloration of chemically sensitive
the finish required on the part. materials.

Straight mineral oils do not have as good lubrication

TYPES OF CUTTING AND GRINDING properties as do the compounded types, but they are lower
FLUIDS in cost. Straight mi-:_--i oils are generally restricted to
light-duty operations on metals that are easier to machine,
Many cutting fluids are available today to satisfy the re- such as aluminum, magnesium, brass and sulfurized or
quirements of moden machine tools. High speed cutting leaded free-machining steels, where the lubrication and
-nd grinding, increased metal removal rates, the emer- cooling requircmeias are not severe. The oils are non-
gence of new tool and work materials, and the demands for corrosive and stable and, if kept clean, can be used almost
smoother finishes and closer tolerances have all contrib- indefinitely. They lubricate all exposed moving parts, and
uted to the continual development of a wider variety of min,- leakage into or from gear boxes, bearings and hy-
fluids that satisfy more specific requirements. drauic system- does not upset a machine's performance.
Although there is no all-purpose cutting fluid. some fluids Fatty oils were once widely used as cutting fluids. The
offer considerable versatility while others are tailored for most common types are lard and rape seed oil. Their use
spefific applications. For economic reasons, most metal- has declined, partly because they are now difficult to obtain
working firms try to use as few different fluids as possible. and are expensive, but mainly because modern additives
Preferred fluids have long life and do not require constant blended with mineral oil are much more effective. Fatty
changing or modifying. oils are very polar and have high "oiliness"-anti-friction
performance-but poor anti-weld characteristics. They oxi-
Each of the basic types of fluids has distinctive features, ad- dize readily and display a tendency to fume and to emit an-
vantages and limitations, although the dividing lit ;s not pleasant odors.
always clearly identifiable. Understanding the.e basic dif-
ferences is necessary to obt. in optimum performance. Compounded cutting oils are made by blending polar ad-
ditives and/or chemica.1y active additives with mineral oil.
The four basic types of cutting fluids are as follows: Polar additives, such as certain fats, oils, waxes dnd syn-
thetic materials, increase he load-carrying and cutting ca-
Cutting oils pability of mineral oil. Com. -ion polar additives are lard oil
and castor oil. The function of any polar additive is to wet
* straigh, and compounded mineral oil (plus addi- and to penetrate the chip/tool interface by reducing the in-
tives) terfacial tension between the carrier mineral oil and the

16-3
-K
16.1 Cutting Fluid Selection and Use
metal. Such additives have been refined to minimize pre- When both chloiine and sulfur are added to cutting oils.
vious objections to the formation of disagreeable odors and anti-weld or EP characteristics are efferfivp over a wider
the tendency to gum. temperature range. Sulfo-chlorinated mineral oil and sulfo-
chlorinated fatty oils are examples of such oils which are
Fatty-mineral oils are combinations of one or more fatty suitable for a wide range of applications.
oils blended in straight mineral oil. Lard oil is frcqueitiy
used for this purpose Fatty oils may comprise up to 40 per- Phosphorus performs as a mild EP lubricant or anti-fric-
cent of the blend depending on the application and are tion additive when added to a cutting oil. The phosphide
quite effective for many operations. The advantages are film breaks down at lower temperatures than do sulfide or
not great and are confined primarily to improvement of fin- chloride films and, therefore, is not as effective an anti-weld
ish in the mac-iining of mild steel, brass, copper and alumi- agent. Phosphorus is most effective in reducing friction and
num Such blends are particularly suitable for machining wear. These oils are nonstaining to most ferrous and non-
the harder types of brass and copper, where straight min- ferrous alloys.
eral oil may not give the finish required and where the use
of more active oils would cause staining. These oils are These basic types of cutting oils can have various additive
widely used in automatic screw machines where the oper- levels and may be used singly or in combination and at var-
ations are not exceptionally severe. ious viscosities to suit various applications. Some recent
developments include oils in which the production of fume
Extreme pressure (EP) additives are added to fluids used and oil-mist have been significantly reduced.
for machining operations where cutting forces are partic-
ularly high, such as tapping and broaching, or for oper- Applications of all compounded cutting oils (both active
ations performed with heavy feeds. Chemical or EP addi- and inactive) are generally limited to machining operations
tives provide a tougher, more stable form of lubrication at on difficult-to-machine metals or form grinding from the
the chip-tool interface. These additives include sulfur, chlo- solid. The high cost, the possible danger from smoke and
rine or phosphorus compounds that react at high temper- fire, and the operator health problems often restrict the use
atures in the cutting zones to form metallic sulfides, chlo- of these oils to operations where other fluids do not provide
rides and phosphides In addition to providing extreme satisfactory performance.
pressure lubrication, these additives provide a film on the
tool surface with anti-weld properties that minimize the
built-up edge. Sulfurized fatty-mineral oi! blends have sul-
fur added in a strongly bonded, inactive form which may be Water-Miscib', (Water-Soluble) Fluids
totally nonstaining. The water-miscible (water-soluble) cutting fluids are pri-
marily used for high speed machining operations because
Active Cutting Oils they have better cooling capabilities. These fluids are also
Active cutting oils (compounded with chemically active ad- best for cooling machined parts to minimize thermal dis-
ditives) include sulfurized or phosphorized mineral oils, tortion.
sulfo-chlorinated mineral oils, and sulfo-chlorinated fatty-
mineral oil blends. These fluids have good anti-weld and Water-miscible cutting fluids are mixed with water at dif-
extreme pressure lubrication qualities which improve tool ferent ratios depending on the machining operation. For
life in high-temperature and high-pressure applications, high-speed chip-making operations, they are normally
They may, however, cause discoloration or staining of cer- mixed 1 part concentrate to 20 to 30 parts water. For
tain metals. many grinding operations where it is desirable to have a
lighter fluid with more cooling action, the ratio is 1:40 or
Sulfur can be added to a cutting oil in the form of sulfu- 1:50. Water-miscible fluids form mixtures ranging from
rized mineral oil or sulfurized fat. The sulfurized mineral emulsions to solutions when mixed with water. Because
oil is more active at lower temperatures and tends to se- water has a high specific heat, high thermal conductivity
verely stain aluminum, copper, brass, bronze and magne- and high heat of vaporization, it is one of the most effective
sium alloys. In comparison, the sulfurized fatty oil (which is cooling media known. Blended with water, the water-
sulfurized at a higher temperature) will not release sulfur as miscible fluids provide the combined cooling and moderate
readily and. therefore, has less tendency to stain nonferrous lubrication required by metal removal operations con-
metals or steel. Oils containing sulfur will form metallic ducted at high speeds and lower pressures.
sulfide films which will act as solid lubricants at temper-
atures up to about 1300F [700C. The water-miscible fluids can be classified as emulsifiable
oils (soluble oils), chemical (synthetic) fluids or semi-
Chlorine reacts and functions in essentially the same man- chemical (semisynthetic) fluids. Fluids within these classes
ner as sulfur. Inhibiting ingredients are added to prevent are available for light-, medium-, and heavy-duty perform-
corrosion of ferrous surfaces, since chlorine is more reac- ance.
tive than sulfur. Chemical reaction is thus restricted to the
chip-tool interface, where the temperatures are high. Emulsifiable Oils
Chlorinated oils form an iron chloride film when reacting Emulsifiable oils are commonly called soluble oils, emul-
with ferrous workpiece materials or high speed steel tools. sions, or emulsifiable cutting fluids. An emulsion is a sus-
This film has a low shear strength and provides low friction pension of oil droplets in water made by blending the oil
up to about 750 0 F 14000C1, beyond which it decomposes. with emulsifying agents and other materials. These emulsi-
Chlorinated oils usually will not stain nonferrous alloys. fiers (soap or soap-like materials) break the cil into minute

16-4
 Cutting Fluid Selection and Use 16.1
particles and keep the particles dispersed in water for long Fatty soluble oils have animal or vegetable fats or oils or
periods of time. Bactericides-usually nonphenolic organic other esters added to the mineral oil content to provide a
compounds specifically approved by the Environmental range of fluids with enhanced lubricating properties.
Protection Agency (EPA)-are added to control the growth
of microorganisms such as bacteria, algae and fungi. If dis- EP soluble oils contain sulfur, chlorine or phosphorus ad-
posal is of no concern, phenolics may be used. The soaps, ditives to improve load-carrying performance Since the
wetting agents, and couplers used as emulsifiers in water- EP concentrate is diluted 5 to 20 times when the emulsion
miscible fluids reduce surface tension signficantly. As a is prepared, the lubricating capability is reduced. Where
result, the liquid has a greater tendency to foam when sub- the lubricating capabilities of soluble-oil emulsions and the
jected to shear and turbulence. For this reason, water- cooling properties of cutting oils are inadequate, EP so-
miscible fluids sometimes cause foaming problems in luble oils can satisfy both requirements in many cases.
operations such as gundrilling or flat-bed and double-disk These fluids, commonly known as heavy-duty soluble oils,
grinding. With the use of special wetting agents and foam have in some cases replaced cutting oils for broaching,
depressants, however, water-miscible fluids can be ren- gear hobbing, gear shaping, and gear shaving.
dered sufficiently nonfoaming to be effective in almost all
operations. Chemical Fluids
Emulsifiable oils combine the lubricating and rust-pre- Chemical (synthetic) fluids are chemical solutions con-
vention properties of oil with water's excellent cooling sisting of inorganic and/or other materials dissolved in wa-
properties. Emulsions, with their cooling-lubricating prop- ter and containing no mineral oil. All of these fluids are
erties, are most effectively used for metalcutting operations coolants; some are also lubricants. Chemical agents that go
with high cutting speeds and low cutting pressures accom- into these fluids include: amines and nitrites1 for corrosion
panied by considerable heat generation. inhibitors; nitrates, for nitrite stabilization; phosphates and
borates, for water softening; soaps and wetting agents, for
Advantages of emulsifiable oils over straight or com- lubrication and reduction of surface tension; phosphorus,
pounded cutting oils include greater reduction of heat, chlorine and sulfur compounds, for chemical lubrication;
cleaner working conditions, economy resulting from dilu- glycols, as blending agents and humectants; and germi-
tion with water, better operator acceptance and improved cides, to control the growth of bacteria.
health and safety benefits. They can be used for practically
all light- and moderate-duty cutting operations, as well as In general, the advantages of chemical fluids include econ-
for most heavy-duty applications except those involving ex- omy, rapid heat dissipation, good size control, detergent
tremely difficult-to-machine materials. Emulsifiable oils properties which help keep the machine surfaces and the
can be used for practically all grinding operations with the coolant systems clean, excellent workpiece visibility, easy
exception of severe grinding operations, such as form, mixing with little agitation, and high resistance to rancidity
thread and plunge grinding where wheel form is a critical and rust. The increased cost of oils, plus OSHA and EPA
factor. Extreme-pressure, compounded emulsifiable oils do requirements, may result in increased use of these and
not suffer from this limitation, other water-miscible fluids.

Cutting fluid manufacturers supply emulsifiable oils as con- A possible disadvantage of chemical fluids that may be en-
centrates that the user prepares by mixing with water. countered in some severe operations is insufficient lubri-
Mixtures range from 1 part oil in 100 parts water to a 1:5 city, which may cause sticking and/or wear of moving ma-
oil-water ratio. The leaner emulsions are used for grinding chine tool parts. The dry, powdery residue or film left by
or light-duty machining operations where cooling is the es- chemical fluids is easy to remove. This residue can inter-
sential requirement. Lubricating prt -erties and rust pre- fere with component movements if allowed to remain on
vention increase with higher concentrtions of oil. The four the machine surfaces. Most of the stickiness is caused by
types of emulsifiable oils are summarized in table 16.1-1. the minerals in the water used. The mineral content in wa-
ter can quadruple in six weeks as water is added to replace
k- that lost by evaporation. Deionized water should be used to
General-purpose soluble oils are milky fluids with min- avoid this problem. Improved lubricating or EP properties,
eral oil droplets 0.2
of Tey
0.0002-inch
inidiaete. to 0.008-inch
re ommoly 10.005
sedat mm of
iluion to however, can be provided. Other limitations may include
0.2 minI diameter. They are commonly used at dilutions of foaming problems in high agitation applications, and high
1:10 to 1:40 for general purpose machining, detergency and alkalinity characteristics which may irri-
tate sensitive hands when the concentration of the mix is
Clear-type (or translucent) soluble oils contain less oil not controlled.
(with higher proportions of corrosion inhibitors) and con-
siderably more emulsifier than do milky emulsions. The Chemical fluids are usually classified into two general
clear type, therefore, consists of oil dispersions with groups: true solutions and surface-active types (see table
smaller oil droplets which are more widely distributed. 16.1-1).
Since there is less dispersion of transmitted light, the fluid
is less opaque, and the result is a translucent liquid. The
translucency is not permanent, though, because often times
the tiny oil droplets tend to coalesce and form larger drop-
lets. These oils are generally used for grinding or for light-
'CAUTION: The use of fluids containing nitrites may present a hazard and
is
andpresently under review by the National Institute of Occupational Safety
Health (NIOSH). Nitrites can react with amines to form nitrosamines
which are carcinogenic. NIOSH may ban or control the use of nitrites incut-
I
duty machining. ting fluids after completion of their review.

16-5

____ ___ ____

-- _~--==- = -- = = ~ --
16.1 Cutting Fluid Selection and Use
TABLE 16.1-1 Water-Miscible Cutting Fluids

CLASS TYPE GENERAL CHARACTERISTICS

Emulsifiable (1) General-Purpose Used at dilutions between 1:10 and 1.40 to give a milky emulsion. Used for general
Oils Soluble Oils purpose machining

(2)Clear-Type Used at dilutions between 1:50 and 1:100. Their high emulsifier content results in
Soluble Oils emulsions which vary from translucent to clear. Used for grinding or light-duty
machining.

(3) Fatty Soluble Used at similar concentrations to (1) and of similar appearance. Their fat content makes
Oils them particularly good for general machining operations on nonferrous metals

(4)EP Soluble Oils Generally contain sulfurized or chlorinated EP additives. Used at dilutions between 1:5
and 1:20 where a higher performance than that given by (1), (2) or (3) is required.

Chemical (1)True Solutions Essentially solutions of chemical rust inhibitors in water Used at dilutions between 1:50
(Synthetic) and 1:1010 for grinding operations on iron and steel.
Fluids
(2)Surface-Active Contain mainly water-soluble rust inhibitors and surface-active load-carrying additives
Chemical Fluids Used at dilutions between 1:10 and 1:40 for cutting and at higher dilutions for
grinding. Most are suitable for both ferrous and nonferrous metals.

(3) EP Surface-Active Similar in characteristics to (2) but containing EP additives to give higher machining
Chemical Fluids performance when used with ferrous metals. Used at dilutions between 1:5 and 1:30.

Semichemical - Essentially a combination of a chemical fluid and a smal! amount of emulsifiable oil in
(Semisynthetic) water forming a translucent, stable emulsion of small droplet size. EP additives are
Fluids usually included permitting their use for moderate- and heavy-duty machining and
grinding applications.

True-solution fluids (without wetting agents), also called Surface-active chemical fluids are extremely fine colloidal
chemical solutions or chemical grinding fluids, primarily solutions composed of inorganic and organic materials dis-
contain rust inhibitors (inorganic and organic nitrites2 ), se- solved in water with the addition of wetting agents (surface
questering agents, amines, phosphates, borates, glycols or active agents). The wetting agents improve the wetting ac-
ethylene or propylene oxide condensates. Some of these tion of the water and provide greater uniformity of both
fluids contain highly developed corrosion inhibitors such as heat dissipation and anti-rust action. This type of fluid may
sodium nitrite 2 (for cast iron), triethanolamine (for both include anti-foaming agents, humectants, mild lubricants
cast iron and steel) and sodium mercaptobenzothiazole (for (organic or inorganic) and water softeners. The lubricating
reducing corrosion on brass, zinc and aluminum). True so- (anti-wear) properties may be provided by a viscous poly-
lutions, used at 1:50 or 1:100 ratios, are clear in appear- glycol compound. Corrosion protection may be provided by
ance but are often colored with dyes to indicate their pres- a mixture of triethanolamine and caprvlic acid, and the for-
ence in water. These fluids are restricted to grinding mulation may include a deactivator for copper alloys.
operations where they prevent rust and permit rapid heat
removal. True solutions have high surface tension (about The surface-active type of chemical fluid has fair lubricity,
equivalent to water). They have a tendency to leave a resi- low surface tension, and good rust-inhibiting properties and
due of hard or crystalline deposits formed by water evapo- usually leaves a dry, hard or powdery residue that is easily
rating. These chemicals can also be added to emulsifiable removed. The slight tendency of these fluids to foam is usu-
oils or to other chemical fluids to enhance their corrosion- ally not a serious problem in most operations. They are
inhibiting properties. usually used at dilutions of 1 part concentrate in 10 to 40
parts water.

EP surface-active chemical fluids are similar to the plain

(general-purpose) surface-active type but have chlorine,
2CAUTION. The use of fluids containing nitrites may present a hazard and sulfur or phosphorus additives to provide extreme-pressure
is presently undcr review by the National Institute of Occupational Safety lubrication effects. These fluids are diluted at one part con-
and Health (NIOSH). Nitrites can react with an.ines to form nitrosammes
which are carcinogenic. NIOSH may ban or control the use of nitrites in cut- centrate to betweet, 5 and 30 parts water for tougher ma-
ting fluids after completion of their review chining operations.

16-6
 Cutting Fluid Selection and Use 16.1
Semichemical Fluids SELECTION OF A CUTTING FLUID
Semichemical fluids or semisynthetic fluids are essentially
a combination of chemical fluids and emulsifiable oils in The proper choice of a cutting fluid depends on many comn-
water. These fluids are actually preformed chemical emul- plex interrelated factors. Of primary concern are machin-
sions that contain only a small amount of emulsified min- ability (or grindability) of the material, compatibility (met-
eral oil. about 5 to 30 percent of the base fluid, which has allurgical. chemical and human) and acceptability (fluid
been added to form a translucent, stable emulsion of small properties, reliability and stability).
droplet size. Since the usual EP additives can be in-
corporated (often more readily in the oil content than in the Machinability
synthetic base), tloe lubricating performance can be varied
to permit using such fluids for moderate- and heavy-duty The selection of the type of cutting fluid for use should be
machining and grinding applications based on:

Semichemical fluids combine some of the best qualities of & Type of machining operation
chemical fluids and emulsifiable oils. The advantages and
limitations are similar to those described for chemical * Material beingmachned
fluids, except that semichemical fluids have better lubri-
cating properties than do chemical fluids. They are also Tool material
cleaner, with better rust and rancidity control than emulsi- * Machining conditions-cutting speed, feed, and depth of
fiable oils.
cut

One of the most important factors in selecting a cutting

Gases fluid is the nature of the cutting operation itself. The vari-
Air is the most common gaseous fluid. It is present under ous machining processes naturally differ in metal removal
atmospheric pressure for dry operations and also present characteristics. The more difficult operations will place
when fluids are used. Air is sometimes compressed to pro- greater demands on a cutting fluid. Selection is, therefore,
vide better cooling, with a stream directed at the cutting a matter of assessing the severity of the machining oper-
zone to remove heat by forced convection. This also can be ation and marrying it to the appropriate cutting fluid. The
used to blow chips away, but safety precautions must be approximate ratings for the machining processes in order
observed. Gases such as argon. helium and nitrogen are of decreasing severity, are as follows:
sometimes used to prevent oxidation of the workpiece and 1. Internal broaching
the chips, but the high cost of these gases generally makes 2. External broaching
them uneconomical for production applications. 3. Tapping
4. Threading
Gases. such as FreonTi or C0 2, with boiling points below 5. Generation of gear teeth
room temperature can be compressed and sprayed into the 6 Deep drilling
cutting zone to provide evaporative cooling. Use of liquid 7. Boring
argon or nitrogen allows cooling to several hundred de- 8. Screw machining with form tools
grees below zero. Care is necessary, however, to prevent
part warpage caused by large temperature differentials.

Advantages of inert gases include good cooling ability, in-

9. High-speed, light-feed screw machining
10. Milling
11. Drilling i
creased tool life, a clear view of the operation, elimination 12. Planing and shaping
13. Turning, single-point tools
of mist. and no contamination of the workpiece, chips or 14. Sawing
machine lubricants. The cost of some of these gases, how- 15. Grinding
ever, can be extremely high.
These ratings cannot be regarded as absolute, since varia-
tions in the tool geometry and workpiece material will
Paste and Solid Lubricants change the severity of the machining operation.
There are also paste and solid lubricants that are usually For heavy-duty machining operations (such a- tapping or
applied manually by brush or by oilcan to the tool or work- broaching), medium- or heavy-duty cutting oils are gener-
piece in operations such as tapping and hand reaming. ally used. Horizontal broaching of steel usually requires a
Grinding wheels are sometimes impregnated with solids heavier-bodied or more-chemically-active oil than does ver-
possessing lubricating qualities. In speciai cases, such as tical surface broaching under comparable conditions. The
knife grinding, wheels are treated with sulfur to produce a heavier oil clings to the horizontal broach better than a wa-
cooler action in wet grinding. Also, external application of ter-miscible fluid, and chemical activity aids in efficient cut-
grease sticks to grinding wheels can provide some lubri- ting. For vertical surface broaching of mild steels, emul-
cation, but this requires performing the operation dry. sions or solutions may be used, but the usual choice is an
Solid waxes in stick form can be used on grinding wheels, oil.
sanding disks or belts, taps, an' - and- or circular-saw
blades for 'ubrication to improve finish and tool life or to Cutting oils can be ranked in order of increasing load-
reduce burring or metal welding. Other solids most often carrying capacity as follows:
used as heavy-duty lubricants include graphite, molybde- 1. Straight mineral oil
num disulfide, pastes, soaps and wax-s. 2. Mineral oil with fatty additives
4

16-7
16.1 Cutting Fluid Selection and Use
3. Mineral oil with chlorinated additives ing the heat generated. They permit heavier cuts to be
4. Mineral oil with sulfurized fatty additives taken, produce smoother finishes, reduce wheel brtak-
5. Mineral oil with free sulfur and sulfurized or chlori- down, and, hence, allow better form control. Oils suffer
nated compounds from the disadvantages of allowing heat buildup in the
workpiece, tending to hold chips in suspension, and smok-
Slow speed operations require the lubricating properties of ing or burning. The messiness of oil vapors is also a
cutting oils As a general rule, cutting oils should be used at nuisance.
cutting speeds below 100 feet per minute 130 m/mini. Cut-
ting oils with EP lubricants are effective in a wide variety In summary, from a machinability viewpoint, cutting and
of machining operations on many materials up to speeds of grinding fluids should be selected to provide the following:
200 feet per minute 160 m/mini. At speeds of about 200 feet
per minute 160 m/minI, chemical action is much less effec- Greater Lubrication
tive than at the lower speeds. Chemical action diminishes
quickly and becomes virtually nil as the cutting speed is in- 0 at relatively low speeds
creased to 400 feet per minute 1120 m/mini.
* on the more diffficult-to-machine materials
Both tapping and threading involve many small cutting
edges in continuous contact with the work throughout the * for more difficult operations
cut. The design of the tools and the nature of these oper-
ations shield the edges of the tools from the flow and the o for better surface finish
cooling effect of the cutting fluid, particularly in tapping Greater Cooling

Drilling can be a difficult operation when done on, ifficult-

to-machine materials. Drilling speeds are generally slower * at relatively high speeds
than those used for other operations because the cutting
edge is in continuous contact with the metal when cutting 0 on the easier-to-machine materials
and the cutting edges are shielded from the flow and benefi-
cial cooling action of the cutting fluid. The preferred fluids 0 for easier operations
for conventional drilling operations are emulsifiable oils
and sulfurized or chlorinated mineral oils. These fluids pro- * where heat buildup in the part is a problem
vide some lubricity to prevent chatter and friction-gener-
ated heat while carrying away the heat generated by chip Types of cutting fluids recommended for various work ma-
formation. Oil-hole drills should be used wherever possible. terials and machining operations are listed in section 16.2.

There are some operations for whigh oils are specially for-
mulated. For example, honing requires the use of a thinner, Other Considerations
paraffinic-base oil. A number of other important factors must be considered
when selecting cutting and grinding fluids. These include
For many high speed operations, such as grinding and turn- compatibility of the fluid with the material being machined,
ing or milling with carbides, the most important benefit is the quality of the water in which it is mixed, tramp oil con-
provided by the superior cooling characteristics of the wa- tamination and the mach-ne tool. The acceptability of the
ter-miscible fluids. In such instances, lubrication and anti- fluid, in terms of its properties, reliability and stability, is
weld properties are less important. At high speeds, time for also important. Other factors to be considered include the
reaction between fluid additives and the workpiece is re- quantity of fluid used and the method of application, facil-
duced to a minimum. Further, the higher relative velocities ities for storing, handling, cleaning or recycling the fluid,
of the work and the tool virtually preclude the fluid's reach- the quality of water used in the aqueous emulsions or solu-
ing the work zone. Consequently, gross cooling is required tions, and the rust and rancidity control necessary. Eco-
to prevent catastrophic tool failure from crater wear, to nomic considerations include any waste treatment facilities
prevent distortion in the workpiece from heat buildup and that may be required prior to disposal. The cutting fluid's
to control workpiece size. effect on the total machining cost per piece must be consid-
ered, since the more expensive fluids may sometimes be
Some emulsifiable oils and chemical fluids are formulated more economical in the long run.
specifically for grinding operations and are used in concen-
trations of 1 part concentrate in 25 to 60 parts water. An Compatibility with Workpiece Material
increase in the richness of emulsifiable oil mixtures from The cutting fluid selected for use must tie compatible with
2.5 percent to 10 percent can improve the grindir- ratio the material being machined. The fluid should not cause _
and the workpiece finish and reduce horsepower require- staining or corrosion of the workpiece. It should prevent
ments. Note that the grinding ratio is a measure of the vol- corrosion of the workpiece during machining, while as
ume of material removed per unit volume of wheel wear. work-in-progress waiting for transfer, and possibly while in
storage for a reasonable time. Care should be taken when
Severe grinding operations, such as form, thread, and selecting coolants from a corrosion standpoint, especially
plunge grinding where wheel form is a critical factor, re- for nonferrous work materials.
quire the use of cutting oils or EP-compounded emulsi-
fiable oils. It shoul, be noted that for the low stress grind- Some copper alloys cannot be machined with highly sulfu-
ing technique, the use of an oil-base fluid results in less rized cutting oils since the active sulfur will stain the ma-
surface distortion. Grinding oils reduce friction, thus reduc- chined surface. Sulphur is often tised in a form in which it

16-8
 Cutting Fluid Selection and Use 16.1
is chemically combined with fatty oils, although for severe residual stresses. Occasionally. data will show little
machining operations it is often used at low concentrations difference between water-miscible fluids and oils: however.
in its natural form as free sulfur. In this latter or active most of these tests involve higher infeed rates or higher
form, however, it is very reactive toward copper. For this wheel speeds. The effect of infeed is more pronounced and
reason, cutting fluids containing free sulfur should never be tends to overwhelm the effects of the fluids. Grinding oils
used in t!ie machining of copper or its alloys, become increasingly effective at wheel speeds below 4,000
feet per minute 120 m/sl. It is apparent that grinding oils
Metals such as aluminum, magnesium and zinc (also galva- are superior for high integrity grinding.
nized steel) are attacked by acids or alkalies, thus causing
corrosion. Selection of a cutting fluid for aluminum de- Compatibility with Water
pends on the alloy. Active sulfur or chlorine additives may Water-miscible fluids must be compatible with the water in
cause staining of some aluminum alloys. There are some which they are mixed. Water quality is perhaps the most
fluids, however, with patented additives that improve fin- important s'ingle factor affecting fluid life. The chemistry
ishes and help prevent staining. The use of highly alkaline and biology of the water have a strong impact on the cool-
grinding fluids on aluminum would probably produce badly ing effectiveness and the life of the coolant. The best cool-
corroded parts. Magnesium and its alloys, for example. ing action can be obtained from very fine emulsions, but
should never be machined or ground with water-miscible such emulsions cannot be made with water that is high in
fluids because the metal has an incendiary effect in water. either hardness or dissolved solids. Many things are af-
Zinc and galvnized steel should not be machined with fected by the hardness level or pH of the water, such as
nitrite-containing fluids; oil-rich emulsions with a pH of ap- rate of biological growth, rust protection, evaporative ef-
proximately 8.0 have been found effective for machining fect, emulsion stability, and foaming. A high chloride or
these metals. Special fluids available for machining copper, sulfate content can negate the rust protection that has been
aluminum and magnesium are listed in section 16.3. built into a coolant formulation. Hard water (over 200
ppm) can break some emulsions, resulting in scum forma-
Ferrous metals dissolve when attacked by acids and rust tion that leads to many performance problems. Soft water
will form. Alkalies form a protective layer on most ferrous (under 100 ppm) often produces excessive foam, especially
metals to prevent corrosion. Cutting fluids for ferrous met- under conditions of high agitation. A
als are therefore kept on the alkaline side-to inhibit rust-
ing of machines and machined parts. Compatibility with the Machine Tool
The cutting fluid must also be compatible with the machine
Fluid concentration should be maintained; otherwise, the tool in which it is being used. The use of water-mistible
rust-inhibiting properties will be reduced. Some rust inhib- fluids with most machines causes few problems. Usually,
itors are attacked by oxygen and acids in the air and in the the drive mechanisms and the feed mechanisms are some
water; eventually, the inhibitors will be used up. distance from the cutting zone, completely enclosed with
their own lubrication system and adequately sealed against
The rust-inhibiting effect of soluble oils is rapidly lost when the ingress of water-containing cutting fluids. With some of
machining cast iron. Therefore, it is advisable to add some the more complex machine tools, however, like automatic
soluble oil concentrate regularly in order to maintain the and semi-automatic lathes and gear cutting and broaching
proper concentration. To prevent corrosion, soluble oils machines. water-miscible fluids cannot be used. Because
must be 2 to 3 times more concentrated when machining many of these machines rely on a cutting fluid to lubricate
cast iron than when machining steel. moving parts near the cutting zone, the use of oils is man-
datory. In other cases, problems have been experie-.ced in
Particular care should be exercised in selecting cutting preventing a water-miscible fluid from reaching drive
fluids used for machining components which are highly mechanisms and, therefore, oils must also be used.
stressed in service and which are exposed to unusual envi-
ronments. For such parts, cutting fluids should be used Acceptability
which will not make the part vulnerable to stress corrosion Another important consideration in selecting cutting fluids
attack in the event that surface films are retained on the is acceptability to the operator. Fluids designed with the
workpiece. At present, the only way of selecting such cut- operator in mind will be clean to use, pleasant and safe to
ting fluids is to choose them on the basis of extensive labo- breathe, nontoxic and free from ingredients harsh to hu-
ratory tests and/or service experience. An alternative is to man skin. Bacterial growth in the coolant should be con-
provide unusual care in washing the cutting fluid away af- trollable before and during use. Fluid clarity makes it eas-
ter machining with due consideration given to the diffi- ier for the operator to see the work while it is being
culties of washing complex finished assemblies, machined. A pleasant-smelling, generally clean, "non- ;9
sticky" fluid helps to make an operator's job more pleasant
Cutting fluid selection can have a dramatic impact on the and productive.
distortion and the residual stresses generated by grinding.
Grinding is commonly done with water-miscible fluids, with
oils or even dry. The differences among them relate to ther- APPLICATION OF CUTTING FLUIDS -
mal cooling action, .ibricity and possibly some chemical
action, Water-miscible fluids have greater cooling capabil- The way in which a cutting fluid is applied has a consid-
uiy and less lubricity than the oils; however, they also im- erable influence on tool life and on the machining operation
pose a greater heat shock on the workpiece. Dry grinding in general. Although there are many extremely effective de-
conditions are not usually compatible with low stress grind- vices and systems for supplying fluids to the cutting area,
ing or high surface integrity. Lubrication is the most impor- special equipment is not generally necessary for good
tant function of the grinding fluid relative to control of results.

16-9 1
16.1 Cutting Fluid Selection and Use
Even the best fluid, however, cannot perform its function fluid to the cutting zone, a copious flow provides cooling ac-
unless it is effectively delivered to the cutting zone. Thus. a tion that prevents undue temperature rise. Proper cutting
fluid -hosen for its lubricating qualities must be directed so fluid application should not be neglected because of in-
that it can form a film at the sliding surfaces. Likewise, a adequate splash guards. Typical coolant flow requirements
fluid used for cooling must gain reasonable access to the are given in table 16.1-2.
cutting edge of the tool. These conditions usually require
that the fluid be forced into the cutting zone so that the heat The geometry of flood application directly influences the ef-
can be removed as it is generated. Continuous application fectiveness of cutting fluids. Nozzles should direct fluid flow
of the cutting fluid is preferable to intermittent application, so that fluid is not thrown off the workpiece or tool by cen-
Sporatic fluid application causes thermal cycling, which trifugal force. Two or more nozzles should be used-one for
leads to the formation and propogation of microcracks in directing fluid into the cutting zone and the other for aux-
hard and brittle tool materials, such as carbides. Besides iliary cooling and flushing away chips.
shortened tool life, intermittent fluid application'can lead to
irregular surface finishes. Turning and Boring
Turning and boring operations require the cutting fluid to
A secondary advantage of proper fluid application is the ef- be directed to the cutting zone where the chips form. This
ficient removal of chips. This also aids in prolonging tool provides good cooling action by enveloping the cutting tool
life, since properly placed fluid nozzles can prevent block- edge and the workpiece. An empirical rule is that the cool-
age or packing of the chips in the flutes of milling cutters ant nozzle should have an inside diameter of at least three-
and drill bits. quarters the width of lathe-type cutting tools.
For heavy-duty turning and boring operations, a second
Manual Application nozzle supplying fluid from below and along the flank of the
Paste and solid lubricants are applied manually by brush or tool is desirable. The flow from the lower nozzle is not hin-
oilcan to the tool and to the workpiece. mainly in tapping. dered by the chip and can be forced between the work and
More recent developments include pressurized aerosol dis- tool to help in providing lubrication at lower speeds.
persants and foams which cling to the tool and workpiece. Dilling and Reaming

Manual application is an effective method where a small For horizontal drilling and reaming, fluid application
number of holes are to be drilled or tapped on a machine through hollow tools is preferable to external application
that is not equipped with a coolant system. When two dif- because it provides adequate flow at the cutting edges and
ferent operations are performed on the same machine, flushes chips out of the hole. Even in vertical drilling, very
manual application may be used in conjunction with the little fluid gets down to the cutting zone because the spiral
flood cooling system of the machine. The flood cooling may flutes (which are designed to pump out the chips) pump out
be used for a drilling operation with a moderately active the fluid. The use of oil-hole drills will solve this problem.
fluid, whereas a highly active cutting oil can be applied
manually for a tapping operation that follows. Milling
Milling operations require the use of two nozzles directing
a copious supply of fluid to both the incoming and the out-
Flood Application going sides of the cutter. The fluid from one nozzle is
The most common method of applying fluids is to flood the pumped through the cutting zone by the cutter teeth, while
tool and workpiece. A low-pressure pump delivers the cut- fluid from the other nozzle washes away the chips as they I

ting fluid through piping and valves to nozzles situated near emerge from the cutter. Standard round nozzles are suf-
the cutting zone. After flooding the cutting area, the fluid ficient for narrow cutters. Wide cutters require using fan-
drains doA n over various parts of the machine into the chip shaped nozzles at least three-quarters the width of the mill-
pan whete it flows to the sump of the coolant pump. The ing cutter to provide good coverage.
volume of the tank must be sufficient to allow time for cool-
ing and for the settling of fine swarf and may require from For face milling, use of a ring-type distributor consisting of |
five to fifty gallons or more depending on the type of a tube with many small holes can be beneficial. This directs j
machine. A course strainer on top of the collecting pan pre- the fluid at all cutting edges and keeps the cutter corn-
vents larger chips from entering the tank and the fine pletely bathed in fluid to provide even cooling. When a par-
strainer at the pump section. Important exceptions are ticular size face mill is used often, the ring-type distributor
grinding, honing. lapping and deep-hole boring machines can be supplemented with a special fan nozzle with a
where high-quality work depends upon removing the finer curved opening to match the cutter radius.
swarf and abrasive particles. Occasions arise when the in-
clusion of filtration equipment on other types of machines Grinding
can avoid the gross co;,tamination and overloading of the A copious flow of cutting fluid at low pressures will gener-
coolant with the metall., particles and help keep the fluid ally provide good results for grinding operations. Where ap-
clean, thus prolonging its useful life. plication of a large volume of fluid results in undue splash-
ing, it is better to install splash guards on the machine than
Flood application of cutting fluids permits a continuous to reduce the coolant flow.
flow of fluid to the cutting zone and is efficient in flushing
away chips. A copious stream of fluid should be applied so The normal methods of applying fluids to grinding oper-
that the cutting tool cdg . and the work are completely en- ations remove little heat before it has dissipated into the
veloped. In addition to supplying an adequate amount of mass of the workpiece. Because high surface speeds are in-

16-10
 Cutting Fluid Selection and Use 16.1
TABLE 16.1-2 Typical Coolant Flow Requirements

OPERATION FLOW AT WORK REMARKS

Turning 5 gal/min [19 L/min].tool

Screw Machining
1 inch [25 mm] dia 35 gal/min [132 L/min]
2 inch [50 mm] dia 45 gal/min [170 L/min]
3 inch [75 mm] dia. 60 gal/min [227 L/mini

Milling
Small cutters 5 gal/min [19 L/min]/tool
Large cutters Up to 60 gal/min [227 L/min]/
tool

Drilling, Reaming
1 inch [25 mm] dia. 2-3 gal/min [7.6-11 L/min]
Drilling, Large 2-3 gal/min x dia., inch
[0.3-0.43 L/min x dia., mm]

Gundrilling
External chip removal type
0.18-0.37 inch [4.6-9.4 mm] dia. 2-6 gal/min [7.6-23 L/min] Fine filtration required.
0.37-0.75 inch [9.4-19 mm] dia. 5-17 gal/min [19-64 L/min]
0.75-1.25 inch [19-32 mm] dia. 10-40 gal/min [38-151 L/min]
1.25-1.50 inch [32-38 mm] dia. 17-50 gal/min [64-189 L/min] Use higher flow rates for
Internal chip removal type deeper holes and the larg-
0.31-0.37 inch [7.9-9.4 mm] dia. 5-8 gal/min [19-30 L/minj est diameters in each
0.37-0.75 inch [9.4-19 mm] dia 8-26 gal/min [30-98 L/min] range.
0.75-1.18 inch [19-30 mm] dia. 26-66 gal/min [98-250 L/min]
1.18-2.38 inch [30-60 mm] dia. 66-130 gal/min [250-492 L/min]

Trepanning
External chip removal heads
2-3.5 inch [51-89 mm] dia. 8-48 gal/min [30-182 L/min] Fine filtration required.
3.5-6 inch [89-152 mm] dia. 16-80 gal/min [61-303 L/min]
6-8 inch [152-203 mm] dia. 32-104 gal/min [121-394 L/min] Use higher flow rates for
Internal chip removal heads deeper holes and the larg-
2.37-6 inch [60-152 mm] dia. 110-215 gal/min [416-814 L/min] est diameters in each
6-12 inch [152-305 mm] dia. 215-340 gal/min [814-1,287 L/min] range. If an emulsion is
12-18 inch [305-457 mm] dia. 340-460 gal/min [1,287-1,741 L/min] used instead of oil,
18-24 inch [457-610 mm] dia. 460-570 gal/min [1,741-2,158 L/min] increase the flow rate.

Honing
Small 3 gal/min [11 L/min]/hole Very fine filtration required.
Large 5 gal/min [19 L/min]/hole

Broaching
Small 10 gal [38 L]/stroke
Large 3 gal/stroke x length of cut, inch
[0.45 L/stroke x length of cut, mm]

Centerless grinding
Small 20 gal/min [76 L/min] Fine filtration required.
Large 40 gal/min [151 L/min]
Other grinding 5 gal/min/inch of wheel width
[0.75 L/min/mm of wheel width]

16-11 1

__ _ __ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ L!
16.1 Cutting Fluid Selection and Use
volved, an entrained film of air usually encloses the grind- hoses that are required for flood cooling. In addition, only
ing-wheel surface, and this prevents penetration of the fluid small amounts of fluids are used. and these generally dry on
into the cutting zone. Special nozzles can be designed the part or can be easily wiped away.
which will force the fluid through the air film and onto the
wheel. These nozzles must be placed as close as possible to Mist systems are often advantageous because they:
the workpiece to prevent complete loss of the fluid by the
centrifugal forces of the wheel. Another method of over- 0 Provide better tool life than cutting dry
coming the air film enclosing the grinding wheel is to use a
close-fitting baffle that interrupts the air flow. creating a 9 Provide coolant when a flood system is not available or
vacuum that sucks the grinding fluid into the wheel-work practical
interface.
* Apply fluids to otherwise inaccessible areas
High-Pressure Application e Provide higher fluid velocities at tool-workpiece inter-
For some operations, such as gundrilling and trepanning, face than possible by flood cooling
high-pressure fluid systems are normally used with fluids
being applied at pressures ranging from 100 to 2,000 psi 0 Reduce costs in some cases
1690 to 13.790 kPal. A gundrilling tool is essentially a
single-point end cutter similar to a boring tool. except that 0 Give better visibility of the workpiece in cut
it has an internal passage for fluid. Trepanning is a hole-
making opera-ion that cuts a cylindrical path into the Disadvantages of mist systems include limited cooling ca-
metal, leaving a solid core. "Ihis core passes through the pability and the need for venting.
hollow cylindrical cutting head as a tool feeds into the
metal. The cutting fluid is pumped around the outside of Two types of mist generators are normally used-the as-
the tool under pressure, forcing chips back through the pirator type and the direct-pressure type. For the aspirator,
center. Cutting fluids for trepanning must have good EP a stream of air is blown over the open end of a tube which
and anti-w-ld properties, must be low enough in viscosity is immersed in the fluid. A partial vacuum is created and
to flow freely around the tool, and must have good oiliness, the fluid is drawn up the tube where it becomes entrained
in the air stream. In the pressurized mist generator, either
Deep-hole drilling presents the problem of maintaining a pressurized gas bottles or shop air may be used to force the
sufficient flow of cutting fluid to the cutting edges. One so- fluid into the air stream.
lution is the use of oil-groove, oil-hole, or oil-tube drills,
which utilize drill-flute space for cutting fluid passages. The
fluid, under 50 to 100 psi 1345 to 690 kPal pressure, is Special Application Methods
transfered to the drill by a rotating gland and is forced Chilled cutting fluids and highly pressurized gases have
directly into the cutting zone. The fluid flowing from the been shown effective in increasing tool life. These methods
hole assists in chip removal. Oil-hole drills have become are more exotic than the conventional application methods.
very popular in recent years. particularly for deep holes. In special cases they may be economically justifiable. They
Their use represents a significant improvement over flood- may prove worthwhile to try in cases where nothing else
ing as the method of getting the cutting fluid to the drill works.
lip.,. Significant increases in tool life and productivity can
also be achieved (that is, oil-hole cooling gives better tool
life at higher speeds than flood cooling does). MAINTENANCE OF CUTTING FLUIDS
High-pressure systems are sometimes used for other oper- Cutting fluids, like any other fluids that are used over and
ations. The high pressure facilitates the fluid's reaching the over again, must be cared for properly. There are several
chip tool interface. In grinding, a high-pressure jet also precautions that should be observed.
serves to clean the wheel.
Cutting Oils
Mist Systems Oil-type fluids perform satisfactorily if applied at full flow
Cutting fluids may also be applied in the form of an air-car- to the tools and the work and if sufficient volume is main-
ried mist. Small jet equipment is used to disperse soluble tained in the system to hold the oil temperature around 700
oil or synthetic water-miscible cutting fluids as very fine to 75F 121 0 to 240 C].
droplets in a carrier such as air. at 10 to 80 psi 169 to 552
kPal, or occasionally as an aerosol. Water-miscible fluids Cutting and grinding oils become contaminated rapidly f
are preferred over oil because oil presents possible health during use. Extraneous materials, chips, dirt, etc., should
hazards and tends to clog. Mist application is best suited to be removed continously or at periodic intervals by filters.
operations where the cutting speed is high and the areas of strainers, centrifuges, or settling tanks. The mechanical
cut are low, as in end milling. Cutting fluids normally edge-type filter, incorporating metal strips or disks as the
chosen primarily for their cooling ability are used for mist filter element, acts principally as a strainer. The absorbent-
application. The very small droplets come into contact type filter uses paper disks, cotton waste, or cloth bags as
with the hot tool, workpiece, or chip and evaporate and the filtering element. Magnetic filters are suitable for sepa-
rapidly remove heat by vaporization. Mist cooling does not ration of ferrous particles. Centrifuging is used for remov-
require the splash guards, the chip pans and the return ing heavy contaminants and particles from oil. Centrifug-

16-12
 Cutting Fluid Selection and Use 16.1
ing, together with a heating unit and settling tanks, is often off a bad odor. is usually caused by bacterial growth. The
used for extracting oil from chips. rotten-egg stench emanating from the sump of a machine
that has been shut down over a weekend is caused by bac-
All cutting oil systems should be drained at intervals, man- teria that attack inorganic sulfates found in all natural wa-
ually cleaned, flushed and replenished with filtered or new ters. A quality cutting fluid and regular use of biocides
cutting oil. Frequency of cleaning depends upon individual where needed are the best insurance against rancidity.
conditions.
Emulsion concentration is not always given the attention it
deserves. In heavy-duty cutting operations. heat at the tool
Emulsifiable Oils causes water to evaporate at a rate faster than the carryoff
Emulsions generally require more maintenance and care of oil on the machined parts. This results in an increased
than do cutting oils. When preparing emulsions, always add oil-to-water ratio, which if carried too far can cause an in-
the oil to at least two or three times as much water. This vert emulsion. The opposite applies to grinding operations
initial mix should be agitated thoroughly while the oil is where oil carryoff is higher and the emulsion becomes in-
being added: otherwise, soap forms which combines with creasingly dilute with use. This may cause rusting unless
the water causing the mineral oil to separate out. If not the concentration is frequently checked and controlled.
enough water is used. or if the water is added to the oil, an
invert emulsion will result (water particles are dispersed in The amount of time that an emulsion is kept in service var-
the oil phase) which is undesirable for metalcutting. Pre- ies widely-anywhere from one week to six months. Cool-
mixed fluids, instead of plain water, should be used for pre- ing an emulsion by mechanical circulation or refrigeration
paring or for alterating the mix concentration. is useful in extending its service life and in producing better
finish. Aeration. although an effective means of cooling an
Water used in preparing emulsions is very important. Hard emulsion, will usually increase microorganism growth
water containing various minerals and salts often hinders which results in reduced emulsion life. In use, emulsions
or impedes emulsification. It is not uncommon for emul- should be held at a temperature between 550 and 70*F 1130
sions made with hard water to "'break-readi.ly that is. to and 210 C.
separate into a stratified condition with a layer of oil or
creamy emulsion floating on the surface. Such separation is Before putting an emulsion into use, wash and flush the
detrimental. On the other hand, water that is too soft will coolant system thoroughly. Deposits of all kinds must be
cause foaming. Use of a specially formulated hard-water removed. Emulsions are extremely susceptible to con-
soluble oil with soft water may lead to the formation of a tamination If there is any reason to suspect that bacteria
bluish-black stain on freshly ground ferrous parts. are present in the system, flush it with a germicidal iolution
before putting in the new emulsion.
Water used for making cutting fluid mixtures should be as
pure as possible for the most economical and trouble-free
use. Boiler water condensate (when available) or deionized Occupational Dermatitis
water (mineral free) should be used. The deionizer removes Dermatitis is not an affliction that must be tolerated. It can
all minerals by chemical absorption so that the effluent is be closely controlled, or eliminateo, by observing simple
equivalent to distilled water Consequently. no residues are principles of cleanliness that the average person observes
left by evaporation of the water, and corrosion effects from at home.
minerals are eliminated.
Dermatitis is frequently. though mistakenly, associated
Pretreatment of hard water is sometimes necessary. Water with the handling of petroleum products, particularly in the
conditioning agents consisting usually of poiyphosphate machine shop where the operator's hands or forearms are
combinations are readily available, as is tri-sodium phos- in prolonged contact with soluble oils and cutting oils.
phate. The general rule for using these materials is to add Combined with dirt, these fluids form grimy compounds
about 1.5 ouncts per 100 gallons 10.11 grams per literl of that may become embedded in the skin, often blocking the
water per grain of hardness. Chemical tteatment of ex- pores and hair follicles. In many cases, these areas become
tremely hard water is far more economical than the pur- infected and dermatitis sets in. This condition may occur
chase of a specially formulated soluble oil. Excessive use of with almost any material that is allowed to remain on the
polyphosphate water conditioners. however, will tend to skin for a long period of time; it is not limited to petroleum
increase bacteria, mold and fungi growth. Where water products. A contributing factor may sometimes be the sol-
makeup rates are high, the use of deionized water is vent action ott .- cutting fluid. Left on the skin. the fluid
preferred. can dissolve tLL; natural skin oils, inflaming the skin and
causing it to crack.
Microorganisms in the water shorten the service life of a
soluble-oil emulsion. Microorganisms of three types-bac- The bactericides used in most cutting fluids generally have
teria, algae, and fungii-are often encountered in soluble no affect on the incidence of dermatitis; however, formal-
oils, and all three have detrimental effects on emulsion sta- dehyde-releasing bactericides may sensitize the skin of
bility. Many soluble oils are compounded with a bacteri- some people. People with thin skin are more susceptible to
cide. but the amount that can be added is limited by its dermatitis. Fair. biond-complexioned people are usually
solubility in the oil. When the emulsion is made, the bac- more susceptible than are dark, oilier-skinned people. For
tericide is further diluted, reducing its effectiveness, hypersensitive workers, the only answer is a switch to an-
other job-one in which they will not be exposed to cutting
Rancidity, the term applied whenever a cutting fluid gives fluids.

16-13
16.1 Cutting Fluid Selection and Use

Maintaining personal cleanliness, keeping the fluid clean. In order to meet federal, state, and local water-pollution-
using commercially available hand creams, barrier creams control laws, all water-miscible cutting fluids should un-
or protective clothing, and installing splash guards on the dergo some sort of treatment before disposal into a lake.
machines-all can help to control dermatitis in the shop. stream. or municipal sewer system. The chemicals consid-
ered as pollutants in water-miscible products are oil.
nitrites, phenols, phosphates, PCB, and heavy metals. The
Machine Cleaning Practice oil content can be broken out of emulsion by an acid or
For mineral-oil-base fluids, machine cleaning can generally aluminum sulfate treatment. The nitrite content of the ef-
be accomplished by periodic removal of chips, metal fines fluent can then be destroyed by treatment with sulfamic
and sludge. followed by flushing with clean cutting oil. acid.

No matter how effective a coolant clarifying system is on In some states effluent containing more than 2 parts per bil-
water-miscible fluids, machine cleaning must be performed lion of phenol or phenolic derivatives is prohibited. Where
eventually. Proper machine cleaning can extend coolant regulations are less st-ingent, phenols can be removed by
life 4 to 6 times. compared to simply removing the old cool- the use of a carbon filter or slurry.
ant and replacing it with fresh coolant.

For machines not in operation, the proper cleaning pro- Recycling Cutting i
cedure is as follows: Recycling of cutting fluids can solve waste-disposal prob-
lems, reduce costs and ease pollution problems. A closed-
1. Pump out old coolant. loop system for cutting fluid recycling will have some loss,
but 90 percent recovery is not unusual. Even lower rates of
2. Clean out chips and oil residue. recovery can justify the experse of a closed-loop system.

3. Add cleaner mixed with water at a ratio of 1:50 to ma- One basic part of a recycling system is some kind of filter to
chine tool (fill reservoir), remove metal chips and grinding swarf. Other elements are
needed to remove tramp oils, to provide makeup fluid, and,
4. Circulate cleaner for at least three hours until machine unless the recycling system is pa-t of a central fluid system,
is clean and apply cleaning solution directly to all ma- to haul, store, and pump fluid in and out of machine sumps.
chine surfaces that are not in contact with circulating
system. A recycling system can be used for separate machines or
used in a central fluid system as described in the following
5. When the mach;ne is clean, pump out cleaner and re- discussion.
move all accumulated sediment from the sump.

6. Fill with enough plain water to circulate through all CENTRAL FLUID SYSTEM
coolant lines and circulate for at least 15 minutes while
rinsing surfaces previously cleaned in step 4. Wherever possible, consideration should be given to the
possible use of central systems for handling of recycled
7. Drain and refill with plain water, circulate, rinse and fluids from groups of machines. This is only practical if the
drain again. machines are using the same cutting fluid throughout. A
group of grinding machines may be linked together to
8. Add new cutting fluid immediately to cover all exposed handle the swarf by means of an integrated conveying sys-
metal surfaces to prevent rusting. tern; however, all the machines must be grinding similar
materials since mixed metals lose their scrap value. The
By thoroughly cleaning a machine each time the coolant central collection of swarf wetted by cutting fluids also re-
needs changing, all bacteria are removed and, con- duces physical handling and improves working conditions.
sequently, are not present to immediately begin degrading g
the fresh coolant. Although a thorough cleaning takes con- Centralized coolant systems enable a plant to better main- 5
siderably more time compared to pumping out and recharg- tain cutting fluids by providing a convenient checkpoint
ing, the coolant will last considerably longer: consequently, with ancillary equipment to better maintain fluid concen- g
machines can be cleaned on a predetermined schedule in- tration. A central system also means that more controls or j
stead of on a "catch-as-catch-can" program. The result is checks can be brought into the evaluation by minimizing J
controllable machine downtime, which is always less ex- the number of samples that need to be checked. Besides
pensive than emergency downtime. providing better control, a central system minimizes
maintenance with a fluid recycling system. Centralized -;ys-
tems usually cost less than a number of individual machire
Disposal of Cutting Fluids units.
Disposal problems with straight oil products are minimized
with proper batch-type recovery equipment. Straight oil One major advantage of the central system is its efficient
fluids can be sterilized and water contaminants removed by removal of metal fines from the cutting fluid with the feasi-
heat. Settling and addition of base concentrates usually re- bility of removing tramp oil by centrifuge or by other
store adequate quality for continued use. When necessary, means. Centrifuging has an additional benefit for the fluid
oil-base fluids should be disposed of by burning (possibly as user. By centrifuging the coolant, both the tramp oil and
a fuel), the metallic fines are removed. With removal of these con-

16-14
 Cutting Fluid Selection and Use 16.1
taminants, about half of the bacteria in the coolant is also ECONOMIC CONSIDERATIONS
removed. since bacteria tend to grow at the interfaces of
the coolant solution and the tramp oil droplets and metallic The cost per piece produced is more important than the ini-
fines. The continuous removal of these contaminants. pe- tial price of a cutting fluid because in many cases more ex-
riodic quality control tests, and the systematic use of addi- pensive fluids may actually be more economical to use. Be-
tives or product concentrates based on these tests-are all cause the cutting fluid is part of a manufacturing system,
major factors which make the central system an effective an economic analysis of cutting fluids must take into co-i-
nieans of realizing extended cutting fluid life. Increased sideration both the costs associated with the fluid itself and
fluid life reduces the disposal problems inherent in the use the costs affected by the fluid. These two cost divisions can
of water-miscible fluids. be further subdivided into direct and indirect costs. In
those cases where the influence of specific costs is great. it
Extending cutting- or grinding-fluid life in central-system is possible to make a rough estimate of th.- savings without
applications requires greater attention to fluid quality con- a complete cost analysis. In any event, the economic justifi-
trol. The large number of machine tools and the productiv- cation of cutting and grinding fluids should include not oniy
ity involved justify greater levels of laboratory effort-not the cost of the fluid but also its effcct on the cost of tools,
only to determine concentration but also to determine ran- wheels, downtime, etc.
cidity-control performance. corrosion protection. volume of
recirculating chips (dirt load) and degree of unwanted con- The selection of cutting fluids varies with the work mate-
taminants. The use of system log records (water. product rial, the operations performed, etc. The benefits, such as
input, concentration, charge dates) and fluid test records reduced machining costs, increased production, decreased
(concentration. pH. bacteria count, dirt load. tramp oil, surface roughness, and greater accuracy, must be balanced
corrosion protection) are vital to monitoring the condition against the costs of having too many different fluids. These
of the cutting fluid and can be useful for identifying correc- include the cost of maintaining a large fluid inventory, fluid
tive action. changing costs, fluid price differentials, and increased
maintenance and disposal costs. Recycling of fluids can re-
duce the increasingly higher costs of fluid disposal.

16-15
.--.
- -~---- -w- - i- -
 FEC3)i4i PAGL BJ.W4OT FI1JZD

JIM

Cutting Fluid Recommendations 16.2

The following tables contain Cutting Fluid Recommenda- Example: Selection of a cutting fluid for peripheral end
tions for the machining operations and work materials milling bf an alloy steel (48-50 Rc).
listed in sections 1 tht -h 8. The code numbers in these
tab!es refer to the folle .g general types of fluids: Step 1. The Cutting Fluid Recommendations tables. sec-
tion 16.2. indicate a preference for a Type 3 fluid
Code No. Type which is an Oil-Heavy Duty. See page 16-22.
0I Dry
Oils-Light Duty (General Pti,,ose) Step 2. The Cutting Fluid Key. section 16.3. lists the fol-
2 Oils-Medium Duty lowing subtypes under Oils-Heavy Duty (see
3 Oils-Heavy Duty pages 16-72 through 16-77):
4 Emulsifiable Oils-Light Duty (General Pur-
pose) Sulfurized Mineral Oil
5 Emulsifiable Oils-Heavy Duty Compounded Sulfurized Mineral Oil
6 Chemicals and Synthetics-Light Duty (Ger.- Chlorinated Mineral Oil
eral Purpose) Sulfurized Mineral Oil + Sulfur. Chlorine. and
7 Chemicals and Synthetivs-Heavy Duty Phosphorus Compounding
8 Special-Light Duty Sulfo-Chlorinated Mineral Oil
9 Special-Heavy Duty Sulfurized Mineral Oil + Fatty Oil
Chlorinated Mineral Oil + Fatty Oil
For each general type of cutting fluid, the Cutting Fluid Sulfo-Chlorinated Mineral Oil + Fatty Oil
Key. section 16.3. provides an extensive list of cutting Compounded Sulfo-Chlorinated Mineral Oil +
fluids by code number, type and trade name. and manufac- FattyOii
turer. For each type of fluid. there are a numl;-r of s-ub- Sulfo-Chlorinated Fatty Oil
types, the choice of which has been left to the user because Sulfurized Fatty Oil
of the lack of more specific machining data. Mineral Oil + Added Fat. Sulfur. Chlorine. and
Phosphorus Compounding
identified by specific
All cutting fluids in section 16.3 are
trade name and by the manufacturer of the fluid. The Cut- From the subtypes listed, select a specific product based on
ting Fluid Key includes all those companies who answered machine tol and workpiece characteristics, company poli-
inquiries regarding the classification of their fluids and does cies concerning use of cutting fluids. availability of a fluid.
not imply recommendation of particular fluids or manufac- preference for a particular cutting fluid supplier. econom-
turers. ics. and other conditions.

ig

I
zl

:1

16-171
16.2 Cutting Fluid Recomnmenciations

TOOL 1. Free Machining Ce-b~n Steels, Wrought 2. Carbon Steels, Wrought

OPERATION MATERIAL
OR
ABRASIVE 100 to 275 to 48 to 85 to 275 to 48 to
275 Bhn 425 Eh, 65 Rc 275 Bhn 425 Shn 65 RC
1.1 Turning, Single Point HSS 1,4,6 2,5,7 3,5,7 1,4,6 2.5,7 3,5,7
- and Box Tools Carbide 0,4.6 0,4, 3 0,4,6 0,4,6 0.4,6 0,4,6
1.3 Turning Diamond - - - - - -

1.4 Turning, Cutoff and HSS 2,5.7 3, 5,6,7 2,5,7 3,5,7 3, 5,7_
Form Tools Carbide 0,4.6 0,4, 5,7 0.4.6 1 0.4,6 5.7
1.5 Threading, Single Point HSS 2,5 36J 2.5 t 3,6 3
_____________ Carbide 1,4,6 1,4,6 1 , 4, J 1,4,6 1,4,6 1,4,6
1.6 Threading, Die HSS 2,5 3.6 3 2,5 3.6 a
__________ Carbide 1,4.6 1,4.6 1,4,6 1.4,6 1,.6 1,4,6
1.7 Hollow Milling HSS 1,4,6 2,5,7 3 1.4,6 2,5,7 3
__________ Carbide 0.4,6 0,4,6 2.5,7 0.4.6 0,4.6 2.5.7
2.1 Face Milling Liss 1,4,6 2,5,7 3 1.4,6 2,5,7 3
______________ uarbide 0.1,4 0,1,4 0,2 0,1.4 0,1,4 0,2

2. aeMligDiamond - - - - - -

2.4 Slab Milling HSS 1,4,6 2,5,7 3 1,4,6 2,5,7 3

_______________ Carbide 0,4,6 0,4,6 ___2 0,4,6 0,4,6 2
2.5 Side and Slot Milling- HSS 1,4,6 2,5,7 3 1,4,6 2,5,7 3
Arbor Mounted Cutters Carbide 0,4, 6 0,4,6 2 0,4, 6 0,4,.6 2
2.6 End Milling-Peripheral HSS 1,4,6 _ 2,5. 7 3 1,4,6 2,5,.7 3
______________ Carbide 0,4,6 0,4,6 3 0,4,6 0.4,6 3
2.8 End Milling-Slotting S 1,4,6 2,5. 7 3 1,4 6 2,.5,7 3
______________ Carbide 0,.6 0,4.6 3 -J, 4.6 0,4.6 3
2.9 Thread Milling HSS 2,5, 7 3,5.,7 3 2,5,7 3,5. 7 3

3.1 Drilling HSS 1.,6 2.5,7 111,4,6 2.5,7 3

Carbide 0.4,6 0,4,6 3 0,41.6 0.4,6 3
3.3 0i14lole or Pressurized- HSS 1,4,6 1,4,6 3 1,4,6 1,4,6 3
Coolant Drilling Carbide 4.6 4,6 2 4.6 4,6 2
3.4 Spade Drilling HSS 1,4.6 1.4,6 3 1,4,6 1,4,6 3
Carbide 0.4,6 0.4,6 2 0,4,6 0.4.6 2
3.5 Gundrilling HSS 1,4,6 2,.7 3 1,4,6 2,5,7 3
Carbide 1,4,6- 1,4,6 2,3 1,4,6 1,4.6 2.3
3.6 Pressure Coolant Reaming HSS 1,5,6 2,6,7 .3 1,5,6 2,6,7 3
(Gun Reaming) Carbide 1,4,6 1.4,6 2,5,7 1,4.6 1,4,6 2,5,7
3.7 Reauming HSS 1,5,6 2.6,7 3 1,5,6 2,6,7 3
______________ Carbide 1.4,6 1.4.6 2,3 1,4.6 1,4,6 2.3
3.9 Boring HSS 1,4,6 2.5,7 3,5,7 1,4.6 2,5,7 3.5,7
Carbide 1 0,4,6 0,4,6 2.4,6 0,4,6 0.4,6 2.4,6
3.11 Boring Diamond - - - - - -

3.12 Counterboring and HSS 1,4,6 2,5,7 3 1,4,6 2,5,7 3

Spotfacing Carbide 0.4,6 0,4,6 3.7 0,4,6 0,4,6 3,7
3.13 Trepanning HSS 1,4.6 2,5,7 3 1 1,4,6 2,5,7 3
_______________ Carbide 1,4,6 1.4,6 __2,3 1,4.6 1,4,6 2,3
3.14 Honing 180 80 90 8080 90

3.15 Burnishing 1,5.7 2,5,7 - 1,5,7 2,5,7 -

4.1 Tapping HSS 1 1,5,7 2,5,7 3 1.5,7 2,5,7 .3

16-18
 50 V F

Cutting Fluid Recommendations 16.2

TOOL 1. Free Machining Carbon Steels, Wrought 2. Carbon Steels, Wrought

OPERATION MATERIAL
OR__ _ _ _ __ _ _ _ _____ _____

ABRASIVE 100 to 275 to 1 48 to 85 to 275 to 1 48 to

275 Bhn 425 8hn J 65 Rc 275 Bhn 425 Bhn 65 Rc
5.1 Planing HSS 1,4,6 2,5,7 3 1,4,6 2,5.7 3
Carbide 0.1,4 0,1,4 2 0,1,4 0,1,4 2
5.2 Broaching HSS 2,5,7 3.5,7 3 2,5,7 3,5.7 3
Carbide 1,4,6 1,4,6 3 1,4,6 *46 3
6.1 Power Mack Sawing HSS 1,4,6 2,5,7 3 1,4,6 2,5,73

6.2 Power Band Sawing HSS 1,4,6 2,5,7 3 1,4,6 2,5,7 3

6.4 Circular Sawing HSS 1,4,6 2,5,7 3 2,5,7 3,5.7 3

6.5 Circular Sawing Carbide 0,1,4 0,1,4 2.3 1.4,6 2,5,7 2,3

6.6 Abrasive Cutoff -1,4,6 1,4,6 3 1,4,6 2 3

7.1 Gear Hobbing HSS 2,5,7 3,5,7 3 2.5,7 3.5.7 3

7.2 Gear Cutting, Straight S257 3,7325. 3573

and Spiral BevulHS257 35.32,7 3573
7.3 Gear Shaping H5S 2.5.7 3,5,7 3 2,5,7 3,5,7 3

7.4 Gear Shaving HSS 2,5.7 13,5,7 3 2,5,7 3,5,7 3

7.5 Gear Grinding, Form -1, 4,6 1,4,6 3 1.4.6 1,4.6 3

8.1 Surface Grinding-Horlz. -464 ,, ,,

Spdl., Recip. Table
8.2 Surface Grinding-Horlz. CN--54--54
Spdi., Recip. Table ____5,4_5,

8.3 Surface Grinding-Horiz. Dimn------

Spdi., Recip. Table_____
8.4 Surface Grinding-Vertical -4.4,3146 2463
SpdI., Rotary Table

8.6 Cylindrical Grinding CBN - - 5,4 - -5,4

8.7 Cylindrical Grinding Diamond - - - - -

8.8 Internal Grinding -4,6 4,6 3 1,4.6 2,4,6 3

8.9 InternalGrinding CBN - - 5,4 -- 5,4

8.10 Internal Grinding Diamond - -- T -- - -

8.11 CenterlessaGrinding -4,6 4,6 3 1.4,6 2.4,6 3

8.13 Abrasive Belt Grinding -0,1,4 0,1.4 1,4,6 0,1,4 0,1,4 1,4,6

8.14 Thread Grinding,___ 1,4,6 1,4,6 3 1,4.6 2,4,6 3

16-19
16.2 Cutting Fluid Recommendations

TOOL 3. Carbon and Ferritic Alloy Steels (High 4. Free Machining Alloy Steels, Wrought
OPERATION MATERIAL Temperature Service)

ABRASIVE 150Oto 150 to 2751to 45 to

200 Bhri 275 Bhn 42581hn 65 Rc
1.1 Turning, Single Point HSS 1,4,6 ______ 1,4,6 2,5,7 3,5,7
and Box Tools Carbide 0,4,6 _____ 0,4,6 0,4,6 0,4, 6
1.3 Turning Diamond --

1.4 Turning, Cutoff and HSS _____ 2,5,.7 2.5,7 2.,5,7 2,5,.7
Form Tools Carbide ______ 0.4,6 0,4,6 5.,7 5,7
1.5 Threading, Single Point HSS ______ 2,5 2,5 2,5 3
________________ Carbide _____ 1,4,6 1,4,6 1,4,6 1.4,6
1.6 Threading, Die HSS ______ 2,5 2, 5 2, 5 3
Carbide 1,4,6 s,.4,6 1,4,6 1.4.,6
1.7 Hollow Milling HSS 1.4,6 -,,5,7 2.,7 3

2.1 Face Milling HSS 1,4,6 1,5,7___ 2,5,7 3

Carbide _____ 0.4 ___ _ 0,4,6 -0.4,6 0, 2
2.2 Face Milling Diamond - -

2.4 Slab Milling HSS ____ 1,4,6 ____ 1,4,6 2,5.7 3

Carbide _____ 0.4,6 ____ 0,4,6 1,4,6 2
2.5 Side and Slot Milling- HSS ____ 1, 4, 6 ____ 1. 5,7 2, 5,7 3
Arbor Mounted Cutters Carbide ______ 0.4,6 0,4.6 1,4,6 2
2.6 End Milling-Peripheral HSS .14,6 ______ 1,4,6 2,5,7 3
________________ Carbide _____ 0,4,6 ____ 0,4,6 0,4,6 3
2.8 End MillIng-Slotting HSS ___1,4,6 ______ 1, 4,6 2,5, 7 3
________ Carbide ______ 0,4.6 ____ 0.4,6 0,4.6 3

2. Tred
lliigHSS 2,5.7 2. 5, 7 3,5, 7 3

3.1 Dril!Ing HSS 1,4,6 1,4,6 2,.7 3

_______________ Carbide _____ 0,4,6 ____ 0,4,6 1,5,7 3
3.3 Oll-Hole orPressurized- HSS ______ 1,4,6 1,4,6 1,4.6 3
Coolant Drilling Carbide ______ 4.6 4,6 4, 6 2
3.4 Spade Drilling HSS _____ 1,4,6 1.4,6 2,5,7 3
Carbide _____ 0,4.6 1____ 0,4,6 1.5,7 2
3.5 Gundrllling HSS _____ 1,4,6 _____ 1,4,6 2,5,7 3
Carbide _____ 1,4,6 _____ 1A46 2,5,7r3
3.6 Pressure Coo~ant Reaming HSS ______ 1,5,6 ______ 1,4,6 2,5,7 3
(Gun Reaminq) Carbide ______ 1.4,6 ______ 1,4.6 1,4,6 2,5,7
3.7 Reaming HSS _____ 1,5.6 1,4,6 2,5,7 3
_________________-Carbide ______ 1,4,6 ______ 1.4,6 1,4,6 2,3
3.9 Boring HSS _____ 1,4,6 ____ 1,4,6 1 2,5,7 3.5,7

3.1 Bo~ngCarmbnae 0,4.6 ____ 0.4,6 4.6 2,4,6

3.12 Counterborlnq and HSS ______ 1,4,6 ______ 2,5,6 1 2,5,7 3 9

Spottacing Carbide _____ 0.4,6 ____ 0,4,6 1,4,6 3.7
3.13 TrepannInq HSS 1,4,6 __ 1.4.6 I 2.5.7 3
Carbide _____ 1,4,6 ______ 1,4,6 1,5,7 2,3 afi

Ho~g80 80 80 90

J2.5,7
3.15 Burnishing 157 1,5,7 2,5,7 -

.1 apngHSS 1,5,7 3,5,7 3

16-20
 Cutting Fluid Recommendations 16.2

TOOL 3. CarLmn and Ferritic Alloy ^t 41., 4. Free Machining Alloy Steels, Wrought
OPERATION MATERIAL Temperature Service)
OR __________

ABRASIVE 150 to '1501to 275 to 45 to

_______ ________ 200 Bhfl 275 Bhfl 425 Bhfl 65 RC
5.1 Planing HSS ____ 1,4,6 1,4,6 2,5.7 3
Carbide _____ 0,1,4 0.4,6 0.4.6 2
5.2 Broaching HSS ______ 2.5,7 _____ 2,5,7 3,5.7 3
Carbide ___ 1,4,6 1,4,6 1,4.6 3Z
6.1 Power Hack Sawing1,614. 2573

6.2 Power Band SawingHS1.6146 2573

6. ~ruarSwigHSS 1.4,6 2.5,7 3.5,7 3

6.5 Circular Sawing Carbide 0, 1.4 1,.4, 6 2, 5, 7 2.,3

6.6 Abrasive Cutoff 1,4,6 1,4,6 2 3

7.1 Gear Hobbing HSS 2, 5. 7 2, 5, 7 3, 5, 7 3

7.2 Gear Cutting, Straight HS2.57,5,7 3573

and Spiral Bevel______

7. er~algHSS 2,5.7 2,5,7 3.5,7 3

7. er~aigHSS 2,5,7 2,5,7 3.5,7 3

7.5 Gear Grinding, Form146146 1463

8.1 Surface Grlnding-Horiz. 4.,6 1,4, 6 2.4.6 3

Spdi., Recip. Table _____

8.2 Surface Grinding-Horiz. CBN -- 5,4

Spdl., Recip, Table
8.3 Surface Grinding-Horlz. Diamond - -
Spdi., Recip. Table -0 1
8.4 Surface Grinding-Vertical 4,6 1,4,6 2.4,6 3
Spdi., Rotary Table
8.5 Cylindrical Grinding 4,6 1,4.6 2,4.6 34

8.6 Cylindrical Grinding CBN -- - 5,4

8.7 Cylindrical GrindingDamn---

8.8 Internal Grinding

8. ntralGinigCBN -- - 5,4

8.10 Internal GrindingDiod---

8.11 Centerles Grinding461,6 2463

8.13 Abrasive Belt Grinding 0.1,4 0,1,4 0,1,4 1,4,6

8.14 Thread Grinding

1,4,6 1.4,6 2,4,6 3

16-21
16.2 Cuffing Fluid Recommendations

TOOL 5. Alloy Steels, Wrought 6. High Strength Stols, Wrought

OPERATION MATERIAL
OR___________
ABRASIVE 125 to 275 to 45 to 225 to 275 to Over
_______ 275 Bhn 425 Bhr, 65 RC 275 Bhri 425 Bllf 45 RC
1.1 Turning, Single Point HSS 1,4.6 2,5,7 3,5.7 1,4,6 2,5,7 3,5.7
and Box Tools Carbide 0,4,6 0,4,6 0,4,6 0,4.6 0,4,6 0,4,6
1.3 Turning Diamond - - - - - -

1.4 Turning, Cutoff and HSS 2,5,7 2,5.7 2,5,7 2.5.7 2,5,7 2,5.7
Form Tools Carbide 0,4.6 5,7 5,7 0.4,6 5,7 5,7
1.5 Threading, Single Point HSS 2.,5 2, 5 3 2,5 2,5 3
Carbide 1,4,6 1.4,6 1,4,6 1,4.6 1.,6 1,4,6
1.6 Threading, Die HSS 2,5 2.5 3 2.5 2,5 3
Carbide 1,4.6 1A46 1,.6 1,4,6 1.4.6 1,4.6
1.7 Hollow Milling HSS 1,5.7 2.5,7 3 1,5,7 2,5.7 3
Carbide 0.4,6 1.4.6 2.5.7 0,4.6 1,4.6 2,5.7
2.1 Face Mlling HSS 1,5,7 2,5,7 3 1,5,7 2.5,7 3
____________ Carbide 0,4,6 0,4.6 0,2 0,4,6 0.4.6 0,2
2.2 Face Milling Diamond - - - - - -

2.4 Slab Milling 1435 1,4.6 2,5.7 3 1.4,6 2.5,7 3

Carbide 0.4,6 1,4.6 2 0.4.6 1.4,6 2
2.5 Side and SlotMllilng- 1165 1.5.7 2.5,7 3 1.5,7 2.5,7 3
Arbor Mounted Cutters Carbide 0.4,6 1,4,6 2 0,4,6 1.4,6 2
2.6 End Milng-Peripheral HSS 1,4,6 2.5,7 3 1.4,6 2,5,7 3
Carbide 0.4.6 1 0,4,6 3 0,4.6 0,4.6 3
2.8 EndMling-Slotting 1156 1.4,6 2,5,7 3 1,4,6 2,5,7 3
______________ Carbide 0,4,6 0,4.6 3 0,4,6 0,4,6 3

29TralligHSS 2,5,7 3,5.7 . 3 2,5,7 3,5,7 3

3.1 Drilling HSS 1,4,6 2,5,7 3 1.4,6 2,5,7 3

____________ Carbide 0,4,6 1 1,5,7 3 0,4,6 1.5,7 3
3.3 Oll~ole or Pressurized- HSS 1,4,6 1.4,6 3 1.4,6 1,4,63
Coolant Drilling Carbide 4,6 4,6 2 4,.6 4.6 2
3A Spade Drilling HSS 1,4,6 2.5,7 3 1.4,6 2,5.7 3
_____________ Carbide 0,4,6 1,5.7 2 0,4,6 1,5,7 2
3.5 Gundrlllng HSS 1,4,6 2.5,7 3 1,4.6 2,5.7 3
Carbide 1,4,6 2,5,7 2,3 1.4,6 2.5.7 2,3
3.6 Pressure Coolant Reaming HSS 1.4,6 2,5,7 3 1,4.6 2,5,7 3
(Gun Reaming) Carbide 1,4,6 1,4,6 2,5,7 1,4,6 1,4.6 2,5,7
3.7 Reaming HSS 1.4.6 2,5,7 3 1,4,6 2.5,7 3
Carbide 1,4,6 1,4.6 2,3 1,4.6 1.4.6 2.3
3.9 Boring 1153 1,4,6 2,5,7 3,5,7 1,4,6 2.5,7 3,5.7
0.4.6 4,6 2,46 0.4.6 46 24.6J
3.11 __ __Boring_ __ Carbide
31BongDiamond - - - -

3.12 Counterboring and HSS 2,5,6 2.5,7 3 2,5.6 2.5,7 3

Spotfacling Carbide 0,4,6 1 1,4.6 3,7 0.4,6 1.4,6 3.7I

3.13 Trepanning 1185 1.4,6 2.5,7 3 1.4,6 2,5.7 3
Carbide 1,4,6 1,5,7 2,3 1.4,6 1,5.7 2,3
3.14 Honing -80 80 90 80 80 90f

3.15 Burnishing -1.5,7 2,5,7 - 1,5.7 2,5.7 -J

4.1 Tapping HSS 2.5,7 3,5.7 3 2.5.7 3.5,7 3

16-22
 Cuffing Fluid Recommendations 16.2

OP~TONTOOL

ABRASIVE 125 to
S.Alloy Steels, Wrought

275 to 45 to
f 225 to
6. High Strength Steels, Wrought

275 to Over
275 Bhn 425 Shn 65 RC 275 Bhii 425 Bhn 45 Rc

5.1 Planing HSS 1,4,6 2.5.7 3 1.4,6 2,5,7 3

Carbide 0,4,6 0,4,6 2 0,4.6 0,4,6 2
5.2 Broaching HSS 2,5,7 3,5,7 3 2,5,7 3,5,7 3
Carbide 1,4,6 1,4,6 1 3 1,4,6 1,4,6 3
6.1 Power Hack Sawing HSS 1.4,6 2.5,7 3 1,4.6 2.5,7 3

6.2 Power Band Sawing HSS 1,4,6 2,5,7 3 1,4,6 2.5.7 3

6.4 Circular Sawing HSS 2,5.7 3,5,7 3 2,5,7 3,5.7 3

6.5 Circular Sawing Carbide 1.4.6 2,5.7 2.3 1.4,6 2,5.7 2.3

5.6 Abrasive Cutotff 1,4.6 2 3 1,4,6 2 3

7.1 Gear Hobbing HSS 2.5.7 3,5,7 3 2,5,7 3,5,7 3

7.2 Gear Cutting, Struight HSS 2,5,7 3,5,7 3 2.5,7 3,5.7 3

and Spiral Bevel________ _______

7.3 Gear Shaping HSS 2.,7 3,5,7 3 2,5,7 3,5,7 3

7.4 Gear Shaving HSS 2,5,7 3.5.7 3 2.5,7 3,5,7 3

7.5 Gear Grinding, Formt 1,4.6 1,4,6 3 1.4,6 1.4.6 3

8.1 Surface Grinding-Hoif

t.. -146 246 ,.
Spdl., RecIP. Table 1,4,6__ 2.4,6__ 3____ 1.4_6__4.6_

8.2 Surface Grlndlng-Horiz. CBN 5- 5,4

Spdil, Recip. Table _________ ____

8.3 Surface Grinding-Hork. Daod -

_________
Spdl., Recip. Table Diamond_

8.4 Surface Grinding-Vertical 1.,_,. ., ,.

SpdL, Rotary Table146 246314,2463
6.5 CylindricaliGrinding 1. 4.6 2,4,6 3 1,4.6 2.4.6 3

8.6 Cylindrical Grinding CBN - - 5,4 - - 5.

8.7 Cylirical Grinding Diamond ----

-

8.8 InternaliGrinding -. 1,4.6 2.,6 3 1.4.6 2.4.6 3

8.9 Internal Grindin CBN - - 54- 5,

8.10 Internal Grinding Diamond - - - - - -

8.11 CenterlessGrinding -1,4,6 2.4,6 3 1,4,6 2.4,6 3

8.13 AbrasiveSoft Grinding -0.1,4 0,1.4 1,4.6 0.1,4 0,1,4 1.4.6

8.14 Thread Grinding -1,4,6 2.4,6 3 1,4.6 2.4,6 3

16-23
16.2 Cutting Fluid Recommendations

8. Tool Steels, Wrought

TOOL 7. Maraglng Steels, Wrought
OPERATION MATERIAL Annealed Hardened
OR _____

ABRASIVE 275 to 50 to 100 to 200 to 325 to J 45 to

_________________ _______ 425 Bhn 52 RC 200 Bhii 325 Bhn 425 Bhfl 65 RC
1.1 Turning, Single Point HSS 2,5,7 3.5.7 1,4.6 2,5.7 2.5.7 3.5,7
and Box Tools Carbide 0,4,6 0.4,6 0,.6 0.4,6 0,4,6 0,4,6
1.3 Turning Diamond - - - - --

1.4 Turning, Cutoff and HSS 2,5,7 2,5,7 2,5.7 2,5,7 2.5,7 3
Form Tools Carbide 5,7 5,7 2.5.7 5,7 5,7 5.6.7
1.5 Threading, Single Point HSS 2.5 3 3 3 3 3
Carbide 1.4,6 1,4,6- 2.5,7 2.5.7 1,4,6 1,4,6
1.6 Threading, Die HSS 2. 5 3 3 3 3 3
______________ Carbide 1,4.6 1.4,6 2,5,7 2.,7 1.,6 1.6
1.7 Hollow Milling HSS 2, 5 3 3 3 -3 3
Carbide 1.4,6 2,5,7 2,5,7 2,5.7 2,5,7 2,5,7
2.1 Face Milling HSS 2.5,7_ 3 2,5.7 2,5.7 3 3
Carbide 0,4.6 0,2 0.4,6 0.,6 0,5,7 0.5,7
2.2 Face Milling Diamond - - - - - -

2.4 Slab Milling HSS 2.5,7 3 2,5.7 2,5.7 3,5.7 3

Carbide 1,4,6_ 2 1.4.6 1,4.6 2.5,7 3.5,7
2.5 Side and Slot Mll~ing- HSS 2.5,7 3 2,5,7 2,5.7 3 3
Arbor Mounted Cutters Carbide 1.4,6 2 1,4,6 1,4.6 2.5,7 2,5,7
2.6 End Millng-Peripheral HSS 2,.5,7 3 2.5,7 2.5.7 3 3_
Carbide 0,4.6 :11.4.6 1,4.6 2.5.7 3,5.7
2.8 End Milling-Slotting HSS 2.5.7_ 3 2,5,7 2,5,7 3 3
Carbide 0.4.6 3 1.4.6 1.4,6 2.5.7 3,5.7
2.9 Thread Milling HSS 3,5,7 3 3 3 3 3

3.1 Drilling HSS 2.,7 3 2.5,7 2,5,7 3 3

Carbide 1.5.7 3 1,4,6 1.4.6 2.5,7 3,5,7
3.3 Oll-Hole or Pressurized- HSS 1,4.6 2 1,4.6 2,5,7 3 3
Coolant Drilling Carbide 1.4.6 2 1,4.6 1,4.6 2.5.7 2.5.7
3.4 Spade Drilling HSS 2,5.7 3 2,5.7 2,5,7 2.5,7 1 3
Carbide 1.5,7 2 1,4,6 1,4,6 2,5.7 2
3.5 Gundrilling HSS 2,5,7 3 3,5.7 2.5.7 2,3 3
______________ Carbide 2.5,7 2.3 -2,5.7 2.5,7 2.5,7 3,5.7
3.6 Pressure Coolant Reaming HSS 2.5.7 3 2 3 3 3
(Gun Reaming) Carbide 1.4,6 2,3 2.5,7 2.5,7 2.5,7 3,5,7
3.7 Reaming HSS 2,5.7 3 3 3 3 3
Carbide
1____________ 1.4,6 2.3 2.4.6 2.4,6 2.5,7 3.5.7
3.9 Boring HSS 2.5,7 3,5,7 2,5.7 1 2.5,7 2.5,7 3,5.7
______________ Carbide 4.6 2.4.6 1,4.6 1.4.6 2,5,7 2.7
3.11 Boring Diamond - - - - - -

3.12 Counterbn'rng and 1155 2.5,7 3 2,5.7 2,5,7 3,5,7 3

Spoffacing Carbide 1.4,6 1 3.7 1.4.6 1,4,6 2.5.7 3,5.7
3.13 Trepanning HSS 1 2.5,7 3 1 3.5.7 1 3,5.7 2.3 3
____________ Carbide 1.5,7 2,3 1 2.5.7 2.5.7 j 2.5,7 3,5.7
3.14 Honing I , I 9

3.15 Burnishing-257-22--

4.1 Tapping 15 .,

16-24
 Cutting Fluid Recommendations 16.2
8. Tool Steels, Wrought

TOOL 7. Maraglng Steels. Wrought

OPERATION MATERIAL A nae
OR Annealedardened
ABRASIVE 275to 50 to 100 to 200to 325 to 45to

425 Bhn 52 R, 200 Bhn 325 Bhn 425 Bhn 65 Rc

5.1 Planing HSS 2.5.7 3 2.5.7 2.5.7 2.5.7 3
Carbide 0.4.6 2 1.4.6 1.4,6 1.5.7 3.5.7
5.2 Broaching HSS 3.5.7 3 2.5.7 2.5.7 3 3
Carbide 2,5,7 3 1,4.6 1, 4,6 3 3
6.1 Power Hack Sawing HSS 2.5.7 3 1.5.7 1.5.7 3 3

6.2 Power Band Sawing HSS 2.5.7 3 1.5.7 1.5.7 3 3

6.4 Circular Sawing HSS 3.5,7 3 2.5,7 2.5.7 3 3

6.5 Circular Sawing Carbide 2.5.7 3 1.4.6 1.4,6 2.5.7 3.5.7

6.6 Abraslve Cutoff 2 3 5.7 5.7 5.7 5.7

7.1 Gear Hobbing HSS 3.5.7 3 2,3 2.3 3 3

7.2 Gear Cutting, Straight

and Spiral Bevel HSS 3.5,7 3 2,3 2.3 3 3

7.3 GearShaping HSS 3.5.7 3 2.3 2,3 3 3

74 GearShaving HSS 3,5,7 3 2.3 2.3 3 3

7.5 Gear Grinding, Form

7- 1.4,6 3 5.7 5.7

I
2.5.7 2.5.7
8.1 Surface Grlnding-Horiz.- 2,4.6 3 5.7 5.7 5
Spdl., Recip. Table -- _2_4.6_3 5.7 _._75.75._

8.2 Surface GrindIng-Horiz. " 5

SpdI., Recip. Table CBN - 5.4 --- - 5._4__

8.3 Surface Grinding-Horiz.

Spdl., Recip. Table Diamond . .... 5 __

8.4 Surface Grinding-Vertical

Spdl, Rotary Table - 2.4.6 3 5.7 5.7 5.7 5.7
8.5 Cylindrical Grinding - 2.4.6 3 5.7 5.7 5.7 5.7

8.6 CylindricalGrnding CBN - 5.4 - - - 5.4

8.7 Cylindrical Grinding Diamond ......

8.8 Internal Grinding 2.4.6 3 5.7 5 5.7

5.4 - - - 5.4
8.9 Internal Grinding CBN -

8.10 Internal Grinding Diamond ......

8.11 Contedles Grinding - 2.4.6 3 5.7 5.7 5.7 5.7

8.13 Abrasive Belt Grnding -- 1.4.6 2,5.7 1,5.7 1.5.7 1.5.7 1.5.7

8.14 Thread Grinding -- 2.4.6 3 5.7 5.7 5.7 5.7

16-25
16.2 Cutting Fluid Recommendations

TOOL 9.~ Nitriding Steels, Wrought 10. Armor Plate, Ship Plate &, 11. Structural Steels, Wrought
OPERATION MATERIAL Aircraft Plate, Wrought
OR _____

ABRASIVE 200 to 60 to 200 to 40 to 100 to Over

350 ahn 65 RC 350 Bhn 45 Rc 300 Bhn 300 Bhn
1.1 Tuming, Single Point HSS 1,4,6 - 2.5.7 3,5,7 1.4,6 2.5,7
and Box Tools Carbide 0,4,6 0,4.6 0.4,6 0,4.6 0.4,6 0.4,6
1.3 Turning Diamond I - - - - - -

1.4 Turning, Cutoff and HSS 2.5.7 - 2.5.7 2.5,7 2,5,7 2.5,7
Form Tools Carbide 4.6 5,7 5.7 5.7 0.4.6 5.7
1.5 Threading, Single Point HSS 3 - 3 3 2.5 2.5
Carbide 1,4,6 1.,6 1,4,6 1,4,6 1,4,6 1,4,6
1.6 Threading. Die HSS 3 _______ 3 3 2,5 2.5
Carbide 1.4.6 1.4.6 0.4,6 1.4,6 0.4.6 0.4.6
1.7 Hollow Milling I-ss 3 - 3 3 2.5 2,5
Carbide 2.5,7 2.5.7 0.4,6 2.5,7 0,4.6 0,4.6
2.1 Face Milling HSS 1.4,6 - 3,5.7 3 1.5.7 2,5.7
Carbide 0,4,6 0,2 0,4,6 0.2 0.4.6 0.4,6
2.2 Face Milling Diamond - - - - - -

2A Slab Milling HSS 1,1,.6 -3.5,7 3 1.4.6 2,5,7

Carbide 0.4.6 2 0.4.6 2 0.4.6 1,4.6
2.5 Side and Sot Milling- HSS 1.4.6 - 3.5.7 3 1.4,6 2,5.7
Arbor Mounted Cutters Carbide 0.4.6 2 0,4.6 2 0.4,6 1.4.6
2.6 End Milling-Peripheral HSS 1.4,6 - 2.5.7 3 1,4,6 2,5,7
Carbide 0.4.6 3 0.4.6 3 0.4.6 0,4.6
2.8 End MiIllng-Slotting HSS 1A46 - 2.7 3 1,4.6 2.5.7
Carbide 0.4.6 3 0,4,6 3 0,4.6 0.4,6
2.9 Thread Milling HSS 2.5.7 - 7 3 2,5.7 3.5,7

3. rligHS146- 2.5.7 3 1,4.6 1 2.5.7

Carbide 0.4.6 3 0.4.6 3 0.4. .,
3.3 Oil-Hole or Pressrized- HSS 1.4.6 - 2,5.7 3 1,.6 2.5.7
Coolant Drilling Carbide 4,6 2 4.6 2 4.6 __ 2.5.7
3.': Spade Drilling HSS 1,4.6 ______ 2,5.7 ___3 1, 4. 1,4.6
Carbide 0.4.6 2 0,4.6 2 0.4,6 0.4.6
3.5 Gundrllln HSS 1.4.6 - 2.5.7 3 1,4.6 2.5,7
Carbide 1.4,6 2.3 2.5.7 2.3 1.4.6 2.5.7
3.6 Pressure Coolant Reaming FISS 1.5,7 - - 2,5.7 3 1.4.6 2.5.7
(Gun Reaming) Carbide 1.4.6 2.5,7 1.4.6 2,5,7 1.4.6 1.4,6
3.7 Reaming HSS 1.4.6 - 2.5.7 3 1.4,6 2,5.7
Carbide 1.4.6 2.3 1.4.6 2.3 1,4.6 1,4.6
3.9 BoigHSS 1,4.6 - 1.4.6 3,5.7 1.4.6 2,5.7
Carbide 2.4.6 2,4,6 2.4,6 2,4.6 0.4.6 4,6
3.11 Boving Diamond - - - - - -

3.12 Counterboring and HSS 2.5.7 -2.5.7 3 2.5.6 2.5,7

Spotfacing Carbide 4,6 3,7 1.4,6 3,7 0.4.6 1.4,6
3.13 Trepanning HSS 1.4,6 - 2.5,7 3 1.4.6 2,5.7
Carbide 1.4.6 2,3 2,.7 2.3 1,4,6 1,5,7
3.14 Honing -90 90 90 90 90 90

3.15 Burnishing -2 - 2 - 1.4.6 2.5.7

4.1 Tapping HSS 2,5.7 3,5.7 1 3 2.5,7 3,7

16-26
 Cutting Fluid Recommendations 16.2

TOOL 9. Nitriding Steels, Wrought 10. Armor Plate, Ship Plate& 11. Structural Steels, Wrought
OPERATION MATERIAL Aicraft Plate, Wrought
OR______ _____

ABRASIVE 200 to 60 to 200 to 40 to 100 to Over

350 ehn 65 RC 350 Bhn 45 Rc 300 Bhn 300 Shri
51PaigHSS 2,5 - 2,5,7 3 1,4,6 2,5,7
Carbide 4.6 2 0.4,6_ 2 0,4.6 0.4.6
5.2 Broaching HSS 2,5.7 3 3.5.7 3,5.7 2.5.7 2,5,7
Carbide 4,6 3 1.5,7 1,5,7 1.5,7 2,5,7
6.1 Power Hack Sawing HSS 1,4.6 3 2.5,7 3,5,7 1.4,6 2,5,7

6.2 Power Band Sawing HSS 1.4.3 3 2.5.7 3.5,7 1.4,6 2,5,7

6.4 Circular Sawing HSS 2,5.7 3 3.5.7 3.5,7 1.4.6 3,5.7

6.5 Circular Sawing Carbide 1.4.6 2.3 1,4.6 1.4.6 1.4,6 2,5.7

6.6 Abrasive Cutoff 1.4.6 3 4,6 4.6 1.4.6 2

7.1 Gear Nobbir~g HSS 2.5,7 3 7 7 2,5.7 3.5,7

7.2 Gear Cutting, Straight HSS 2.5.7 3 7 7 2,5,7 3.5,7

and Spiral Bevel_____ __________ __ ___ _ _ _ _

7.3 GearShaping HSS 2,5,7 3 7 7 2.5.7 3.5.7

7.4 Gear Shaving HSS 2,5,7 3 7 7 2.5.7 3.5,7

7.5 G-ear Grinding, Form 2,5,7 3 2.5 3.5 1.4.6 1.4.6

8. urae~idlgHoi.4.6 3 4,6 4.6 1,4.6 2.4.6

Spdl., Recip. Table___________
8.2 Surface Grinding-HoriLz CBN - 5.4----
Spdl., Recip. Table__________
8.3 Surface Grinding-Horiz. Diamond ------
Spdl., Recip. Table______ _____ __ ____ _____

8.4 Surface GrInding-Verticai .l , . ., ..

Spdi., Rotary Table 4,6___ 3____ 4.6__ 4.6_.4_6 2.4,

8.5 Cylindrical Grinding 4.6 3 4.6 4.6 1.4.6 2.4,6

8.6 Cylindrical Grinding CBN - 5,4 - - - -

8.7 Cylndrical GrindingDimn -- ---

8.DItenamrodigdB - 5. - - - -

8.10 Internal GrindingDimn --- --

8.1Cetres~lnlg4.6 3 4,6 4.6 1.4.6 2.4.6

8.13 IntralveGrndng_014 146 014 01, 014 257

8.14 Thread Grinding 4,6 j 3 7 7 1,4.6 2.4.6

16-27
16.2 Cutting Fluid Recommendations

OPERATION
TOOL
MATERIAL
12. Free Machinng Stanless Steels,
Wrought
f 13. Stainless Steels, Wrought
iorniuc and Austenitic
OR ________________

ABRASIVE 135 to Over 135 to 275 to

275 Bhn 275 Bhn - 275 Bhn 375 Bhin
1.1 Turning, Single Point HSS 2.5.7 2.5.7 ______ 2,5.6 2.5.7
and Box Tools Carbide 0,4.6 0.4.6 0.4.6 0.4.6

1.4 Turning, Cutoff and HSS 2.5,7 2.5.7 9.5.7 2

Form_____Tools ___ Carbide 1.4.6 1.4.6 ______ 4.6 2.5,7 ____

1.5 Threading, Single Point HSS 2,5 2.5 ______ 3 3

_________________ Carbide 1.4,6 1,.6 ______ 2.5.7 2.5.7 ____

1.6 Threading, Die HSS 2,5 2.5 3 3 _____

________________ Carbide 1.4,6 1,4.6 2.5.7 2.5,7 ____

1.7 Hollow Milling HSS 2.5 2.5 3 3 _____

_________________ Carbide 0.4.6 0.4.6 2.5.7 2.5,7 ____

2.1 Face Milling HSS 1,4,6 1.4.6 ______ 2.5.7 2.5,7 ____

Carbide 0.,6 0,4.6 ____ 0.4.6 0.4.6

2.4 Slab Milling HSS 1,4.6 1.4.6 2.5,7 2,5.7

Carbide 1.4.6 1,4,6 ______ 1.4.6 1,5.7 _____

2.5 Side and SlotMilling- HSS 1,4.6 1,4.6 ______ 2,.7 2,5.7 ____

Arbor Mounted Cutters Carbide 1,4.6 1.4.6 1.4.6 1.5.7 ____

2.6 End Millng-Pedpheral HSS 1.4.6 1.4,6 ___2.5.7 2.5.7

Carbide 0.4.6 0.4.6 _____ 0.4.6 0.4.6 _____

2.8 End Milling-Sottng HSS 1.4.6 1,4.6 2,.7 2.5.7

________________ I Carbide 0.4.6 0.4.6 0.4.6 0.4,6 _____

2.9 Thread Milling S2233

3.1 Drilling _______ 1,4,6___ 1.4___6 2.5,7 2,5,7 _____

_________________ Carbide 1,4.6 1.4.6 _____ 1.4,6 1.5,7

3.3 Ofl-Hole orPressurized- HSS 1,4,6 1,14.6 2.,7 2.5.7 _____

Coolant Drilling Carbide 1,4.6 1.4,6 1.4,6 1.4.6 _____

3A4 SpadeDrilling HSS 1,4.6 1,4,6 2.5,7 2.5,7 _____

Carbide 1,4,6 1,4.6 1.4,6 1.4,6 _____

3.5 Gundrilling HSS 2.,7 2.,7 2,5,7 2.5,7 ____

Carbide 1.4,6 1.4.6 2.5,7 2.5,7 _____

3.6 Pressure Coolant Reaming IISS 2 2 3 3 ____

(Gun Reaming) Carbide 1,4.6 1,4.6 2,5.7 2,5.7

3.7 Reaming HSS 2 2 3 3 ____

Carbide 1,4,6 1.4.6 2,5.7 2.5, ____

3.9 Boring HSS 1,5.6 1,5.6 _____ 2,5.7 2.5.7 ____

________________ Carbide 0.4.6 0,4.6 ____ 1.4.6 2.5.7 ____

3.11 Boring Diamond - -

3.12 Counterboring and H-15 1.5,6 1.5.6 2.5,7 2.571_ ___

Spotfacing Carbide 1.4.6 1,4.6 ______ 2.5,7 2.5.7 ____

3.13 Trepanning HSS 3,5,7 3,5,7 _____ 3,5.7 3.5 _____7

Carbide 1.4,6 1,4.6 ____ 2.,7 2.5.7 ____

3.4Hn~g-90 90 90 90

3.15Burnishing 222

4.1 TappingHS233 [ 3

16-28
 Cutting Fluid Recommendations 16.2
13. Stainless Steels, Wrought
Steels,
TOOL 12. Free Machining Stainless
OPERATION MATERIAL Wrought Fenic and Austenitic
OR
ABRASIVE 135 to Over 135 to 275 to
275 8hn 275 Bhn 275 Bhn 375 Bhn
5.1 Planing HSS 1.4.6 1.4.6 2.5.7 2.5.7
Carbide 1,4.6 1.4.6 1.4.6 1.4.6
5.2 Broaching HSS 2.5.7 3 2.5,7 3
Carbide 1,4.6 2,3 1,4.6 2.3
6.1 Power Hack Sawing HSS 1.5.7 3.5.7 1 5.7 3.5.7

6.2 Power Band Sawing HSS 1.5.7 3.5.7 1.5.7 3.5.7

6.4 Circular Sawing HSS 2.5.7 3.5.7 2.5,7 3.5.7

6.5 Circular Sawing Carbide 1.4.6 4.6 1.4.6 4.6

6.6 AbrasveCutoff 5.7 2.5.7 5.7 2.5,7

7.1 GeaHobbing HSS 2.3 2 2.3 2

7.2 Gear Cutting, Straight S2.22,2

and HSS 2.3 2 2.3 2

7.3 Gear Shaping HSS 2.3 2 2.3 2

7A Gear Shaving HSS 2.3 2 2.3 2

7.5 Gear Grinding, Form - 2.3 2 5,7 5.7

8.1 Suface Grnding-Hot 5.7 1.4.6 5.7 5.7

Spdl, Recip. Table -__,__1.4._5.7_._7_
8.2 Surface Grltding-Ho. CBN - - --
Spdl., Recip. Table
8.3 Surface ~~~
8.3Gdinding-Motr Diamond ----

Spdl, Recip. Table Diamond

8. Surface Grinding-Vertical 57 1.4.6 5.7 5.7

8.5 Cy-ledrcalGrnding- 5.7 1.4,6 5.7 5.7

8.6 Cylindrical Grinding CBN - - - -

8.7 Cylindrical Grinding

8.8 In l Grinding - 5.7 1.4.6 5.7 5.7

8.9 Internal Grinding CBN - - - -

8.10 Internal Grinding Diamond - - - -

8.11 er oing 5.7 1.4.6 5.7 5.7

8.13 AbrasiveSoft Grndg - 0.2.5 0.1.4 0.2.5 0.2.5

8.14 ThradGrinding 5.7 5.7 5.7 5.7

16-29
16.2 Cutting Fluid Recommendations
1 ~13. Stainless Steels, Wrought!
TOOL 13._StainlessSteels,_Wrought _ 14. Precipitation Hardening Stainless Steels,
OPERATION MATERIAL Martensitic Wrought

ABRASIVE 135 to J 275 to 48 to 150 to

275 Shn 425 Bhn 56 Rc 440 Bnn

1.1 Turning, Single Point HSS 2.5.6 2.5.7 3.5.7 _ .5.7

and Box Tools Carbide 0.4,6 0.4.6 0.4.6 0.4.6
1.3 Turning Diamond ....-

Turning, Cutoff and HSS 2.5.7 2 3 2

1A
Form Tools Carbide 4.6 1.5.7 5.6.7 1.5.7

1.5 Threading. Single Point HSS 3 3 3 3

_Carbide 2.5.7 1.5.7 2.5.7 1.5.1
1.6 Threading, Dle HSS 3 3 3 3
Carbide 2.5.7 1.5. 7 2.5.7 1.5. 7
1.7 Hollow Milling HSS 2 2 3 2 _
Carbide 0.1.,4.6 1.5.7 2.5.7 1.5.7 1
2.1 Face Milling HSS 2.5.7 1.5.7 3 1.5. 7 _

0.4.6 0.5.7 0,4.6

2. aeMligCarbide 0.4.6
2.2 Face Milling Diamond - I - - -

2.4 Slab Milling HSS 2.5.7 2.5.7 3 2.5.7 . _

Carbide 1.4.6 1.5.7 3.5.7 1.5.7

2.5 Side and Slot Miling- HSS 2.5.7 2.5.7 3 2.5,7
Arbor Mounted Cutters Carbide 1.4.6 1.5.7 2.5.7 1.5.7
2.6 End Milling-Peripheral HSS 2.5.7 2.5.7 3 2.5.7
Carbide 0. 4.6 0.4.6 3.5.7 0.4.6
2.8 End Milling-Slotting HSS 2.5. 7 2.5.7 3 2.5. 7
Carbide 0.4.6 0.4.6 3.5.7 0.4.6 __
2.9 Thread Milling HSS 2 3

3.1 Drilling HSS 2.5.7 2 3- 2

Carbide 1.4.6 1.5.7 3.5.7 1.5.7
3.3 Oil-Hole or Pressurzed- HSS 2.5.7 2.5.7 3 2
Coolant Drilling Carbide 1.4.6 1.4.6 2.5.7 _ 2.5.7
3.4 Spade Drilling HSS 2.5.7 2 3 2
Carbide 1.4.6 2.5.7 2.5.7 2.5.7

3.5 Gundrllng HSS 2.5.7 2 3 2

Carbide 2.5.7 2.5.7 3.5.7 1.5,7
3.6 Pressure Coolant Reaming HSS 3 3 3 3 |
(Gun Reaming) Carbide 2.5.7 2.5.7 3.5.7 ._ 2.4.6 _

3.7 Reaming HSS 3 3 3 3 _ _

Carbide 1.5.7 2.5.7 " 3.5.7 2.4.6 _

3.9 Boring HSS 2.5.7 2.5,7 3.5.7 2,5.7

Carbide 1.4.6 2 2,5.7 2 |
3.11 Boring Diamond
DCarid 2, 27 2
3.12 Counterboring and HSS 2.5.7 2.5.7 3 2.5.7
Spoftadng Carbide 2. 5,7 2.5,.7 3.5, 7 2,.5.7

3.13 Trepanning HSS 3.5.7 2 3 2

Carbide 2.5.7 2.5.7 . 5.7 2.5.7

3.14 Honing 90 90 90 90

3.15 Burnishing 2 2 2 2

4.1 Tapping H 3 2
HSS 3 2 3

16-30
 Cutting Fluid Recommendations 16.2
13. Stainless Steels. Wrought I
1
TOOL 1S Se14. Precipitation Hardening Stainless Stee,
OPERATION MATERIAL nt rxj.t
OR
ABRASIVE 135 to 275 to 48 to 150 to
275 Shn 425 Shn 56 Rc 440 Bhn
5.1 Planing HSS 2.5.7 2.5.7 "3 "_2.5.7
Carbide 1,4.6 04,6 3.5.7 0.4.6
5.2 Broaching HSS 2.5.7 3 3 3
Carbide 1,4.6 2.3 3 2.3
6.1 Power Hack Sawing HSS 1.5.7 3.5.7 3 3.5.7

6.2 Power Band Sawing HSS 1.5.7 3.5.7 3 3.5.7

6.4 Circular Sawing HSS 2.5.7 3.5.7 3 3.5.7

6. Circular Sawng Carbide 1.4.6 4.6 3 5.7 4.6

6.6 Abrasive Cutoff 5.7 2.5.7 5.7 2.5.7

7.1 Gear Hobbing HSS 2.3 2 3 2

7.2 Gear Cutting, Straight HSS 2.3 2 3 2

and Spiral Bevel
7.3 Gear Shaping HSS 2.3 2 3 2

7.4 Gear Shaving HSS 2.3 2 3 2

7.5 Gear Grinding, Form 5.7 2 2.5.7 2

8.1 Surface
8.1 Griniding-Hodf,
Stadl..dTe -o - 5.7 1.4.6 5.7 1.4.6
Spdl,. Recip. Table ____ ____

8.2 Surlace Grinding-HoriL CBN - 5.4

Sp-., Recip. Table _

8.3 Sot face Grinding-Horiz. Daod ..

83 Diamond - --
Spdl, Recip.Table
8.4 Surface
8.4 RaryGrntrgVati.ad - 5.7 1.4.6 5.7 1.4.6

8.5 CylindricalGrlnng- 5.7 1.4.6 5.7 1.4.6

8.6 Cylindrical Grinding CBN - - 5.4

8.7 Cylindrical Grinding Diamond - - -

- 5.7 1.4,6 5,7 1.4.6

8.9
s~ ztma
Internal Grinding
CBN -- -54
5,4 -

8.10 Internal Grinding Diamond ....

8.11 Centerless Grinding 57 1.4.6 5.7 1.4.6

8.13 Abraive SOGe~n g - 0.1.4 0.1.5 1.5.7 1.5.7

- 5.7 1.4.6 5.7 1.4.6

16-31
16.2 Cutting Fluid Recommendations

TOOL 15. Carbon Stools, Cast 16. Alloy Steels, Cast

OPERATION MATERIAL
oRn_____
ABRASIVE 100 to Over 150 to 250 to Over
300 Bhn 48 Rc ______ 250 Bhn 400 Bhn 48 Rc
1.1 Turning, Single Point HSS 1,4,6 2.5,7 1.,6 2,5,7 3,5.7
and Box Tools Carbide 0,4.6 0,4,6 _____ 0,4.6 0,4,6 0,4.6
{1.3__Turning Diamond - - - -

1.4 Turning, Cutoff and HSS 2,5,7 3,5,7 ______ 2.,7 2,5,7 2,5.7
Form Tools Carbide 0.4,6 0.4,6 ______ 0.4.6 5,7 5,7
1.5 Threading, Single Point HSS 1 2.5 3.6 ______ 2,5 2,5 3
Carbide 1,4,6 1.4,6 1.4.6 1,4,6 1,4.6
1.6 Threading, Die HSS 2,5 3,6 2,5 2,5 3
Carbide 1,4,6 1.4,6 1,4.6 1.4,6 1,4,6
1.7 Hollow Milling HSS 1,4,6 2.5,7 1,5,7 2,5,7 3
Carbide 0,4.6 0.4,6 ____ 0.4,6 1.4,6 2.5,7
2.1 Face Milling HSS 1,4,6 2,5,7 1,5,7 2,5.7 3
Carbide 0.1,4 0.1.4 0.4.6 0,4,6 0,2
2.2 Face Milling Diamond - - - -

2.4 Slab Milling HSS 1,4,6 2,5,7 1,4,6 2,5,7 3

Carbide 0,4.6 0,4,6 ______ 0,4,6 1, 4, 6 2
2.5 Side and Slot Milling- HSS ., 4, 6 2,5, 7 _____ 1,5, 7 1 2,5. 7 3
Arbor Mounted Cutters Carbide 0,4, 6 0,4,6 ______ 0,4,6 _F 1. 4. 6 2
2.6 End Milling-Peripheral HSS 1,4, 6 2, 5, 7 1.4, 6 2,5.,7 3
Carbid.) 0,4,6 0.4.6 0,4,6 0,4,6 3
2.8 End Milling-Slotting HSS 1,4, 6 2.5. 7 _____ 1,4, 6 2.5,.7 3
________________ Carbide 0.4.6 0.4,6 1____ 0,4,6 0.4,6 3
2. hedMligHSS 2.5,7 3,5,7 2,5.7 2.5.7 3

3.1 Drilling HSS 1,4,6 2,5,7 1,4,6 2.5,7 3

Carbide 0,4,6 O'...6 0.4.6 1.5,7 3
3.3 Oll-Hole or Pressurized- HSS 1,4,6 1,4,6 1,4,6 1.4,6 3
Coolant Drilling Carbide 4.6 4,6 4,6 4,6 2
3.4 Spade Drilling HSS 1.4,6 1,4,6 ______ 1.4,6 2.C,7 3
Caroide 0.4,6 0,4,6 0.4,6 1,5,72
3.5 Gundrilling HSS 1,4,6 2,5,7 1,4,6 2.5,7 3
_______________ Carbide 1,4,6 1,4,6 1,4,6 2.5,7 2,3
3.6 Pressure Coolant Reaming HSS 1,5,6 2,6,7 1,4,6 2,5,7 3
(Gun Reaming) Carbide 1.4,6 1,4.6 1,4.6 1,4,6 2,5.7
3.7 Reaming HSS 1,5,6 2,6.7 1,4,6 2,5,7 3
Carbide 1,4,6 1 1,4.6 1,4,6 1,4,6 2,3
3.9 Boring HSS 1,4,6 2,5,7 ____ 1,4.6 2,5,7 3.,7 4
Carbide 0,4,6 0.4,6 -0,4,6 4.6 2,.6
3.11 Boring Diamond - - - - -

3.12 Counterboring and HSS 1.4,6 2,5,7 ____ 2,5.6 2,5.7 34

Spottacing Carbide 0,4,6 1 0.4,6 0.4,6 1.4,6 3.7
3.13 Trepanning HSS 1,4,6 2,5.7 ____ 1.4,6 2,5,7
_______________ Carbide 1.4,6 1. 4.~f- ____ 1.4,6 1,5,72,
3.14 Honing -80 80 80 80 90

3.15 Burnishing -1,5,7 2,5,7 1,5,7 2.5.7

4.1 Tapping HSS 1,5,7 2,5,7 2,5,7 3.,73

16-32
 Cutting Fluid Recommendations 16.2

TOOL 15. Carbon Steels, Cast 16. Alloy Steels. Cast

OPERATION MATERIAL
OR ___________ _____

ABRASIvE 100 to Over 150 to 250 to Over

______ 300 Bh n 48 RC 250 Bhn 400 Bhf 48 Rc
5.1 Planing HSS 1,4,6 2,5,7 1,4,6 2.5,73
______________ Carbide 0,1.4 0,1.4 0,4,6 0,4,62
5.2 Broaching HSS 2.5,7_ 3 2,5.7 3,5,7 3
___________ Carbide. 1,4,6 3 1,4,6 1.4,6 3
6.1 Power Hack Sawing HSS 1,4,6 3 '), 4.6 2,5.7 3

6.2 Power Band Sawing HS1,4,6 3 1,4,6 2 ,7 3

6.4 Circular Sawing HS2,5,7 3 2,5,7 3,5,7 3

6.5 ClrcularSawlng Carbide 1,4.6 2.3 1.4,6 2,5,7 2,3

6.6 Abrasive Cutoff I., 1,,

7.1 Gear Hobbing HSS 2,5,7 3 2,5.7 3,5,7 3

7.2 Gear Cutting, Straight HS2.57 32,,7 3,573

7.3 Gear Shaping HSS 2,5,7 3 2,5,7 3,5,7 3

74GahaigHSS 2.5,7 3 2,5,7 3,5,7 3 3

7.5 Gear Grinding, Form 146314, ,,

8.1 Surface Grinding-Horiz.146314, 2463

Spdl., Recip. Table ____ ____ I____

8.3 Surface Grinding-Horiz. Ciamond,4 - - 5,
SpdI., Recip. Table
8.4 Surface Grlrnding-Vericaz.,. ,46 2463-
Spdi., Rotary Table _____ _____ - _ _

8.5 Sulrfc Grinding- -tca 1,4.6 3 1,4,6 2,46 3

8.6 Cylindrical Grinding 1,4, 5,44

3 2,, 3

8.7 Cylindrical Grinding iamnd54 ,

8.8 CinralGrinding Dimn 1,, ,, ,.

8.9 Internal Grinding

09ItraGrnigCBN - 5,4 - - 5,4

8.10 Internal Grinding Diamond ----

8.11 Centerless Grinding 1,4,6 3 1,4,6 2,4.6 3

8.1 Abrasive Belt Grinding -0,1,4 1,4,6 0,1,4 0,1,4 1,4,6

8.14 Thread Grinding-1,63146 2463

16-33
16.2 Cutting Fluid Recommendations
18. Stainless Steels, Cast
TOOL 17. Tool Steels, Cast
OPERATION PMIWERIAL Austenitic and FerrItlc
on ________________

ABRASIVE 150 to 325 to 48 to 135 to

250 Bhn 375 Bhn 65 R, _____ 210 Bhn _____

1.1 Turning, Single Point HSS 1,4,6 2,5,7 3,5,7 ___2,5.6

and Box Tcois Carbide 0. 4. 6 0,4,.6 0.,4.,6 _____ 0.4.,6

1.3 TurnIng Diamond - - -

1.4 Turning, Cutoff and HSS 2,5,7 2,5,7 3 _____ 2,5,7

Form Tools Carbide _____ _____ _____ 4. 6 _____

1.5 Threading, Single Point HSS 3 3 3 _____ 3 ___

Carbide 2,, 1,4.6 1,,625_

1.6 Threading, Die HSS 3 3 3 _____3

Carbide 2,, ,, ..
1.7 Hollow Milling HSS 3 3 3 13
Carbide .5. 2. 2.5.7 2.5,7__
2.1 Face Milling HSS 2,5.7 3 3 2.5,.7 __

Carbide 0.,6 0.5.7 0,5,7 0.4.6 ____

2.2 Face Milling Diamond - - -

2.4 Slab Milling HSS 2,5,.7 3.5.,7 3 ______ 2,5,7

______________ Carbide 1.4,6 2,5,7 3,5,7 1,4,6
2.5 Side and Slot Mill~ng- HSS 2,.5,7 1 3 3 2,5.,7
1_____
Arbor Mounted Cutters Cdrbide 1.4.6 2,5.7 2,5,7 ____ 1.4.6
2.6 End Milling-Peripheral HSS 2,5.7 3 3 ___2.5. 7
_________________ Carbide 1,4,6 2,5.7 3,5,7 ______ 0,4.6
2.8 End Milling-Slotting HSS 2. 5.7 3 3 ______ 2.5.7 _____

_______________ Carbide 1.4.6 2.5.7 -3.5.7 0.4,6

2.9 Thread Milling H 3333

3.1 Drilling _______ 2.5____7 3_____ 3__________ 2,5, 7 _____

_________________ Carbide 1.4,6 2,5,7 3,5,7 _____ 1.4.

3.3 O1l-Hole or Pressurized- HSS 1.,4.6 2, 5, 7 3 ______ 2.5.,7 ____

Coolant Drilling Carbide 1,4,6 2,5,7 2,5,7 _____ 1.4.6 ____

3.4 Spade Drilling HSS 2.5,7 2,5,7 32,5,7

________________ Carbide 1,4,6 2,5,7 2 ____ 1,4.6
3.5 Gundrilling HSS 3,5,7 2,5,7 3 2, 5.7
3. resreCoan eaig Carbide 1 2.5,7 2,5,7 3,5,7 2.5,7
3. rsueCoatRaig HSS 2 3 3 3 _____

(Gun Reaming) Carbide 2,5,7 2,5,7 3,5,7 _____ 2.5,7

3.7 Reaming IISS 3 33 3
_____________ Carbide 2,4,6 2,5,7 3,5.7 2,5,7
3.9 Boring j7HSS 2,5,7 2,5,7 3,5.7 2.5,7
_________________

3.11 Boring IDiamond

Carbide 1,4.6
-
2.5,7
-
2,5,7
-
______

____
1,4,6 1

3.12 Counterboring and HSS 2,5,7 3,5,7 3 -2,5,7

Spotfacing Carbide 1,4,6 - 2,5,7 3.5,7 ______ 2,5,7 ____

3.13 Trepannlng HSS 3.5,7 2,3 3 3,5,7 -

Carbide 2,5,7 2,5.7 3.5.7 ______ 2,5.7 ____

3.4Hn~g-90 90 90 90

3.15 Burishing-22-2

4,1 Tapping HSS 3 3 3 3

16-34
 Cutting Fluid Recommendations 16.2

TOOL
1
17. Tool Steels, Cast
18. Stainless Steels, Cast
OPERATION MATERIAL Austenitic and Ferrfitlc
OR ________________
ABRASIVE 150 to 325 to 48 to 135 to
250 Bhn 375 Bhn 65 Rc 210OBhn
5.1 Planing HSS 2,5,7 2,5,7 3 2,5,7
Carbide 1,4,6 1,5,7 3,5,7 1,4,6
5.2 Broaching HSS 2, 5, 7 3 3 2,5. 7
Caroide 1,4,6 3 3 1,4,6
6.1 Power Hack Sawing HSS 1,5,7 3 3 1.5.7

6.2 Power Band Sawing fHSS 1,5,7 3 3157

6.4 Circular Sawing HSS 2,5,7 3 3 2,5,7

6.6 Circular Sawing Carbide 1,4, 6 2.5,7 3.5. 7 1,4, 6

6.6 Abrasive Cutoff 5,7 5,7 5,7 5.7

7.1 Gear Hobbing HSS 2,3 3 3 2, 3

7.2 Gear Cutting, Straight HSS 2.3 3 3 2.3

and Spiral Bevel______
7.3 Gear Shaping HSS 2.3 3 32,

74SaigHSS 2,3 3 3 2,3

7.5 Gear Grinding, Form 5,7 2.,5,7 2,5.7 5,~7

8.1 Surface Grinding-Horiz. 5,7 5,7 5,7 5.7

SpdI., Recip. Table_____________
8.2 Surface Grlndlnq-llorz. CBN - - 5,4
Spell., Recip. Table ____________________________ _____

8.3 Surface Grinding-Horiz. Diamond --

Spdl., Recip. Table_____
8.4 Surface Grinding-VertIcal 5,7 5,7 5,7 5,7
Spdl., Rotary Table _____ __________

8.5 Cylindrical Grinding 7575757-

8.6 Cylindrical GrindingCB--5.

8.7 Cylindrical Grinding Diamond ---

8.9 Internal Grinding B--5.

8.10 Internal GrindingDamn---

8.11 Centerless Grinding 5.7 5,7 5.7 5.7

8.13 Abrasive Belt Grinding 1,5,7 1.5.7 1,5.7 0,2,5

8.14 Thread Grinding 5.7 5,7 5.7 57

16-35
16.2 Cutting Fluid Recommendations

TOOL 18.___
Stainless____Steels,___Cast _ 19. Precipitation Hardening Stainlesa Steels,
OPERATION MATERIAL Martenslu~c Cast
ON ____ ____ ____ ____

ABRASIVE 135Sto 275 to 325 to

275 Bhn 425 Bhn -450 Bhn
1.1 Turning, Single Point HSS 2.5.6 2.5.7 _____ ____ 2.5,7
and Box Tools Carbide 0,4,6 0.4.6 0.6
1.3 Turning Diamond - -

1.4 Turning, Cutoff and HSS 2,5,7 2 _____ 2

Form Tools Carbide 4,6 1. 5. 7 1.5. 7
1.5 Threading, Single Point HSS 3 3 3 _____

Carbide 2.5,7 1.5,7 1,5,7

1.6 Threading, Die HSS 3 3 3
________________ Carbide 2.5,7 1,5,7 1,5,7
1.7 Hollow Miliiing HSS 2 2 ______ 2
Carbide 0,1,4,6 1,5,7 1,5.7
2.1 Face Milling HSS 2,5,7 1,5,7 1.5,7 _____

_______________ Carbide 0,4,6 0,4,6 0,4,6

2.2 Face Millilng Diamond - -

2.4 Slab Milling HSS 2.,.7 2, 5, 7 1_____ 2,5, 7

Carbide 1.4,6 1,5.7 ______1,5.7

2.5 Side and Slot Milling- HSS 2.5,7 2,5, 7 2,5, 7

Arbor Mounted Cutters Carbide 1,4,6 1,5,7 ____ 1,5.7
2.6 End Milling-Peripheral HSS 2, 5, 7 2,5.,7 2,.5, 7
Carbide 0.4.6 0.4,6 ____ 0.4.6
2.8 End Milling-Siotting HSS 2,.5, 7 2,5.,7 _____ 2,5,.7
Carbide 0.4.6 0.4.6 ____ 0,4,6

2.9 Thread Milling HSS 3 2 2

3.1 Drilling HSS 2,5,7 2 ____ ____ 2
_________________ Carbide 1,1~.6 1.5.7 ______ 1.5.7

3.3 Oil-Hole or Preesurized- HSS 2,5. 7 2.5

5,

3.4 Spade Drilling HSS 2,5,7 2 _____ ____ 2

Carbide 1.4.6 2.5,7 ____ ____ 2,5,7
3.5 Gundrilling HSS 2,5, 7 2 _____ 2 _____

Carbide 2,5, 7 2.5,7 ______1,5.7

3.6 Pressure Coolant Reaming HSS 3 3 ______3 ____

(Gun Reaming) Carbide 2,5.7 2,5.7 ______2.4.6 _____

3.7 Reaming HSS 3 3 ______3 ____

Carbide 1.5.7 2.5,7 ____ 2.4,6 ____

3.9 Boring HSS 2,5.7 2.5,7 ____ 2.5,7 ____

________________ Carbide 1.4.6 2 ______ 2 ____

3.11 Boring Diamond - - A

3.12 Counterbormrg and HSS 2,5, 7 2,5,7 2,5, 7 ____

Spottacing Carbide 2,5, 7 2,5.7 2.5,7 _____

3.13 Trepannlng HSS 3, 5, 7 2 _____ _____ 2

_______________ Carbide 2.5,7 2,5,7 _ ___ ____ 2,5,7 ____

31Hoig90 90 90
3.15 Burnishing 2 2 2

4.1 Tapping HSS 3 2 2

16-36
 Cutting Fluid Recommendations 16.2

TOOL 18 tils tes at19. Precipitation Hardening Stainless Steels,

OPERATION MATERIAL MrestcCast

ABRASIVE 135 to 1 275 to 325 to

275 Bhn 425 Bhn 450 Bhn
5.1 Planing HSS 2.5.7 T 2.5.,7 2,5, 7
Carbide 1,4,6 0,4.6 ______ 0.4,6 _____

5.2 Broaching HSS 2.,5,7 3 3

Carbide 1,4,6 2.3 ______ 2,3 _____

6.1 Power Hack Sawing HSS 1,5,7 3, 5. 7 3.5,7

6.2 Power Band Sawing HSS 1,5,7 3,5,7 3.5,7

6.4 Circular Sawing HSS 2,.7 3,5,7 3.5,7

6.5 Circular Sawing Carbide 1,4, 6 4, 6 4,6

6.6 Abrasive Cutoff 5,7 2,5.7 2. 5, 7

7.1 Gear Hobbing HSS 2. 3 2 2

7.2 Gear Cutting, Straight HSS 2.,3 2 2

and Spiral Bevel _____

7.3 Gear Shaping HSS 2,3 2 2

7.4 Gear Shaving HSS 2,3 2 2

7.5 Gear Grinding, Form 5,7 2 2

8.1 Surface Grinding-Horiz. 5.7 1,4,.6 1, 4, 6

Spdl., Recip. Table _____

6.2 Surface Grinding-Horlz. CB--

Spdi., Recip. Table__________
8.3 Surface Grinding-Horiz. Damn-
Spdl., Recip. Table _____

8.4 Surface Grinding-Vertical571.,6,46

SpdI., Rotary Table
8.5 Cylindrical Grinding 5 ,. ,.
___________________5___7_ 1,, ,,

8.6 Cylindrical Grinding CBN -

I
8.7 Cylindrical GrindingDaon-
________________Diamond____ ________ _______ _______ _______

8.8 Internal Grinding

5,7 1,4,6 1,4,6U

8.9 Internal Grinding CBN - - I

8.10 Internal Grinding Diamond -

8.11 Centerless Grinding 5,7 1,4,6 1.4,6

8.13 Abrasive Belt Grinding 0,1,4 0.1.5 1.5,7

8.14 Thread Grinding 5 ., ,.

5.7 1., _ 1.4,6_ _

16-371
 N _

16.2 Cutting Fluid Recommendations

OPEATONTOOL 20. Austenitic Manganese Steels, Cast j21. Gray Cast Irons

ABRASIVE 1501to 1201to 45 to

-220 Shn -3208Bhn 60 RC
1.1 Turning, Single Point HSS -4,6 T -

and Box Tools Carbide ____ 3,5 0.4, 6

1.3 Turning Diamond

1.4 Turning, Cutoff and HSS 3,5 4,6-

Form Tools Carbide _ __ 3,5 _ ____ 0,4.6
1.5 Threading, Single Point HSS ______ ___ 4,6-
_______________ Carbide ______ _____ _____ 0.4,6-
1.6 Threading, Die HSS _ _____ 4,6-
_______________ Carbide ______ _____ _____ 0,4,6-
1.7 Hollow Milling HSS ______ ____ _____ 5,7
____________Carbide _ _____ 3.,5 _ ____ 5, 7-
2.1 Face Milling HSS __ _ _ _ _ _ _ _ 4,6-
Carbide ______ 3.5 ______ 0,4,6
2.2 Face Milling Diamond -

2.4 Slab Milling HSS _ _____ 4,6 -

Carbide ______0,4,6 -

2.5 Side and Slot Milling- HSS ___ ___ ______ ______ 4.6 -

Arbor Mounted Cutters Carbide ____ _ 3.,5 _ ____ 0,4, 6 -

2.6 End Milling-Peipheral HSS ______ _____ 4.6 -

Carbide ____ 0,4,6 -

2.8 End Milling-Slotting HSS _________________ 4,6 -

________________ Carbide ____________ 0.4,6 -

2.9 Thread Milling HSS -4.6 -

3.1 Drilling HSS ____ _ 3.,5 _ ____ 4.,6-

Carbide __ ___ 3.5 _ ____ 0,4,6-
3.3 Oil-Hole or Pressurized- HSS __________ 4,6-
Coolant Drilling Carbide 3.5 ____ 4.6-
3.4 Spade Drilling HSS ___ 4,6-
__ __ ____ __ __ __ _ Carbide _ ____ 3,5 _ ____ 0,4.6-
3.5 Gundrilling HSS ______ ______ _____ 1,86 - _____

Carbide 3,5 1,86-

3.6 Pressure Coolant Reaming HSS -4,6-
(Gun Reaming) Carbide _____ 4.6-
3.7 Reaming HSS -4.6
Carbide ______ 4.6 - _____

3.9 Boring HSS _____ __________ 4,6-

Carbide 3,5 _ ____ 0,4.6-
3.11 Boring Diamond - -3

3.12 Counterboring and HSS ______ 4,6-

Spotf acing Carbide ______ 3.5 0,4,6 -

3.13 Trepanning HSS ______ 1.86-j

3.14 Honing Crie186

3.15 Burnishing 5,7-

4.1 Tapping HSS 4.6-

16-38
 Cutting Fluid Recommendations 16.2

TOOL 20. Austenitic Manganese Steels, Cast 21. Gray Cast irons
OPERATION MATERIAL

ABRASIVE 150t0 120 to 45 to

- 2208hn - 3208Bhn 60 Rc

5.1 Planing HSS 4.6 -

Carbide -0.4.6 -

5.2 Broaching HSS 5,7 -

Carbide -0,4,6 -

6.1 Power Hack Sawing HSS 3.5 4,6 -

6.2 Power Band Sawing HSS 3.5 4,6 -

6.4 Circular Sawing HSS 354,.6 -

6.5Cirulr Crbde
Swig ,50.4,6 -

6.6Abasie utof .54.6 -

7.1Ger obbngHS -4.6 -

7.2Gea Cttig,
HS trigh -4.6 -

and4. Sprlee

7.4 Gear Shaving HSS -4.6 -

7.5 Gear Grinding, Form -4,6 5,7

8.1 Surface Grinding-Horiz. 465.

SpdI., Recip. Table__ _________

8.2 Surface Grinding-Horiz. B- ,

Spdl., Recip. Table__ _________

8.3 Surface Grinding-Horlz imn

Spdi., Recip. Table_____________ ____ _____

8.4 Surface Grinding-Vertical

Spdi.. Rotary Table3.4657
8.5 Cylindrical Grinding354.57

8.7 Cylindrical GrindingDamn--

8.8 CInrnal Grinding-3.4657

8.9 Internal Grinding B-54

8.10 Internal Grinding Diamond -

8.11 Centeriess Grinding -3,5 4.6 5.7

8.13 Abrasive Belt Grinding 3.5 0.4.6 0.5,7

8.14 Thread Grinding 3,5 4.6 5,7

16-39
16.2 Cutting Fluid Recommendations

TOOL 22. Compacted Graphite Cast Irons 23. Ductile Cast Irons
OPERATION MATERIAL
OR
ABRASIVE 185 to 120 to 53 to
255 Bhn 400 Bhn 60 Rc

1.1 Turning, Single Point HSS 4,6 4,6 -

and Box Tools Carbide 0, 4. 6 0.4,6 -

1.3 Turning Diamond - -

1.4 Turning, Cutoff and HSS 4,6 4.6 -

Form Tools Carbide 0.4 6 0.4,6 -

1.5 Threading, Single Point HSS 4,6 4,6 -

Carbide 0,4.6 0.4.6 -

1.6 Threading, Die HSS _ _4,6 4,6 -

Carbide 0,4,6 0,4.6 -
1.7 Hollow Milling HSS 5,7 5.7 -
Carbide 5, 7 5,7 -
2.1 Face Milling HSS 4,6 4.6 -
Carbide 0,4.6 0.4,6 -
2.2 Face Milling Diamond - --

2.4 Slab Milling HSS 4,6 4,6 -

Carbide 0,4.6 0.4,6 -

2.5 Side and Slot Milling- HSS 4, 6 4. 6 -

Arbor Mounted Cutters Carbide 0.4, 6 0.4. 6 -
2.6 End Milling-Peripheral HSS 4, 5 4,6 -
Carbide 0.4,6 0.4,6 -
2.8 End Milling-Slotting HSS _ 4.6 4,6 -
Carbide 0.4,6 0.4.6 -
2.9 Thread Milling HSS 4.6 4. 6 -

3.1 Drilling HSS 4,6 4.6 -

- Carbide 0,.4,6 0,4,6 -

3.3 OI-Hole or Pressurized- HSS 4,6 4,6 -

Coolant Drilling Carbide 4, 6 4, 6 -

3.4 Spade Drilling HSS 4,6 4,6 -

Carbide 0,4,6 0,4,6 -

3.5 Gundrlling HSS 1,86 1,86 -

Carbide 1.86 1.86 -
3.6 Pressure Coolant Reaming HSS 4.6 ,4,6 -
(Gun Reaming) Carbide 4, 6 4.6 - _

3.7 Reaming HSS 4,6 _ 4.66

4,
Carbide 4,6 4,6 -

3.9 Boring HSS 4,6 4,6 -

Carbide 0,4,6 0.4,6 -
3.11 Boring Diamond -

3.12 Counterboring and HSS" 4,6 4.6 _

Spoffacing Carbide 0.4, 6 0,4, 6 -

3.13 Trepanning HSS 1,86 1,86 -

Carbide 1,86 1,86 -

3.14 Honing - 80 80 -

3.15 Burnishing 5,7 5.7

4.1 Tapping HSS 4,6 4.6

1
16-40
 Cutting Fluid Recommendations 16.2

OP~TONTOOL

ABRASIVE
1 22. Compacted Graphite Cast Irons

185 to 120 to
23. Ductile Cast Irons

53 to
________________ 255 Bhn 400 Shn 60 Rc
5.1 Planing HSS _____ 4.6 __ 4,6 -

Carbide 0.4.6 ____ _ 0.4.6 -

5.2 Broaching HSS 5.,7 5,7 -

Carbide 0.4.6 ____ 0.4.6 -

6.1 Power Hack Sawing HSS _____J 4,6 4,6 -

6.2 Power Band Sawing HSS 4,6 4.6 -

6.4 Circular Sawing HSS 4.6 4.6 -

6.5 Circular Sawing Carbide 0.4.6 0,4.6 0.5.7

6.6 Abrasive Cutoff 4, 4,6 5.7

7.1 Gear Hobbing HSS 4,6 4,6 -

7.2 Gear Cutting, Straight

and Spiral Bevel_____
HSS j4.6 4,6-

7.3 Gear Shaping HSS 4,6 4,6-

7.4 Gear ShavingHS 464.-

7.5 Gear Grinding, Form

-4.6 4,6 1 5.7

8.1 Surface Grinding-Horiz.

Spdl., Recip. Table -4,6 4.6 5,7
8.2 Surface Grindlng-Horiz. B
SpdI., Recip. Table , 54
t
- _____

83 Surface Grndlng-Horli. Diamond -

Spdll., Recip. Table_____4

8.4 Surface GrInding-Vertical 4.6 4,65,

Spdl., Rotary Table _____ __________ __________ 57 _____

8.7 Cylindrical Grinding Liaon

4,6 4.6 1 5,7

8.8 internal Grindinu 4. .A.

8.9 Internal Grinding CBN -- 5.4

8.10 Internal Grinding Diamond

8.11 Centerless Grinding4.4,57

8.13 AbrasiveSoft Grinding 0.4.6 0.4,6 0.,7

8.14 Thread Grinding 4,6 4,6 5,7

16-41
16.2 Cutting Fluid Recommendations

TOOL 24. Malleable Cast Irons 25. White Cast Irons (Abrasion Resistant)
OPERATION MATERIAL
OR
ABRASIVE 110'o
o Over 450 to
260 Bhn 52 R - 600 Bhn
1.1 Turning, Single Point HSS 4.6 - 4.6
and Box Tools Carbide 0.4.6 - 0.4.6
1.3 Turning Diamond -- -

1.4 Turning, Cutoff and HSS 4.6 - 4.6

Form Tools Carbide 0.4,6 - . ... 0.4.6
1.5 Threading, Single Point HSS 4.6 --
Carbide 0.4,6 -
1.6 Threading, Die HSS 4.6 _ -- _
_.________ Carbide 0.4.6 -

1.7 Hollow Milling HSS 5.7 -

Carbide 5.7 -
2.1 Face Milling HSS 4.6 -
Carbide 0.4.6 - 0.4.6
2.2 Face Milling Diamond -- -

2.4 Slab Milling HSS 4.6 -

Carbide 0.4.6 -
2.5 Side and Slot Milling- HSS 4.6 --
Arbor Mounted Cutters Carbide 0.4.6 - 0.4.6
2.6 End Mlling-Peripheral HSS 4.6 - -
Carbide 0. 4.L - 0.4,6
2.8 End Milling-Slotting HSS 4.6 --
Carbide 0.4.6 -
2.9 Thread Milling HSS 4,6 -

3.1 Drilling HSS 4.6 - 4.6

Carbide 0.4.6 - 0.4.6
3.3 Oil-Hole or Pressurized- HSS 4,6 - 4.6
Coolant Drilling Carbide 4.6 - 0.4.6
3.4 Spade Drilling HSS 4.6 - 4.6
Carbide 0.4.6 - . 0.4.6 |
3.5 Gundrilling HSS 1.86 --
Carbide 1.66 -
3.6 Pressure Coolant Reaming HSS 4.6 -
(Gun Reaming) Carbide 4.6. -
3.7 Reaming HSS 4.6 - 4.6
Carbide 4.6 -- 0.4.6

3.9 Boring HSS 4.6 -

Carbide 0.4,6 - 0.4.6 {
3.11 Boring Diamond - -

3.12 Counterboring and HSS 4.6 -

Spoffacing Carbide 0.4.6 - 0.4.6,"
3.13 Trepanning HSS 1.86 --
Carbide 1.86 -
3.14 Honing - 80 - 80

3.15 Burnishing 57 -

4.1 Tanping HSS 4.6 - 4.6

16-42
 Cuffing Fluid Recommendations 16.2

TOOL 24. Malleable Cast Irons 25. White Cast Irons (Abrasion Resistant)
OPERAIION MATERIAL
OR
ABRASIVE 110 to Over 450 to
260 8hn 52 Rc 600 Shn
5.1 Planing H3S 4.6 - --
Carbide 0.4.6 --
5.2 Broaching HSS 5.7 --
Carbide 0.4.6 --
6.1 Power Hack Sawing HSS 4.6

6.2 Power Band Sawing HSS 4.6

GA Circular Sawing HSS46 -

6.5 Circular Sawing Carbide 0.4.6 0.5. 7 0,5. 7

6.6 Abrasive Cutoff 46 5.7

7.1 Gear Hobbing HSS 4.6 --

7.2 Gear Cutting, Straight HSS 4.6

and Spiral Bevel 4,6_--
7.3 Gear Shaping HSS 4.6 --

7.4 Gear Shaving HSS 4.6 -

7.5 Gear Grinding, Form 4.6 5.7

8.1 Surface Grinding-Horiz.

Spdl., Recip. Table -- _4.6 5._7 57

8.2 Surface GrInding-Horlz. CBN -

5.4 _
Spdl., Recip. Table _ _ _ _

8.3 Surface Grindlng-HorIz. Diamond - _

Diamond _
Spdl, Recip. Table
8.4 Surface Grinding-Verticall
Spdl, Rotary Table 46 5.7 5.7

8.5 Cylindrical Grinding

8.6

8.7
Cylindrical Grinding

Cylindrlcal Grinding
-

CBN

Diamond
j 4.6

-
5.7

5.4

-
5.7

8.8 Internal Grinding 4,6 5.7 5.7

8.9 Internal Grlding CBN - 5.4

8.10 Internal Ginding Diamond - -

8.11 Centerless Gin 4.6 5.7 5.7

8.13 Abrash Belt Grinding 0.4.6 0.5.7 0.5.7

8.14 Thread Grinding 4.6 5.7 5,7

16-43
16.2 Cutting Fluid Recommendations

OPERATION
TOOL
MATERIAL
26. High Silicon Cast Irons J -
27. Chromium-Nickel Alloy
Castings
ABRASIVE - 2 ~ -275 to 375 Bhn

1.1 Turning, Single Point HSS _____ ____ 3.5.7 _ ___

and Box Tools Carbide __ __________ 5.7 ______

1.3 Turning Diamond _______I______ ____________

1.4 Turning, Cutoff and HSS j _____ 3,5.7 _____

Form Tools Carbide _____ __ ___j _____ 5.7 _ ___

1.5 Threading, Single Point HSS________ ___1 ____ _____

Carbide _____ _____ _____

1.6 Threading, Die tISS___ __ ____ _____

1.7 Hollow Milling HSS-

Carbide _______ ______ _____

2.1 Face Milling HSS _____ __ __________ 3.5.,7

Carbide ______5.7 ____

2.2 Face Milling Diamond

2.4 Slab Milling HSS ______

Carbide ______ ______ _____

2.5 Side and Slot Milling- HSS - 3.5.7 ____

Arbor Mounted Cutters Carbide ______ ___________ 5.7 _____

2.6 End Milling-Peripheral HSS ___________ 3.5.7 _ ___

Carbide _____ _____1_____ 5.7

2.8 End Milling-Slotting HSS _____ _____3.5.7 _ __

Carbide _____ _____ _____

2.9 Thcead Milling3.7

3.1 Drilling HSS _____ _____ ___ __ ______ 3.5.7

Carbide ______ _____ ______ _____

3.3

3.4
O1l-Hole or Pressurized-
Coolant Drilling
Spade Drilling
I
IHSS
HSS
Carbide
_ ____ _ _ _

______

_____
_ _ __ 3.5.7
5.7
3.5,7
____

_____________ Carb-!de ______ _____ _____ _____ ____

3.5 Gundrilling lISS -

(Gun Reaming) Carbide ___________ ______ _____

3.6 Pressure Coolant Reaming HSS ____ ___ ____ ____

(Gun___Reaming) ___ Carbide _____ _________

3.7 Reaming HSS _____ ____ ____ ____ 3,5.7

Carbide - 5.7 ____

3.9 Boring HSS - ___ _ 3,5.7 ____

j
_____j

3.1 orngCarbide - 5.7 I____

3.11 oringDiamond

3.12 Counterboring and IISS __5.7___I____ 3____

Spotfacing Carbide 5.7 ____
_ _ __ _ _
3.13 Trepanning ____ __

Carbide _____ _____ fa____

3.14 Honing g

3.15 BurnIshing

4.1 Tapping HSS 2.3

16-44 A
_ ___ _ _ _ _ _ __ _ I
- - - - ~-~- _7
 Cutting Fluid Recommendations 16.2

TOOL 26. High Silicon Cast Irons 2.CasmiumNicelAla

OPERATION MATER IAL Csig

ABRASIVE -52 R - 275 to 375 8hn

______________________(500 kg) ______

5.1 Planing HSS ___ ______ ____

13
Carbide
5.2 Broaching HSS ______ ___________

Carbide _______

6.1 Power Hack Sawing H____5_7

6.2 Power Band Sawing HSS- 5.7.3

6.4 Circular Sawing HSS 5.7.3

6.5 Circular Sawing Carbide -5.7.2

6.6 Abrasive Cutoff5.57

7.1 Gear Hobbing 55

H1S

7.2 Gear Cutting, Straight S

an Sia Bevel_ _ _

7.3 Gear Shaping S

7.4 Gear Shaving

7-5 Gear Grinding Form-

8.1 Suface Gio-Hortr. 5.7 2.3

Spdl, Recip. Table______ ____ ____

8.2 Surface Grindling-Horlz. CBN 5.4

8.3 Surface Giindf-oriz. Dimn

8.4 Surface, GrindIng-Vertical 5.7 2.3

8. yicrclG~g5.7 2.3

8.6 Cytinlical Griming CBN 5.4

8.7 Cydrica! Grinding Diamond

8.10 Internal Grinding --

6.9 l~~nding5.mo2.

8.11 Centeres Grinding5.

6.13 Abrasive Bet Grin"n 0.5.7

8.14 Thread Grinding5.

5.7 2U
16-45U
16.2 Cuffing Fluid Recommendations

TOOL 28. Aluminum Alloys, Wrought 29. Aluminum Alloys, Cast 30. Magnesium Alloys,
OPERATION MATERIAL Wrought
OR
ABRASIVE 3G to 150 Bhn 40 to 1258nn50 to 90 Bhn
(500 kg) (500 kg) (500 kg)
1.1 Turning, Single Point HSS 4, 6, 82 _ 4,6, 82 1,88
and Box Tools Carbide 0, 4, 6 0.4,6 1,88
1.3 Turning Diamond 0, 4 6 0,4,6 1.88

1.4 Turning, Cutoff and HSS 4, 6 82 4, 6, 2 1,88

Form Tools Carbide 0, 4, 6 0,4,6 1,88

1.5 Threading, Sigle Point HSS 0,1,82 .. 0,1, 82 1,88

Carbide 0,1,82 0,1.82 1,88
1.6 Threading, Die HSS 0,1,82 0,1,82 . . 1,88
Carbide 0,1,82 0,1 82 1,88
1.7 Hollow Milling HL-S 0,1,82 0,1,82 1,88
Carbide 0,1,82 0,1,82 1,88
2.: Face Milling HSS 0,1,82 0,1,82 1,88
Carbide 0,1,82 0,1,82 1,88
2.2 F~ce Milling Diamond 0,4, 6 0,4, 6 1,88

2.4 Slab Milling HSS 0, 1,82 0,1,62 1,68

Carbide 0,1,82 0,1,82 1,88
2.5 Side and Slot Milling- HSS 0,1,82 . 0,1,82 1. 88
Arbor Mounted Cutters Carbide -. 1,82 0, 1,82 1,88
2.6 End Milling-Peripheral HSS 0,1,82 0,1.82 1,88
Carbide 0,1,82 0.1.82 1,88
2.8 End Milling-Slotting HSS 0,1,82 0.1,82 1,88
2.__ThreadMilling_ Carbide 0,1,82 0,1,82 1,88
2.9 Thread Milling HSS 0,1,82 0,.1,82 1,88

3.1 Drilling HSS 0,1,82. 0,1,82 1,88

Carbide 0,1,82 0,1,82 1,88 _-

3.3 OIl-Hole or Pressurized- HSS 1,82 1,82 1,88

Coolant Drilling Carbide 1,82 1,82 I 1,88
3.4 Spade Drilling HSS 1,82 _. 1,82 1.88
Carbide 0,82 0,82 88
3.5 Gundrlling HSS 1,82 1.82 1,88
Carbide 1,82 1,82 1.88
3.6 Pressure Coolant Reaming HSS 12 .... 1,82 _ ' 1,88 _
(Gun Reaming) Carbide 1,82 1,82 1,88
3.7 Reaming HSS 0,1,82 0,1,82 1,88
1

3.9 Boring
Carbide
HSS
Carbide
0,1,82
40.4,
6,82
6
' 1,82
4,6,82
0, 4, 6
___ ___ j 1,88
"1,1,88
88 j
3.11 Boring Diamond 0 4,6 0,4,6 1,88

3.12 Counterborlng and HSS 4,6,82 4,6,82 1,88

SpotfacIng Carbide 0,4,6 0,4,6 , 1,88
3.13 Trepanning HSS 1,82 1,82 1, 88.
Carbide 1,82 1,82 1,88
3.14 Honing 80 80 80

3.15 Burnishing 1,82 1,82 1

4.1 Tapping HSS 0,1,82 0,1,82 1,88

16-46

K
 Cutting Fluid Recommendations 16.2

TOOL 28. Aluminum Alloys, Wrought 29. Aluminum Alloys, Cast 30. Magnesium Alloys,
OPERATION MATERIAL Wrought
OR
ABRASIVE 30 to 150 Bhn 40 to 125 Bhn 50 to 90 Bhn
(500 kg) - (500 kg) - (500 kg)
5.1 Planing HSS 4,6,82 1 4,6,82 1.88
Carbide 0.4,6 0,4,6 1,88
5.2 Broaching HSS 4,6,82 4,6, 82 0,1,88
Carbide 0,4,6 0.4,6 0,1,88
6.1 Power Hack Sawing HSS 0, 1,82 0, 1,82 0,1,88

6.2 Power Band Sawing HSS 0,1,82 0,1,82 0.1.88

6.4 Circular Sawing HSS 1,82 1,82 1,88

6.5 Circular Sawing Carbide 0, 1.82 0,1,82 0. 1,88

6.6 Abrasive Cutoff 1,82 1,82 0,1,88

7.1 Gear Hobbing HSS 1.82 1,82 0,1,88

7.2 Gear Cutting, Straight HSS 1.82 1,82 1,88

and Spiral Bevel _S_18_____8

7.3 Gear Shaping HSS 1,82 1,82 0, 1,88

7.4 Gear Shaviny HSS 1,82 1,82 0,1,88

7.5 Gear Grinding, Form 1,82 1.82 1.88

8.1 Surface Grlnding-Horiz. 1,82 1,82 1.88

SpdIl., Recip. Table
8.2 Surface Grlnding-Horiz.
Spdl., Recip. Table
8.3 Surface Grinding-Horiz.
Spdl., lecip. Table
8.4 Surface Grinding-Verilcal 1,
Spdi., Rotary Table -- _1,82 1,82 1,88

8.5 Cylindrical Grinding -- 1,82 1,82 1,86

8.6 Cylindrical Grinding CBN - - -

8.7 Cylindrical Grinding Diamond - - -

8.8 Internal Grinding 1,82 1,82 1.88

8.9 Internal Grinding CBN -

8.10 Internal Grinding Diamond -

8.11 Centedress Grnding 1,82 1,82 i.88

8.13 Abrasive Belt Grinding - 1,82 1,82 1,88

8.14 Thread Grinding 1,82 1,82 1,88

16 7 _

16-47
16.2 Cutting Fluid Recommendations

TOOL 31. Magnesium Alloys, Cast 32. Titanium Alloys, Wrought 33. Titanium Alloys, Cast
OPERATION MATERIAL
OR __________

ABRASIVE 50Oto 90Bhn 110to 150to

(500 kg) -440 Bhn -350 Bhn -

1.1 Turning, Single Point HSS 1,88 ___ 83 -33 _____

a-d Box Tools Carbide 1, 88 0. 83 0 83

1.3 Turning Diamond 1,88

1.4 Turning, Cutoff and HSS 1, 88 _____ 83, 91 83.,91 _____

Form Tools Carbide 1,88 ______ 83 83 _____

1.5 Threading, Single Point HSS 1. 88 ____ 83,91 83,91

_________________ Carbide 1, 88 83 _____ 83 _____

1.6 Threading, Die HSS 1,88 ____83.91 83,91

_________________ Carbide 1. 88 83 83
1.7 Hollow Milling HSS 1.88 83.91 ______ 83.91
_________________ Carbide 1, 88 _____ 83 _____ 83
2.1 Face Miiiing HSS 1, 88 83, 91 ____83, 91
Carbide 1,88 _____ 0.,83 _____ 0, 83
2.2 Face Milling Diamond 1.88

2.4 Slab Milling HSS 1, 88 83. 91 _____ 83, 91

Carbide 1.,88 83 83 ____

2.5 Side and Slot Miling- HSS 1,88 83.91 83. 91

Arbor Mounted Cutters Carbide 1, 88 0.,83 83 _____

2.6 End Milling-Peripheral HSS 1,88 83,91 83.91 ___

_________________ Carbide 1, 88 83 83
2.8 End MIllIng-Slotting HSS 1, 88 83,91 83.9111
Carbide 1, 8v 83 83
2.9 Thread Milling HSS 1. 88 83.91 83,91

3.1 Drilling H-ISS 1,88 83,91 _____ 83,91

_________________ Carbide 1,88 _____ 83 _____ 83
3.3 Oil-Hole or Pressurized- HSS 1, 88 _____ 83. 91 83, 91 3
Coolant Drilling Carbide 1, 88 _____ 83 83
3.4 Spade Drilling HSS '1.'88 _____ 83,.91 83,91
_________________ Carbide 88 0, 83 _____ 0.,83
3.5 Gundriiling HSS 1. 88 ____ 83.,91 83. 91
Carbide 1.88 ______ 83.91 ______ 83.91
3.6 Pressure Coolant Reaming HSS 1.,88 _____ 83, 91 83, 91
(Gun Reaming) Carbide 1.88 _____ 83,91 _____ 83,91
3.7 Reaming H1SS__ 1.88 ______ 83.91 ______ 83,91 _____

Carbide 1.88 ____ 83.91 ______ 83.91

3.9 Boring 1135 1,88 ____ 83,91 ______ 83,91 ____

Carbide 1, 88 _____ 83, 91 3, 91

9____
3.11 Boring Diamond 1,88

3.12 Counterboring and HSS 1.88 ____83,91 83.91 _____

Spotf acing Carbide 1, 88 83 83 ______

3.13 Trepanning HSS 1.,83 _____ 83, 91 83, 91

T
________________ Carbide 1 1,88 83 83 ____

3.14 Honing - 80 90 90

3.15 Bumlsh~ng ]

4.1 Tapping

_ _ _ _ _ _
HSS

_ L
1.88

_ _ _
1,83

_ _ _ _ _ _I
1.83

16-48
 Cutting Fluid Recommendations 16.2

OPRTINMTEOOL 31. Magnesium Alloys, Cast 32. Titanium Alloys, Wrought 33. Titanium Alloys, Cast

ABRASIVE 50 to 90 hn li0to 1501to

____________________(500 kg) -440OBhn -350 Bhn 4
5.1 Planing HSS 1,83 83, 91 ____ 83.,91
___________________ Carbide 1, 88 ______ 83 ______ 83
5.2 Broaching HSS 0. 1.88 83, 91 _ ____ 83,91
___________ Carbide 0,1,88 183.91 _ ___ 83,91 1
6.1 Power lI3,Qk Sawing HSS 0. 1, 88 183, 91 83, 91

6.2 Pov,ar Band Sawing HSS 0,1, 88 83, 91 83.,91

6.4 Circular Sawing HSS 1,88 83,91 83,91

6.5 Circular Sawing Carbide 0. 1, 88 83,91 8.9

6.6 Abrasive Cutoff -0.,1, 88 81,83 81.,83

7.1 Gear Hobbing HSS 0, 1.88 1, 83 1,8

7.2 Gear Cutting, Straight HSS 1. 88 1,83 1, 83

and Spiral Bevel ___________

7.3 Gear ShapingHS0,181,31.3

7.4 Gear Shaving HSS 0. 1, 88 1, 83 1,883

7.5 Gear Grinding, Form-1.88.831.3

Ginln-orz.
8. Srfc -1,88 81,.83 81.,83

8.2 Surface Grinding-Horiz. CB-

Spdi., Recip. Table 1_8__1,8381_8
8.3 Surface Grinding-Horiz. Damn -

SpdI., Recip. Table _____ ____

8.4 Surface Grinding-Vertical -1, 88 81,83 81, 83 14

Spdi., Rotary Table
8.5 Cylindrical Grinding -1 88,38.8

8.6 Cylindrical Grinding B-

8.7 Cylindrical Grinding Diamond-

8.8 Internal Grinding -18 18 18

8.9 Internal GrindingCN-

8.10 Internal GrindingDimn-

8.11 Centeriess Grinding -1,88 81,83 81, 83

8.13 Abrasive Belt Grinding -1,88 81,83 81,83

8.14 Thread Grinding -18 18 18

16-49f
16.2 Cutting Fluid Recommendations

TOOL 34. Copper Alloys, Wrought 35. Copper Alloys, Cast 36. Nickel Alloys, Wrought

OPERATION MATERIAL and Cast

OR
ABRASIVE 10 to 40 to 80 to

10ORS 425 Bhn 360 Bhn

1.1 Turning, Single Point HSS 4,6,87 4,6,87 3,5,7
and Box Tools Carbide 4, 6 4,6 0,5,7
1.3 Turning Diamond 4,6,87 4,6.87 -

1.4 Turning, Cutoff and HSS 4,6,87 4,6,87 3,5,7

Form Tools Carbide 4.6 4,6 5.7
1.5 Threading, Single Point HSS 1,87 1,87 3,5.7
Carbide 0,1.87 0,1.87 5.7
1.6 Threading, Die HSS 1,87 1.87 3,5,7
Carbide 0, 1,87 0.1.87 5,7
1.7 Hollow Milling HSS 1,87 1,87 3,5,7
.. ... (_Carbide 0,1,87 0.1.87 2,5.7
2.1 Face Milling HSS 4, 6. 87 4,6. 87 3,5, 7
Carbide 4.6 4, 0 0,5,7
2.2 Face Milling Diamond 4.6.87 4,6. 87 -

2.4 Slab Milling HSS 4, 6, 87 4,6, 87 3.5,7

Carbide 4.6. 87 4,6.87 2. 5, 7
2.5 Side and Slot Milling- HSS 4, 6,87 4.6,87 3.5.7
Arbor Mounted Cutters Carbide 4.6.87 4.6, 87 2., 5.7
2.6 End MIllIng-PerIpheral HSS 4,6, 87 4.6.87 3,5,7
Carbide 4.6.87 4,6.87 0.5,7
2.8 End Milling-SlottIng HSS 4.6.87 4, 6,87 3.5, 7
Carbide 4.6, 87 4, 6,87 0.5.7
2.9 Thread Milling HSS 1,87 1,87 3,5. 7

3.1 Drilling HSS 4, 6, 87 4, 6,87 3,5, 7

Carbide 4,.6,87 4.6,87 0.5.7|
3.3 OIl-Hole or Pressurized- HSS 4,6.87 4.6,87 3,5, 7 i
Coolant Drilling Carbide 4,6,87 4.6,87 2,5,7
3.4 Spade Drilling HSS 4, 6, 87 4. 6,87 3.5.7 4
__ _ _ _ Carbide 4,6,87 4.6.87 0,5,7
3.5 Gundrilling HSS 1,86.87 1,86,87 3.5. 7
Carbide 1,86,87 1,86,87 2,5.7 _

3.6 Pressure Coolant Reaming HSS 1,87 1,87 5,7,3

(Gun Reaming) Carbide 1,87 1.87 5.7,2
3.7 Reaming HSS 1,87 1,87 5,7.3 _

Carbide 1,87 1,87 5.7.2

3.9 Boring HSS 4,6.87 4,6.87 5,7,3
Carbide 4.6 4,6 0.5,7
3.11 Boring Diamond 4,6,87 4,6,87 -

3.12 Counterboringand HSS 4,6,87 4,6.87 - 5,7.3

Spoffacing Carbide 4.6 4.6 5,7.2
3.13 Trepanning HSS 1,86,87 1,86,87 2.86
3.14_Honing_ Carbide 1,86,87 1,86,87 5,7.2
3.14 Honing 80 80 90

3.15 Burnishing 1.87 1,87

4.1 Tepplng HSS 1,87 1,87 2,3

16-50
 Cutting Fluid Recommendations 16.2

TOOL 34. Copper Alloys, Wrought 35. Copper Alloys, Cast 36. Nickel Alloys, Wrought
OPERATION MATERIAL and Cast
OR
ABRASIVE 10 to 40 to 80 to
100 RA 425 Bhn 360 Bhn
5.1 Planing HSS 4,6, 87 4.6,87 5, 7.3
Carbide 4,6 4.6 0.5,7
5.2 Broaching HSS 4.6,87 4,6,87 5, 7,3
Carbide 4,6.87 4,6,87 5. 7,3
F 1 Power Hack Sawing HSS 1,87 1.87 5.7,3

f.2 Power Band Sawing HSS 1.87 1,87 5,7.3

6.4 Circular Sawing HSS 4,6, 87 4.6, 87 5. 7.3

6.5 Circular Sawing Carbide 1, 87 1,87 5,7, 2

6.6 Abrasive Cutoff 187 187 5.7

7.1 Gear Hobbing HSS 1 87 1,87 -

7.2 Gear Cutting, Straight HSS 1.87 1,87

and Spiral Bevel
7.3 GearShaping HSS 1,87 1.87 -

7.4 Gear Shaving HSS 1,87 1,87 -

7.5 Gear Grinding, Form 1,87 1,87

8.1 Surface Grlndlng-Horz. 1,87 1.87 2.3

Spdl., Recip. Table
8.2 Surface Grdnding-Horz. CBN -
Spdl., Recip. Table
8.3 Surface Grdnding-Horlz. Diamond 4. 87 4. 87
Spdl., Recip. Table _

8.4 Surface Grinding-Vertical - 1,87 1.87 2,3

Spdl., Rotary Table
8.5 Cylindr!cal Grinding -- 1,87 1,87 2, 3

8.6 Cylindrical Grinding CBN -

8.7 Cylindrical Grinding Diamond 4,87 4,87 -

8.8 Internal Grinding 1,87 1,87 2.3

8.9 Internal Grinding CBN - - -

8.10 Internal Grinding Diamond 4,87 4.87 -

8.11 Centerles Grindlng 1,87 1.87 2.3

8.13 Abasive Belt Grinding 1,87 1,87 3

8.14 Thread Grinding 1,87 1,87 2.3

16-51
16.2 Cutting Fluid Recommendations

TOOL 37. Beryllium Nickel Alloys, 38. Nltlnol Alloys, Wrought 39. High Temperature Alloys,
OPERATION MATERIAL Wrought and Cast Wrought and Cast
OR
ABRASIVE 200 to 47 to 210 to 140 to
425 Brin 52 Rc 515 Bhln - 475 Bhn

1.1 Turning, Single Point HSS 3,5,7 - 2.5 7 3,5. 7

and Box Tools Carbide 5,7 - 1,4,6 0,.4.6
1.3 Turning Diamond - - -

1.4 Turning, Cutoff and HSS 3.5. 7 - 3,5, 7 3

Form Tools Carbide 5, 7 - 2,5.7 3

1.5 Threading, Single Point HSS 3 - 3.5,7 3

Carbide - - 2.4,6 2.5,7
1.6 Threading, Die HSS 3, 5, 7 - 3.5,7 3
Carbide - - 2,4,6 2.5.7
1.7 Hollow Milling HSS - - 2,3 3
Carbide - - 2 2,5,7
2.1 Face Milling HSS 3, 5, 7 - 2.3 2,5
Carbide 5,7 - 2,3 0,3
2.2 Face Milling Diamond - - -

2.4 Slab Milling HSS 3.5.7 - 3

Carbide - - - 3
2.5 Side and Slot Milling- HSS 3, 5. 7 - 2,3 3
Arbor Mounted Cutters Carbide 5, 7 - 2. 3 3
2.6 End Milling-Peripheral HSS 3,5, 7 - 2,3 3
Carbide 5, 7 - 2,3 3
2.8 End Milling-Slotting HSS 3,5, 7 - 2.3 3
Carbide - - 2,3 3
2.9 Thread Milling 3,5.7 - 2.3 3

3.1 Drilling HSS 3,5, 7 - 2.3 3

Carbide - - 2,3 3
3.3 OIl-Hole or Pressurized- HSS 3, 5. 7 - 2.3 3 _

Coolant Drilling Carbide 5, 7 - 2.3 3

3A Spade Drilling HSS 3,5.7 - 2.3 3
Carbide - - 2.3 3
3.5 Gundrilllng HSS - - 2.3,86 3 Z.
Carbide 5.7 - 2,3 3
3.6 Pressure Coolant Reaming HSS - - 2,3 3
(Gun Reaming) Carbide - - 2,3 3 _--

3.7 Reaming HSS 3,5.7 - 2,3 3

Carbide 5,7 - 2,3 3
3.9 Boring HSS 3.5.7 - 2.5.7 3.5,7
Carbide 5,7 - 2.5.7 3
3.11 Boring Diamond ....

312 Counterboring and HSS 3.5,7 - 2,5.7 3

Spoffacing Carbide 5, 7 - 2.5. 7 3
3.13 Trepanning HSS 3. 5,7 - 2,3,86 3
-Carbide 5.7 - 2.86 3
3.14 Honing 90 - 90 90

3.15 Burnishing

4.1 Tapping HSS 3.94 - 2.3 3

16-52

-.. . . ..- - .
 Cutting Fluid Recommendations 16.2

TOOL 37. Beryllium Nickel Alloys. 38. NItl.nol Alloys, Wrought 39. High Temperature Alloys,
OPERATION MATERIAL Wrought and Cast Wrought and Cast
on
ABRASIVE 200 to 47 to 210to 140 to
425 Bhn 52 Rc 515 Bhn 475 Bhn
5.1 Planing HSS - -- - -
Carbide - .

5.2 Broaching HSS 5.3 - - 3

Carbide 5.7.3 - - 3
6.1 Power Hack Sawing HSS 5, 7. 3 - 2.3 3

6.2 Power Band Sawing HSS 5,7,3 - 2,3 3

6.4 Circular Sawing HSS 5.7,3 - 2.3 3

6.5 Circular Sawing Carbide 5.7,2 5,7,2 2.3 3

6.6 Abrasive Cutoff 5.7 5,7 2.3 5,7

7.1 Gear Hobbing HSS - - - 3

7.2 Gear Cutting, Straight HSS

and Spiral Bevel 3
7.3 Gear Shaping HSS - - -

7.4 Gear Shaving HSS - - -

7.5 Gear Grinding, Form - - 3

8.1 Surface Grinding-Horiz - 2.3 2.3 2.3 3

Spdl., Recip. Table 2
8.2 Surface Grinding-Horiz. CBN - - - 5,3
Spdl., Recip. Table
8.3 Surface Grinding-Horiz. Diamond -

Spdl., Recip. Table Diamond_....___

8.4 Surface Grinding-Vertical
Spdl., Rotary Table --
_2,_3 2, 3_2,_3_3
8.5 Cylindrical Grinding - 2.3 2.3 2.3 3

8.6 Cylindrical Grinding CBN 5.3

8.7 Cylindrical Grinding Diamond ...

8.8 Internal Grinding _ 2,3 2.3 2.3 3

8.9 Internal Grinding CBN - - - 5.3

8.10 Internal Grinding Diamond

8.11 Centerleu Grinding _ 2,3 2,3 2,3 3 '

8.13 Abrasive Belt Grnding 3 3 23 3

8.14 Thread Grnding - 2.3 2.3 2.3 1

16-53
16.2 Cutting Fluid Recommendations

TOOL 40. Refractory Metals, Wrought. 141. Znc All" , 42. Lead 43. TIn Alloys, 44. Uranium,
OPERATION MATERIAL Cast and P/M Cast Alloys, Cast Cast Wrought
OR[
A8I1ASIVE 170to 80 to 10 to 20 Bhn 15 to 30 Bhn 56 to

320 Bhn 100 Bhr (500 kg) (500 kg) 58 R,

1.1 Turning, Single Point HSS 3.5 0.4 - - 4.6
and Box Too;s Carbide 2.5 0 - 4,-
4,6
1.3 Turning Diamond - - - -

1.4 Turning, Cutoff and HSS 3.5 0.4 - - 4.6

Form Tools Carbide 2.5 0 - - 4.6
1.5 Threading, Single Point HSS -- 0.1.4 - - 4.6
Carbide - 0.1 - - 4.6
1.6 Threading, Die HSS - 0.1.4 - - 4.6
Carbide - (.1 - - 4.6
1.7 Hollow Milling HSS 3.5.7 0.1.4 - -. 6
Carbide 2.5.7 04.6
0.1 ----
2.1 Face Milling HSS 2.5 0 1 - - 4.6
Carb!de 2.5 0 - - 4.6
2.2 Face Milling Diamond - - - -
2.4 Slab Milling HSS 3.5 0.1.4 - - 4,6
Carbide - 0.1 - -- 4.6
2.5 S:de and Slot Mll[.j- HSS 3.5 0.1.4 - - 4.6
Arbor Mounted Cutters Carbide 2.5 0 - - 4.6

2.6 End Milling-Peripheral HSS 2.5 0.1.4 - - 4.6

Carbide 5 0.4 - - 4.6
2.8 End MIllpg-Slottlng HSS 2.5 0.1.4 - - 4.6
Carbide 5 0.4 - - 4.6
2.9 Thread Milling HSS 3 0.1.4 - - 4.6

3.1 Drilling HSS 3 0.1.4 - - 4.6

Carbide 2 0.4 - - 4.6
3.3 Oil-Hole or Pressurized- HSS 3 1.4 - - 4.6
Coolant Drilling Carbde 2 1.4 - 4.6
S3.4 Sr'de Drilling HSS 3 0.1.4 - - 4,6
-Carbide 2 0.4 - - 4.6
3.5 Gundrilling HSS 3 1.86 - - 4.6
Carbide 2 1.88 - - 4.6
3.6 Pressure Coolant Rvaming HSS 3 1.4 - - 5.7
(Gun Reaming) Carbide 3 1.4 - - 4.6
3.7 Reaming HSS 3 0.4 - - 5.7
Carbide 3 0.4 - - 4,6
3.9 Boring HSS 3.5 0.4 - - 3
Carbide 2.5 0 - - 3
3.11 Borlrg Diamond - - -

3.12 Counterboring and HSS 3.5 0.4 - - 5.7

Spotfacing Carbide 2.5 I 0.4 - - 4.6

3.13 Trepanning HSS 3 4.86 - - 3

Carbide 2 1.4 -- - 3
3.14 lining 90 90 - 90

3.15 Burnishing

4.1 TapplnC HSS 3 1 4

16-54
 Cutting Fluid Recommendations 16.2

TOOL 40 Rercory Meas ruh,14l. Zinc Alloys.4.Led13 Tin Alloys, 44. Uranium,
OPERATION MATERIAL Cast and P/M Cast jAlloys, Cast Cast jWrought
ABRASIVE 1701to 0 o 10 to 20Bhn 15 to 3OBhn 56 t
320 Bhn 100 Bhn (500 kg) (500 kg) 58 RA
5.1 Planing HSS - - - f - -
Carbide -- - t - -

5.2 Broaching HSS -0,1,4 - - -

Carbide -0.1 - - -

6.1 Power Hack Sawing HSS 3 1.4 0. 0. 4.6

6.2 Power Band Sawing HSS 3 1.4 0. 0* 4. 6

6.4 Circular Sawing HSS 3 1.4 0. 0* 5.7

6.5 Circular Sawing Carbide 3 0,4 00 0* 5,7

6.6 Abrasive Cutoff -1.83 0OA - - 4.6

7.1 Gear 4obbing HSS - 1.4 --

7.2 Gear Cutting. Straight HSS

4
-1.4-
and Spiral Bevel
7.3 Gear Shaping HSS -1,4 ---

7.4 Gear Shaving HSS -1.4 -

7.5 Gesar Grinding. Form -- 1.4 - --

8.1 Surface Grinding.-Horiz. 1.83 4 - -4.6

Spdl., Recip. Table_____ _______ _________

8.2 Surface Grinding-Horiz.

Spdl.. Recip. Table j N-----

8.3 Surface Grinding-Horiz- imn

Spdi., Recip. Table _____

8.4 Surface Grinding-Veitica: 8 4 4,-

Spdl., Rotary Table __________

8.5 Cylindrical .rndng

1-3 4.6

8.7 Cylndrical GrindingDion

- 183 - -4.

8.7 Cinral Grinding B----

8.10 Internal GrindingjDaod

8.11 CnterlesGrinding -18 .

8.13 Abrasive Belt Grinding -3.91

8.14 Thread Grinding 1, t 4 -4.6

*Compressed sir may be used to facilitate chip removal.

16-55
16.2 Cuffing Fluid Recommendations

TOOL 45 Zicnu Alloys, Wrought 47 owe 48. Machinable Carbides 49. Carbides
OPERATION MATERIAL Metal Alloys
OR__ _ _ _ _____ __ _ _ _

ABRASIVE 140 to All 40 to 68 to 89 to

1 280 Bhn Hardness 51 Rc 70 Rc 94 RA
1.1 Turning. Single Point
and Box Tools f HSS
Carbide
1.4.,6
4,6 _____ __________
--

1.3 Turning Diamond -

1.4 TurnIng. Cutoff and HSS 1,5.7 -

Form Tools Carbide 4.6a--

1.5 Threading, Single Point HSS 1.,5. 7 ---

___________________ arbide 5.7a--

1.6 Threading, Die HSS 1,5.7a--
Carbide 5. 7
1.7 Hollow Milling HSS 1.5,7a--
Carbide 4.6a
2.1 Face Milling HSS 1,4,6a---
__________________ Carbide 4.6a
2.2 Face Milling Diamond -

2.4 Slab Milling HSS 1.5.7 --

____________________ Carbide 4.6 __________

2.5 Side and SlotMllilng.- HSS 1.5.7 ---

Arbor Mounted Cuatters Carbide 4.6 _____

2.6 End MIlling-Perlpheral HSS 1.5,7a---

__________________ Carbide 4.6a---
2.8 End MIlling-SlottIng H-SS 1.5.7a
____________________ Carbide 4.6 _____ _____ ______ _____

2.9 Thread Milling HSS 2.5.7

3.1 Drilling HSS 1.5.7---

Carbide 4.6
3.3 Oil-ole or Pressurized- 1155 1.5. 7- -

Coolant Drilling Carbide 4.6 _____

3.4 Spade Drilling H-15 1.5.7 ---

Carbide 4.6 ---

3.5 Gundrilling HSS 1.5.7--

Carbide 4.6- -

3.6 Pressure Coolant Reaming

(Gun Reaming) ICarbide
HSS 1.5.7
4.6_____
---

3.7 Reaming 1155 1,5,7 ___ ____ AQ___

_____________ Carbide 4.6 !0-

3.9 Boring HSS 1,5.7__ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _

Carbide 4.6 EA--

3.11 Borlng Diamond - --

3.12 Cot-vnterborlng and HSS; 1. 5. 7 ---

Spottacing Carbide 4.6 _ ___ _____

3.13 Trepanning HSS 1.5.7 --

__________________ Carbide 4.6 ---

3.4 onng-90 *80 ' 80 80

3.15 Burnishing

4.1 Tappln"15

-use the samre cutting fluid as for cast alloys unless prohibited by partis
requirements for cleanliness; and Porosity.

16-56
 Cutting Fluid Recommendations 16.2

OPERATION
J TOOL
jMATERIAL
45. Z3rconium Alloys, Wrought 47 Powe
Metal Alloys
48. Machinable Carbides 49. Carbides
OR _ _ _ _ ____

ABRASIVE 240 to All 40Oto 68 to 89 to

20SnHardness 51 Rc 70 Rc 94 R
5.1 Planing HSS -
Carbide -

5.2 Broaching HSS 5.7 _____ _____

Carbide 4.6 _____

6.1 Power Hack Sawing HSS 4.6 *0 -

6.2 Power Band Sawing HSS 4.6 0 -

6.4 Circular Sawing HSS 5.7 *0 -

6.5 Circular Sawing Carbide 4.6 *0 -

6.6 Abrasive Cutoff -4.6 -

[7A Gear HoWN HSS 2,5.7 --

7.2 Gear Cutting, Straight HSS 2,5.7 ---

and Spiral Bevel _ _ _ _ _ _ _ _ ____

7.3 Gear Shaping 2.5.7,5,7

7A4 Gear Shaving IHSS 2,5.7 --

7.5 Gear Grinding, Form -28

8.1
Grldlng..-orlz.
Surace -2.81 0.6 046046

8.2 Surface Grinding-Horlf CBt

Spdl, Recip. TAblW____
8.3 Surface Grinding-Horir iaod-
SpdL, Recip. Table I ___________

8.4 Surface Grinding-Verca Dimn 2.1046 046 046

SpdL. Rotaly Table__ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _

8.5 C lL Roa l r i ingle 2.81 0.4 ,6 0 .4 .6 0.4 .6

8.6 Cyidrical GrindingCB- --

8.7 Cylindrical GrindingDi on- -44

3.8Ginin
ten - 2.8 0.. ..- ..

8.9 Internal GrindingCB-

381 Internal GrindingDimn *-44

8.1 ene~esGrndng-2.81 *0.4.6 0.4. 04.6

= 8.13 AbraaleGrndng-23 046 0446

8.14 ItralGrinding -28 .. . .

-U~sethe same cutting fluid astfor zast alloys unless prohibited by part
requirements for cleanlinelss and porosity.

16-57
16.2 Cutting Fluid Recommendations

TOOL So. Free Machining Magnetic 51. Magnetc Alloys I 52. Free Machining Controlled
OPERATION MATERIAL Alloys Expansion Alloys
OR I
ABRASIVE 185 to 185 to 1 45 to 125 to1
240 Bhn 240 Bhn 58 RC 260 Bhn -

1.1 Turning, Single Point HSS 1 5,7 1.6, 7 - 1,5.7

and Box Tools Carbide - - --
1.3 Turning Dai ,ond ... i

1.4 Turning, Cutoff and

Form Tools
HSS
Carbide
j i.5.7
2.5.7
. 1,5,
2.5.7
-
-
1.5,7
2.5.7
!

1.5 Threading, Single Point HSS ..-

Carbide . _..
1.6 Threading, Die HSS - - - --
I Carbide - - - -

1.7 Hollow Milling HSS I -

Carbide - -

2.1 Fzce Milling HSS 1.5.7 1.5,7 1.7

__ .______
_Carbide - -

2.2 Face Milling Diamond .-.

2.4 Slab*ll'ing HSS 1.5.7 1.5.7 - 1,5.7

Carbide - - - -
2.5 Side and Slot MIilng- HSS 1.5 7 1,5.7 - 1.5,7
A.bor Mounted Cutters Carbide - 2.5, 7 - -
2.6 End Mtllk-g-Peripheral HSS 1.5.7 1.5.7 - 1.5.7
Carbide - - -
2.8 End Milling-Slotting HSS 1.5,7 1.5.7 - 1.5.7
Carbide - - -
2.9 ThreadMllllng Hss 5.7 1.5.7 - 1.5.1

3.1 Drilling HSS 1.5.7 1.5,7 - 1.5.7

Carbide - - -

3.3 Olt-Hole or Pressurized- HSS 1.5.7 1.5.7 -- 1.5.7 _

Coolant Drilling Carbide - -

3.4 Spade Drilling HSS 1.5.7 1.5.7 -

Carbide ..

3.5 Gundrilling .HSS

Carbide ....
3.6 Pressure Coclznt Reaming I HSS ....
(Gun Reaming) tarbide .... __ _

3.7 Reaming HSS 1.5,7 1.5.7 - 1.5.7

Carbide 2.5.7 2.5.7 - 2.5,7 !
3.9 Boring HSS 1.5.7 1. 57 1.5.7
Carbide ..

3.11 Boring
IDiamond
D aroid
-
...
____ - 11___ ____

3.12 Counterborlng and HSS 1,5.7 15 7- -1.5.7

Spotfacing Cari-- - I 2.5 - - 15 --

3.13 Trepanning HSS -

_
3.14 Ho~g j Carbide
90
...
90 - 90

3.15 Burnishing -

4.1 Tapping HSS 2.3 2.3 -. 3

16-58
 Cutting Fluid Recommendations 16.2

OPERATION
TOOL
MATERIAL
JO. Free Machining Magnetic
Alloys
31. Magnetic Alloys 52. Free Machining Controlled
Expansion Alloys
OR
ABRASIVE 185 to 185 to 45 to 125 to
240 Bhn - 240 Bhn I 58 Rc 250SBhn
5.1 Planing HSS -...
C a rb id e - ...
5.2 Brc.aching H s 5.7.3 5.7.3 - 5 7.3
Carbide 5.7.3 5.7.- 5. 7.3
6.1 Power Hack Sawing HSS 5.7. 3 5.7.3 - 5.7.3
6.2 Power Band Sawing HSS 5.7. 5.7.3 - 5.7.3

6.4 Circula. Sawfng HSS 5.7,3 5.7.3 - 5.7.3

6.5 CircularSawing Carbide 5.7.2 5.7.2 - 5.7,2

6.6 Abrasive Cutoff -- 5.7 5.7 2.3 5.7

7.1 Gear Hobbing HSS - - -

7.2 Gear Cutting. Straight I S ..

_ _ _
and Spiral Bevel
0
7.3 Gear Shaping HS ....

7.4 Gear Shaving -

__________ IHS5
7.5 Gear Grinding. Form ---
8.1 Surface Grinding-Horiz. 2.3 2.3 2.3 2.3
Spdl. Recip. Table
8.2 Surface Grinding-Horz. CBN ....
Spdl, Recip. Table
8.3 Surface Grinding-Horiz. Diamond ...
Spdl, Recip. Table

8.4 Surface Grinding-Vertical 2.3 2.3 2.3

Spdl., Rotary Table 2.3
8.5 Cylindrical Grinding
Roayal .2.3 2.32.23
8.6 Cylindrical Grinding CE, j -

8.7 Cylindrical Gnindin'2 Diamond Iff ....-

8.8 Internal Grinding 1 .3 2.3 2.3 2 -3

8.9 Internal Grinding CBN - - 2.3

8.10 Internal Grinding Diamono -..

8.11 Centeess Ginding

8.13 Abrasive Belt Grinding
1 2.3
3
23
23
2. 23
3 23

8.14 Thread Grinding _ 2.3 2.3 2.3 2.3

16-5
16-59
16.2 Cutting Fluid Recommendations

54. Carbois & Graphites 55. Glasses & Ceramics

TOOL 53. Controlled Expansion
OPERATION MATERIAL Alloys Machinable O
OR .... ._ _ Glass-Ceramic Other
ABRASIVE 125 to 40 to 100 250 Over
250 Bhn Shore Knoop 800 Knoop
1.1 Turning, Single Point HSS 1,5 7 - 4.93 -
and Box Tools Carbide - -- 4,93 -
Turning Diamond - 4,93 -

Turning, Cutoff and HSS 1,5,7 - 4,93 -

Form Tools Carbide - 4,93 -

[_
1.5 Threading, Single Point
_ __ _ _
HSS
Carbide
HSS
-
---- 4.93
4.93
-
-

1.6 Threading, Die -..

Carb id e - -- -
1.7 Hollow Milling a
HSS e - .
GarL; Je - --

2.1 Face Millh.g HSS 1, 5,7 -- --

Carbide - - -

2.2 Face Milling Diamond - 4, 93

2.4 Slab Milling HSS 1,5,7 4.93

,_
Carbide -..

2.5 Side and Slot Milling- HSS 1.5,7 . . - ... 4,93 -

Arbor Mounted Cutters Carbide - 4.93 -

2.6 End Mililng-Peripheral HSS 1,5, 7 - 4,93 -

Carbide - 4,93 -
2.8 End Milling-Slotting HSS 1,5,7 -- 4.93 -
C a rb ide ....
2.9 Thread Milling HSS i s. I - 4,93 -

3.1 DrillingSS 1,5,7 _ - ._ 4,93 --

Carbide ....

3.3 Oil-Hole or Pressurized- HSS 1,5,7 -- 4,93 --

Coolant Drilling Carbide - - - 4,93 -

3.4 Spade Drilling HSS - -- 4,93 -

Carbd__-- -- 4,93 -
3 .5 G u n d dllln g HS S ....
Carbide .. 1.
3.6 PresoureCoolant Reaming HSS - j - - -
(Gin Reaming) Carbide -..

3.7 Reaming HSS 1,5,7 -- -

Carbide 2, 5, 7 -- -- --
3.9 Boring HSS 1.5,7 -- 4.93
Carbide - 4.93 --
3.11 Boring Diamond - 493
HSS1,5 -4. 93 -

3.12 Counterborlni, sr.. HSS 1,5,7

SpotfacIng Carbide - 4,93 --
3.13 Trepanning H SS ....
Carbide ...
3.14 onl.kg 9- 93

3.iS Burnishing

4.1 Tapping HSS 2.3 -

16-60
_ _ _.I
 Cutting Fluid Recommendations 16.2

TOOL53. Controlled Expansion 54. Carbons &Graphite*

155. -
Glasses & Ceramics
OPERATION MATERIAL Alloys Machinable Ohe
OR _______ Giass-.eamil Ote
ABRASIVE 125 to 40Oto 100 I 250 I Over

5. Panng250 Bhn -Shore -Knoop 800 Knoop

__________________ Carbide
5.2 Broaching HSS 5,7,3 _____ 0'*
Carbide 5,.7,3 01 -

6.1 Power Hack Sawing HSS 5. 7. 3 04, 93

6.2 Power Band Sawing HSS 5.7,3 0'4,93-

6.4 Circular Sa1wing HSS 5,7, 4,93

6.5 Circular Sawing Carbide 5, 7, 2 0' 4, 93 -

6.6 Abrasive Cutoff 5,7 0' - 4,93

7.1 Gear Hobbing HSS

7.2 Gear Cutting, Straight HSS

and Spiral Bevel__________________
7.3 Gear Shaping HSS

7.4 Gear Shaving HSS

7.5 Gear Grinding, Form 2

8.1 Surface __________ -iz

3 *4,93 4.93
Spdi., Recip. Table
8.2 Surface Grindig-Horiz. CBN M
Spdi., Recip. Tablet
8.3 Surface Grinding-Horiz. Daod -0 ,349
4,93_
____ 4,93__.
Spd1i., Recip. Table Diamond_ _____ _____

8.4 Surf acs, Grinding-Vertical 230 ,349

Table 0_____ 4,93___ 4,93__
Spdi., PIotary 2___3

8.5 Cylindrical Grinding -2,3 0' 4,93 4.,93 M8

8.6 Cylindrical Gt~nding CBN--

8.7 Cylindrical Grinding Daod -0 -49 .3-

8.8 Internal Grinding -23~ .349

8.9 Internal GrIndii.ij CBN _4- -

8.10 Internal Grinding Daod -0 9 9

8.1 enereDiGininm23ond__ t0* ___ 4.93 4.93

8.13 AC. enBeltGrinding W

3 I 0 4.93 4, 3
8.14 Thread Grinding
-2.3
I .
0* 4,93 . 93

be used to aid swanf removal

-Compressed air mnay

16-61 Z
16.2 Cutting Fluid Recommendations

TOOL 56. Plastics 58. Flame (Thermal) Sprayed Materials 60. Precious 61. Rubber
OPERATION MATERIAL Metals
OR
ABRASIVE I

1.1 Turning, Single Point HSS 0,4,6 1 - -

and Box Tools Carbide 0,4.6 1 - -

1.3 Turning Diamond 0,4, 6 -

1.4 Turning, Cutoff and HSS 0.4.6 - 1

Form Tools Carbide 0,4, 6 - -- --

1.5 Threading, Single Point HSS 3. 4, 6 -- -- --

Carbide -..

1.6 Threading, Die HSS 0, 4, 6 -

Carbide - ..
HSS 0,4, 6 -- --
1.7 Hollow Milling
Carbide - -
2.1 Face M illing H SS 0,4, 6 -- -- --
C ar b id e 0, 4 , 6 -- -- --
2.2 Vace Milling Diamond I 0,4,6 -

2.4 Slab Milling HSS 0,4, 6 -- -- --

Carbide 0,4,6 -- -- --
2.5 Side and Slot Milling- HSS 0,4, 6 -- -- --
Arbor Mounted Cutters Carbide 0,4, 6 -- -- .. --
2.6 End Milling-Peripheral HSS 0,4,6
Carbide 0,4, 6 -- --. --
2.8 End Milling-Slotting HSS 0,4, 6 -- -- --
Carbide 0,4,6 -- -- --
2.9 Thread Milling HSS 0.4,6

3.1 Drilling HSS 0, 4,6 -- - -- -

Carbide 0,4, 6 -- -- --
3.3 OIl-Hole or Pressurized- HSS -
Coolant Drilling Carbide -....

3.4 Spade Drilling HSS 0, 4,6 -- -- --

__ _ _ _ _ _ _ _ _ --Carbide - -- -- --
3.5 Gundrilllng HSS .
Carbide -- -- --
3.6 Pressure Coiaent Reaming HSS -
(Gun ReamInG1 Carbide -..

3.7 Reaming HSS 0,4,6

Carbide 0.4.6 -- -- --
3.9 Boring HSS 0,4,6 ___- -
C4rb.de6 0 .46.-

K.12 .31 Orig

Counterboring and

Spotfaclng
Diamond
HSS

Carbide
0, 4,6
0,4.6

0.4.6
_ -
-

.-
_
-

--
- -

3.13 Trepanning HSS .

,.__ __ Carbide - --. -- -- --
3.14 Honing 80

3.15 Burnishing

4.1 Tapping HSS 30Bumishlng..4..

16-62
 Cutting Fluid Recommendations 16.2
60. Precious
TOOL 56. Plastics i 58. Flame (Thermal) Sprayed Materials eals 61. Rubber
OPERATION MATERIAL Silve,
OR _
ABRASIVE

5.1 Planing HSS .

Carbide .
5.2 Broaching HSS 0,1,4,6 -- -- --
Carbide 0,1,4,6
6.1 Power Hack Sawing HSS 0,1,4,6 4,6 81

6.2 Power Band Sawing HSS 0,1,4,6 ,-4,6 81

6.4 Circular Sawing HSS 0,1,4,6 - 4.6 81

6.5 Circular Sawing Carbide 01,46 - 4,6 81

6.6 Abrasive Cutoff - 0,1,4,6 -

7.1 Gear Hobbing HSS 0, 1,4, 6

7.2 Gear Cutting, Straight HSS 0.1,4, 6

and Spiral Bevel
7.3 Gear Shaping HSS 0,1,4, 6

7.4 Gear Shaving HSS 0, 1,4, 6 -

7.5 Gear Grinding, Form _ 0,1,4,6 0,4,6 - -

8.1 Surface Grinding-Horiz. - 0, 1.4, 6 0,4,6 4,6 4,81

Spdl., Reclp. Table
8.2 Surface Grlnding-Horiz. CBN - -
_ _ _
Spdl., Recip. Table ____

8.3 Surface Grindlng-Horiz. Diamond - - 0,4,81

Spdl., Recip. Table
8.4 Surface Grinding-Vertical 0,1,4.6 0,4,6 4, 6 4. 81
Spdl., Rotary Table
8.5 Cylindrical Grinding _ 0,1,4,6 0,4,6 4.6 4,81

8.6 Cylindrical Grinding CBN -- -

8.7 Cylindrical Grinding Diamond - - - 0,4,81

8.8 Internal Grinding - 0. 1.4, C 0,4,6 4,6 4,81

8.9 Iniernal Grinding CBN -..

8.10 Internal Grinding Diamond - - 0,4.81

8.11 Centerless Grinding 0 0,6 4.6 4.81

8.13 Abrasive Belt Grinding 0,1,4,6 4.6 4,81

8.14 Thread Grinding - 0,1,4.6 04.61 1 4,81

16-63
 PECMING PA(Z BLAN[-NOr FIL2D

Cutting Fluid Key 16.3

CODE
NO. TYPE AND TRADE NAME MANUFACTURER

0 DRY

1 OILS-LIGHT DUTY (GENERAL PURPOSE)

Straight Mineral Oil
Lafayette Blending Oil 41 American Oil & Supply Co.
Amoco Neutral Oil. AMOLITE Oil No. 10 thru 68 Amoco Oil Co.
Econ Oil 5. Econ Oil 10 Ashland Oil, Inc.
Diamond Oils, Topaz Oils. Gascon Oils Atlantic Richfield Co.
Mineral Oil H-5 BP Oil. Inc.
Bruko 1C. Bruko 2C. Bruko 3C. Bruko 4C Bruce Products Corp.
Chevron Utility Oil Grade 46 Chevron !'.S.A. Inc.
CITGO Amplex 22. CITGO Amplex 32. CITGO Amplex 46 Cities Service Co.
Cook-Cut B-1. Cook-Cut B-5. Swiss-Cut 1816 Cook's Industrial Lubricants. Inc.
CORAY. FAXAM Exxon Co., U.S.A.
BLENDING OIL 3333 Franklin Oil Corp. (Ohio)
Gulf No. 372 Oil Gulf Oil Corp.
I.C. 41233. International Machine Oil #1 International Chemical Co.
IRMCO 248. IRMCO 249 International Refining & Mfg. Co.
Anza Oil Lubrication Co. of America
VANISHING OIL Magnus Div.. Economic Lab Inc.
Kleer Kut Tri-Work Pillsbury Chemical & Oil, Inc.
Vehicle 6 Process Research Products
43 OIL. 46 OIL G. Whitfield Richards Co.
SYN-KUT 100, SYZ-KUT 300 Henry E Sanson & Sons. Inc.
Space Age Blending Oil Space Age Chemlube
Spindel Oil No. 2 and 4 Specialty Products Co.
Mineral Seal Oil, Factoil 39 Standard Oil Co. (Ohio)
Starcut-37 Star Oil Company
SUZICUT 113 Sun Petroleum Products Co.
300 Oil 5. 522 Oil 19. Almag Texaco Inc.
NB BLENDING OIL Tower Oil & Technology Co.
W&B Cutting O'13016 The White & Bagley Co.
Magnacut. Macco Blending Oil Witco Chemical Corp.
R-100 CUTTING OIL Arthur C. Withrow Co.
ZURN BLENDING OILS O F Zurn Co.

Straight Fatty Oil

Lafayette Lard Oil #2 American Oil &Supply Co.
Brukut 11, Brukut 20 Bruce Products Corp.
Cook-Cut A-1I Cook's Industrial Lubricants. Inc.
W. S. LARD OIL Franklin Oil Corp. (Ohio)
I.C. #661-A. l.C 41259 International Chemical Co.
IRMCO 040 International Refining & Mfg. Co.
Modoc Lard Oil Lubrication Co. offAmerica
DO-12 Magnus Div., Economics Lab Inc.
Gipco Lard #1 Pillsbury Chemical & Oil, Inc.
Special Prime Lard Oil Reilly-Whiteman, Inc.
CUTZOL F.O. 512 Rust-Lick, Inc.
SYN-LARD Henry E. San:-on & Sons, Inc.
fi'ooiie
254 Specialty Proc ucts Co.

16-65 M
__________
16.3 Cutting Fluid Key
CODE
NO. TYPE AND TRADE NAME
MANUFACTURER
1 OILS-LIGHT DUTY (GENERAL PURPOSE)
(Continued)
Straight Fatty Oil (Continued)
LARD OIL Oil 1948
W&B Lard
EWS LARD OIL (CODE 626) Tower Oil & Technology Co
The White & Bagley Co.
Arthur C. W:throw
Co.
Mineral Oil + Fatty Oil
Lafayette SCF-20
American Oil &Supply Co.
AMOCUT Oil No. 144-F
ARCO ML OilsAooOiC. Amoco Oil Co.
Bezora 22
Bzau 22 Atlantic Richfield Co.
Sparkut NF BP Oil. Inc.
Cook-Cut 25. Cook-Cut 30. Cook-Cut 1711 Bruce Products Corp.
FANOX N 33 Cooks Industrial Lubricants, Inc
B-650 CUTTING OIL Exxon Co., U.S.A.
Franklin Oil Corp (Ohio)
Gulfcut I IA
Habcoo1344 Gulf Oil Corp.
H & B Petroleum Co.
Cut-Max 110. Cut-Max 135
I.C. U152, I.C. #880 E. F. Houghton ? Co.
IRMCO 240, IRMCO 242 International Chemical Co
MINERAL LARD OIL International Refining & Mfg. Co.
LPSI LP2.LPS3 Keystone Div., Pennwalt Corp.
DO-A L-12 . LPS Research Laboratories. Inc.
Magnus Div., Economics Lab Inc.
Mobilmet 33. Mobilmet 34. Mobilmet 35
Kleer Kut Dual Work Mobil Oil Corp.
Triple C 5500 Pillsbury Chemical & Oil, Inc.
Non-Ferrous Aid Pro-Cheni Inc.
Petrolard 116, Petrolard 112 Process Research Products
NEAR-A-LARD OIL. SPECIAL NEAR-A-LARD OIL Reilly-Whiteman, Inc.
G. Whitfield Richards Co.
CUTZOL F 0.506. CUTZOL F 0. 509
SYN-KUT 115. SYN-KUT 135 Rust-Lick, Inc.
Space Age Blending Oil-Plus Henry E. Sanson & Sons. Inc.
Toolife 250, Toolife 251, Toolife 256 Space Age Chemlube
Factokut L-2 Specialty Products Co.
Starcut-3950 Standard Oil Co. (Ohio)
Star Oil Company
SUNICUT 150
Sun Petroleum Products Co.
Extra Cutting Oil
TOWER E- 3u Texaco Inc.
Tower Oil & Technology Co.
W&B Minolard Cutting Oil
Magnacut 40 The White & Bagley Co.
''ITHROKUT 104 CUTTING OIL Witco Chemical Corp.
LARDOLEUM 5 Arthur C. Withrow Co.
0 F Zurn Co.
Mineral Oil + Additives
Lafayette B-I 6
American Oil & Supply Co.
AMOCUT Tn-Purpose Cutting Oil
Promax 1110 Amoco Oil Co
Ashland Oil Inc.
Clairo Oils
Sevora 37. Lumaro 25. Lumaro 36 Atlantic Richfield Co.
Belco 1727 Cutting Oil B? Oil. Inc.
Be-Ray Co., Inc.
Brukut 177-X Bruce Products Corp.

16-66
 Cutting Fluid Key 16.3
CODE
NO. TYPE AND TRADE NAME MANUFACTURER

1 OILS-LIGHT DUTY (GENERAL PURPOSE) (Continued)

Mineral Oil + Additives (Continued)
Chevron Metalworking Fluid 504 Chevron U.S.A Inc.
Cook-Cut 70 Cooks Industrial Lubricants. Inc
CURTIS 32-AS Curtis Systems. Inc.
EBONITE DUAL PURPOSE 702 Franklin Oil Corp. (Ohio)
Cmdepol 150. Cindepol 300 E F. Houghton & Co.
I C. #852-A International Chemical Co.
IRMCO 200 Series International Refining& Mfg. Co.
121 Wax Cut S.C. Johnson & Son. Inc.
LPS 1. LPS 2. LPS 3 LPS Research Laboratories. Inc.
Clear-Cut Ax Lubrication Co. of America
L-67. Magna-Draw 10 Magnus Div. Economics Lab Inc.
Translube. Metkut 310 Metalloid Corp.
Mobilmet 33. Mobilmet 34. Mobilmet 35. Mobilmet Omicron. Mobilmet Upsilon Mobil Oil Corp.
Magno Kut #11 Pillsbury Chemical & Oil, Inc.
PC Lapping Oil. LE-2 Process Research Products
NEAR-A-LARD #1 90-H OIL. #4-B OIL. #3-B OIL G Whitfield Richards Co.
CUTZOL 101-C Rust-Lick, Inc.
SYZ-KUT 216. SYZ-KUT 236 Henry E. Sanson & Sons Inc.
Space Age Blending Oil-Plus Space Age Chemlube
Tooiife VO Specialty Products Co.
Sulkleer 177X Standard Oil Co. (Ohio)
Starcut-3180 Star Oil Company
SUNICUT 330 Sun Petroleum Products Co.
Cleartex B Texaco Inc.
TOWERCUT F-901 Tower Oil & Technology Co.
VSCC 5468 Van Straaten Chemical Co.
W&B Cutting Oil 2169 The White & Bagley Co.
WITHROKUT 102 CUTTING OIL Arthur C. Withrow Company

Mineral Oil + Sulfur and Chlorine Compounding

Lafayette B-1 15 American Oil & Supply Co.
Promax 1220 Ashland Oil, Inc.
Chevron Metajwurking Fluid 502 Chevron U.S.A. Inc.
CITGO Cutting Oil 400 Cities Service Co.
Habcool301a H & B Petroleum Co.
IRMCO 200 Series International Refining & Mfg. Co.
Magno Kut #1 Pillsbury Chemical & Oil, Inc.
FRIGIDOL TRANSPARENT CUTTING OIL G. Whitfield Richards Co.
SYN-KUT 9-L Henry E. Sanson & Sons. Inc.
Space Age Blending Oil-Plus. Space Age T-61 Cutting Oil Space Age Chemlube
SUZICUT 350 Sun Petroleum Products Co.
Dualtex Texaco Inc.
W&B Cutting Oil 2169 The White & Bagley Co.
Macco Honing Oil. Macco Broach Oil 4-50, Epcut 31 -BS-1, Maccut 16 Witco Chemical Corp.
WITHROKUT 114 CUTTING OIL Arthur C. Withrow Co.

Mineral Oil + Fatty Oil + Additives

Promax 5352 Ashland Oil, Inc.
Cook-Cut 70 Cook's Industrial Lubricants. Inc.

16-67
____
- -5---- - ----- - - -~-- - -
16.3 Cutting Fluid Key
CODE
NO. TYPE AND TRADE NAME MANUFACTURER

1 OILS-LIGHT DUTY (GENERAL PURPOSE) (Continued)

Mineral Oil + Fatty Oil + Additives (Continued)
DAUBERT MACRON M Daubert Chemical Co.
TF-460 Metalloid Corp
CUTZOL 400-A Rust-Lick. Inc.
Dual Action Cutting Fluid 42 Tapmatic Corp.

2 OILS-MEDIUM DUTY
Sulfurized Mineral Oil
Lafayette B-1 6 American Oil & Supply Co.
AMOCUT Cil No. 1195. AMOCUT Oil No. 159S Amoco Oil Co.
Promax 1004 Ashland Oil. Inc.
Cutting Oil 70. Cutting Oil 100. Cutting Oil 160 Atlantic Richfield Co.
Lumaro 24A BP Oil. Inc.
Brukut 4 Bruce Products Corp.
PETROCHEM 709 Champions Choice. Inc.
Cook-Cut 10. Cook-Cut 4985-Clear Cook's Industrial Lubricants. Inc.
DAUBERT GARIA S Daubert Chemical Co.
PEERLESS CUTTING OIL 3307 Franklin Oil Corp. (Ohio)
IRMCO 269 International Refining & Mfg. Co.
C-5. C-41. C-42. C-47 Lubrication Co. of America
Fine Kut 41 Pillsburv Chemical & Oil. Inc.
FRIGIDOL CUTTING OIL G. Whitfield Richards Co.
CUTZOL S.O 5ul Rust-Lick. Inc.
SYN-KUT 845 Henry E. Sanson & Sons Inc.
Toolife 100 Specialty Products Co.
Starcut-3719 Star Oil Company
SUZICUT 300 Sun Petroleum Products Co.
W&B Sulfurized Mineral Oil 3197 The White & Babley Co.

Compounded Sulfurized Mineral Oil

Lafayette B-1 6 American Oil & Supp!y Co.
AMOCUT Oil No. 11 5FS. AMOCUT Oil No. 155FS Amoco Oil Co.
Promax 1220 Asiiaid Oil. Inc.
Tulkut 160. Honol Oils Atlantic Richfield Co.
Lumaro 34A. Sevora 26A. Sevora 41A. Sevora 53A BP Oil, Inc.
Brukut 41,V. Brukut 102SR Bruce Proaucts Corp.
PETROCHEM 703 Champions Choic", Inc.
Chevron Metalworking Fluid 502 Chevron U.S.A. Inc.
L 2051. L 2052 Chrysler Corp.
DAUBERT GARIA C.DAUBERT GARIA H Daubert Chemical Co.
PEERLESS CUTTING OIL 967 Franklin Oil Corp.(Ohio)
IRMCO 259 International Refiniing & Mfg. Co.
RINCON 180 Lubrication Co. of America
CUTTING COMPOUND No. 6 Magius Div.. Economics Lab Inc.
Mobilmet 25. Mobilmet 26. Mobalmet 715. Mobilmet 735. Mobilmet A!pha.
Mobilmet Sigma Mobil Oil Corp.
Fine Kut 41 Pillsbury Chemical & Oil, Inc.

16-68
 Cuffing Fluid Key 16.3

CODE
NO. TYPE AND TRADE NAME MANUFACTURER

2 OILS-MEDIUM DUTY (Continued)

Compounded Sulfurized Mineral Oil (Continued)
FRIGIDOL L-6 CUTTING OIL G. Whit.eld Richards Co.
SYZ-KUT 2023 Henry E.Sanson & Sons, Inc.
Space Age Z-33 Cutting Oil Space Age Chenlube
Sulkleer 19E, Sulkleer 30. Sulkleer 102S. Sulkleer 163A Standard Oil Co. (Ohio)
Starcut-3531 Star Oil Company
SUZICUT 400 Sun Petroleim Products Co.
TREFOLEX Cutting Compound Trefolex Industries, Inc.
VSCC 5601 Van Straaten Chemical Co.
W&B Cutting Oil 2151 The White & Bagley Co.
B-5 CUTTING OIL Arthur C. Withrow Co.

Chlorinated Mineral Oil

Lafayette CP-6535 American Oil & Supply Co.
AMOCUT Tri-Purpose Cutting Oil Amoco Oil Co.
TECTYL H-i40. PROMAX 1940 Ashland O!, Inc.
Chevron Metalworking Fluid 504 Chevron U.S.A. Inc.
Cook-Cut 4938, Cook-Grind 4903 Cook's Industrial Lubricants, Inc.
Cindol 3106 E. F. Houghton & Co.
I.C #484-M. I.C. #484-MS International Chemical Co.
Hon-E-Kut 740-3 Lubrication Co. of America
CUTTING COMPOUND No. 2, MAGNU DRAW 30 Magnus Div., Economics Lab Inc.
Taplube, Translube, Multi-slide 21 Metalloid Corporation
Spun Gold 41 Pillsbury Chemical & Oil. Inc.
Rapid Tap Relton Corp.
LUBE-A-TUBE "EP"#6COMPOUND, LUBE-A-TUBE "EP" 4214-P
COMPOUND G. Whitfield Richards Co.
CUTZOL 101 -C,CUTZOL 711 Rust-Lick, Inc.
CLARET-KUT 21 Henry E.Sanson & Sons, Inc.
Space Age Z-34 Cutting Oil Space Age Cherlfube
Toolife 703, Toolife 705 Specialty Products Co.
Starcut-3260 Star Oil Company
SUNICUT 201 Sun Petroleum Products Co.
Dual Action Cutting Fluid #1 Tapmatic Corp.
VSCC 5487-G Van Straaten Chemical Co.
W&B Cutting 2981 The White & Bagley Co.

Sulfo-Chlorinated Mineral C11

Lafayette A-13 American Oil & Supply Co.
AMOCUT Oil 117 BCS Amoco Oil Co.
Promax 1401, Pronmax 1455 Ashland Oil, Inc.
Brukut #*7 Bruce Products Corp.
PETROCHEM 704 Champions Choice, Inc.
Chevron Metalworking Fluid 503 Chevron U.S.A. Inc.
L 402, L 405, L 407 Chrysler Corp.
MITEE Clear Thread Cutting Oil DAP, Inc.
I.C. #1280-A International Chemical Co.
IRMCO 220 International Refining & Mfg. Co.
LCA Speed-Cut 105,102,104, 104B, 103 Lubrication Co. of America
Flash Kut 101 Pillsbury Chemical & Oil, Inc.

16-69
71- 7n
16.3 Cuffing Fluid Key
CODE
NO. TYPE AND TRADE NAME MANUFACTURER

2 OILS-MEDIUM DUTY (Continued)

Sulfo-Chlorinated Mineral Oil (Continued)
FRIGIDOL 4401 -T COMPOUND G. Whitfield Richards Co.
SYN-KUT 99-L Henry E. Sanson & Sons. Inc.
Space Age Z-35 Cutting Oil Space Age Chemlube
Starcut-3531 Star Oil Company
SUNICUT 510 Sun Petroleum Products Co.
W&B Cutting Oil 2151 The White & Bagley Co.
"WADCO'"Cutting and Threading Oil J. C. Whitlam Manufacturing Co.

Sulfurized Mineral Oil + Fatty Oil

Lafayette F-14 American Oil & Supply Co.
AMOCUT Oil No. 155FS Amoco Oil Co.
Promax 1023 Ashland Oil. Inc.
Autokut Oils P tlantic Richfield Co.
Sevora 26A, Sevora 41A. Sevora 53A BP Oil. Inc.
PETROCHEM 703 Champions Choice. Inc.
Cook-Cut 15, Cook-Cut 40. Cook-Cut 1880 Cook's Industrial Lubricants. Inc.
MITEZ Dark Thread Cutting Oil DAP. Inc.
DAUBERT GARIA C, DAUBERT GARIA H Daubert Chemical Co.
PENNEX N 40 Exxon Co.. U.S.A.
PEERLESS 930 Franklin Oil Corp. (Ohio)
Gulfcut 31A, Gulfcut 31C Gulf Oil Corp.
IRMCO 259 International Refining & Mfg. Co.
Clear Cutting Oil C-47 Lubrication Co. of America
... lvlUict 24. Iviubihnet 25, Mobilmet 26. Mobilmet 37. Mobilmet 715.
Mobilmet 735, Mobilmet Alpha, Mobilmet Sigma Mobil Oil Corp.
Flash Kut 101 Pillsbury Chemical & Oil. Inc.
FRIGIDOL BASE -A*COMPOUND G. Whitfield Richards Co.
CUTZOL C.F.O. 507 Rust-Lick, Inc.
SYZ-KUT 320 Henry E Sanson & Sons. Inc.
Space Age Z-36 Cutting Oil Space Age Chemlube
Toolife 1 3 Specia.., Products Co.
Sulkleer 30 Standard Oil Co. (Ohio)
Starcut-3570 Star Oil Company
SUN ICUT 400 Sun Petroleum Products Co.
W&B Cutting Oil 1749 The White & Bagley Co.
WITHROKUT 132 CUTTING OIL Arthur C. Withrow Co.

Chlorinated Mineral Oil + Fatty Oil

Lumaro 36 BP Oil. Inc.
L 415 Chrysler Corp.
Cook-Cut 55. Swiss-Cut 51 Cook's Industrial Lubricants, Inc.
CURTIS 64-AS Curtis Systems. .nc.
DAUEERT MACRON M Daubert Chemical Co.
PEERLESS 1211 Franklin Oil Corp. (Ohio)
I.C. #152-S. I.0. 4818 International Chemical Co.
IRMCO 754 International Refining & Mfg. Co.
Hon-E-Kut Lubrication Co. of America
EL CUT S Magnus Div.. Economics Lab Inc.
Metkut 4310, TF-308 Metalloid Corp.

16-70
 Cutting Fluid Key 16.3
CODE
NO. TYPE AND TRADE NAME MANUFACTURER

2 OILS-MEDIUM DUTY (Continued)

Chlorinated Mineral Oil + Fatty Oil (Continued)

Spun Golu 412 Pillsbury Chemical & Oil. Inc.
Petrosan EP43 Reilly-Whiteman. Inc.
NEAR-A-LARD #190-LV OIL. NEAR-A-LARD 413 G. Whitfield Richards Co.
CUTZOL C.F 0. 509. CUTZOL LC. HONZOL 11 -B Rust-Lick. Inc.
SYN-KUT 3401. SYN-KUT M-2 Henrl, E. Sanson & Sons Inc.
Toolife 150. Toohfe Swiss Sc, ew Machine No. 3 Specialty Products Co.
Starcut-3360 Star Oil Company
W&B Cutting Oil 2871 The White & Bagley Co.
WITHROKUT 110 CUTTING OIL Arthur C. Withrow Co.

Mineral Oil With Fatty Compounding + Sulfur and Chlorine Additives

Promax 5352. Promax 1310 Ashland Oil. Inc.
Cilora 19A. Lumaro 40A BP Oil. Inc.
Brukut 9. Brukut 102. Brukut 102S. Bruko D-648 Bruce Products Corp.
Chevron Metalworking Fluid 503 Chevron U.S.A. Inc.
L 2045 Chrysler Corp.
CITGO Cutting Oil 425 Cities Service Co.
Cook's RTP Cutting Oil 4768 Cook's Industrial Lubricants, Inc
DAUBERT GARIA D Daubert Chemical Co.
DORTAN N 14 Exxon Co., U.S.A.
Habcool 250 H & B Petroleum Co.
I.C. 4634 International Chemical Co.
Mobilmet 715. Mobilmet 735 Mobil Oil Corp.
Triple C 53611 Pro-Chem Inc
FRF-9i i2 Process Research Products
FRIGIDOL #401-P COMPOUND G. Whitfield Richards Co.
SYN-KUT 725. SYN-KUT 750 Henry E. Sanson 8&Sons Inc.
Space Age Z-37 Cutting Oil Space Age Chemlube
Sulkleer 177X Standard Oil Co. (Ohio)
SUNICUT 352 Sun Petroleum Products Co.
Transultex A.Transultex F Texaco Inc.
TOWERCUT F-932 Tower Oil & Technology Co.
W&B Cutting Oil 2688 The White & Bagley Co.
WITHROKUT 136 CUTTING OIL Arthur C. Withrow Co.
ZURNKUT 3 L X O F Zurn Co.

Sulfo-Chlorlnated Mineral Oil + Fatty Oil

Lafayette C- i 15 Amcrican Oil & Supply Co.
AMOCUT Oil 139 BCS Amoco Oil Co.
Promax 1002 Ashland Oil. Inc.
Belco Cutting Oil 1735 Bel-Ray Co.. Inc.
PETROCHEM 704 Champions Choice, Inc.
Chevron Metalworking Fluid 503 Chevron U.S.A. Inc.
( ook-Cut 4984-Dark. Cook-Cut 4889 Cook's Industrial Lubricants, Inc.
No. 80 Cutting Oil DoALL Co.
DORTAN N 34 Exxon Co., U.S.A.
Gulfcut 41 M Gulf Oil Corp.
Cut-Max 206 E. F. Houghton & Co.
I.C. 4283-C International Chemical Co.

16-71
16.3 Cutting Fluid Key
CODE
NO. TYPE AND TRADE NAME MANUFACTURER

2 OILS-MEDIUM DUTY (Continued)

Sulfo-Chlorinated Mineral Oil + Fatty Oil (Continued)
IRMCO 268 International Refining & Mfg. Co.
Flash Kut 11 Pillsbury Chemical & Oil. Inc.
FRIGIDOL #401 COMPOUND G. Whitfield Richards Co.
SYZ-KUT 206, SYN-KUT 226. SYN-KUT 246 Henry E. Sanson & Sons Inc.
Space Age Z-38 Cutting Oil Space Age Chemlube
Toolife 202 Specialty Products Co.
Starcut-3531 Star Oil Company
SUZICUT 500 Sun Petroleum Products Co.
W&B Cutting Oil 2688 The White & Bagley Co.
Maccut 11 Concentrate. Maccut 16 BGA, Maccut 1652 DO. Maccut 19 BG Witco Chemical Corp.
ZURN ULTRAKUT 70 S 1 0 F Zurn Co.

Compounded Sulfo-Chlorinated Mineral Oil + Fatty Oil

Lafayette C-75 American Oil & Supply Co.
AMOCUT Oil 168 EC Amoco Oil Co.
Promax 1002 Ashland Oil. Inc.
Transkut Oils Atlantic Richfield Co.
Cilora 39A, Cilora 59A BP Oil, Inc.
PETROCHEM 704 Champions Choice. Inc.
Chevron Metalworking Fluid 503 Chevron U.S.A. Inc.
Cook-Cut 20. Cook-Cut 1545 Cook's Industrial Lubricants. Inc.
DAUBERT GARIA D Daubert Chemical Co.
Gulfcut 41D. Gulfcut 4 1E Gulf Oil Corp.
I.C, #1884-T International Chemical Co.
IRMCO 215 International Refining 8 Mfg. Co.
LUBRICOOL 175 Larson Chemical Specialties
Magno Base 201 Pillsbury Chemical & Oil. Inc.
Gear Lap 2S Process Research Products
FRIGIDOL ,401-PX COMPOUND G. Whitfield Richards Co.
BOOSTER-KUT 50 Henry E. Sanson & Sons. Inc.
Space Age Z-39-Cutting Oil Space Age Chemlube
Starcut-3671 Star Oil Company
SUNICUT 500 Sun Petroleum Products Co.
TOWERCUT D-904 Tower Oil & Technology Co.
VSCC 5299 Van Straaten Chemical Co. "
W&B Cutting Oil 2688 The White & Bagley Co.
Maccut 1652 DO, Maccut 18-L Witco Chemical Corp.

3 OILS-HEAVY DUTY
Sulfurized Mineral Oil
AMOCUT Oil No. 159S Amoco Oil Co.
PETROCHEM 709 Champions Choice, Inc.
CITGO Cutting Oil 110 Cities Service Co.
Cook-Cut 4985-Clear Cook's Industrial Lubricants, Inc.
PEERLESS 3307 Franklin Oil Corp. (Ohio)
Smooth Cut 111. 112,113,114 Lubrication Co. of America

16-72
 Cutting Fluid Key 16.3
CODE
NO. TYPE AND TRADE NAME MANUFACTURER

3 OILS-HEAVY DUTY (Continued)

Sulfurized Mineral Oil (Continued)
Komp Kut 5493 Pillsbury Chemical and C-1 Inc
SYN-KUT 2023 AB H-enry E. Sanson & So.-- Inc.
Space Age 49-1 -Cutting Oil Space A,-- Chenmlube
Starcut-3068 Star Oil Company
SUNICUT 300 Sun Petroleum Products Cc,
W&B Sulfurized Mineral Oil 3197 The White & Bagley Co.

Compounded Sulfurized Mineral Oil

AMOCUT Oil No. 189FS. AMOCUT Oil No. i 55FS Amoco Oil Co
Promax 1130-S Ashland Oil. Inc.
Cilora 39A. Cilora 59A. Luniaro 40A. Sevora 53A BP Oil. Inc.
Belco Cutting Oil S-1 191 Bel-Ray Co.. Inc.
Bruko D-269 Bruce Products Corp.
PETROCHEM 703 Champions Choice. Inc.
CITGO Cutting Oil 120 Cities Service Co.
Cook-Cut 4669. Cook-Cut 4770. Cook's Base 4876 Cook's Industrial Lubricants. Inc.
DAUBERT GARIA D. DAUBERT GARIA G Daubert Chemical Co
PEERLESS 977. PEERLESS 967 Franklin Oil Corp. (Ohic4
Mobilmet 27. Mobilmet 45. Mobilmet 814. Mobilmet 826. Mobilmet 833.
Mobilmet Gamma. Mobilmet Omega Mobil Oil Corp.
Gipco"A*' Pillsbury Chemical and Oil. Inc.
FRIGIDOL CUTTING OIL G. Whitfield Richards Co.
SYN-KUT BASE 55 Heary E. Sanson &Sons. Inc.
Space Age 49-2 Cutting Oil Space Age Chemlube
Sulkleer 30. Suilkleer 102S Standard Oil Co. (Ohio)
Starcut-30tb8 Star Oil Company
SUNICUT 415 Sun Petroleum Products Co.
TOWER B-I 136 Tower Oil and Technology Co.
VSCC 5299 Van Straaten Chemical Co.
W&B Cutting Oil 2555 The White & Bagley Co.

Chlorinated Mineral Oil

Lafayette CP-6535 American Oil & Suppsy Co.
Proma,:Q-1 013 Ashland Oil. Inc.
Bruko D-337 Bruce Products Corp.
Cooks Base 1241. Cooks Base 4676 Cook's Industrial Lubricants. Inc.
PEERLESS 1211. TAPPING COMPOUND 1715 Fran~klin Oil Corp. (Ohio)
I.C. 4871 International Chemical Co.
.22 Wax Cut S. C. Johrsoa &Son. Inc.
KOOLMIST FORMULA #88 TAP WAX Kool Mist Corp.
DO-91. DO-2A. MAGNU DRAW 40. MAGNU DRAW SOL.4
CHLOROLUBE 50H Magnus Div.. Economics Lab Inc%
Hon-E-Cut 740.741. 742 Lubrication Co. of America
Plastrol. Metdraw 407. Metdraw 446 Metalloid Corp.
Spun Gold #i3 Pillsbury Chemical and Oil. Inc.I
Die Gard 84 Reilly-Whiteman. Inc.
LUBE-A-TUBE; 81 COMPOUND C- Whitfield Richards Co. :
CUTZOL 711 Rust-Lick. Inc.
CLARET-KIJT 35. CLARET-BASE Henry E. Sanson &Sons. Inc.

16 -73

- - ---- - ~ ~ ~ -zEPA
16.3 Cuffing Fluid Key
CODE
NO. TYPE AND TRADE NAME MANUFACTURER

3 OILS-HEAVY DUTY (Continued)

Chlorinated Mineral Oil (Continued)
Space Age 49-3 Cutting Oil Space Age Cherlube
Toolife 720. Toolife 740. Toolift- 770 Specialty Pro-ducts Co
Starcut-3260 Star Oil Company
SUNICUT 201 Sun Petroleum Products Co.
TOWER A-1123 Tower Oil and Technology Co.
VSCC 5487-G Van Straaten Chemicai Co.
W&B Cutting Oil 2981 The White & Bagley Co.
WITHROBASE 434 CONCENTRATE At hur C. Withrow Co.

Sulfurized Mineral Oil + Sulfur, Chlorine, and Phosphorus Compounding

Bruko D-643 Bruce Products Corp.
Cook-Cut 4749. Cook-Grind 4806. Cook-Cut 4895. Cook's Base 4601 Cook's Industrial Lubr;caris. Inc.
IRMCO 793 International Refining & Mfg. Co.
VISTA*KUT Heavy Duty Lubrication Co. of America
Triple C 5401 Pro-Chem Inc.
SYN-KUT FGO Hearv E. Sanson & Sons !nc
Toolife 203 Speciaitv P.'oducts Co.

Sulfo-Chlorinated Mineral Oil

Lafayette A-I 3 Amc: ican Oil & Supply Co.
AMOCUT Oil No. 139 BCS. AMOCUT Oil No. 209 BCS Amoco Oil Cc.
Prornax 1455-S Ashland Oil. Inc.
PETROCHEM 707 Champion-s Choice. Mc.
Chevron Metalworking Fluid 503 Chevron U.S.A. Inc.
CITGO Cutting Oil 130 Cities Service Co.
Cook-Cut 4515 Cooks Industrial Lubricants. Inc.
I.C. _1226 International Chemical Cc..
Thread Mate 101. 110. 202.225 Lubrication Co. of America
Tapeze X-2. Thredwell Metalloid Corp.
Black Velvet Pillsbur- Chemical and Oil. Inc.
FRIGIDOL TRANSPARENT CUTTING OIL. FRIGIDOL BASE L
COMPOUND G. Whitfield Richards Co.
CLARET-KUT 570. CLARET-KUT 27 Henry E. Sanson & Sons Inc.
SWEPCO 705 Heavy Duty Cutting Oil Eouthwctern Petroleum Corp. |
Space Age Chemlube
Space Age 49-4 Cutting Oil
Toolife 201 Specialty Products Co.
Starcut-3033 Star Oil Company
SUNICUT 510 Sun Petroleum Products Co.
TOWERCUT D-908 Tower Oil and Technolog" Co.
W&B Cutting Oil 2151 The White &Bagley Co.

Sulfurized Mineral Oil + Fatty Oil

AMOCUT Oil No. 189FS. AMOCUT Oil No. 155FS Amoco Oil Co.
Promax 1023. Promax 1130-S. Promax 1160 Ashland Oil. Inc.
Autokut Ois Atlantic Richfield Co.
Cook's Honing Oil 1995. Cook-Cut 1998. Cook-Cut 4950 Cook's Industrial Lubricants. Inc.
No. !20 Cutting Oil DoALL Co.
PEERLEISS 930 Frank!in Oil Corp. (Ohio)
Gulfcut 31C Gulf Oil Corp.

16-74
 Cutting Fluid Key 16.3
CODE
NO. TYPE AND TRADE NAME MANUFACTURER

3 OILS-HEAVY DUTY (Continued)

Sulfurized Mineral Oil + Fatty Oil (Continued)
IRMCO 266 International Refining & Mfg. Co
KEYCUT 101 Keystone Division/Pennwalt Corp.
Mobilmet 27. Mobilmet 29. Mobilmet 45. Mobilmet Gamma, Mobilmet Omega Mobil Oil Corp.
Spun Gold 414 Pillsbury Chemical and Oil. Inc.
FRIGIDOL BASE "A"COMPOUND G.Whitfield Richards Co.
CUTZOL SFO-507 Rust-Lick. Inc.
SYN-KUT 310 Henry E. Sanson & Sons, Inc.
Space Age 49-5 Cutting Oil Space Age Chemlube
Toolife 102 Specialty Products Co.
Sulkleer 30 Standard Oil Co. (Ohio)
Starcut-361 Star Oil Company
SUNICUT 400 Sun Petroleum Products Co.
W&B Cutting Oil 2555 The White & Bagley Co.
WITHROBASE 424 CONCENTRATE Arthur C. Withrow Co.
Chlorinated Mineral Oil + Fatty Oil
TECTYL H-2, PROMAX 1002, TECTYL H-22. PROMAX 1022 Ashland Oil, Inc.
Bruko D-591, Bruko D-579 Bruce Products Corp.
Swiss-Cut 57,Swiss-Cut 71, Swiss Base 1956 Cook's Industrial Lubricants, Inc.
CURTIS 55-CUT Curtis Systems, Inc.
No. 150 Cutting Oil DoALL Co.
Cut-Max 568 E. F. Houghton & Co.
I.C. 0484-EW, I.C. #845 International Chemical Co.
IRMCO 754 International Refining& Mfg. Co.
X-60 Metalloid Corp.
Die Gard 89 Reilly-Whiteman, Inc.
NEAR-A-LARD #20-A OIL G.Whitfield Richards Co.
CUTZOL LC, HONZOL I1-B Rust-Lick, Inc.
CLARET-KUT 10 Henry E. Sanson & Sons, Inc.
SWEPCO 725 EXTRA Heavy Duty Cutting Oil Southwestern Petroleum Corp.
Space Age 49-6 Cutting Oil Space Age Chemlube
Toolife 254. Toolife Swiss Screw Machine No. 1. Toolife Swiss Screw
Machine No. 2 Specialty Products Co.
Starcut-3361 Star Oil Company
TOWER A-1 123 Tower Oil and Technology Co.
W&B Cutting Oil 2872 The White & Bagley Co.
WITHROBASE 436 CONCENTRATE Arthur C. Withrow Co.

Sulto-Chlorinated Mineral Oil + Fatty Oil

Lafayette C-13 American Oil & Supply Co.
AMOCUT Oil No. 139 BCS, AMOCUT Oil No. 209BCS, AMOCUT
Oil No. 309 BCS Amoco Oil Co.
Promax 1310 Ashland Oil, Inc.
Cilora 39A 1? Oil. Inc.
Bruko D-621A Bruce Products Corp.
PETROCHEM THREAD KUT DARK Champions Choice, Inc.
Chevron Metalworking Fluid 503 Chevron U.S.A. Inc.
CITGO Cutting Oil 140 Cities Service Co.
Cook-Cut 1685, Cook-Cut 4949, Cook-Cut 4559 Cook's Industrial Lubricants, Inc.

16-75

-I
16.3 Cutting Fluid Key
CODE
NO. TYPE AND TRADE NAME MANUFACTURER

3 OILS-HEAVY DUTY (Continued)

Sulfo-Chlorinated Mineral Oil + Fatty Oil (Continued)
No. 240 Cutting Oil DoALL Co.
DORTAN N 36 Exxon Co.. U.S.A.
Gulfcut 45A Gulf Oil Corp.
Cut-Max 236, Cut-Max Base 7 E. F. Houghton & Co.
I.C. #283-C. I.C. #629. I.C. #1220-A International Chemical Co.
IRMCO 229 International Refining & Mfg. Co.
Threadmate 110 Lubrication Cr of America
Black Velvet 77 Pillsbury Chem'cal and Oil, Inc.
LUBE-A-TUBE "EP-MR" #6 OIL, FRIGIDOL #401 -P COMPOUND G. Whitfield Richards Co.
SYN-KUT SPECIAL 725, SYN-KUT SPECIAL 750 Henry E. Sanson & Sons. Inc.
Space Age 49-7 Cutting Oil Space Age Chemlube
Sulkleer 19E, Sulkleer 102S, Sulkleer 163A Standard Oil Co. (Ohio)
Starcut-3031 Star Oil Company
SUZICUT 501 Sun Petroleum Products Co.
TOWERCUT D-908 Tower Oil and Technology Co.
VSCC 5495 Van Straaten Chemical Co.
W&B Cutting Oil 2698 The White & Bagley Co.
Maccut 11 Concentrate, Maccut 16 BGA. Maccut 1652 DO Witco Chemical Corp.
WITHROKUT 158 CUTTING OIL Arthur C. Withrow Co.

Compounded Sulfo-Chlorinated Mineral Oil + Fatty Oil

Lafayette B-16 American Oil & Supply Co.
Promax 1022 Ashland Oil, Inc.
Ordnance Oils Atlantic Richfield Co.
Belco 730-S Cutting Oil Bel-Ray Co., Inc.
Bruko D-647, Bruko D-637 Bruce Products Corp.
PETROCHEM THREAD KUT DARK Champions Choice, Inc.
Chevron Metalworking Fluid 503 Chevron U.S.A. Inc.
Cook-Cut 20, Cook-Cut 1545, Cook-Tap #1, Cook-Tap 1157 Cook's Industrial Lubricants, Inc.
DAUBERT GARIA D, DAUBERT GARIA G Daubert Chemical Co.
PENNEX N 47 Exxon Co., U.S.A.
Gulfcut 45B. Gulfcut 21D Gulf Oil Corp.
Habcool 318, Habcool 277 H & B Petroleum Co. P-m
I.C. #815-A, I.C. #1894 International Chemical Co.
IRMCO 790 International Refining & Mfg. Co.
M-60-3 S. C. Johnson & Son, Inc.
Exzact 750 Lubrication Co. of America
Black Velvet 25 Pillsbury Chemical and Oil, Inc.
LUBE-A-TUBE "EP-M" COMPOUND, FRIGIDOL #401-A COMPOUND G. Whitfield Richards Co.
BOOSTER-KUT PLV
Space Age 49-8 Cutting Oil
Toolife 205
Henry E. Sanson & Sons, Inc.
Space Age Chemlube
Specialty Products Co.
I
Starcut-3461 Star Oil Company
SUNICUT 500 Sun Petroleum Products Co.
TOWERCUT D-908 Tower Oil and Technology Co.
VSCC 5510-R, VSCC 5700 Van Straaten Chemical Co.
W&B Cutting Oil 2192 The White & Bagley Co.
Maccut 1652 DO, Maccut 18-L Witco Chemical Corp.
WITHROKUT 203 CUTTING OIL Arthur C. Withrow Co.

16-76
 Cutting Fluid Key 16.3
COUE
NO. TYPE AND TRADE NAME MANUFACTURER

3 OILS-HEAVY DUTY (Continued)

Sulfo-Chlorinated Fatty Oil
Promax H-333 Ashland Oil. Inc.
Cook's Compound A710 Cook's Industrial Lubricants, Inc.
IRMCO 252 International Refining & Mfg. Co.
Elcoa Base 201 Lubrication Co. of America
Magno Base 41 Pillsbury Chemical and Oil. Inc
LUBE-A-TUBE "EP-M" COMPOUND G. Whitfield Richards Co.
SYN-KUT 99 Henry E. Sanson & Sons Inc.
Space Age 49-9 Cutting Oil Space Age Chemlube
Toolife 208 Specialty Products Co.
W&B Base 2844 The White & Bagley Co.

Sulfurized Fatty Oil

Promax H-3 Ashland Oil, Inc.
Cadrex #1, Safrex #1 Cook's Industrial Lubricants, Inc.
IRMCO 055 International Refining & Mfg. Co.
Nu-Mac 11 Lubrication Co. of America
CUTTING BASE 66 Magnus Div., Economics Lab Inc.
Gipco Base 11M Pillsbury Chemical and Oil, Inc.
FRIGIDOL BASE "V" COMPOUND, FRIGIDOL BASE "VR" COMPOUND G. Whitfield Richards Co.
CUTZOL SFO-507 Rust-Lick, Inc.
SYN-KUT 340 Henry E. Sanson & Sons Inc.
Toolife Base 17, Toolife 404 Specialty Products Co.
W&B Base L The White & Bagley Co.
"RUGGED CUT" Cutting and Threading Oil J. C. Whitlam Manufacturing Co.
WITHROBASE 423 CONCENTRATE Arthur C. Withrow Co.
Mineral Oil + Added Fat, Sulfur, Chlorine, and Phosphorus Compounding
Cook's Base 4601. Cook-Cut 4749, Cook-Grind 4806 Cook's Industrial Lubricants, Inc.
Gulfcut 41H Gulf Oil Corp.
I.C. #1885 International Chemical Co.
IRMCO 791 International Refining 8 Mfg. Co.
LUBRICOOL 280 Larson Chemical Specialties
Specialube H-104 Lubrication Technology, Inc.
Sintolin X-2 Process Research Products
SYN-KUT FGO Henry E. Sanson & Sons Inc.
Sultex F Texaco Inc.
ZURN ULTRAKUT 70 S O F Zurn Co.

4 EMULSIFIABLE OILS-LIGHT DUTY (GENERAL PURPOSE)

Soluble Oil
Lafayette Soluble Oil #1 American Oil & Supply Co.
AMOCOOL Soluble Oil, Amocool Soluble Oil Amoco Oil Co.
Adsol 1, Adsol 100 Ashland Oil, Inc.
Crystex Sol. Oil, Emulsicool Sol. Oil, RISO Sol. Oil, Sol Oil DO, Sol. Oil Z,
Tooltex Sol. Oil, No. I Sol. Oil, 943 Sol. Oil Atlantic Richfield Co.
Soluble Oil #371, Fedaro CM, Fedara GS. Fedaro HW, Fedaro SB BP Oil, Inc.

16-77

~
.--- l m..- - - o - . . , . _- . _ -- - . : _ .. .
16.3 Cutting Fluid Key
CODE
NO. TYPE AND TRADE NAME MANUFACTURER

4 EMULSIFIABLE OILS-LIGHT DUTY (GENERAL PURPOSE) (Continued)

Soluble Oil (Continued)
Barco Soluble Oil 15 Bel-Ray Co. Inc.
Brusol A Bruce Products Corp.
PETROCHEM SOLUBLE OIL Champions Choice. Inc.
Chevron Soluble Oil Chevron U.S.A. Inc.
L 470. L 481. L 493. L 3022 HW. L 3033 NB Chrysler Corp.
CITGO Cutting Oil 205. CITGO Cutting Oil 210 Cities Service Co.
Cook-Cool 500. Cook-Cool 1235 Cook's Industrial Lubricants. Inc.
COOL SPEED 500. DAUBERT DROMUS B Daubert Chemical Co.
No. 470 Soluble Oil DoALL Co.
KUTWELL 30. KUTWELL 40 Exxon Co.. U.S.A.
TOOL COOL 1854 Franklin Oil Corp. (Ohio)
Fremont-7040. Fremont-7042. Fremont-7043. Fremont-7045 Fremont Industries, Inc.
Gulfcut Soluble Oil Gulf Oil Corp.
Habcool 747 H & B Petroleum Co,
A.S.O. E. F. Houghton & Co.
!.C. #1651. Tooleze #2000 International Chemical Co.
KEYCUT SOLUBLE OIL Keystone Division/Pennwalt Corp.
301. 303. 304. 333, 309, 322 Solutie Oils Lubrication Co. of America
CLEAN CUT. MAGNA COOL CC. EL SOL R Magnus Div./Economics Lab Inc.
TRIM SOL LC Master Chemical Corp.
Metsol. Oxitrol Air-O-Mist Metalloid Corp.
Hamikut Harry Miller Corp.
Mobilmet S-123. Mobilmet S-127. Mobilmet 104 Mobil Oil Corp.
Oakite Formula 59 Oakite Products. Inc.
Cutlass C 5500 Pillsbury Chemical & Oil. Inc.
Polar Sol 500 Polar Chip, Inc.
Triple C 3000 Pro-Chem Inc.
Rycosol 19, Cupromul 23 Reilly-Whiteman, Inc.
LUBE-WELL D-100 SPECIAL SOLUBLE OIL. LUBE-WELL S-42
SOLUBLE OIL G. Whitfield Richards Co.
CUTZOL WS-10. CUTZOL WS-11 Rust-Lick, Inc.
SYN-SOL D A, SYN-SOL 60, ANTISEPTIC SOLUBLE OIL Henry E. Sanson & Sons Inc.
Space Age T-61 Cutting Oil, Space Age Z-33 Cutting Oil. Space Age Z-34
Cutting Oil, Space Age Z-35 Cutting Oil, Space Age Z-36 Cutting Oil,
Space Age Z-37 Cutting Oil, Space Age #78, Soluble Oil 20-1 Space Age Chemlube
Toolife 301 Specialty Products Co.
Staysol 4X. Staysol 77 Standard Oil Co. (Ohio)
Starsol-2950 Star Oil Company
SECO, SECO 11 Sun Petroleum Products Co.
Soluble Oil D Texaco Inc.
TOWERSOL H-978 Tower Oil & Technology Co.
VSCC 255-A, VSCC 653 Van Straaten Chemical Co.
W&B RP Soluble Oil 1999 The White & Bagley Co.
Macco 163, 230-JL-3. Grinding oil 445 Witco Chemical Corp.
WITHROSOL 310 SOLUBLE OIL, WITHROSOL 315 SOLUBLE OIL Arthur C. Withrnow Co.
ZURNSOL 19 0 F Zurn Co.

16-78
 Cutting Fluid Key 16.3
CODE
NO. TYPE AND TRADE NAME MANUFACTURER

4 EMULSIFIABLE OILS-LIGHT DUTY (GENERAL PURPOSE) (Continued)

Semichemical
AMOCOOL Transparent Coolant Amoco Oil Co.
Brukool 127 Bruce Products Corp.
COOL SPEED 515 Daubert Chemical Co.
TOOL COOL AR SOLUBLE Franklin Oil Corp. (Ohio)
I.C. 124 Intei national Chemical Co.
IRMCO 302 International Refining & Mfg. Co.
Hamikleer Harry Miller Corp.
CHOICE-CUT Monroe Chemical Co. Inc.
Hy Kut 9737 Pillsbury Chemical & Oil, Inc.
Triple C 3020 Pro-Chem Inc.
Sintolin OP2. HD Process Research Products
Rycosol 60 SDG Reilly-Whiteman. Inc.
GWR COMPOUND G. Whitfield Richards Co.
CUTZOL WS-5100 Rust-Lick. Inc.
SYN-KUT 125-P Henry E. Sanson & Sons. Inc.
Ami-Lube X-15 Tron-X Research Corp.
VSCC 938 Van Straaten Chemical Co.
W&B Lubricant 1888 The White & Bagley Co.
Macco 158-C, Macco Syncrocut 167-DM-9, New Solube-D Witco Chemical Corp.

Semlsynthetic
Brukool 82-C. Brukool 121 Bruce Products Corp.
12 D 192 Chrysler Corp.
Cook-Coolex 40, Cook-Cool 1300, Cook-Cool 4893 Cook's Industrial Lubricants. Inc.
COOL SPEED 363 Daubert Chemical Co.
TOOL COOL 1369 Franklin Oil Corp. (Ohio)
I.C. #343-S International Chemical Co.
J-Cool. Trampol-X, Coldstream S. C. Johnson & Son. Inc.
CLEAR-CUT C Larson Chemical Specialties
Heavy Duty 302 Carbo-Flo, Florosol Lubrication Co. of America
Hamikleer Harry Miller Corp.
CHOICE-CUT Monroe Chemical Co. Inc.
Hy Kut 105 Pillsbury Chemical & Oil, Inc.
Triple C 2670 Pro-Chem Inc.
Sintolin OP2,HD Process Research Products
LUBE-WELL "CD- COMPOUND G. Whitfield Richards Co.
CUTZOL WS-15. CUTZOL WS-30 Rust-Lick, Inc.
SYZ-KUT H Henry E. Sanson & Sons, Inc.
Toolife 316 Specialty Products Co.
SUNICOOL 6 Sun Petroleum Products Co.
ME II Super Concentrate (Recirculating) Tapmatic Corp.
Ami-Lube X-20 Tron-X Research Corp.
VSCC 537. VSCC 545-E Van Straaten Chemical Co.
W&B Concentrate 3100 The White &Bagley Co.
Macco Syncrocut 980-W-1, Macco Syncrocut 980-MM-2 Witco Chemical Corp.

16-79
16.3 Cutting Fluid Key

CODE
NO. TYPE AN[ TRADE NAME MANUFACTURER

5 EMULSIFIABLE OILS-HEAVY DUTY

Sulfurized Fatty Soluble Oil
Lafayette Soluble Oil #60 American Oil & Supply Co.
AMOCOOL HD Soluble Oil Amoco Oil Co.
PETROCHEM 100 Champions Choice. Inc.
L 485 HW Chrysler Corp.
Soluble Cadrex 1838 Cook's Industrial Lubricants, Inc.
KUTWELL EP 66 Exxon Co.. U.S.A.
TOOL COOL 1342 Franklin Oil Corp. (Ohio)
Gulfcut Heavy Duty Soluble Oil Gulf Oil Corp.
All Purpose Base E. F. Houghton & Co.
I.C. #1648 International Chemical Co.
IRMCO 340 International Refining & Mfg. Co.
Hamikut Harry Miller Corp.
WHEELMATE 819 Norton Co.
Foil Kut 5350 Pillsbury Chemical & Oil. Inc.
Triple C 3002 Pro-Chem Inc.
FRIGIDOL #222 COMPOUND. FRIGIDOL #222-T COMPOUND G. Whitfield Richards Co.
ANTISEPTIC ALL PURPOSE BASE Henry E. Sanson & Sons, Inc.
Toolife 303 Specialty Products Co.
Solopex-2760 Star Oil Company
TOWER G-941 Tower Oil & Technology Co.
Macco Hi Sul 588-EM Witco Chemical Corp.
WITHROSOL 320 SOLUBLE OIL Arthur C. Whitrow Co.

Chlorinated Soluble Oil

Lafayette Soluble Oil #71 American Oil & Supply Co. C I
AMOCOOL SS Fluid Amoco Oil Co.
Adsol 2 Ashland Oil. Inc.
Trukut EP-C Atlantic Richfield Co.
12 U 49. L 485 HW Chrysler Corp.
CIMPERIAL 18. CIMPERIAL 1010, CIMPERIAL 1011 Cincinnati Milacron. Products Div.
CITGO Cutting Oil 215. CITGO Cutting Oil 220 Cities Service Co. ;!
Cook-Cool 2020. Cook-Cool 4782, Cook-Cool 4718 Cook's Industrial Lubricants. Inc.
CURTIS S-6, CURTIS S-7. CURTIS S-21. CURTIS S-DD-100 Curtis Systems, Inc.
COOL SPEED 2010 Daubert Chemical Co.
TOOL COOL 1385. TOOL COOL 1485 Franklin Oil Corp. (Ohio)
Hocut 733. Hocut 747 E. F. Houghton & Co.
I.C. #922 International Chemical Co.
MAGNU DRAW 10. MAGNU DRAW 30, MAGNU DRAW 40,
MAGNU DRAW SOL, CHLOROLUBE SOH Magnus Div./Economics Lab Inc. F4_
TRIM SOL Master Chemical Corp.
Plastrol, Metsol WOS Metalloid Corp.
Hamikut Harry Miller Corp.
PRIME-CUT Monroe Chemical Co., Inc.
WHEELMATE 607 Norton Co.
Sword Kut C5100 Pillsbury Chemical & Oil, Inc.
Sintolin E-1 Process Research Products
Rycosol 69 Reilly-Whiteman Inc.
LUBE-WHEEL S-47-H SOLUBLE OIL, LUBE-WELL S-47 SOLUBLE OIL G. Whitfield Richards Co.
CUTZOL WS-10. CUTZOL WS-20, CUTZOL WS-5050 Rust-Lick, Inc.

16-80
- - =~.=- --
 Cuffing Fluid Key 16.3

CODE
NO. TYPE AND TRADE NAME MANUFACTURER

5 EMULSIFIABLE OILS-HEAVY DUTY (Continued)

Chlorinated Soluble Oil (Continued)
TOOLMATE. SYN-SOL 1000 Henry E. Sanson & Sons Inc.
Space Age 49-3-Cutting Oil Space Age Chemlube
Toolife 315 Specialty Products Co.
Staysol 743 Standard Oil Co. (Ohio)
Starsol-2800 Star Oil Company
EMULSUZ 51 Sun Petroleum Products Co.
TOWERSOL G-966 Tower Oil & Technology Co.
VSCC 710 Van Straaten Chemical Co.
W&B HD Soluble Oil 2213 The White & Bagley Co.
Macco 472. Macco 472-MPA. Macco 478. Macco 768 MTS-3 Witco Chemical Corp.
WITHROSOL 323 SOLUBLE OIL Arthur C. Whitrow Co.

Sulfo-Chlorinated Fatty Soluble Oil

Lafayette Soluble Oil #71 American Oil & Supply Co.
Adsol 3 Ashland Oil, Inc.
Trukut EP-SC Atlantic Richfield Co.
Fedaro EPSC BP Oil. Inc.
Bel-Ray WS-6-HD Bel-Ray Co., Inc.
Brukool 100. Brusol C. Brukool 131 Bruce Products Corp.
PETROCHEM 101 Champions Choice. Inc.
CIMPERIAL 20 Cincinnati Milacron, Products Div.
Cook-Cool 1400 Cook's Industrial Lubricants. Inc.
DAUBERT DROMUS SD Daubert Chemical Co.
POWER-CUT No. 360 DoALL Co.
TOOL COOL 1397 Franklin Oil Corp. (Ohio)
Habcoos 312 H & B Petroleum Co.
Hocut 3210-X, Permasol HD-20 E. F. Houghton & Co.
I.C. 0939-NP International Chemical Co.
IRMCO 335 International Refining & Mfg. Co.
LUBRI-FLO 1000, LUBRI-FLO 440 Larson Chemical Specialties
EP COOLANT, MAGNA COOL EP, EL SOL-SC Magnus Div./Economics Lab Inc.
TRIM SOL S Master Chemical Corp.
Hamidraw Harry Miller Corp. A
Mobilmet 140, Mobilmet 160 Mobil Oil Corp.
MONROE HD Monroe Chemical Co., Inc.
WHEELMATE 810, WHEELMATE 811 Norton Co.
Rapier Kut 5200 Pillsbury Chemical & Oil, Inc.
Triple C 3011 Pro-Chem Inc.
Sintolin E-100 Process Research Products
LUBE-WELL S-43 SOLUBLE OIL G. Whitfield Richards Co.
CUTZOL PB-I 0 Rust-Lick, Inc.
SYN-SOL 300 Henry E. Sanson & Sons. Inc.
SWEPCO 720 Water Soluble Cutting Oil Southwestern Petroleum Corp.
Space Age 49-4-Cutting Oil Space Age Chemlube
Staysol EPSC Standard Oil Co. (Ohio)
Solopex-2770 Star Oil Company
EMULSUN 54 Sun Petroleum Products Co.
Soluble Oil HD, TEXGOLD Texaco Inc.
TOWERSOL G919 Tower Oil & Technology Co.

16-81
16.3 Cuffing Fluid Key
r.-.DE

riO. TYPE AND TRADE NAME MANUFACTURER

5 EMULSIFIABLE OILS-HEAVY DUTY (Continued)

SuJlo-Chlorinated Fatty Soluble Oil (Continued)
VSCC 700. VSCC 708 Van Straaten Chemical Co.
Macco Extrudoil 51 -DE. Spermasol EP. Kelcut 203-EP-Soluble Witco Chemical Corp.
WITHROSOL 322 SOLUBLE OIL Arthur C. Whitrow Co.
ZURNTURN 004 O F Zurn Co.

Semichemical
AMOCOOL SS Fluid Amoco Oil Co.
BrukooI 129 Bruce Products Corp.
CIMPERIAL 15 Cincinnati Milacron. Products Div.
COOL SPEED 515 Daubert Chemical Co.
Libricoolant 930 Sol. Oil (Mineral with natural sulfur) DuBois Chemicals
I.C. 41667 International Chemical Co.
IRMCO 302 International Refining & Mfg. Co.
TRIM EP Master Chemical Corp.
Hamikleer Harry Miller Corp.
CHOICE-CUT Monroe Chemical Co.. Inc.
Hy Kut 9737 Pillsbury Chemical & Oil. Inc.
POLAR SOL 510 Polar Chip. Inc.
Triple C 3010 Pro-Chem Inc.
LUBE-A-TUBE "XAM' COMPOUND G. Whitfield Richards Co.
CUTZOL WS-5100 Rust-Lick. Inc.
SYN-SOL Henry E. Sanson & Sons. Inc.
Space Age "Will-Cut'" Space Age Chemlube
Ami-Lube SX-15 Tron-X Research Corp.
VSCC 707 Van Straaten Chemical Co.
W&B EP Concentrate 2828 The White & Bagley Co.
Syncrocut 167-DM-9. Macco 158-C Witco Chemical Corp.
ZURNSOL 253 0 F Zurn Co.

Semisynthetic
Brukool 66. Brukool 128 Bruce Products Corp.
Cook-Coolex 40 Cook's Industrial Lubricants. Inc.
COOL SPEED 363 Daubert Chemical Co.
Fremont-7030. Fremont-7031. Fremont-7032. Fremont-7033.
Fremont-7035. Fremont-7036 Fremont Industries, Inc.
I.C. 321K International Chemical Co.
IRMCO 303 International Refining & Mfg. Co.
Slipstream 54. Coldstream S. C. Johnson & Son. Inc.
Hon-E-Cool Lubrication Co. of America
Hamikleer Harry Miller Corp.
CHOICE-CUT Monroe Chemical Co., Inc.
Oakite Formula B-S0 Oakite Products, Inc.
Hy Kut 9734 Pillsbury Chen,.ical & Oil. Inc.
Triple C 2511 Pro-Chem Inc.
GWR COMPOUND G. Whitfield Richards Co.
CUTZOL WS-15. CUTZOL WS-30 Rust-Lick. Inc.
SYN-SOL DURO 55,P.O. CUTTING LIQUID Henry E. Sanson & Sons Inc.
Space Age "Will-Cut- Space Age Chemlube
Toolife 316 Specialty Products Co.

16-82
 Cutting Fluid Key 16.3
CODE
NO. TYPE AND TRADE NAME MANUFACTURER

5 EMULSIFIABLE OILS-HEAVY DUTY (Continued)

Semisynthetic (Continued)
ME II Super Concentrate (Recirculating) Tapmatic Corp.
Ami-Lube Regular Tron-X Research Corp.
VSCC 550-P Van Straaten Chemical Co.
W&B Concentrate 3100 The White & Bagley Co.
Macco 980-W-1. Macco Syncrocut 980-MM-2 Witco Chemical Corp.
ZURNSOL 254 0 F Zurn Co.

6 CHEMICAL AND SYNTHETICS-LIGHT DUTY (GENERAL PURPOSE)

Solutions
CAMPBELLENE. CAMPBELLENE NO-NITRITE Allison Campbell Div./Acco
Industries
Lafayette Soluble #91 American Oil & Supply Co.
AMOCOOL Transparent Coolant Amoco Oil Co.
Adcool I Ashland Oil. Inc.
Brukoo1130. Brukool 77. Brukool 78 Bruce Products Corp.
PETROCHEM CHEMICAL COOLANT Champions Choice. Inc.
L 1549.12 D 192 Chrysler Corp.
CIMFREE 104. CIMFREE 106. CIMFREE 108 Cincinnati Milacron. Products Div.
Cook-Cool 1975 (Grinding). Cook-Cool 4988 (Grinding) Cooks Industrial Lubricants. Inc.
COOL SPEED 77-45. COOL SPEED 36 Daub-:rt Chemical Co.
Kleen-Kool DoALL Co.
Lubricoolant 925. Lubricoolant 926 DuBois Chemicals
Fremont-5018 Fremont Industries. Inc.
Houghto-Grind 60 E. F. Houghton & Co.
I.C. 124 International Chemical Co.
IRMCO 120. IRMCO 110 International Refining & Mfg. Co.
50 Cool. TL-131. Millstream S. C. Johnson & Sen. Inc.
KEYCUT 106 Keystone Division/Pennwalt Corp.
KOOLMIST FORMULA #78 COOLANT Kool Mist Corp.
LPS 1. LPS 2. LPS 3 LPS Research Laboratories. Inc.
BLUE COOLANT NF Magnus Div./Economics Lab Inc.
TRIM 9106. TRIM 9106CS. TRIM REGULAR. TRIM
7030. TRIM 5050. TRIM 2575, TRIM MIST. TRIM 9106WA Master Chemical Corp.
Metgrind #432. Metgrind #468 Metalloid Corp.
Hamikleer Harry Miller Corp.
MC"tROE RI Monroe Chemical Co.. Inc.
WHEELMATE 464. WHEELMATE 467 Norton Co.
Oakite Formula A. Oakite Formula C. Oakite Formula G Oakite Products. Inc.
Hone-Rite 306 Pillsburv Chemical & Oil, Inc.
Polar Chip 347 Polar Chip. Inc.
Sintolin R30. Aqualap 15C Process Research Products
Rycosol 66 Reilly-Whiteman. Inc.
GWR #110 G. Whitfield Richards Co.
RUST-LICK G-25-j. RUST-LICK G-25-AH, VVTRO.NT Rust-Lick, Inc.
MIRROR-KOOL M-1. MIRROR-KOOL M-15 Henry E. Sanson & Sons. Inc.
Kool-Aide I Space Age Chemlube

16-83
__ __ _____i -
16.3 Cuffing Fluid Key

CODE
NO. TYPE AND TRADE NAME MANUFACTURER

6 CHEMICAL AND SYNTHETICS-LIGHT DUTY (GENERAL PURPOSE) (Continued)

Solutions (Continued)
Toolife 305 Specialty Products Co.
Molecular Edge (Squirt on). ME 11Super Concentrate (Recirculating) Tapmatic Corp.
TOWERKEM W-21 10 Tower Oil & Technology Co.
Ami-Lube Clear Tron-X Research Corp.
VSCC 990 Van Straaten Chemical Co.
Bio-Cool 500 Westmont Industrial Products
W&B Grinding Concentrate 1500 The White & Bagley Co.
Syncrocut 980-CE-3. Syncrocut 850-A-3 Witco Chemical Corp.
WITHROKOOL 334 CHEMICAL COOLANT Arthur C. Withrow Co.
ZURN KOOLKUT 0 F Zurn Co.

Synthetic Emulsions
Q-77 Coolant Concentrate Associate Technical Sales Co.
L 1542 Chrysler Corp.
CIMCOOL S2 Cincinnati Milacron. Products Div.
COOL SPEED 363 Daubert Chemical Co.
KUTWELL 82 Exxon Co., U.S.A.
Hocut 711 E. F. Houghton & Co. 4i
I.C. #922 International Chemical Co.
Specialube 994 Lubrication Technology, Inc.
Hamikleer Harry Miller Corp.
MONROENN Monroe Chemical Co.. Inc.
WHEELMATE 405, WHEELMATE 414. WHEELMATE 419.
WHEELMATE 613 Norton Co.
Hy Kut 105 Pillsbury Chemical & Oil. Inc.
Polar Cut 400 Polar Chip, Inc. 24
Triple C 2010 Pro-Chem Inc.
Rycosol 77, Rycosol 87 NF Reilly-Whiteman, Inc.
LUBE-WELL D-171 SOLUBLE OIL G. Whitfield Richards Co.
CUTZOL WS-15 Rust-Lick, Inc.
MIRROR-KOOL G-70 Henry E. Sanson & Sons, Inc.
Kool-Aide XII Space Age Chem!ube
Toolife 316 Specialty Products Co.
SUNICOOL 6 Sun Petroleum Products Co.
Ami-Lube Syn-12 Series Tron-X Research Corp.
W&B Lubricant 1888 The White & Bagley Co.

7 CHEMICAL AND SYNTHETICS-HEAVY DUTY

Solutions
CAMPBELLENE, CAMPBELLENE NO-NITRITE Allison Campbell Div./Acco
Industries
Lafayette Synthetic #102 American Oil & Supply Co.
Adcool 2 Ashland Oil, Inc.
Brukool 106 Bruce Products Corp.
PETROCHEM 130Z Champions Choice, Inc.
12 U 176,12 U 182 B Chrysler Corp.

16-84
 Cutting Fluid Key 16.3
CODE
NO. TYPE AND TRADE NAME MANUFACTURER

7 CHEMICAL AND SYNTHETICS-HEAVY DUTY (Continued)

Solutions (Continued)
CIMFREE 234, CIMFREE 238. CIMFREE 305. CIMFREE 307 Cincinnati Milacron. Products Div.
Cook-Cool 1975 (Grinding). Cook-Cool 4988 (Grinding) Cook's Industrial Lubricants. Inc.
POWER-CUT HD-600 DoALL Co.
TOOL COOL 268 Franklin Oil Corp. (Ohio) -
Fremont-701 0. Fremont-701 1 Fremont Industries. Inc.
Gulfcut Soluble CB-2 Gulf Oil Co. p.
Hocut 702. Hocut 4206. Hydra-Cut 496 E. F. Houghton & Co.
I.C. 2614 International Chemical Co.
IRMCO 111 International Refining & Mfg. Co.
KOOLMIST FORMULA #77 COOLANT Kool Mist Corp.
CLEAR-CUT 44 Larson Chemical Snecialists
Empactosol Lubrication Co. of America
Specialube 67D. Specialube 75 Lubrication Techn,og%". Inc.
TRIM HD. TRIM EP Master Chemical Corp.
Metchem f-429. Metchem #474 Metalloid Corp.
Hamikleer Harry Miller Corp.
WHEELMATE 658. WHEELMATE 689 Nortoa Co.
Kool Kut X350 Pillsbury Chemical & Oil. Inc.
POLAR CHIP 347L Polar Chip. Inc.
Sintolin ROD Process Research Products
GWR COMPOUND G. Whitfield Richards Co.
VYTRON. RUST-LICK G-52 Rust-Lick. Inc.
E-COOL. MIRROR-KUT G-7 Henry E. Sanson & Sons Inc.
Kool-Aide III Space Age Chemlube
Toolife 311 Specialty Products Co.
Molecular Edge (Squirt on). ME IISuper Concentrate (Recirculating) Tapmatic Corp.
TOWERKEM W-2110 Tower Oil & Technology Co.
A.i-Lube 1OX-C!ar Tron-X Research Corp.
VSCC 951. VSCC 936 Van Straaten Chemical Co.
Bio-Cool 700 Westmont Industrial Products
W&B Concentrate 3100 The White & Bagley Co.
S)ncrocut 105. Syncrocut 172 Witco Chemical Corp.
WITHROKOOL 340 CHEMICAL COOLANT Arthur C. Withrow Co.
ZURN ALL MET 6 O F Zurn Co.

Synthetic Emulsions
Adcool 3 Ashland Oil. Inc.
Brukoo1132 Bruce Products Corp.
12 U 41 Chrysler Corp.
CIMCOOL FIVE STAR 40. CIMCOOL S4. CIMCOOL S8 Cincinnati Milacron. Products Div.
COOL SPEED 363. COOL SPEED 515 Daubert Chemical Co.
I.C. #922 International Chemical Co.
Specialube 997A. Specialube 998 Lubrication Technology, Inc.
Hamikleer Harry Miller Corp.
MONROE NN Monroe Chemical Co., Inc.
WHEELMATE 603. WHEELMATE 613. WHEELMATE 674 Norton Co.
Hy Kut 9734 Pillsbury Chemical & Oil, Inc.
POLAR EZE 444 Polar Chip, Inc.
Triple C 2510 Pro-Chem Inc.

16-85
16.3 Cutting Fluid Key
CODE
NO. TYPE AND TRADE NAME
MANUFACTURER
7 CHEMICAL AND SYNTHETICS-HEAVY DUTY
(Continued)
Synthetic Emulsions (Continued)
Rycosol 99Rel-himn.I.
LUBE-WELL _X_ COMPOUND G. lWhite nIcs.
CJJTZOL WS-15GIhtildRcad o
KoING K31L Henry E. Sanson & Sons. Inc.
SToolife31 Specialty Products Co.
Ami-Lube Syn-12X Series trOilX ResacnCrp
VSCC 950. VSCC 938 rnXRsacCop
W&B ubriant 300Van Straaten Chemical Co.
WITHROKOOL 339 CHEMICAL COOLANT The White & Bagley Co.
2520 OOLKU OOLKU
ZURN
ZURN 252Arthur C. Withrow Co.
F Zurn Co.

8 SPECIALS-LIGHT DUTY
80 Honing Oil-Light Duty
Lafayette KM-16AmicnOl&SplCo
AMOCUT Oil No. 62FC Amorca Oil o. p~vCo
Econ S. Promax 1074 Ashlan oil. C.
HeonolOil Atlantic Richfield Co.
Bezora 3BP Oil. Inc.
Bruko D-666 (non-ferrous). Bruko D-667 (ferrous)
PETROCHEM HONING OIl Bruce Products Corp.
CIM FREE 104. CIMPREE 200. CIMFREE 23-4. Champions Choice. Inc.
CIMPREE 238 Cincinnati Milacron. Products Div.
Cook 250Comp undCook-s
Industrial Lubricants. Inc.
DAUBE
HDaubert T GA IA Chemical Co.
MICR
5: 9 .10Ex
C O OL IC- Cell.O Tool& A brasive
MENTOR28Products
MENfcTO .G
28 lfu Exxon Co.. U.S.A.
GR ulf
I DGut h . G u fc ut ulf O il C orp .
I.C 2785.
M C29 International Chemical Co.
IRMC.OLP 2 . IRMCO 22 International Refining a Mfg. Co.
L PS 1. L 2 LPS LPS Research Laboratories. Inc.
ELU3RHinOl H13 Larson Chemical Specialties
Lco H1ngOl2 Lubrication Co. of America
L-12 Magnus Div.JEconotics Lab Inc.
TRIM REGULAR. TRIM 7030. TRIM SOL LC
Master Chemical Corp.
TF 382Metalloid Corp.
HamiubeHarry Miller Carp.
Alumicut
Msi ea oe.Ic
VacmuJ 3A Msi ea oe.Ic
Hone~te711Mobil Oil Corp.
GRA Honing Oil Hone~ie 711Pillsbury Chemical & Oil. Inc.
Process Research Products
Petros n 102Reilly-W hiteman. Inc-
GWR HONING OIL
G. Whitfield Richards Co.
HONZOL 11-B
Rust-Lick. Inc.
SYN--IOE M-LVHenry E. Sanson &Sons Inc.

16-86
 Cutting Fluid Key 16.3
CODE
NO. TYPE AND TRADE NAME
MANuFACTrURER
8 SPECIALS-LIGHT DUTY (Continued)
80 Honing Oil-Light Duty (Continued)
Toolife Honing Oil
Factokut H Specialty Products Co.
SUNICtIT 102 Standard Oil Co. (Ohio)
MAN-845. CK-50 (for cast iron and a!uminuin only) Sun Petroleum Products Co.
Almag Sunnen Products Co.
TOWER D-204 Texaco Inc.
VSCC 5551 -A Tower Oil & Technology Co.
Bio-Hone 252 Van Straaten Chemical Co.
W&B Honing Oil 2088 Westmont Industrial Products
Macco Honing Oil The White & Bagley Co.
WITHROKUT 104 CUT TING OIL Witco Chemical Corp.
Arthur C. Withrow Co.
81 Chemical Grinding Fluids: Amine Nitrite Solution, Sodium
itrite Solution, etc.
(NOTE: Products with * are Nitrite Fr'~e. See Chemical Fluids
in section 15. 1.)
Bet-Ray Coolant 12X
Brukool 77, Brukool 106 Bel-Ray Co., Inc.
Cook-Cool 1975*, Cook.Ct-ol 4988* Bruce Products Corp.
COOL SPEED 77-45, COOL SPEED 363*. COOL SPEED Cook's Industi ial Lubricants, Inc.
36* Daubert Chemical Co.
DuBois 910 Synthetic (sodium nitride solution), DuBois
915 DuBois Cheni-cals
TOOL COOL 1392
Coolant R se 100 Franklin Oil Corp. (Ohio)
I.C. 445, I.C. 124* E. F. Houghton &Co.
Electrisol 308 International Chemical Co.
Lubrication Co. of America
TRIM 91 06*, TRIM REGULAR. TRIM 7030. TRIM
TRIM 2575*. TRIM HD, TRIM EP, TRIM 9106WA*, 5050,
TRIM HM, T-RIM TI GRIND TRIM CLEAR,
Metgrind 4468* Master Chemical Corp.
Immunui, Hamikleer Metailuid Corp.
MONROE NN*, MONROE RI* Harry Miller Corp.
WHEELMATE 203, WHEELMATE 205 Monroe Cherrical Co., Inc.
flone Rite 3795 Norton Co.
Pola- Chip 34 7*, GRINDEX I IB Pillsbury Chemical 8s Oil, Inc.
XSS-30A Polar Chip, Irc.
VYT,7ON. RUST-LICK B, RUST-LICK G-25-j, RUST-LICK Reilly-Whiteman, Inc.
G-25.AH*,
RUST-LICK G-1 066D0utLcIc I -

MIRROR-KOOL G-5, MIRROR-KUT G-7*

Kool-Aide IV' Hrt-iEk Ianc. onIc
Space Age Chemnlube
Starsyn-5
VSC,:' 5551 -A, Van Straaten 920*, Van Straaten 936* Star Oil Company
W&B Grinding Coolant E-55 Van Straaten Chemical Co.
Syncrocut 172 The White & Bagley Co.
Witco Chemical Corp.
82 Cutting Fluid for Aluminum
CAMPBELLENE NO-NlITIRITE
Allison Campbell Div./Acco
Lafayette SM-1 12 Industies
AMOCUT Oil No. 62FC American Oil & Supply Co.
Promax 1074, Promax 1075 Amoco Oil Co.
ARCO ML Oils, Clairo Oils Ashland Oil, Inc.
Atlantic Richfield Co.

16-87

_ _ _ _
16.3 Cutting Fluid Key

CODE
NO. TYPE AND TRADE NAME MANUFACTURER

8 sl".,1ALS-LIGHT DUTY (Continued)

82 Cutting Fluid for Aluminum (Continued)
Fedora EPSC, Bezora 22 BP Oil, Inc.
Brukool 127. Bruko D-680 Bruce Products Corp.
PETROCHEM 709 Champions Choice, Inc.
Chevron Metalworking Fluid 504, Chevron Soluble Oil Chevron U.S.A. Inc.
CIMCOOL AL, CIMCOOL S2. CIMCOOL S4. CIMCOOL S8.
CIMFREE 234. CIMFREE 305, CIMPERIAL 15, CIMPERIAL 16,
CIMPERIAL 1010, CIMPERIAL 1011 Cincinnati Milacron. Products Div.
CITGO Cutting Oil 400 Cities Service Co.
Cook-Cut 1711, Cook-Cut 30, Cook-Cool 1235 (Water soluble) Cook's Industrial Lubricants, Inc.
COOL SPEED 515 Daubert Chemical Co.
No. 120 Cutting Oil, No. 470 Soluble Oil DoALL Co.
Freon T-B1. Freon HV-3 E. I. DuPont Co. Inc.
Gulfcut lID Gulf Oil Corp.
Habcool202 H & B Petroleum Co.
Cindol 3411, Cindol 3101, Cindol 3102, Cindol 3103 E, F. Houghton & Co.
I.C. 41231-A, I.C. 4131-A International Chemical Co.
IRMCO 249, IRMCO 242, IRMCO 278 International Refining & Mfg. Co.
121 Wax Cut, Slipstream 54, Coldstream, J-Cool S. C. Johnson & Son, Inc.
LPS 1, LPS 2, LPS 3 LPS Research Laboratories, Inc.
LUBRI-FLO 1000 Larson Chemical Specialties
Vista-Kut Lubrication Co. of America
DO-5A Magnus Div./Economics Lab Inc.
TRIM SOL LC, TRIM SOL, TRIM 9106 WA, TRIM HD Master Chemical Corp.
WOS, Metsol, TF-306 Metalloid Corp.
Hamikut Harry Miller Corp.
Alumicut (Al) Mistic Metal Mover, Inc.
PRIME-CUT Monroe Chemical Co., Inc. a-
WHEELMATE 607, WHEELMATE 674 Norton Co.
Sword Kut C51 00, Sabre Kut 5400 Pillsbury Chemical & Oil. Inc.
Polar Cut 400 Polar Chip, Inc.
Triple C 3010 Pro-Chem Inc.
Sintolin E-1 Process Research Products
Petrosan 116, Rycosol 19 Reilly-Whiteman, Inc.
A-9 (Al) Relton Corp.
LUBE-WELL S-4A SOLUBLE OIL, LUBE-A-TUBE "XAM" COMPOUND G. Whitfield Richards Co.
CUTZOL WS-10, CUTZOL WS-11, CUTZOL WS-20, CUTZOL
WS-5050, CUTZOL WS-500-A Rust-Lick, Inc.
SYN-KUT 105 Henry E. Sanson & Sons, Inc.
Kool-Aide I, Kool-Aide IV, Kool-Aide XII Space Age Chemlube
Toolife 250, Toolife 304 Specialty Products Co.
Factokut A-50-C, Factokut L-2, Staysol EPSC Standard Oil Co. (Ohio)
Starcut-3902 Star Oil Company
TAP MAGIC ALUMINUM Steco Corp.
SUNICUT 150 Sun-Petroleum Products Co.
Molecular Edge (Squirt on), ME II Super Concentrate (Recirculating),
Dual Action Cutting Fluid 42 Tapmatic Corp.
Almag Texaco Inc.
TOWERCUT E-915 Tower Oil & Technology Co.
Ami-Lube X-1, Series Tron-X Research Corp.

16-88
 Cutting Fluid Key 16.3
CODE A
NO. TYPE AND TRADE NAME MANUFACTURER

8 SPECIALS-LIGHT DUTY (Continued)

82 Cutting Fluid for Alumir.m (Continued)
VSCC 45, VSCC 653 Van Straaten Chemical Co.
Bio-Cool 700 Westmont Industrial Products
W&B Cutting Oil 3016 The White & Bagley Co.
ALUMTAP Winfield Brooks Co., Inc.
Macco 230-JL-3 Witco Chemical Corp.
WITHROKUT 101 CUTTING OIL Arth-'r C. Withrow Co.

83 Cutting Fluid for Titanium-Light Duty

CAMPBELLENE. CAMPBELLENE NO-NITRITE Allison Campbell Div./Acco
Industries
AMOCOOL Soluble Oil Amoco Oil Co.
Promax 1002 Ashland Oil, Inc.
Crystex Sol. Oil, Emulsicool Sol. Oil, Sol. Oil DO, Sol. Oil Z,
Tooltex Sol. Oil, No. 1 Sol. Oil, 943 Sol. Oil, Autokut Oils Atlantic Richfield Co.
Fedora EPSC BP Oil, Inc.
Brukool 4-37d Bruce Products Corp.
Chevron Metalworking Fluid 503 Chevron U.S.A. Inc.
CIMFREE 234, CIMFREE 238, CIMCOOL S4, CIMCOOL
FIVE STAR 40 Cincinnati Milacron, Products Div.
Cook-Cool 1235. Cook-Coolex 40 Cook's Industrial Lubricants, Inc.
COOL SPEED 515 Daubert Chemical Co.
POWER-CUT HD-600 DoALL Co.
Freon T-B1, Freon HV-3 E. I. DuPont Co. Inc.
Hocut 711, Cindol 3212 E. F. Houghton & Co.
I.C. #48, I.C. 124 International Chemical Co.
IRMCO 278 International Refining & Mfg. Co.
TL-131 S. C. Johnson & Son, Inc.
LPS 1, LPS 2, LPS 3 LPS Research Laboratories. Inc.
Threadmate 2254 Lubrication Co. of America
TRIM TI GRIND, TRIM REGULAR, TRIM 7030, TRIM 9106WA,
TRIM HD, TRIM SOL Master Chemical Corp.
Metkut #310 Metalloid Corp.
Hamikut Harry Miller Corp.
Alumicut Mistic Metal Mover, Inc.
CHOICE-CUT, PRIME-CUT, MONROE HD Monroe Chemical Co., Inc.
WHEELMATE 602 Norton Co.
Hone Rite TI-Cut Pillsbury Chemical & Oil, Inc.
Polar Chip 347 Polar Chip, Inc.-
Sintolin OP2 Process Research Products
Rycosol 66 Reilly-Whiteman, Inc.
GWR COMPOUND G. Whitfield Richards Co.
CUTZOL WS-S00-A, VYTRON, CUTZOL 400-A Rust-Lick, Inc.
MIRROR-KUT G-7, SYN-SOL 300 Henry E. Sanson & Sons, Inc.
Kool-Aide IV, Kool-Aide XII Space Age Chemlube
Staysol EPSC, Sulkleer 163A Standard Oil Co. (Ohio)
EMULSUN 31, EMULSUN 51 Sun Petroleum Products Co. _

Transultex D, Sultex D Texaco Inc. E

Ami-Labe X-12 Series Tron-X-ResearcIr Corp.
VSCC 550 Van Straaten Chemical Co.
W&B Cutting Oil 2151 The White & Bagley Co.

16-89
16.3 Cutting Fluid Key
CODE

NO. TYPE AND TRADE NAME MANUFACTURER

8 SPECIALS-LIGHT DUTY (Continued)

83 Cutting Fluid for Titanium-Light Duty (Continued)
Bio-Cool 500 Westmont Industrial Products
Macco 478 Witco Chemical Corp.
WITHROKUT 210 CUTTING OIL Arthur C Withrow Co
84 Compressed Gas, Freon, Liquid CO 2
Freon T-B1, Freon HV-3 E. I. DuPont Co. Inc

85 Grinding Fluid for Ferrous Metals

CAMPBELLENE, CAMPBELLENE NO-NITRITE Allison-Campbell Div./Acco
Industries
Promax 1310 Ashland Oil, Inc.
RISO Soluble Oil Atlantic Richfield Co.
PETROCHEM 108 Champions Choice. Inc.
Chevron Soluble Oil Chevron U.S.A. Inc.
CIMFREE 104. CIMFREE 234, CIMFREE 238, CIMFREE 305.
CIMFREE S4, CIMCOOL S8, CIMCOOL FIVE STAR 40, CIMPERIAL
1010, CIMPERIAL 1011. CIMPERIAL 18, CIMPERIAL 20 Cincinnati Milacron, Products Div.
Cook-Cool 1975. Cook-Cool 4988 Cook's Industrial Lubricants, Inc.
COOL SPEED 36, COOL SPEED 77-45 Daubert Chemical Co.
Kleen-Kool. No. 470 Soluble Oil DoALL Co.
Fremont-50i 8M. Fremont-5019X, Fremont-7013 Fremont Industries, Inc.
I.C. 41676 International Chemical Co.
IRMCO 120 International Refining & Mfg. Co.
Millstream. TL-131 S. C. Johnson & Son, Inc.
LCA Trans Sol 303 Lubrication Co. of America
Specialube 67D Lubrication Technology, Inc.
MAGNA COOL CC, CLEAN CUT, EL SOL R, BLUE COOLANT NF Magnus Div./Economics Lab Inc.
TRIM REGULAR, TRIM 7030, TRIM 9106, TRIM 9106WA,
TRIM SOL. TRIM SOL S, TRIM CE, TRIM HD, TRIM EP, TRIM 5050.
TRIM 9106CS, TRIM HM, TRIM CLEAR Master Chemical Corp.
Metsol Metalloid Corp.
Hamikleer, Hamigrind Harry Miller Corp.
PRIME-CUT, CHOICE-CUT. MONROE HD, MONROE RI Monroe Chemical Co., Inc.
Kool Grind 9054 Pillsbury Chemical & Oil, Inc.
Polar Chio 347 Polar Chip, Inc.
Gear Lap RIG-12 Process Research Products
Rycosol 66 Reilly-Whiteman, Inc. N
SEMI-FLUID VASTOLEIN COMPOUND, GRIND-WELL 4110
GRINDING COMPOUND G. Whitfield Richards Co.
RUST-LICK G-25-J. RUST-LICK G-25-AH, VYTRON, RUST-LICK
G-1066D, CUTZOL WS-15 Rust-Lick. Inc.
POWERD OIL FOR GRINDING Henry E. Sanson & Sons Inc.
Kool-Aide I, Kool-Aide IV, Kool-Aide XII Space Age Chemlube
Toolife 100, Toolife 102, Toolife 103 Specialty Products Co.
Factocool 65 Standard Oil Co. (Ohio)
Star S.M. 3732 Star Oil Company
SECO 14,3% EMULSION Sun Petroleum Products Co.
Ami-Lube Regular Tron-X Research Corp.
W&B Grinding Coolant E-55, W&B Grinding Concentrate 1500 The White & Bagley Co. r

16-90
 Cutting Fluid Key 16.3
CODE
NO. TYPE AND TRADE NAME MANUFACTURER

8 SPECIALS-LIGHT DUTY (Continued)

85 Grinding Fluid for Ferrous Metals (Continued)
Bio-Cool 500S Westmont Industrial Products
Syncrocut 980-W-1 Witco Chemical Corp.
WITHROKUT 117 CUTTING OIL Arthur C. Withrow Co.

86 Cutting Fluids for Gun Drilling and Trepanning

AMOCUT Gundrill Oil Amoco Oil Co.
Promax 5352. Promax IU02. Promax 1074. Promax 1455-S Ashland Oil. Inc.
Ordnance Oils Atlantic Richfield Co.
Cilora 19A BP 01". Inc.
Brusol A. Bruko D-666 Bruce Products Corp.
PETROCHEM 710 Champions Choice, Inc.
Chevron Metalworking Fluid 503 Chevron U.S.A. Inc.
CIMFREE 305, CIMPERIAL 1010. CIMPERIAL 1011. CIMPERIAL 20 Cincinnati Milacron. Products Div.
Cook-Cut 1940 Cook's Industrial Lubricants. Inc.
DAUBERT GARIA H, DAUBERT GARIA T Daubert Chemical Co.
Gulfcut 44A. Gulfcut 45A Gulf Oil Corp.
I.C. #814-A International Chemical Co.
IRMCO 229 International Refining & Mfg. Co.
LUBRI-FLO 1000 Larson Chemical Specialties
Threadmate Gun Drilling Oil 5110 Lubrication Co. of America
TRIM SOL S. TRIM EP. TRIM HD, TRIM SOL Master Chemical Corp.
Metkut #310 Metalloid Corp.
Hamikut Harry Miller Corp.
Mobilmet 25, Mobilmet Alpha Mobil Oil Corp.
PRIME-CUT, CHOICE-CUT, MONROE HD Monroe Chemical Co., Inc.
Thio Glo 162 Pillsbury Chemical & Oil, Inc.
Polar Chip 347 Polar Chip, Inc.
Triple C 5201 Pro-Chem Inc.
FRIGIDOL L-6 CUTTING OIL, NEAR-A-LARD #20-A G. Whitfield Richards Co.
CUTZOL SCFO-504 Rust-Lick, Inc.
SYN-KUT GUN DRILLING OIL C Henry E. Sanson & Sons Inc.
Kool-Aide IV Space Age Chemlube
Toolife 202, Toolife 203 Specialty Products Co.
Factocoo1 65 Standard Oil Co. (Ohio)
Starcut-3075 Star Oil Company
SUNICUT 425 Sun Petroleum Products Co.
Transultex A, Transultex F Texaco Inc.
TOWERCUT F-932, TOWERCUT B-825 Tower Oil & Technology Co.
Super Ami-Lube Tron-X Research Corp.
VSCC 5468 Van Straaten Chemical Co.
W&B Cutting Oil 2190 The White & Bagley Co.
Bio-Cool 500 Westmont Industrial Products
Macco GD 100-12 Witco Chemical Corp.
WITHROKUT 125 CUTTING OIL Arthur C. Withrow Co.
ZURNKUT 3 L X 0 F Zurn Co.

16-91
16.3 Cutting Fluid Key

CODE
NO. TYPE AND TRADE NAME MANUFACTURER

8 SPECIALS-LIGHT DUTY (Continued)

87 Cutting Fluids for Copper
Lafayette Soluble Oil #70, Lafayette SCF-20 American Oil & Supply Co.
AMOCUT Oil No. 106BC. AMOCUT Oil 62FC, AMOCOOL SS Fluid Amoco Oil Co.
Promax 1074. Promax 1075, Promax 1710 Ashland Oil, Inc.
ARCO ML Oils. Clairo Oils Atlantic Richfield Co.
Bezora 22. Fedora EPSC BP Oil. Inc.
Belco 1727 Cutting Oil Bel-Ray Co.. Inc.
PETROCHEM 712 Champions Choice, Inc.
Chevron Utility Oil Grade 46. Chevron Mctalworking Fluid 504,
Chevron Soluble Oil Chevron U.S.A. Inc.
CIMCOOL AL. CIMCOOL S2. CIMCOOL S4. CIMPERIAL 16.
CIMPERIAL 1010, CIMPERIAL 1011 Cincinnati Milacron. Products Div.
Cook-Cut 30, Cook-Cut 25, Cook-Cool 1235 (Water Soluble) Cook's Industrial Lubricants, Inc.
COOL SPEED 500, DAUBERT MACRON M Daubert Chemical Co.
No. 120 Cutting Oil, No. 150 Cutting Oil, No. 470 Soluble Oil DoALL Co.
Gulfcut 44A, Gulfcut 45A Gulf Oil Corp.
I.C. #1440-M, I.C. #1873, Tooleze #2000 International Chemical Co.
IRMCO 242, IRMCO 282 International Refining & Mfg. Co.
J-Cool, Trampol-X S. C. Johnson & Son, Inc.
MINERAL LARD OIL Keystone Division/Pennwalt Corp.
LUBRI-FLO 1000 Larson Chemical Specialties
Elcoa Copper Cutting Oil 204N Lubrication Co. of America
MAGNA COOL CC. CLEAN CUT. CUTTING COMPOUND 6 Magnus Div./Economics Lab Inc.
TRIM SOL, TRIM CE, TRIM 9106, TRIM 9106CS, TRIM 9106WA Master Chemical Corp.
Alumicut Mistic Metal Mover, Inc.
Mobilmet 306 Mobil Oil Corp.
PRIME-CUT Monroe Chemical Co., Inc.
Sword Kut C5100 Pillsbury Chemical & Oil, Inc.
Polar Chip 347 BBC Polar Chip, Inc.
Triple C 5000 Pro-Chem Inc.
Sintolin E-1 Process Research Products
Petrosan 116. Cupromul 23 Reilly-Whiteman, Inc.
LUBE-WELL S-42-M SOLUBLE OIL, LUBE-WELL S-60-T SOLUBLE
OIL, PERFECTED LUBE-WELL -AA" COMPOUND G. Whitfield Richards Co.
CUTZOL WS-1 1 Rust-Lick, Inc.
MIRROR-KUT G-7. SYN-KUT 125 Henry E. Sanson & Sons, Inc.
Kool-Aide IV, Kool-Aide XII Space Age Chemlube
Toolife 251, Toolife 304 Specialty Products Co.
Factokut A-50-C, Factokut L-2, Staysol EPSC Standard Oil Co. (Ohio)
Starcut-3902 Star Oil Company __

TAP MAGIC ALUMINUM Steco Corp.

SUNICUT 201 Sun Petroleum Products Co.
Cleartex B, Soluble Oil D Texaco Inc.
TOWER E-933 Tower Oil & Technology Co.
Ami-Lube BR Tron-X Research Corp. NOS
VSCC 545, VSCC 653 Van Straaten Chemical Co.
W&B Minolard Cutting Oil The White & Bagley Co.
Bio-Cool 500 Westmont Industrial Products
ALUMTAP Winfield Brooks Co., Inc.
Macco 768-1 Witco Chemical Corp. -E

16-92

5-- --
 Cutting Fluid Key 16.3
CODE

NO. TYPE AND TRADE NAME MANUFACTURER

8 SPECIALS-LIGHT DUTY (Continued)

87 Cutting Fluids for Copper (Continued)
WITHROKUT 103 CUTTING OIL Arthur C. Withrow Co.
ZURNSOL 254 0 F Zurn Co.

88 Cutting Fluids for Magnesium

(PRECAUTION: Consult with cutting fluid supplier or manufacturer to be sure fluids do not contain water or other
chemicals which may support combustion of magnesium.)
Lafayette BM-1 12 American Oil & Supply Co.
AMOCUT Oil 62FC Amoco Oil Co.
Econ Oil 5 Ashland Oil, Inc.
ARCO ML Oils, Clairo Oils Atlantic Richfield Co.
TAP 99 Beechem Laboratories
Mineral Oil H-5 BP Oil, Inc.
PETROCHEM THREAD KUT LIGHT Champions Choice, Inc.
Chevron Metalworking Fluid 504 Chevron U.S.A. Inc.
CITGO Cutting Oil 400 Cities Service Co.
Cook-Cut B-5, Cook-Cut 1711 Cook's Industrial Lubricants, Inc.
No. 150 Cutting Oil DoALL Co.
Gulfcut lID Gulf Oil Corp.
I.C. #1880 International Chemical Co.
IRMCO 249, IRMCO 242, IRMCO 282 International Refining & Mfg. Co.
KOOLMIST TAP SUPREME Kool Mist Corp.
Elcomag 215 Lubrication Co. of America
DO-SA Magnus Div./Economics Lab Inc.
Alumicut Mistic Metal Mover, Inc.
Kleensol 792 Pillsbury Chemical & Oil. Inc.
Petrosan 112 Reilly-Whiteman, Inc.
A-9 Relton Corp.
NEAR-A-LARD OIL. #3-B OIL G. Whitfield Richards Co.
SYN-KUT 105 Henry E. Sanson & Sons, Inc.
Kool-Aide IV, Kool-Aide XII Space Age Chemlube
Toolife 250 Specialty Products Co.
Mineral Seal Oil Standard Oil Co. (Ohio)
TAP MAGIC ALUMINUM Steco Corp.
SUNICUT 102 Sun Petroleum Products Co.
Almag Texaco Inc.
TOWERCUT E-915 Tower Oil & Technology Co.
Ami-Lube NC Tron-X Research Corp.
W&B Cutting Oil 3016, W&B Minolard Cutting Oil The White & Bagley Co.
ALUMTAP Winfield Brooks Co., Inc.
Macco Magnacut Witco Chemical Corp.
LARDOLEUM 0 F Zurn Co.

89 Tapping Fluids, Compounds and Paste*

Adsol 3, Promax H-1 Ashland Oil, Inc.
CIMTAP, CIM'1 a? 11 Cincinnati Milacron, Products Div.
Cook-Tap #1, Cook-Tap #2, Cook-Tap #3 Cook's Industrial Lubricants, Inc:
Tapping Cream DoALL Co.
Habcool 344 H &B Petroleum Co.

16-93
16.3 Cutting Fluid Key

CODE
NO. TYPE AND TRADE NAME MANUFACTURER

8 SPECIALS-LIGHT DUTY (Continued)

89 Tapping Fluids, Compounds and Pastes (Continued)
TRIM TAP LIGHT. TRIM TAP HEAVY Master Chemical Corp.
Taps-All. Taplube Metalloid Corp.
Alumicut Mistic Metal Mover. Inc.
COOL-TOOL Monroe Chemical Co.. Inc.
TAPZOL. CUTZOL WS-20 Rust-Lick. Inc.
THREADMATE Henry E. Sanson & Sons. Inc.
Space Age #20 Tapping Lube Space Age Chemlube
TAP MAGIC The Steco Corp.
Cutting Compound. Dual Action Cutting Fluid #1. Dual Action
Cutting Fluid #2 Tapmatic Corp.
TREFOLEX Cutting Compound Trefolex Industries. Inc.
W&B Cutting Oil 2192 The White & Bagley Co.
TAPFREE Winfield Brooks Co.. Inc.

9 SPECIALS-HEAVY DUTY
90 Honing OIl-Heavy Duty
AMOCUT Gundrill Oil Amoco Oil Co.
Promax 1130 Ashland Oil. Inc.
Honol Oils Atlantic Richfield Co.
Bezora 3 BP Oil. Inc.
Bruko D-666 (non-ferrous). Bruko D-667 (ferrous) Bruce Products Corp.
PETROCHEM 708 Champions Choice. Inc.
Cook's Honing Oil 1995 Cook's Industrial Lubricants, Inc.
DAUBERT GARIA T Daubert Chemical Co.
MICROCOOL IC-9 HONING OIL (Concentrate). MICROCOOL IC-9S: 80-20 Ex-Cell-O Tool &Abrasive
Products
I.C. #155 International Chemical Co.
IRMCO 229 International Refining & Mfg. Co.
LPS 1. LPS 2. LPS 3 LPS Research Laboratories, Inc.
Threadmate Honing Oil 228 Lubrication Co. of America
TRIM SOL S. TRIM EP, TRIM HD Master Chemical Corp.
Metcool 222, Metcool 999 Metalloid Corp.
Vacmul 3D, Vacmul 21C Mobil Oil Corp.
United Base Pillsbury Chemical & Oil. Inc.
PRP 9112 Honing Additive Process Research Products
Petrosan EP43 Reilly-Whiteman, Inc.
FRIGIDOL HONING OIL G. Whitfield Richards Co.
HONZOL 411-B Rust-Lick, Inc.
SYN-HONE MM Henry E. Sanson & Sons, Inc.
Factokut H Standard Oil Co. (Ohio)
Star-3701 Star Oil Company
MAN-852 (Sulfur Free), MB-30 Sunnen Products Co.
Transultex A Texaco Inc.
TOWER D-204 Tower Oil & Technology Co.
VSCC 5299-A Van Straaten Chemical Co.
W&B Honing Oil 2088 The White & Bagley Co.
Biu-Hone 253 Westmont Industrial Products
Macco Honing Oil Witco Chemical Corp. _4

16-94

- T A- ---
 Cutting Fluid Key 16.3
CODE
NO. TYPE AND TRADE NAME MANUFACTURER

9 SPECIALS-HEAVY DUTY (Continued)

91 Cutting Fluids for Titanium-Heavy Duty

CAMPBELLENE. CAMPBELLENE NO-NITRITE Allison Campbell Div./Acco
Industries
AMOCOOL HD Soluble Oil Amoco Oil Co.
Promax 1022 Ashland Oil. Inc.
Autokut Oils Atlantic Richfield Co.
Brukool 4-37d Bruce Products Corp.
CIMFREE 305. CIMPERIAL 1010. CIMPERIAL 1011. CIMPERIAL 20 Cincinnati Milacron. Products Div.
Cook-Coolex 40. Cook-Cool 2020. Cook-Cool 1400 Cook's Industrial Lubricants. Inc.
POWER-CUT HD-600. No. 470 Soluble Oil DoALL Co.
Fron T-Ri Freon HV-3 E. I. DLWUtIt Co. Inc.
I.C. #48-SDW. I.C. 124 International Chemical Co.
IRMVO 282 International Refining & Mfg. Co.
TL-131 S. C. Johnson & Son, Inc.
LPS 1. LPS 2. LPS 3 LPS Research Laboratories. Inc.
Empact 51 Lubrication Co. of America
TRIM HD. TRIM SOL, TRIM REGULAR Master Chemical Corp.
X-60 Metalloid Corp.
MONROE HD, PRIME-CUT. CHOICE-CUT Monroe Chemical Co.. Inc.
Rapier Kut 5200 Pillsbury Chemical & Oil. Inc.
Polar Chip 347 Polar Chip. Inc.
Rycosol 69 Reilly-Whiteman, Inc.
FRIGIDOL L-6 CUTTING OIL G. Whitfield Richards Co.
CUTZOL 400-A. CUTZOL WS-500-A. VYTRON Rust-Lick, Inc.
MIRROR-KUT G-7-M. BOOSTER KUT PLV,SYN-SOL 600 Henry E. Sanson & Sons Inc.
SUNICUT 520 Sun Petroleum Products Co.
Transultex D. Sultex D Texaco Inc.
Ami-Lube Super NC Tron-X Research Corp.
VSCC 708 Van Straaten Chemical Co.
Bio-Cool 500 Westmont Industrial Products
W&B HD Soluble Oil 2945 The White & Bagley Co.
Macco 478 Witco Chemical Corp.
ZURNAGENT BD 0 F Zurn Co.

92 Biodegradable Soluble Oil

Adsol 3 Ashland Oil, Inc.
Brukool 82-c. Bruko D-680 Bruce Products Corp.
Cook-Cool 4639D Cook's Industrial Lubricants. Inc.
IRMCO 303 International Refining & Mfg. Co.
Kool Kut X350 Pillsbury Chemical & Oil. Inc.
Triple C 2100 Pro-Chem Inc.
Rycosol 11 Reilly-Whiteman, Inc.
LUBE-WELL "CD" G. Whitfield Richards Co.
SYN-SOL 50, MIRROR-KUT G-7 Henry E. Sanson & Sons Inc.
ME II Super Concentrate (Recirculating) Tapmatic Corp.
Bio Ami-Lube Tron-X Research Corp.
VSCC 938 Van Straaten Chemical Co.
ZURNAGENT BD 0 F Zurn Co.

16-95
16.3 Cutting Fluid Key

CODE
NO. TYPE AND TRADE NAME MANUFACTURER

9 SPECIALS-HEAVY DUTY (Continued)

93 Ceramic and Glass Soluble Oil
Soluble Oil #371 BP Oil. Inc.
PETROCHEM 101 Champions Choice. Inc.
CIMCOOL S2. CIMCOOL S4. CIMFREE 234. CIMFREE 238 Cincinnati Milacron, Products Div.
Cook-Coolex 40 Cook's Industrial Lubricants. Inc.
Hocut 219. Hocut 702, Hocut 714 E. F. Houghton & Co.
I.C. #993-G International Chemical Co.
IRMCO 189 International Refining & Mfg. Co.
130 Wax Cool. Slipstream 54 S. C. Johnson & Son, Inc.
Ceramasol 3031 Lubrication Co. of Amprira
PRIME-CUT ivionroe Chemical Co., Inc.
Hy Kut 6638 Pillsbury Chemical & Oil, Inc.
Solap 30. MON-60 Process Research Products
Rycosol 77 Reilly-Whiteman, Inc.
LUBE-WELL -CD" G. Whitfield Richards Co.
CUTZOL WS-20. CUTZOL WS-15 Rust-Lick, Inc.
SYN-GRIND 60-P Henry E. Sanson & Sons, Inc.
Kool-Aide XII Space Age Chemlube
Glassgrind Oil Standard Oil Co. (Ohio)
VSCC S-212 Van Straaten Chemical Co.
W&B Lubricant 1888 The White & Bagley Co.
Grind Rite 174 Witco Chemical Corp.

94 Tapping Fluids, Compounds and Pastes

Promax H-7, Promax Q-1 013, Promax H-333 Ashland Oil, Inc.
CIMTAP, CIMTAP II Cincinnati Milacron, Products Div.
Cook-Tap #1,Cook-Tap #2, Cook-Tap #3 Cook's Industrial Lubricants, Inc.
CURTIS DD-50, CURTIS DD-80, CURTIS DD-1 00,CURTIS DD-200,
CURTIS SDD-1 00 (emulsifiable) Curtis Systems, Inc.
Tapping Compound DoALL Co.
TAPPING COMPOUND 1715 Franklin Oil Corp. (Ohio)
Habcool 318 H & B Petroleum Co.
Tapeze #1271 (Paste) International Chemical Co.
Kool Mist Corp. M
KOOL MIST FORMULA #88 TAP WAX
TRIM TAP LIGHT. TRIM TAP HEAVY Master Chemical Corp.
Tapeze X-2 Metalloid Corp.
Alumicut Mistic Metal Mover, Inc.
COOL-TOOL Monroe Chemical Co., Inc.
Rapid Tap, A-9 (for aluminum) Relton Corp.
TAPZOL, VYTRON TAPPING COMPOUND Rust-Lick, Inc.
TOOLMATE TAP Henry E. Sanson & Sons, Inc.
Space Age #23 Tapping Lube Space Age Chemlube
Startap-3202 Star Oil Company
Cutting Compound, Dual Action Cutting Fluid #1, Dual Action
Cutting Fluid #2 Tapmatic Corp.
TREFOLEX Cutting Compound Trefolex Industries, Inc.
W&B Base 2844 The White & Bagley Co.
MOLY-DEE TAPPING FLUID Arthur C. Withrow Co.

16-96

v- _ _ - _ _ -
 SECTION 17
POWER AND FORCE
REQUIREMENTS
IN MACHINING

17.1 Determining Forces in Machining......................7

17.2 Determining Power Requirements in Machining................1
17.3 Estimating Forces in Turning .................................................................... 7
17.4 Estimating Torque and Thrust in Drilling...................72 17-23

17-11
 EME1O PAS BL~aM-NOT FILM~

Determining Forces in Machining 17.1

The forces produced in turning and milling can be deter- The equations given in these three figures provide the
mined by the use of dynamometers such as those shown in means for calculating power and torque from the dyna-
figures 17.1-1 and 17.1-2. The drill dynamometer shown mometer readings in both English and metric units.
ir. figure 17.1-3 measures the torque and the thrust force.

Vc Transient surface
Feed per revolution

Thrust
force
Ft

Determination of English Unit Parameters Determination of Metric Unit Parameters

I sing Unit htp Values Using Unit kW Values

d = Depth of cut, in lips - d Depth of cut, mm kW5 CIs

33,000OX
Dt=Workpiece diameter, in
Dt Workpiece dimete,mm
E = Efficiency of spindle drive h I ps E =Efficiency of spindle drive m= S
Fc =Ctigfre bE
Fc Cutting force, N
fr=Feed per revolution, in E~
f, Feed per revolution, mm
hpm - Horsepower at motor 0 = l2xdxfrxVc lCWm = Power at motor, kW =dxf~xVe
lips = Horsepower at spindle kWs - Power at spindle, kW
P =Unit power, hp/inI/min P hps P Unit power. kWlCm'lmin p
o Metal removal rate, in 3 /min Q0 Metal removal rate. cin mi Q
Ts-Torque at spindle, in-lb D, Ts Torque at spindle, N-in TS Fcx 2
Vc =Cutting speed, fpmn TS F0 x- V0
2 Cutting speed, mlmin 2

63,030 x lips TS 9
549 x cW 5
TS rpm p

Figure 17.1-1 Forces and power !inturning.

17-3
 17.1 Determining Forces in Machining

Dynamometer X-
protected by cover

Dynamometer bole dynamometer

to vise 4 places
Y

Dynamometer fastened to
subplate and bolted to -Strain gages at each corner
tableM
Three-force dyamometer designed
especially
machining forces during milling (end milling for measuring= i
shown).

Determination of English Unit Parameters

Determination of Metric Unit Parameters
Using Unit hp Values A
Us~ing Unit kW ValuesA
d - Depth of cutin
ftFcs d epth of cut mm
E - Efficiency of spindle driv~e kW s F- C
E -Efficiency of spindle driIve
ft Fed,
: inch/tooth bps ft Feed. mmltoor.h
n = Number of teeth in cutter W
h E n
hpmn = Horsepower at motor -Number of teeth in cutter yr E
lcWm - Powier at motor, kcW
hp$s Horsepower at spindle 0 wxdxftxnxrpm kWs = Power atspindlekW
P ,Unit power, hplin- /min wJxdxftxnxrpm

Qo ea P =Ui oe.klm1i
eoa ae li
Ts = Torque at spindle, in-lb 0 -Metal removal rate, cm3 /min f,. W
Tr = Torque art spindle, N-m0
Vc-Cutting speed., fPmn
T 6_3.030 x bps Vc
Fc = Cutting force, lb = Cutting speed, mlmin
3 rp =
29 x kWs
Cutting force. N T
w = Width of cut, in rpmFm
-...

W =Wdho um

Figure 17.1-2 Forces and power in milling.

17-4
 Determining Forces in Machining 17.1

/J

Strain
gagesj
jTest piece

Strain

Base

Determination of English Unit Parameters Determination of Mob*i Unit Parameters

Using Unit hp Values Using kW Values
0
d =Ts x rpm
O Drldimtrinhps Ts x rpm
Dd = Drill diameter, mm kWs
E = Efficiency of spindle drive E Efficiency of spindle drive
-
fe=Feed, inchlrevolutionu hm Lp$ fr Foed, mmlrevolution
= kW
bs , Horsepower at mozor 3
E kWs Power at spindle. kW
hpmn Horsepower at spindle km=Kma oo.k
P =Unit power. hplm 3
l/min rpm Po2eratmotrpm
4Xi Unit poatef.W/crn'Imn
-~r~ 0*AJA~!I
0 AkMtal removal rate, in'Imin 0 - Mewa nemoa rate, cm'lrrun
Ts-Torque at spindle, in-lb P p Ts - Torque at spindle. N-m k~
Vc - Cutting Wpeed VC - Cutting Ied mlmina
49
Ts 5WOx fr xd' x P
Ts 7$x~frxOdxP

Figur 17.1-3 Forces and power in drilling.

%-

17-5
 PRECEDING PA( ALAW-NOT FILVD

Determining Power Requirements in Machining 17.2

The power required in machining can be determined by vided in figures 17.2-3 through 17.2-10 for deternining the
several different methods as follows: power required for turning, milling, drilling and broaching.

Use of a watt meter or ammeter at the spindle motor.

This is the simplest and most practical method of measur. A list of the equations, data sheets, and ,dignment charts
ing power. The watt meter is more accurate and reaches for determining the power requirements and other per-
greatest accuracy when the motor is loaded to full load. tinent information on machining for both English and met-
The power required at the cutter can be estimated by sub- ric units is as follows:
tracting the idle power from the power produced while
cutting. Tables 17.2-1 and 17.2-2 - Shop Formulas foi Turn-
ing, Milling, Drilling and Broaching
Calculation of power from the cutting force. In order to
utilize this method, it is necessary to measure the forces at Tables 17.2-3 and 17.2-4 - Unit Power Require-
the cutting tool using a dynamometer such as one shown in ments for Turning, Drilling and Milling
figure 17.1-1, 17.1-2 or 17.1-3. From the cutting force val.
ues, F,, as measured with the turning dynamometer, the Figures 17.2-1 and 17.2-2 - Unit Power Require-
power at the spindle can be calculated. The power at the ments for Surface Broaching
spindle in drilling can be calculated from the torque meas-
ured by the drill dynamometer in figure 17.1-3. To deter- Figures 17.2-3 and 17.2-4 - Alignment Chart for
mine the power in milling, the torque must be measured Determining Metal Removal Rate and Motor Power in
with a torque dynamometer, and the power calculated from Turning
the torque values. The power at the motor is determined by
dividing the power at the spindle by the efficiency of the Figures 17.2-5 and 17.2-6 - Alignment Chart for
spindk system. See figures 17.1-1 to 17.1-3 and the align- Determining Metal Removal Rate and Motor Power in
ment chart. figure 17.2-11. Face Milling

Calculation of power from published values of unit Figures 17.2-7 and 17.2-8 - Alignment Chart for
power requirements. An adequate estimate of power in Determining Motor Power in Drilling
machining can be made from the unit power requirements
given in table 17.2-3 and figure 17.2-1 or table 17.2-4 and Figures 17.2-9 and 17.2-10 - Alignment Chart for
figure 17.2-2. The power is determined by multiplying the Determining Metal Removal Rate and Motor Power in
unit power requirements (hp/"n3 /min or kW/cm3/min) by Surface Broaching
the rate.of metal removal (in3/min or cm 3/min). The equa-
tions for performing these operations are given in tables Figure 17.2-11 - Alignment Chart for Estimating
17.2-1 and 17.2-2. In addition, alignment charts are pro- Spindle Drive Efficiency

17-7
17.2 Determining Power Requirements in Machining
TABLE 17.2-1 Shop Formulas for Turning, Milling, Drilling and Broaching-English Units

PARAMETER TURNING MILLING DRILLING ] BROACHING

Cutting speed, fpm V, .262 x Dt x rpm V .262 x D., x rpm Vc .262 x Dd x rpm V,
Revolutions per minute rpm - 3.82 x rpm = :3.82 x rpm 3382x-
DD, Dd _______

Feed rate,lIn/min fm f. xrpm 1,, ~n

x x rpm f, f~rpm-
x

fmt
Feed ~er tooth, In - = n x rpm __________

LL L
Cutting time, min = L t =2L
m

Rate of metal removal, in3/mln Q 12xdxf~xV, 0 wxdxfm d x=f 0 =12xwxdxV.

Horsepower required at spindle* htp, = Ox P hp, - Ox P hp, - Ox P

Horsepower required at motor* hp. =-Qx hp,,- Q- hpm= - p 0 -X

ftP

Toqea
pnl .=63030 ftp,1 , 63030 hp, T 63030 hp,
Toqu a sinleT, rpm rpm = rpm ________

SYMBOLS: Df - Diameter of workplace inturning, Inches hp, -Horsepower at spindle

D - Diameter of milling cutter. inches L =Length of cut, Inches
Dd= Diameter of drill. Inches n -Number of teeth Incutter
d _ Depth of cut, inches P - Unit power, horsepower per cubic Inch per minute
d,- Total depth per stroke Inbroaching, inches 0 - Rate of metal removed, cubic Inches per minute
E - Efficiency of spindle drive rpm - Revolutions per minlute of work or cutter
f = Feed rate, Inches per minute T, - Torque at spindle, t. -h-pounds
f,- Feed, Inches per revolution t - Cutting time, minutes
I,- Feed. Inches per tooth V,- Cutting speed, feet per minute
hpm = Horsepower at motor w - Width of cut, Inches
*Unit power data are given intabie 17.243 for turning, milling and driiiing, and Infigure 17.2-1 for broaching.

7 '4
 Determining Power Requirements in Machining
17.2
TABLE 17.2-2 Shop Formulas for Turning,
Milling, Drilling and rroachlngMetric Units
PARAMETER TURNING MILLING DRILLING BROACHING
Cutting speed, m /m n V:-,
-,
r

Revolutions per minute __ -10OO V-'. _

p rpm.= IXx OV j
1000v~ 0-_
____- |
Feed rat, mm/mm f r rn pf p

Feed per tooth, mm

f-. ..
, -xT, -- rpm- , - -- a---h-

Cuttng time, m en t N t t

Rate of metal removal, ccb/mcn c nti erp m

Power required at spindleinWdl

Power required at motor*... nwo meters
0L iln . . .
utrmlietr imtrou X""
egha ilmtr L _ Q :

Torque at spindle :..... U

..- i

millimetrs-per-revolutio
r-Feed,
SYMBOLS. D, = Diameter of workplce inturning, millimeterst'. Cutin t...me minutes-
_-'
:
kW, = Power atspindle, kW
D= -- Diameter of
Dd of drill,
millingmillimeters
cutter,mlimeters nL - Number
Length ofofcut, millimeters
teeth in cutter
ndtp = Total
Depthdepth
; cut,per
millimeters
stroke in broaching. millimeters QP = Rate
= Unit power,
of metalkanowatts
removed,percubic
cubiccentimeters
centimeter per
per minute
minute
E Efficiency of spindle drive
rpm =Revolutions per minute of work or cutter
f, -.Feed rate, millimeters per minute
T. - Torque at spindle, newton-meters
f, = Feed, millimeters per revolution
t = Cutting time, minutes
f, - Feed, millimeters per tooth
V Cutting apeed, meters per minute
IkW = Power at motor, kW
*Unit power data are given in table 17.2-4 for turning, w -Width of cut, millimeters
milling and drilling, and in figure 17 2-2 for broaching.

t
==

17-9
-- = I
- II
= _ -|
17.2 Determining Power Requirements in Machining

TABLE 17.2-3 Average Unit Power Requirements for Turning, Drilling and Milling-English Units
UNIT POWER*
hp/in3/min
TURNING P, MILLING P.,,
HSS AND DRILLING Pd HSS AND
MATERIAL HARDNESS CARBIDE TOOLS HSS DRILLS CARBIDE TOOLS
(feed .005-020 ipr) (feed .002-.008 ipr) (feed .005-.012 ipt)
Sharp Dull Sharp 1 Dull Sharp Dull
Bhn Tool Tool Tool Tool Tool Tool

STEELS, WROUGHT AND CAST 85-200 1.1 14 1.0 13 1.1 1.4

Plain Carbon 35-40 R, 1.4 1.7 14 1.7 1.5 19
Alloy Steels --
Tool Steels 40-50 R, 1.5 1.9 1.7 2.1 1.8 2.2
50-55 Rc 2.0 2.5 2.1 2.6 21 26
55-58 Rc 34 4.2 26 3.2" 26 3.2

CAST IRONS 110-190 0.7 0.9 1.0 1.2 0.6 0.8

Gray, Ductile and Malleable 190-320 1.4 1.7 16 20 1.1 1.4

STAINLESS STEELS, WROUGHT AND CAST 135-275 1.3 1.6 1.1 1.4 1.4 1.7
Ferritic, Austenitic and Martensitic 30-45 R, 1.4 1.7 1.2 15 1.5 1.9

PRECIPITATION HARDENING 150-450 1.4 1.7 1.2 15 1.5 1.9

STAINLESS STEELS
TITANIUM 250-375 1.2 1.5 1.1 1.4 1.1 1.4
HIGH TEMPERATURE ALLOYS 200-360 2.5 3 1 2.0 2.5 2.0 2.5
Nickel and Cobalt Base
Iron Base 180-320 16 2.0 12 15 1.6 2.0
REFRACTORY ALLOYS 321 2.8 3.5 26 3.3* 2.9 3.6
Tungsten
Molybdenum 229 20 2.5 1.6 2.0 1.6 2.0
Colurrbium 217 1.7 2.1 1.4 1.7 15 1.9
Tantalum 210 2.8 3.5 2.1 2.6 2.0 2.5
NICKEL ALLOYS 80-360 2.0 2.5 1.8 22 1.9 2.4

ALUMINUM ALLOYS 30-150 0.25 0.3 0.16 0.2 032 0.4

500 kg

MAGNESIUM ALLOYS 40-90

500 kg 0.16 0.2 0,16 0.2 0.16 0.2

COPPER 80 Re 10 12 0.9 1.1 1.0 1.2

COPPER ALLOYS 10-80 RB I 0.64 0.8 0.48 0.6 0.64 0.8
80-100 R, 1.0 1.2 08 1.0 1.0 12

*Power requirements at spindle drive motor, corrected tot 80% spindle drive efficiency.
Carbide

17-10
 Determining Power Requirements in Machining
17.2
TABLE 17.2-4 Average Unit Power Requirements
for Turning, Drilling and Milling-Metric
Units
UNIT POWER*
kW/ctro/min,
TURNING P,
MILLING P,
MATERIAL HARDNESS HSS AND DRILLING P,
CARBIDE TOOLS HSS DRILLS HSS AND
I CARBIDE TOOLS
(feed .12-.50 mm/r) (feed .05-.20 mm/r) (feed .12-.30 mm/r)

Bhn Tool
Sap Dull
Tool
Sharp
Tool
Dull
Tool
fSharp
Dull
Tool Tool
STEELS. WROUGHT AND CAST 85-200 "00 M 06" 06 005 05 0064-
Plain Carbon354R,
Alloy Steels350R06 _6Jg_ =x nS i& z
Tool Steels 40-50 R~ 07 04 07 08
08 08 677 09 08 06
10
50-55sR, 09 14 96 11tj8 V096 2H18_
55-58 Rc -15- -- 9---
CAST IRONS
~ 46U 3x411
4 2
110-190 0632 04MU46
Gray, Ductile and Malleable 05 02M3
190-320 04~ 6=-7715 09 050 16
STAINLESS STEELS, WROUGHT AND CAST
Ferritic, Austenitic and Martensitic
135-275 .0 .073~ 064-
VSii -06-4 .077
30-45 R, 064-~ 077 .055- -068. 068 08W
PRECIPITATION HARDENING
STAINLESS STEELS 150-450 &064 .0177 -. 055 068~ .068 - 088-
TITANIUM
250-375 .055~ 08 050
HIGH TEMPERATURE ALLOYS .064- 050D 964
Nickel and Cobalt Base 20036 .114 141_ .01_11_
2030 -1 ~1t .1
01 -1 9 1
Iron Base
180-320 -__07.3- 091 .055 '068 _073 .091-
REFRACTORY ALLOYS__
Tungsten 321 ___
- 127M 159h' .i118~ 1st
.- -13= 164-
Molybdenum 229 -.01- =114 .073= D91= 073D
Columbium 091w
217 07__ 9 064-
Tantalum 077 06"~ =086Z
210 127 159 09-6
NICKEL ALLOYS 1:l18 01 WE1 IA
80-360 091 MF-14 082 400j 7 10
ALUMINUM ALLOYS
301 50 01- Gtf
500 kg 07 009 MaI- 1
___ _
MAGNESIUM ALLOYS
40900____7_
500 kg OQ 09 00739 EM
COPPER 7009
z gb
80 R8 6 __ _0_5__=_4
COPPER ALLOYS
10-80 R, 029 .06 iW22-
80-100 Re _027- 029 - 03
7055
E948- Q"04-=
*Power requirements at spindle drive motor,
corrected for 80% spindle drive efficiency.I
Carbide

17-11
17.2 Determining Power Requirements in Machining

-C

CLC

a)l

0. -C

C 0.
C CO U
CC

C)
--

C.) 0

00

0
(a

CDC

0 0

(D
f

E._

0 ~0
0 D ~ ')(D

00 C.

0 0

UIWJ/cuI/di. 'Jamod !ufl__

17-12
I--

Determining Power Requirements in Machining 17.2

CO)

CO

C CL
CaC
'2a)

n a)

(0 0
'2V)
~0
00

CDC

o
0

0)
C

'C

E, CP

CC U

ulw/coO/M

17-13
17.2 Determining Power Requirements in Machining

C C00 a l)) 0 ")

0 >

00
320~~~ 0 . 0

-0
I

C
0,~ W

Ln 0 00 0 000
0' f _
E0 0 - CJ 1 V n' ' -O
. u 111i~efill ETL
-0i.

00
U)
~~. 0
12- CL

000 0z /L r
00

C - 00

/ a,

00 0 L

/ x

0000a

000000 000 0 3MD

WE t~C E.
4 C1 C=

C00
I - C,0)

a~a 0 cMC.

C~ x

0. 0 0

*= 0>
0 0
11 0) C1 -0 aCO to
0 to
0 IT
0
C
0
Ci
0CC", .Z
0 0 3
0E; 0 6 O

ILOU x 0

17-14
 Determining Power Requirements in Machining 17.2

>

.1.1.1 1 C

0200

I@

CLC

(p
0p 0 00 30 0 00 00
CDD
CD - .- " C- ~CDC ) - - CJ M~ V to Co ' CL
Eo2 ,* . 1 I I Iii ,I . 1. 1.1. 00

X2 CLu

e.~
co~ 0
,0 E

/ 0 C
/C 2
00 o0 0 U

0~ 00

- CCD
- C) /N -0 000D

00 ~ t2C ct-: ~
LI~l 1,11tI I. I E ~
1/0
00~

IE C, IM
0~~
0 C 0 0 ~
.. DoC)- ~~~~~~~I (s- C

E LL

.2

17-15
17.2 Determining Power Requirements in Machining

Ov .2 0) Of D V

E
C 0 0 00 0 v 0 mC
>) 'jja-Ips
Ui i 6 C'iC; %0 0 C >
W

0 E S=

E f x 0D
0C 0 C.d
q, 0L 0 0v 00

E 0

Oul 0

- c'u
l 00
00i

Ca

0 S 0

CC

oY 0 0)
0 0L 0 S

Oall a)p
00 /
o0 0 C) 1)

. . .0 0 0

CLO )A 0O 00 0D LO
I N a C

2-2

.0 IC

Ct DCO ) 0 U)
0W A
0~~ 00
6 6 o 6
o

17 16
 Determining Power Requirements in Machining 17.2

0:)0 000 0 0'

M ii) 00 ?-

E/
00 0 0 0 CO COm v M, N 0
EU~ C?
Ur -l0 000 >
0
;- -UaIpds %O98+1 0 0 133
660 000 0 0
.SL
E tfll fll 03

xE

0' 0 00 0 0 00 0 ,0' 0 C
'T 11 100

:.sc O ,- 0. , C) .
C14

K .- 0

EE
C> Oa0 0
0..00
0~~~~-
) 00 00 ,01

0 000 00 0000 Cl
I n O liii ' -

E0 > 0a

00

EoX

V C IE fi lI I I I I II o
f >Oc
E

E #~ I :* -

U,~~C
.C0 N

00 Cl

- us C

E. I 0

7 -17
17.2 Determining Power Requirements in Machining

CO (D In c.
(-

0 (2 0 0 00 0

C'

00

CL 0

0 U

0 _

~ c j0 0

LC S .
0 e-I 0
5
0 ~~~~ 000

0 0
~~0

CwDO 0I Xa =- a,

o aC 0

C0 5 - 0 -
v3 =

COC"
0. 000 x Cca g
00 S..-

tro -C 4)~~-

0 CD
EE
0C

CL A

17-18
 Determining Power Requirements in Machining 17.2

(D CE~~ ) )
-- 0 0~l0 0 0 0

C O5

0.0
i s0

000 N0 O
j n , Ca I, W0C
00

0 0

0 0

Ix IL -0
E 3)
0 E
00 0),

uLn E Eac
WOc~
IL 0 C C
j

0 -R
I ~S a
0.0
a- 0

0 40

C
C-

E v
.. 0 ,0 0 0 0 ~
0, ED)C OS n a C0)L=

CL-4

171
17.2 Determining Power Requirements in Machining

Q
Vc Metal
Broach .mremovalt
speed x rate hp at
fpm -t inVmin motor
100 dt
Total stock T 30 5
80 removed P -66
per stroke hp/in/min -
0in :-%20 0.3 -8
-- 0.30 I \ 0.4 10
-020 / 15 , 0.5
40 t 06
0,8
Width of -0.10 10 1.0 ,15
I30 cut 1 N'
0. 8 20
0.0S -2.0
20N t 0.04
6 3.0
0o
5 4.0
-0.02
02 -4 40
10 3N 0.01 -3 50
-s0
-8 4 -60
-5
-6 280
-5 - =10 b
1 -100
4

Examiple:
Mhterial: Cast iron - HSS tools Q 12 Vc x w x dtin/min
Chipload 0.005 in/tooth l xP QxP
V, 30 fPor w - 1.5 in E 0.7
dt = 0.040 in 0 = 22 in'/min
3
P = 0.7 hplin /min hpm = 22hp

*See figre 17.2-1 for Unit power values Ithpm at motor for 70% drive efficiencv

Figure 17.2-9 Alignment chart for determining metal removal rate and motor horsepower in surface
broaching with high speed steel broaching tools-English units.

17-20
 Determining Power Requirements In Machining 17.2i

kWmt
Motor
power
VC kW
Broach
Speed
m/min

T~4050 CJ
Toa
Meta
rea
removal

dt cm3/min

-30 soc
removed
per stroke P 0.01
mm 400 kWV/cm 3/min
_10
Width of/ 306
15 cut
mm
/0.02
5
5 200 ;003
10 0.4 10
3 -0.05
102 -0.06k
/008 15
20 10. 10
20 100 2
-4 \-30 -0.5 -80 -0.20
S40 / -0.4 -030 3
500

100% 0.2 -40

2 / j- 40 5
200 13060

20

Example:
Material: Cast iron -HSS tools
0-Vxxtmli
Chipload 0.13 mm/tooth
QxP QxP
Vc~ = ~nm
38mm E 0.7
dt = 1 mm = 380cm3/min
P - 0.03 kW/cml/min Pm -16.3 kW e
Lf
*See figure 17.2fo Uit o ervl s t kWrn at motor for 70% Drive Efficiency

Figure 17.2-10 Alignment chart for determining metal removal rate and motorpoeinsrae_
broachinrg with high speed broaching tools-Metric units.
_

17-211
17.2 Determining Power Requirements in Machining
Number of units
Index operating in sequence
points in transmission drive Efficiency

Antifriction 075
bearings

o 80
C

-10
- 9 -085
N8
7
6
5

4 -090
Spur gears 8
underload 3 0 91
(pairs)
0.92

0 93

V-belt 0 94
drives A
Example: 1
0.95

Motor 1 V-belt drive

096
8 Bearings
UL
3 Pairs of gears

0.97
II

LINE A 1 V-belt drive efficiency; 0.95

LINE B 3 Pairs of gears efficiency; 0 91 X -- X
LINE C: 8 Bearings efficiency, 0.92 0.98
Total Efficiency z 0.95 x 0 91 x 0.92 = 80%

Figure 17.2-11 Alignment chart foo estimating spindle drive efficiency.

17-22
 Estimating Forces in Turning 17.3

The turning forces listed in tables 17.3-1 to 17.3-3 are The forces listed are as follows:
based upon a systematic analysis of empirical data; never-
theless, these values are to be applied only as starting Tangential or cutting force, Ft
points. Most of the data were derived from the following Radial force, Fr
sources: Feed force, Ff

The values in tables 17.3-1 to 17.3-3 provide the turning

Kaczmarek. J. 1976. Principles of machining by cut- force in pounds for a unit depth of 1.0 inch. In order to cal-
ting, abrasion and erosion. Stevenage, England: Peter culate the estimated cutting force in pounds, multiply the
Peregrinus Ltd. values given in the tables by the depth of cut in inches (to
convert to newtons, multiply force in pounds by 4.48222).
Konig, W. and Essel. K. 1973. Spezifische Schnitt- Example: Material: Steel, 175 Bhn
kraftwerte tir die Zerspanung metallischer Werkstoffe Rake angle: -5'
(Cutting force data for the machining of metallic mate- Side cutting edge angle (SCEA): 150
rials). Dusseldorf, West Germany: Verlag Stahleisen. Feed: 0.015 inch per revolution
Depth of cut: 0.250 inch
Kronenberg. M. 1966. Machining science and appli- Rcad the following values from the force tables: F
cation. Oxford, England: Pergamon Press. 4890. F, = 1648, Ff = 2500. Forces for this example
are calculated as follows:
Zorev. N. N. 1966. Metal cutting mechanics. Oxford.
England: Pergamon Press. Tangential or cutting force = 4890 x 0.250 1223
pounds
Radial force = 1650 x 0.250 413 pounds
Metcut Research Associates Inc. Internal reports. Feed force = 2500 x 0.250 = 625 pounds

TABLE 17.3-1 Turning Force Data for a Unit Depth of Cut of t 1 Inch
(Data based on turning with carbide tool at 80 to 200 feet per minute)
1
SCEA: 0 SCEA: 150 SCEA: 300 SCE.4 450
MATERIAL TOOL FEED
AND RAKE PER
HARDNESS ANGLE REV. F,* F,' Fit Ft F, Ff F Fr F F, F, F
degrees in lb lb. lb. lb. lb. lb. lb. lb. lb. lb. lb. lb.

Cast iron .005 2.061 598 1.383 2.078 602 1,407 2,133 614 1,487 2,238 638 1,647
260-320 Bhn 010 3,498 1.050 1,947 3,527 1,057 1,980 3,619 1,078 2,094 3,798 1,120 2,320
.015 4,766 1,460 2,378 4,806 1,470 2,420 4,932 1,500 2,558 5,175 1,558 2,835
to .020 5,936 1,844 2,742 5,985 1,856 2,790 6,142 1,895 2.950 6,445 1,968 3,268
I1.025 7038 2,211 3.062 7,096 2,225 3,116 7,282 2,272 3,293 7,640 2,360 3,648
+ .030 8:088 2,564 3,350 8,155 2,580 3,410 8,370 2,634 3,603 8,780 2.736 3,992
040
.0 0
10,074
11,944
3,240
3,883
3.862
4,312
10,157
12,043
3,260
3,908
3,930
4,388
10,424
12,358
3.328
3,990
4,153
4,637
10,937
12,966
3,457
4,144
4,602
5,138

.005 2,680 1,016 2.418 2,702 1,023 2,461 2,773 1.044 2,600 2,910 1,084 2,882
.010 4.548 1.785 3,407 4,585 1.796 3,467 4,706 1,833 3,664 4.937 1,904 4,060
015 6,197 2.480 4,162 6,248 2,497 4,236 6,412 2,548 4,476 6,727 2,648 4,960
to .020 7,718 3.135 4,798 7,780 3,155 4,882 7,985 3.220 5,160 8,378 3,345 5,717
tO .025 9,150 3.758 5,357 9,226 3,783 5,450 9,467 3,860 5,760 9,933 4,010 6,383
-10 .030 10.516 4.358 5.862 10.603 4,387 5.965 10,880 4.478 6,30-. 11,416 4.650 6.985
.040 13,097 5,507 6,757 13,205 5,543 6,876 13,550 5,657 7,267 14,218 5,876 8,052
.050 15,528 6,602 7,544 15,656 6,645 7,677 16,066 6,782 8,113 16,857 7,044 8,990

NOTE: To calculate force in pounds, multiply values given by depth of cut

in inches. To convert to newtons, multiply force in pounds by 4.48222.
IF,,-Tangential or Cutting force
IF, - Radial force
IF, = Feed force

17-23
 [I
17.3 Estimating Forces in Turning
TABLE 17.3-2 Turning Force Data for a Unit Depth of*- !. 1 Inch
(Oata based on turning witt. carbide too' at 200 to 600 feet per .et

SCEA: 00 SCEA: 150 SCEA: 300 SCEA: 450

MATERIAL TOOL FEED _ ___
AND RAKE PER
HARDNESS ANGLE REV. Ft F,* F,' Ft F, F, F, F, Ff F, F, F,
degrees in lb. lb. lb. lb lb. lb lb. lb. lb. lb. lb. lb.

Cast iron .005 1.195 340 100 1.204 343 813 1.232 350 857 1.288 362 946
160-200 Bhn .010 2,056 608 1,140 2.070 610 1,160 2,120 623 1.224 2,216 644 1,350
+5 015 2,824 852 1.405 2.845 857 1,430 2,913 873 1,507 3.044 903 1.663
.020 3.538 1,082 1.629 3.564 1,088 1.657 3,650 1.108 1,747 3,814 1,147 1,928
to .025 4,213 1,303 1.827 4.245 1,310 1,858 4,347 1,335 1.960 4,542 1,380 2,162
+10 .030 4,860 1.517 2.006 4,897 1.525 2,040 5,014 1,554 2.152 5.240 1,607 2,375
.040 6,088 1,927 2,326 6.134 1.938 2,365 6,280 1,974 2.494 6.563 2,012 2,753
.050 7,250 2.320 2.608 7,305 2,334 2,653 7,480 2.377 2,797 7,816 2.458 3,087

.005 1.555 590 1,400 1.566 593 1,424 1,604 604 1.502 1.676 625 1,658
.010 2,675 1,050 2,000 2,695 1,056 2,034 2,760 1,075 2,145 2,884 1,112 2,367
015 3,675 1,470 2,463 3,703 1,480 2,505 3,790 1,507 2.640 3.962 1,558 2,915 27
-5 .020 4,603 1.868 2,855 4.638 1,880 2,903 4,750 1,914 3,062 4.963 1,980 3.378
to .025 5,482 2,250 3.202 5,523 2.263 3.256 5.656 2.304 3,434 5,910 2,385 3,790
-10 .030 6.323 2,618 3,516 6,371 2,634 3,576 6,524 2,683 3.770 6,817 2,775 4,160
.040 7,920 3,327 4.076 7,980 3,346 4,145 8.172 3,408 4,370 8,540 3,526 4,824
.050 9,433 4,006 4.570 9,504 4,030 4,648 1 9,732 4.104 4,902 10,170 4,246 5,410

Cast iron .005 1,636 474 1,097 1,649 477 1,116 1 1,692 486 1.180 1,775 505 1,306
200-260 Bhn .010 2,780 833 1,546 2,804 838 1,573 2,876 856 1,662 3,016 888 1,840
.015 3,793 1,160 1,890 3,824 1,167 1,924 3,923 1.190 2.032 4,114 1,236 2,250
.020 4,727 1,466 2,180 4,765 1,476 2,218 4.890 1,506 2,344 5,127 1,563 2,596
to .025 5,607 1,758 2.435 5.653 1,770 2,478 5,800 1.806 2,618 6,082 1,875 2,900
I +10 .030 6,447 2,040 2,665 6.500 2,054 2,712 6,668 2.096 2,866 6,993 2,176 3,174
.040 8,034 2,580 3.073 8,100 2,597 3,128 8,310 2,650 3,305 8,715 2,750 3,660
.050 9,530 3,095 3,433 9,608 3,115 3.493 9,858 3.178 3,690 10,338 3,300 4,088
.005 2,126 806 1.918 2.143 811 1,952 2,200 828 2,062 2,306 860 2.284
.010 3,614 1,418 2.704 3,644 1,427 2,752 3,738 1,457 2,908 3,920 1,512 3.220
.015 4,930 1.974 3,306 4,970 1,987 3,364 5,098 2,027 3.555 5,347 2,104 3.938
to .020 6,144 2.495 3,813 6,194 2,511 3,880 6,355 2,563 4.100 6,664 2,660 4,540
to .025 7,288 2,993 4,258 7,348 3,012 4,334 7.538 3,074 4,578 7.905 3,190 5,072
-10 .030 8,380 3.473 4.660 8.448 3,495 4,743 8,668 3.566 5,012 9,090 3,703 5.552
.040 10,444 4,390 5,375 10,530 4,418 5,470 10,803 4,508 5,780 11,328 4,680 6.402
.050 12,390 5.2-,o 6,004 12,490 5,300 6,110 12,815 5,408 6,456 13,438 5,615 7.150
NOTE,To calculate force in pounds. multiply values given by depth of cut
in inches To convert tonewtons, multiply force in pounds by 4.48222.
=F,- Tang ilial or Cutting force
IF, - Radial force
F, - Feed force

34
17-24
a-
 Estimating Forces in Turning 17.3
TABLE 17.3-3 Turning Force Data for a Unit Depth of Cut of 1 Inch
(Data based on turning with carbide tool at 300 to 600 feet per minute)

SCEA: 00 SCEA: 150 SCEA: 300 SCEA: 450

MATERIAL TOOL FEED
AND RAKE PER
HARDNESS ANGLE REV. Ft* Fr' Fit Ft F, F, F, Fr F F, F, F
degrees in lb lb. lb. lb lb. lb lb lb. lb. lb lb. lb.

Steels 005 1,853 541 1,116 1,870 552 1,146 1,928 588 1,244 2,038 662 1,449
135-200 Bhn 010 3,062 725 1,324 3,092 740 1,360 3,186 788 1,476 3,369 886 1,719
.015 4,108 860 1,463 4,148 877 1,502 4,274 934 1,630 4.520 1.050 1,900
to 020
025 5,060
5.950 970
1,066 1,570
1,660 5,110
6,006 990 1,612 5,265 1,055 1,750 5.567 1,186 2,039
+ 10 030 6,790 1 150 1,736 6,855 1,088
1.174 1,703
1,782 6.190
7,064 1,158
1,250 1,850 6,545 1,303 2,155
1,934 7,469 1,407 2,254

.040 8,365 1,300 1,863 8,444 1,326 1,912 8,702 1,412 2,076 9.200 1,588 2,420
.050 9,832 1,427 1,968 9,927 1,456 2.020 10,230 1,550 2,194 10,816 1.744 2,556

.005 2,136 860 1,646 2,155 873 1,682 2,215 914 1,804 2,333 996 2,054
.010 3,582 1,285 2,112 3,614 1.304 2,160 3,715 1,365 2,316 3,911 1,488 2.037
.015 4,846 1,624 2,444 4,890 1.648 2,500 5.027 1,726 2,680 5,293 1,880 3,050
.020 6,006 1,918 2,711 6.060 1,946 2,772 6,230 2,038 2,973 6.560 2,220 3,384
to .025 7.093 2,182 2,938 7,156 2,215 3.004 7,358 2,318 3,222 7,747 2,526 3,668
-10 .030 8,127 2,425 3,138 8,198 2,460 3,208 8,430 2,577 3,440 8,875 2,807 3,917
.040 10,070 2,864 3,480 10,160 2,906 3,558 10,446 3.043 3.816 11.000 3,315 4.344
.050 11,895 3.258 3,772 12,000 3,306 3.856 12,338 3,462 4,135 12,990 3,771 4,708

Steels .005 1,942 497 1,183 1,960 504 1,213 2.015 529 1,313 2,121 577 1,522
200-325 Bhn 010 3,256 738 1,429 3,285 748 1,466 3,378 785 1.587 3.556 856 1.838
015 4,405 929 1,596 4,444 943 1,638 4.570 988 1,773 4.812 1,078 2,054
020 5,460 1,095 1.727 5,508 1,111 1,772 5,662 1,165 1,918 5.963 1,270 2,222
to10 025 6,447 1,243 1,836 6,504 1,262 1,882 6,688 1,323 2.038 7,042 1,443 2.362
.030 7,386 1,380 1,930 7.452 1,400 1,980 7,662 1,467 2,142 8,067 1.600 2,483
.040 9.153 1,62b 2,088 9,234 1,650 2,140 9.494 1,728 2,318 9,997 1,886 2,686
050 10,810 1,845 2,218 10,905 1.872 2,275 11,212 1,963 2.463 11.806 2.142 2,854

.005 2,192 1,040 1,842 2,214 1,058 1,888 2,285 1,117 2,038 2,422 1,235 2,350
010 3,592 1,478 2.262 3,628 1,504 2,318 3,743 1,587 2,503 3.968 1,754 2,886
-5 015 4,795 1,815 2,551 4,842 1,846 2,614 4.997 1.948 2.823 5,297 2,154 3,256
.020 5.885 2,100 2,779 5,945 2,136 2,848 6,134 2,254 3,075 6.502 2,491 3,546 _
to .025 6,900 2,350 2,969 6,969 2,390 3,042 7.191 2,523 3.285 7,623 2,790 3,788
-10 .030 7,857 2,578 3,134 7,936 2,622 3,212 8.189 2,767 3,468 8,680 3,058 4.000
.040 9,644 2,982 3,414 9.740 3,033 3,498 10,052 3,200 3,777 10.655 3.538 4,356
050 10,306 3,338 3,647 11,420 3,395 3,737 11,784 3,584 4,036 12,490 3.962 4,654

NOTE- To calculate force in pounds. multiply values given by depth of cut

ininches. To convert to newtons, multiply force in pounds by 4.48222
IF, - Tangential or Cutting force
F, - Radial force
IF, - Feed force

I /
17-25
17-25
 PRECEDING PAG BLANK-NOT FINED

Estimating Torque and Thrust in Drilling 17.4

Tables 17.4-1 and 17.4-2 are tabulations of drilling torque In the table for standard point drills, locate 200 Bhn
and thrust values in English units derived from formulas steel, read down the data column for a 1/2-inch drill to
given in the paper "On the drilling of metals. 2-The torque the 0.006-inch feed per revolution and read 124 inch-
and thrust in drilling" by M. C. Shaw and C. J. Oxford. Jr.. pounds torque and 735 pounds thrust
Transactionsof the ASME 79 (January 1957). p. 139-148.

Example: Find the torque and thrust when drilling

steel at 200 Bhn with a 1/2-inch diame-
ter standard point drill using a feed rate Tables 17.4-3 and 17.4-4 give torque and thrust values for
of 0.006 inch per revolution, the same materials in metric units.

TABLE 17.4-1 Torque and Thrust Values for Drilling with Standard Point Drills

MATERIAL FEED TORQUE, ,ich-pounds THRUST, pounds

AND PER -
HARDNESS REV. Drill Diameter, in Drill Diameter, in
in , ,/2 34 1 1 1'1 2 'A '4 '1 3 1 1',/ 1Y2 2

Steels 00005 1.4 . . . . . . . !-44 - - - - - - -

200Bhn 001 2.5 8.5 . . . . . . 65130 - - - - -
002 4.415 52 . - -102 194 382 - - - -
.003 6 21 71 - - . 135250 478 - - - -
004 8 26 90 183 - 166304 568 832 - - -
.006 11 36 124 253 414 617 856 1,43C 1224 403 735 1,058 1.368 1,687 2.030 2,796
.008 - 45 156 318 521 776 1.078 1.800 - 496 891 1 269 1,629 1,997 2.388 3.246
.010 - 54 187 381 623 928 1,288 2.152 - 584 1,039 1.469 1.876 2.292 2.728 3,674
.012 - - 216 440 721 1,074 1,491 2,490 - - 1.182 1.662 2,115 2.575 3,054 4.085
.015 - - 259 527 862 1.283 1.7822.976 - - 1,387 1.939 2.458 2.983 3.524 4.677
.020 - - 325 663 1,085 1.615 2,243 3,746 - - 1.711 2.378 3.001 3.629 4.269 5.614
.025 - - - - 1.297 1.931 2.681 4.478 - - - - 3,517 4,244 4,976 6.505
.030 . - - - 5.782 . - . . . . . . 7,360

Steels 0.0005 1.9 - - - - 56 - - - - - - -

300Bhn .001 3.211 - - .- 84 168 - - - - - -
002 5.619 67 . - - 132 251 494 - - - - -
.003 7.8 27 92 . - - 175 324 618 - - - - -
.004 9 33 116236 - - - -1 215 293 733 1.075 - - - -
.006 14 46 160 327 535 796 1.106 1.847 290 521 950 1.367 1.767 2.179 2.622 3.611
.008 - 58 202 411 673 1.003 1.392 2.325 - 640 1.151 1.639 2.104 2,580 3.084 4.193
.010 - 70 241 492 805 1.199 1.664 2.779 - 754 1.342 1.898 2.424 2.961 3.523 4,745
.012 - - 279 569 932 1.386 1.925 3.216 - - 1,526 2.146 2.732 3.327 3.945 5.276
.015 - - 334 680 1.114 1,658 2.302 3.844 - - 1.791 2.504 3.175 3,854 4.552 6.041
.020 - - 420 856 1,402 2.087 2.897 4.839 - - 2.211 3.071 3.876 4,688 5,514 7.251
.025 - - - - 1.676 2.495 3.463 5.785 - - - - 4.543 5,481 6.428 8.402
.030 --- - 6.693 . . . . . . . 9.507

Steels 0005 2 . - - - 62 - - - - - - -
400Bhn .001 3.512 - - - 92 185 - - - - - -
.002 6.221 73 . . . - 144 274 542 - - - - -
.003 8.529 101 . . . - 192 355 678 - - - - -
004 11 37 127 259 - - - 236 431 805 1.179 - - - -
006 15 51 176 358 586 874 ,.213 2,026 318 571 1.041 1.499 1.940 2.390 2.876 3.961
.008 - 64 222 451 739 1.100 1.527 2,550 - 702 1.262 1.797 2,307 2.829 3,383 4.598
.010 - 76 265 539 883 1.314 1.825 3.048 - 827 1.472 2.081 2.659 3.247 3,864 5.204
012 - - 306 624 1.022 1.521 2.112 3.527 - - 1,674 2.354 2,996 3.648 4,327 5.787
015 - - 366 746 1,221 1.818 2.524 4.216 - - 1.965 2,747 3.482 4.227 4.993 6.625
.020 - - 461 939 1.537 2.289 3.178 5,307 - - 2.425 3.368 4.251 5.142 6.047 7.953
.025 - 1.838 2.736 3.799 6.345 - - - - 4.982 6.012 7.050 9,215
030 -- --- - - - - 7.341 - - - - - - - 10,430

17-27
17.4 Estimating Torque and Thrust in Drilling
TABLE 17.4-1-Continued
MATERIAL FEED TORQUE, inch-pounds THRUST, pounds
AND PER
HARDNESS REV. Drill Diameter, in Drill Diameter, in

in 1 12 3/ 1 1 1 '2 2 1A IA , 3/. 1 1, 1A Y 2

Aluminum 0005 0.4 - . - . - .13 - - - - - -

Alloys .001 07 25 - - . . 19 38 - - - -
002 1.3 4.3 15 - 30 56 111 - - -
003 1.8 6 21 - . . . 39 73 139 - - -
004 2.2 76 26 53 - - - - 49 89 166 243 - -
006 3.1 11 36 74 121 180 250 417 66 118 214 308 399 492 592 815
.008 ! - 13 46 93 152 226 314 525 - 145 260 370 475 583 696 947 A
010 ( - 16 55 111 182 271 376 628 - 170 303 428 547 669 796 1.072
.012 - - 63 128 210 313 435 726 - - 345 485 617 751 891 1.191
015 - - 75 154 251 324 520 868 - - 404 566 717 870 1,028 1.364
.020 - - 95 193 317 471 654 1.093 - - 499 694 875 1,05t 1,245 1.637 v
.025 . . . . 378 563 782 1,306 - - - - 1,026 1.238 1,451 1,897
030 - - - 1,511 . . . . . . . 2.147

Magnesium 0005 0 .2 2 - - - 7.3 3. . . . . .

Alloys 001 0.4 1.4 - . . . . 11 22 - -
.002 0.7 2.5 8.6- - - - - 17 32 64 - - - - -
.003 1 34 12 - - - - - 23 42 80 - - - - -
004 1.3 4.3 15 30 - - - - 28 51 95 139 - - - -
.006 1.7 6 21 42 69 103 143 238 33 59 109 158 205 254 307 427
008 - 7.5 26 53 87 129 180 300 - 83 148 211 272 333 398 541
010 - 9 31 64 104 155 215 359 - 97 173 245 313 382 455 612
.012 - - 36 73 120 179 250 415 - - 197 277 352 429 509 681
.015 - - 43 89 144 214 297 496 - - 231 C23 410 497 587 780
.020 - - 54 110 181 269 374 624 - - 285 396 500 605 711 936
.025 . . . . 216 322 447 746 . . 586 707 829 1,084
.030 -64. . .
-84 . . . . . 1,227

Copper .0005 0.8 . . . . . . . 25 . . . . . . .

Alloys 001 1.5 5 - - - - - - 38 76 - - - - -
.002 2.5 8.7 30 - - - - - 60 113 223 - - - - -
003 3.5 12 42 - - - - - 79 146 279 - - - - -
1.00-4 44 15 52 107 - - - - 97 177 331 485 - - - -
.006 6.1 21 73 148 242 360 499 834 131 235 429 617 798 983 1,184 1,630
008 - 26 91 186 304 453 629 1,050 - 289 520 740 950 1.165 1,393 1,893
010 -- 31 109 222 364 541 751 1,255 - 341 606 857 1.095 1.337 1,591 2,143
012 - - 126 257 421 626 870 1.452 - - 689 969 1.234 1,502 1.782 2,383
.015 - - 151 307 503 749 1,039 1,736 - - 809 1,131 1,434 1,740 2,056 2,728
.020 - - 190 387 633 942 1,308 2.185 - - 998 1,387 1,750 2.117 2490 3.275
.025 .. 757 1,127 1.564 2,612 - - - - 2,052 2.475 2.903 3.795
.030 . . . . . . . 3,023 . . . . . . . 4,293

Leaded .0005 0. - - - - - - - 13 - - - - - - -
Brass .001 0.7 2,5 - - - - - - 19 38 - - - - - -
.002 1.3 4.3 15 - - - - - 30 56 111 - - - - -
003 1.8 6 21 - - - - - 39 73 139 - - - - -
.004 2.2 7.6 26 53 - - - - 49 89 166 243 - - - -
006 3.1 10 36 74 121 180 250 417 66 118 21 4 308 399 A92 592 815
.008 - 13 46 93 152 226 314 525 - 145 259 370 475 583 696 947
010 - 16 55 111 182 271 376 628 - 170 303 428 547 669 796 1,072
012 - - 63 128 210 313 435 726 - - 344 485 616 751 891 1,191
015 - - 75 154 252 374 520 868 - - 404 566 717 870 1.028 1.364
.020 - - 95 193 317 471 654 1,093 - - 499 694 875 1,059 1,245 1.637
.025 378 563 782 1.306 - 1,026 1,238 1.451 1,897
.0301 . . . . . . . 1,511 .. - - - 2,147

17-28
 Estimating Torque and Thrust in Drilling 17.4
TABLE 17.4-2 Torque and Thrust Values for Drilling with Split or Crankshaft Point Drills

MATERIAL FEED TORQUE, inch-pounds z THRUST, pounds

AND PER I
HARDNESS IREV. Drill Diameter, in Drill Diameter, in

in I Vs '12 3/4 1 1% 112 2 I4 1 1 1, 2

__ i i _ _ _ _ _ _ _ _i

Steels 0.0005 1 3 - - - . . 23 - - - - - -
200 Bhn 001 1 23 79 - - 40 71 - - - - - -
002 39 14 48 - 70 122 216 - - - - -
003 54 19 66 - 96 169 297 - - - - -
004 6.9 24 83 173 - - - - 1121 212 372 519 - - - -
006 9-5 33 115 239 401 599 831 1.395 167 292 512 714 905 1.091 1.273 1.630 -
-008 - 42 145 300 504 754 1.046 1.756 - 368 643 895 1.133 1.364 1.588 2.028
.010 - 50 173 359 603 901 1.251 2.099 - 439 768 1.067 1.350 1623 1.888 2405
012 - - 200 416 698 1,042 1.447 2.429 - - 3;7 1.233 -. 553Z 1.372 2.171 2.768
.015 - 239 497 834 i 246 i.730 2.904 - - 1,060 1,471 1.858 2,230 2.591 3.290
- - 30G 525 r.50 i.56 2.178 3.655 - 1.332 1.848 2333 2.798 3.248 4.116
.025 z . 1.255 1.875 2.603 4.369 . - - 2.784 3.337 3.872 4.902
3
.0 0 - - - 5.055 . . . . . . . 5,657

Steels 0.0005 1.7 . . . . . . . 30 . . . . . . .

300 Bhn 001 2.9 10 . . . . . . 52 91 . . . . . .
002 5.1 "5 62 - - - - - 1 90 158 279 - - - - -
.003 7 24 85 - - - - - 1124 218 383 - - - - -
.004
-006 9
12 31
43 107
149 223
308 -517 -773 -
1,074 -
1.802 1156
26378273 480
662 671
922 116
1,169 1.0
1,409 1.4
1,644 20
2,106
008 - 54 187 388 651 973 1.351 2.268 - 475 831 1.156 1.464 1.762 2.052 2.619
010 - 64 224 464 779 1.164 1.615 2,711 - 567 992 1.378 1.744 2.096 2.439 2.107
012 - 259 537 901 1.346 1.869 3,137 - - 1.146 1,592 2.013 2,418 2.811 3,575
015 - - 309 642 1,077 1.609 2.235 3.751 - - 1.369 1,900 2.400 2,881 3.347 4,249
.020 - - 389 808 1.356 2,026 2.813 4,721j- - 1.720 2,387 3.014 3.614 4.195 5,317
.025 - - - - 1.621 2,422 3.363 5,644 - - - - 3,597 4.311. 5.002 6.332
030 - - - - - - - 6,530 - - - - - - - 7,307

Steels 0005 18 - . . .. .j 33 - - - - - - -
400Bhn 001 32 11 . . . . . . 57 100 - - - - - -
002 5.6 19 68 - - - - 99 173 306 - - - - -
.003 7.7 27 94 - - - - -. 136 239 420 - - - - -
,004 9.7 34 118 244 - - - 172 300 527 736 - - - -
006 13 47 163 338 568 848 1.178 1.976 1237 414 726 1.011 1.283 1,546 1,803 2.310
008 - 59 205 426 714 1,068 1,482 2.488 - 521 911 1.268 1.606 1.932 2.250 2.873
.010 - 70 245 509 854 1.276 1.772 2.974 - 622 1.088 1.512 1.913 2.299 2.675 3.407
.12 - - 284 589 988 1, 477 2.050 3,441j - 1,257 1,746 2.208 2.652 3,083 3.921
015 - - 339 704 1.181 1,765 2.451 4.113 1 - 1.501 2.084 2.633 3.160 3.671 4.661
020 - 427 886 1.487 2.222 3.085 5.178 -- 1.887 2,618 3.305 3.964 4.601 5.832
.025 - - 1.778 2.656 3.688 6.190 . - - 3.945 4.728 5.486 6.945
.030 -. . . . . . . 7.162 . . . . . . . 8.014

Aluminum .00 0 0.4. . . . . . . 6 .8. . . . . . .

Alloys 001 0.7 2.3 12 21
002 1.1 4 14 .. . 20 36 63 -. . . . .
03 1.6 55 19 . . . . . 28 49 87 - - - - -

004 2 7 24 50 - . . . 35 62 108 152 - - - -

.006 2.8 9.6 34 70 117 175 242 407 49 85 149 208 264 318 371 476
.008 - 12 42 88 147 220 305 512 - 107 188 261 331 398 463 591
.010 - 14 50 105 176 263 365 612 - 128 224 311 394 473 551 701
.012 - - 58 121 203 304 422 708 - - 259 359 455 546 635 807
.015 - - 70 145 243 363 505 847 - - 309 429 542 651 756 960
.020 - - 88 182 306 457 635 1,066 - - 389 539 681 816 947 1.201
.025 . . . .- 366 547 759 1.274 -. . . . 812 973 1.129 1.430
.030 ----- -- - 1.475 - .- 1.650

17-29
Uh
17.4 Estimating Torque and Thrust in Drilling
TABLE 17.4-2-Continued
MATERIAL j FEED TORQUE, inch-pounds T

AND iPER
HARDNESS! REV. Drill Diameter, in Drill Diameter, :n
I , / 1/, 3/i 1 11, 11 2 V2 3/1 1 1'/ 1'12 2

Magnesium 00502 - - - - - - - 39- - - - - -

Alloys 001I 0.4 13 - - - - - 6712 - -
002 j0.7 23 8- - - - -'12 20 36 -
003 0.9 32 11 - - - - - 16 28 49 -
004 11 4 14 29 - - - - 20 35 62 87
006 1.6 55 19 40 67 100 138 2321 28 49 85 119 151 182 212 272
008 - 69 24 50 84 126 174 293 - 61 107 149 189 227 265 338
010 83 29 60 100 150 208 350 - 73 128 178 225 270 315 401
012 - 33 69 116 174 241 405 - 148 205 260 312 363 461
'015), 40 83 139 208 288 484 177 245 310 372 432 548
020 I 50 104 175 261 363 609 222 308 389 466 541 686
025 - - 209 312 434 728 - - 464 556 545 6-17
030 -- 843 - 943
i t|
,
Copper i 0005 08 . . . . . . -. 14 . . . . . . .
Alloys 1001 1.3 46 - . . .. 23 4-1 - - - - -
002 2.3 8 28 . . . . .- 41 71 126 - - - -
1003 32 11 39 . . . . - . 56 98 173 - - - -
1004 4 14 49 101 - - - - 71 123 217 303 - - -
006 5.5 19 67 139 234 349 485 814 198 171 299 416 528 637 743 951
008 - 24 84 175 294 440 610 1.024 - 214 275 522 661 796 927 1.183
0-0 - 29 101 209 352 525 730 1.225 - 256 448 622 788 947 1,102 1.403
-012 117 242 407 608 e44 1,417 518 719 909 1.093 1.270 1.614
015 - - 140 290 486 727 1.00, 1.694 - - 618 858 1.089 1.301 1.512 1.919
.020 I 176 365 612 915 1,270 2,132 - - 777 1.078 1,361 1.632 1.895 2.401
.025 . - 732 1.094 1.519 2,549 -- - 1.624 1.947 2,259 2,860
030--- -- -- -- 2,949 - - - 3,330
IJ r_____________ _____________

Leaded -0005 0.4 . -.- 6.8- - - - - - -

Brass 001 0.7 23 . - 12 21 .
1002 11 4 14 - - - 20 36 63 - - - - -
003 1.6 5 19 - . . - . 28 49 87 -
004 2 7 24 50 . .. 35 62 108 152 - - - -
.006 i 2.8 9.6 34 70 117 175 242 407 50 85 149 208 264 318 371 476
008 - 12 42 88 147 220 305 512 - 107 188 261 331 398 463 591
010 - 14 50 105 176 263 365 612 - 128 224 311 394 473 551 701
I 012 - - 58 121 203 304 422 708 - - 259 359 455 546 635 807
015 - - 70 145 243 363 505 847 - - 309 429 542 651 756 960
020 - - 88 182 306 457 635 1,066 - - 389 539 681 816 947 1,201
025 - - - - 366 547 759 1,274 - - - - 812 973 1.129 1.430
.030 . 1.475 . - . .. . 1.650

-73

i 4

17-30
 Estimating Torque and Thrust in Drilling 17.4
TABLE 17.4-3 Torque and Thrust Values for Drilling with Metric Standard Point Drills

MATERIAL FEED TOROUE, nowton-mrelors THRUST, nowtons

AND PER . . . . . -------
. ... ..-
- - - - - -. . .. ..... . . ....
HARDNESS REV. Drill Diameter, mm Drill Diameter, mm

mm 3 6 12 18 25 30 35 50 3 6 12 18 25 30 35 50

Sto(Jl .013 0.16 - - - - - - - 196 - - - - - - -

200 Bhn .025 0.28 0.96 - - - - - - 289 578 - - - - - -
.050 0.50 1.70 5.88 - - - - - 454 883 1,700 - - - - -
.075 0.68 2.37 8.02 - - - - - 802 1,139 2,128 -. . . . .
.102 0,90 2.94 10.17 20.68 - - - - 7,406 1,352 2,527 3,700 . . . .
.15 1.24 4.07 14.00 28.59 47 70 97 162 1,000 1,793 3,270 4,706 6,085 7,504 9,030 12,437
.20 - 5,08 17.6 38 59 88 122 203 - 2,206 3,963 5,638 7,246 8,883 10,822 14,439
.25 - 6.10 21 43 70 105 146 243 - 2,598 4,622 6,534 8,345 10,195 12,135 18,343
.36 - - 24 50 81 121 188 281 - - 5,258 7,393 9,408 11,454 13,585 18,171
.40 - - 29 60 97 145 201 336 - - 6,170 8,625 10,934 13,271 15,676 20,804
.50 - - 37 75 123 182 253 423 - - 7,613 10,678 13,349 16,143 18,989 24,972
.65 - - - - 147 218 303 506 - - - - 15,644 18,878 21,692 28,936
.75 - - - - - - - 653 - - - - - - - 32,739

Steels .013 0.21 - - . . 249 - - - - - - -

300 Bhn .025 0.36 1.24 - . . . . . 374 750 - - - - - -
.050 0.63 2.15 7.57 . . . . . 587 1,117 2,197-- - - - -
.076 0.88 3.05 10.4 - . . . . 778 1,441 2,749 - - - - -
.102 1.01 3.73 13.1 26.7 - - - - 946 1,303 3,263 4,782 - - - -
15 1.53 5.20 18.1 36.9 60.4 89.9 125 208 1,20 2,318 4,226 6,081 7,88 9,693 11,63 18,083
.20 - 6.55 22.8 46.4 76.0 113 157 263 - 2,847 5,120 7,291 9,359 11,476 13,718 18,651
.25 - 7.90 27.2 55.8 91 135 188 314 - 3,354 5,970 6,443 10,782 13,171 15,671 21,107
.38 - - 31.5 64.3 105 157 217 363 - - 6,788 9,546 12,153 14,800 17,548 23,469
.40 - - 37.7 76,8 126 187 299 434 - - 7.967 11,138 14,123 17,143 20,248 26,872
.50 - - 47.5 98.7 158 236 327 547 - - 9,835 13,68 17.241 20,853 24,527 32,264
.65 - - - - 189 282 391 854 - - - - 20,208 24,380 28,593 37,374
.75 - - - - 756 - - - - - - -. 42,289

Steels .013 0,23 - - - - 276 - -

400 Bhn .025 0.40 1.38 - - - 409 823 - -
,050 0.70 2.37 8.24 -- - 643 1,219 2,411 -
.075 0.96 3.28 11.4 .- - 854 1,579 3,015G.-
.102 1.24 4.18 14,4 29.3 .- 1,050 1,918 3,581 6,245 - - - -
,15 1.69 5,76 19.9 40,4 86.2 98.7 137 229 1,415 2,540 4,830 6A8 8,830 10,631 12,793 17,819
,20 -- 7.23 25.1 50.9 83.5 124 173 288 - 3,123 5,614 7.993 10,262 12A84 15,048 20,453
.25 - 8.58 29.9 60.9 99.8 148 206 344 - 3,679 6,548 9,257 11,828 14,443 17,188 23,149
,36 - - 34.8 70.5 115 172 239 398 - - 7,448 10.471 13,327 16,227 19,247 25,742
.40 - - 41,3 84.2 138 205 285 476 - - 8,741 12,219 15,489 18,803 22,210 29,489
.50 - - 52.0 106, 174 259 359 600 - - 10,787 14,982 18,910 22,873 26,898 35,377
.65 - - - - 208 309 429 717 . - - 22,181 26,743 31,360 40,990
.75 - - - - - - - 829 - - - 46,395

Aluminum .013 0.05 - - - - - - - 57.8 . . . - -

Alloys .025 0.08 0.28 - - - - - - 84.5 169 . . . . . .
.050 0.15 0.49 1.69 - - - - - 133 251 494 -. - - -
.075 0.20 0.68 2.37 - - - - - 173 325 818 - - .
.102 0.25 0.86 2.94 5.99 - - - - 218 396 738 1,080 -- - - -
.15 0.35 1.19 4,07 8,36 13.7 20.3 28.2 47,0 294 525 952 1,370 1,775 2,188 2,633 3,625
,20 - 1A7 5.20 10,5 17.2 255 35.5 59.3 - 645 1,157 1,646 2,113 2,593 3,096 4,212
.25 - 1.81 6.21 12.5 20.6 30.6 42.5 71 - 756 1,348 1.904 2,433 2,976 3,41 4,768
.36 - - 7.11 14.5 23.7 35.4 49.1 82 - - 1,535 2.157 2,745 3,341 3,963 5,298
.40 - - 8.47 17.4 28.3 42.2 .8.8 98 - - 1,797 2.518 3,189 3,870 4,573 8,097
.50 - - 10.'7 21.8 35.8 53.2 73.9 124 - - 2,220 3,087 3,892 4,710 5.538 7.282
.85 . - - - 42.7 3.6 88.4 148 "- - - - 4,564 5,507 6,454 8,438
.75 -. . . . 171 . . . - - . 9,550

17-31
17.4 -Estimating Torque and Thrust in Drilling
TABLE 17.4-3-Continued

MATERIAL FEED TORQUE, ti,:wvtof rnu!:r- THRUST, rlst.'u,

AND PER
HARDNESS REV. Drill Diameter, rnr Drill Diameter uyrn

mm 3 6 12 18 25 30 35 50 3 6 12 18 25 30 35 50

M ,rjr.,.rn .013 0023 - - - - - - - 32 - - - - -

AIIOy , .025 0.045 0.158 - - - - - - - - -
050 0.079 0.282 0971 - - - - - 75 142 285 - - - -
075 0,113 0.384 1.34 - - - 102 187 356 - - - -
102 0,147 0.486 1.69 3.45 - - 125 227 423 618 - - -
S15 0.192 0.678 2.37 4.75 7.'I 11.64 16.16 26.9 147 262 485 703 912 1,130 1,368 1,900
'20 - 0.874 2.94 5.99 9,83 i46 20.3 33.9 - 369 658 939 1,210 1,481 1.770 2,406
.25 - 1.02 3.50 7.23 11.8 17.5 ?4.3 40 - 431 770 1,090 1,392 1,700 2,024 2,722
36 - - 4.07 825 13.6 20.2 28.2 46.9 - - 876 1,232 1,58 1.90b 2,264 3,029
.40 - - 486 10.1 16.3 24.2 33.6 56 - - 1,028 1.437 1.824 2.210 2,610 3,470
50 - - 6.10 12.4 20.5 30.4 42.3 70.5 - 1,268 1,761 2,224 2,691 3,163 4,164
.65 - - - - 24.4 36.4 50.5 84.3 - - - - 2,607 3,145 3,688 4,822
.75 - - - - - - - 97.6 - - - - - - - 5,458

.013 0.090 - - - - - 113 - - - -

AIloys .0251 0,169 0.565 - - - - 169 338 - - -
.050 u.2A2 0.983 3.39 - - - 287 503 992 -. .-
075 0.395 1.36 4.75 - - - 351 64is 1.241 - -.
102 0.497 1.71 5.88 12.1 - - 431 787 1.472 2,157 -. . .
.15 0,689 2.37 8.25 16.7 273 40.6 56.4 94.2 583 1,045 1.908 2,745 3,550 4373 5,267 7,250
2' - 2.94 103 21 34.3 51.2 71.1 119 - 1.286 2.313 3.292 4.226 5.182 6,198 8,420
25 - 3,50 12.3 25 41 61.1 849 142 - 1,517 2,896 3.812 4,870 5.947 7,077 9.533
.36 - - 14.2 29 47.6 70.7 98.3 164 - - 3,065 4,310 5,489 8.681 7,927 10,600
.40 - - 17,1 34.7 56.8 84.8 117 196 - - 3,600 5,030 6.379 7,740 9,146 12,135
50 - - 21.5 43.7 71.5 106 148 247 - - 4,439 6.170 7,784 9,417 11,078 14,58
65 - - - - 85.5 127 177 295 - - - - 9,128 11,009 12,913 16,881
75 - - - - - - - 342 - - - - - - - 19,096

Leadld 013 0.045 - - - - 56.5 - - - - - -

f3r;w,'s 025 0.079
0.282 - - - 64.5 169 - -. . . . .
0 50 0 14 7
. 0.486 1.69 - - 133 251 494 - . . .
.075 0.203 0.678 2.37 - - 173 325 618 - . . .
102 0,249 0.859 2.94 5.99 -. . . 218 396 738 1.061 - - - -
.15 0.350 1.19 4.07 8.36 13.7 20.3 28.2 47 294 525 952 1,370 1,775 2,188 2.633 3,625
I20 - 1.47 5.20 10.5 17.2 25.5 35.5 59.3 - 645 1,152 1,646 2.113 2,93 3,096 4,212
25 - 1.81 6.21 12.5 20.6 30.6 42.5 70.9 - 756 1,348 1,904 2.433 2,976 3,541 4,768
.36 - - 7.11 14.5 23,7 35.4 49 82 - - 1,530 2,157 2,740 3340 3,963 5,298
.40 - - 8.47 17.4 28.5 42.3 588 96 - - 1,797 2.518 3,189 3.870 4,573 6,067
.50 - - 10.7 21.8 35.8 53.2 73.9 123 - - 2,220 3,087 3.892 4.710 5,538 7.282
65 . - - 42.7 63.6 88.3 147 - - - - 4.564 5.507 0,454 8,438
.75 . . . . . . . 171 - - - - - - 9,550

17-32
 Estimating Torque and Thrust in Drilling 17.4
TABLE 17.4-4 Torquo and Thrust Values for Drilling with Motric Split or Crankshaft Point Drills

MATERIAL FEED! TORQUE. rT. r~, r. THRUST, noviMt.

AND PER
HARDNESS REV Drill lDIamelr. rrrn Drill Dl .molor.,ti

mm 3 0 12 18 25 30 35 5 3 8 12 18 25 30 35 .0
013 0.15
'","1 - - - - - - - 102 - - - - - - -
100 ho .50 0 0. -. . . . . 178 318 . . . . . .

.050 0,44 1.58 6 42 . 311 543 " 1 . . . . .

.075 0.61 2.15 7.46 - - - - - 427 752 1.321 - - - - -
.102 0.78 2.71 9.38 20 - - - - 538 943 1.855 2309 - - - -
.15 1.07 3.73 13 27 45 68 94 158 743 1.300 2.277 3.176 4,026 4,853 5.663 7,250
.20 - 4,75 18.4 34 57 85 118 198 - 1,637 2.880 3,981 5.040 6,067 7.064 9,021
.25 - 5.64 19.5 41 6 102 141 237 - 1,953 3,416 4,746 6,005 7,219 8,398 10,698
30 - - 22.5 47 79 118 103 274 - - 3,946 5,485 6,930 8,327 9,684 12,313
,40 - - 27 56 94 141 195 328 - - 4,715 0,543 8,285 9,920 11.525 14,635
50 - - 34 71 119 177 248 413 - - 5,925 8,220 0,378 12.46 14.440 18,309
65 - - - - 142 212 294 494 - - - - 12,364 14,844 17,224 21805
.75 - - - - - - - 571 - - - - - - - 25.164

.013
.,,*- 0.19 - - - - - - - 133 - - - - - - -
lOO IS?,ff .025 0,33 1.13 - - - - - - 231 405 - - - - - -
050 0,58 203 7 - - - - - 400 703 1.241 - - - - -
075 0.79 2.71 9.8 - - - - 552 970 1,704 - - - - -
.102 1.01 3.50 12.1 252 - - - 694 1,214 2,136 2.965 - - - -
.15 1.38 4.8 16.8 34.6 .A 87.3 121 204 961 1,801 2,945 4,100 5,200 6,268 7,313 9.388
20 - 8.10 21.1 43.8 73.8 110 153 256 - 2,113 3.69 5,142 0.512 7.83 9.128 11,650
25 - 7,23 25.3 524 86 132 182 306 - 2,522 4,413 8,130 7.758 9,323 10.649 13,820
38 - - 29.2 606 102 152 211 354 - - 5,O8 7,062 8.954 10.758 12,504 15,902
40 - - 34.9 72,5 122 162 2W 424 - - 6,000 8.452 10.676 12,815 14.888 18,900
so - - 44 91.3 153 229 315 533 - - 7,60 10,018 13,407 18,076 18,60 23,651
'65 - - - 183 274 380 83 - - - - 16,000 19.176 22.250 28,166
.75 - - . . 73 - - - - - - - 32503

,!,;I 013 0.20 - - 147 - - - - - - -

,11r)00Uh 025 0.36 1.24 .- 2 446 - - - - - -
.050 0.63 2.15 7,86 .- 440 770 1,31 - - - - -
.075 0.87 3,06 10.6 . . .- 605 1,03 1,88 - - - - -
,102 1.10 3.64 13.3 27,6 - - - - 765 1,334 2,344 3,274 - - - -
.15 1.47 5.31 18.4 38.2 64.2 85.8 133 223 1,054 1,842 3,229 4,497 5,707 6,877 8,020 10,275
.20 - 8.66 23.2 48,1 80.7 121 187 281 - 2318 4,052 5,640 7.144 8,594 10,008 12,780
25 - 7,91 27.7 57.5 96.8 144 200 336 - 2,767 4,840 6,726 8,610 10,226 11,900 15,155
36 - - 32.0 6.5 112 167 222 309 - - 5.591 7,767 9,822 11,797 13,714 17,441
.40 - - 38.3 79.5 133 1"9 277 466 - - 8,677 9,270 11.712 14,050 16,529 20,733
.50 - - 48.2 100 1N 251 349 5" - - 8,394 11,645 14,700 17,633 20,40 25,942
'68 - - - - 200 300 417 700 - - - - 17548 21.031 24,403 30.893
.75 . . . . . . . 610 . . . . . . . 36,648

Al ,,rr, .013 005 - - 30.2 - . . . . . .

Allo% .025 0.06 0.26 - 53.4 93A --
060 0.12 0.45 1.56 -89 160 20
.075 0.18 0.62 2.15 - - - - - 125 218 -- -
.102 0.23 0.79 2.71 5.6 - - - - 15 276 48 676 - - -
15 0.36 1.06 3.84 7.91 13.2 19. 2/.4 4.0 218 378 863 9 1,174 1.415 1,650 2,117
20 - 1.3 4.75 9.9 16.8 24. 34.5 57.8 - 478 .6 1,161 1,472 1.770 2.0 Z9
25 - 1,58 56 11.9 19.9 29.7 41.2 69.1 - 56 96 1,363 1,753 2,104 2,451 3,118
36 - - 6.5 13.7 22.9 34.3 47.7 80.0 - - 1,152 ,5.7 2,024 2.429 2.,825 3.90
.40 - - 7.90 16.4 27.5 41.0 57.1 66&7 - - 1,375 1,908 2410 2,6 3,363 4.270
.50 - - 9.94 20,61 34,6 51.6 71.7 120 - - 1.720 29 21,029 2,830 4,212 6,342
.66 . - - 41,4 61.S 86.8 144 - - - - 3,612 4,337 5022 6,360
75 . .- 167. - -. . . . . . 7,340

17-33
C7.4, Estimating Torque and Thrust in lri ing

T'A0L|.
t 1 .4-4 -Colell#nu~d

MAfTia IAL. I11 VOlJUI

fI .,,,.0,,, ,.i,, 1'HIIUI , l.mwlowl
ANID 1l'f
IlAIIC)ltfl IltV 0,111 (Jlrnlav.ar.',, Drill Dl,.,,llr,It',

MI n t2 18 20 30 3D 50

';Iu,,
, 131 0023 . .... ..... 1l, .. . . . . . .
All 0 tS 0045 0141 - .- . . '"-t 53,4 - - - -
v) (0 0/ 024)0 003 . .. 331 118 160 - - -
9 tt) 0102 0302 124 -.. 11. 128 216 - - -
102 0124O.452 1.58 328 . 89 100 276 387 - - - -
IS 0.141 0421 2,10 575 1 11
42 1,)6 we2 120 218 378 629 672 WO09 43 1,210
20 - 01110 2,71 065 94(C 142 1, 33,1 271 476 03 641 1,010 1,179 1,003
5 - 0038 3.28 68 113 M. 216 3.i - 328 509 792 1,000 1,200 1,400 1,784
'10 - - 3,73 7,80 13, 191 21,2 45.1 - - 656 912 1,157 1,386 1,015 2,060
40 - - 42 038 1&. 23,0 3.', 1 45 - - 787 I,090 1,379 1,055 1,922 2,430
- - s) 11 4 1u 29.5 41 0e8 4 - - 968 1,370 1,730 2,073 2,406 3,001
,.. 23 C 353 4') ;3' - - - - 2,064 2,471 2,890 3,034

W 0 OA 02 - - -. -. -..

A 2O, 0.141 0020 - . . . 102 182 - - - -.

0510 021Y) 0904 114 -- - 102 310 600 - - - - -

W
032124 4,41 - - - - 436 770 - -
102 0451 1 58 5.4 114 - 310 547 90 1,340 - -
10 0021 2.15 7157 107 2 4 39.4 646$ 9,0 436 701 1.33 1,W 2,349 2,634
3,300 4,230
" - 2.71 049 198 392 49.7 .6,9 110 - 902 1.223 2,321 2,940 3,541'
4,124 5,202
M - 328 114 736 30 M 093 62,5 131 - 1,139 1.995 2,707 3,500 4,902 0,240
4,212
14 - - 13.2 2173 41 60,1 9A4 160 - - 2,304 3,196 4,043 6,649 7,160
4,662
40 - - )8 328 04,9 62,1 114 191 - - 2,149 3W817 4,A44 6,720 6,530
5,7 7
- - 19,9 41 2 0",1 103 143 241 - - 3,46 4,765 6,054 7,250 0,429 10,60
5 . . . 621 124 172 268 - - - - 7,224 6,0 10,049 12,722
15 - .- - - 333 - - - - - - - 14,670

I ,-,-1 013 0,04 - - 30,2 - - - - - -

02,0 0079 0.260 - 53,4 934 - - - - -
000 0 124 0,462 1,b8 . . . . . 69,0 160 200 - -. .
(76 01,1 0021 21 . . . . .. 125 216 37 - - - - -
102 022 0,791 2 71 IS .. . . . 10 270 460 076 - . - -
15 0310 1.06 364 701 132 19,8 273 440 222 376 663 2 I,174 1415 1,0 2,117
20 - 1 36 4,7 9,94 166 24,9 346 016 - 470 136 1,1611172 1,770 2,000 2,629
26 - 1,. 56 11.9 19 29,7 412 690 - 69 99 ,33 V. 2004 2,450 ,118
36 - - 6.55 137 229 343 47.7 600 - - 1,152 1,57 A0A4,429 2,826 3,90
40 - - 7,90 16,4 27,5 41.0 7.0 9f.7 - - 1,375 1,900 2410 2,6. 3,43 4,270
so -9 - 94 206 346 616 717 120 - - 1,730 2.3962,02 ,0M, 4,212 5,342
1$55 - - - 4 1
- I 8,6 144 . . - 31,114--''1102 1M

17-34
 SECTION 18
SURFACE TECHNOLOGY

18.1 Introduction to Surface Technology .................-- 1..................3.......................

18-3
Trends and Concerns ........................ ................... ............................................................. 18-3
Relationship of Surface Texture and Surface Integrity ...............................-................... - 18-3
Econom ics ............................. 1..........3...............................
1P-3
Q uality Assurance ................................................ ..... 18-33.....................................

18.2 Surface Texture ........................................................ 1..........................................

18-5
hatroduction ....................................................................................................................... 18-5
Surface Texture Defined .................................................................................................... 18--5
Surface Texture Sym bols ................................................................................................... 18-6
Surface Texture Measurem ent ........................................................................................... 18-9
Surface Texture Produced by the Machining Process ..................................................... 18-11
M achining Cost and Surface Texture ............................................................................... 18-12
Dim ensional Tolerance Versus Surface Texture ........................................................... - 18-12
Surface Texture and Quality Assurance ........................................................................... 18-12
Preferred Roughness Values ........................................................................................... 18-14
Theoretical Roughness Produced by Milling Cutters and by Lathe Tools ........................ 18-15

18.3 Surface Integrity ...................................................................................................................... 18-39

Introduction ...................................................................................................................... 18-39
Definitions ................................................................................................................. 18-39
Benefits from the Application of Surface Integrity Practices ................. 18-39
Problems Amenable to Surface Integrity Discipline ............................................... 8-39
Altered M aterial Zones (AM Z) .................................................................................... -18-40
..
AM Z Definitions ....................................................................................................... 18-42
Evaluation Techniques..................................................................................................... 18-45
Process Intensities and Surface Integrity .................................................................. 18-47
Metallographic Sectioning and Special Preparation Techniques ............................. 18-47
M icrohardness Determ inations ................................................................................. 18-47
Residual Stress Determ ination ............................................................................... 18-49
Fatigue Strength Testing .......................................................................................... 16-51
Stress Corrosion Cracking ........................................................................................ 18-54
Com bined Effects ..................................................................................................... 18-54
General Guidelines ........................................................................................................... 18-56
Precautions in Use of Guidelines .............................................................................. 18-56
Key Indicators of Need for Surface integrity Control ............................................... 18-56
Guidelines for Material Removal Process in General ................................................ 18-56
Comparison of Altered Material Zones from Material Removal Processes ................ 18-57
Im plementing Surface Integrity Program s ................................................................. 18-57

18-1
18 SURFACE TECHNOLOGY
Specific Guidelines ..................................................... 18-59
Specific Guidelines and Data for Mechanical Material Removal Processes ....... 18-59
Specific Guidelines and Data for Abrasive Material Removal Processes .-............... - 18-74
Specific Guidelines and Data for Electrical Material Removal Processes ................ 18-91
Specific Guidelines and Data for Thermal Material Removal Processes .................. 18-98
Specific Guidelines and Data for Chemical Material Removal Processes ....... 18-111
Specific Guidelines and Data for Post-Treatment Processes to Aid Surface
Integ rity ............................................................................. .......... ... ..... .. .... 18- 116
Surface Integrity by Materials-High Cycle Fatigue Results ........... ........ 18-123
Quality Assurance for Surface Integrity .................................. 18-127
Specific Guidelines and Special Comments on Quality Assurance for Surface
Integrity ............................................... 18-.332.
Economics and Applications of Surface Integrity .......................... 18-133
Selected Sources of Surface Integrity Data .................................................................... 18-134
References ............. ............................................ ............. ............................ 18-134
Biblio g ra phy .......................................................................................................... 18- 135

18-2
 Introduction to Surface Technology 18.1
One of the principal design considerations for highly While most alterations occur in the first 0.015 inch 10.38
stressed components should be the surface condition pro- mini below the surface, this distance can be a significant
duced during manufacturing. This consideration must in- part of the total thickness of the thinner parts being de-
clude a thorough review of the surface alterations resuiting signed. In addition, it should be noted that many com-
from specific machining opta dons. Surface technology is ponent failures have originated within the first few
the activity that describes, details, and evaluates the condi- thousandths inch below the geometrical surface. These
tion of both the surface and the surface layers of manufac- facts alone support the need for design, manufacturing, and
tured components. The historical emphasis on surface tex- quality assurance engineers to exhibit interest in and un-
ture (rough-.ess, waviness, and lay) has been extended to derstanding of both aspects of surface technology-surface
include the assessment of effects just below the surface, texture and surface integrity-in order to produce safe, re-
that is, surface integrity, thereby including the influence of liable and long life cL Dnponents.
the outermost boundary of a component as well as those
outermost layers which differ measurably from the base The influence of manufactured surfaces on component
material. properties h.- been investigated most extensively for th~e
material removal processes. Figure 18.1-1 shows the sur-
face technlogy effects studied to date. During machining,
TRENDS AND CONCERNS process energies blend with work material properties to
produce a wide variety of these surface effects. Surface ef-
In recent years, the demand for increased safety, reliability, fects produced during the machining process affect the
and service life has caused considerable attention to be di- properties of the work material and in turn of the com-
rected to the pronounced influence of the types of surface ponent reliability, as shown in figure 18.1-2. Studies have
conditions produced by various manufacturing methods on demonstrated that each material remova! process has its
the resulting properties and performance of components own effect on each work material. It has also been shown
once in service. New and unusual service requirements and that for each process the intensity or energy level may have
conservation of energy and/ - materials have brought a distinctive effect on the specific metallurgical state of the
..bout the use of thinner sections of improved (and more dif- work material.
jicult to fabricate) materials and the introduction of design A
criteria that employ these materials much closer to their
full potential. While part drawings continue to call out con- ECONOMICS
figuration, dimensions, tolerances and material properties,
surface quality specifications must be added to complete The cost of producing a machined component increases as
the component definition. All the design elements noted surface specifit ations increase. Sophisticated and exten-
above are intimately interrelated and directly affect com- sive surface texture or surface integrity requirements are
ponent cost and producibility. justifie" only if they are necessary for the component part
to fulfill its function. Many parts require only a roughing
The manufacturer, recognizing the above dasign trends operation to attain their desired shape and tolerance. Fin-
and characteristics, also must be concerned with the at- ishing operations may improve quality but they add cost,
tainment of accuracy in thinner parts where distortion from and while emphasis on surface integrity considerations in-
processing stresses is a frequent result. Some of the newer creases component reliability, cost also may increase. To
and higher performance alloys used in the thinner and eliminate unnecessary costs it is important to apply texture
lighter parts also are like!y to be altered or more sensitive and integrity specifications selectively to only those areas
to thermal gradients or the heat generated by some proc- of a part where they are needed, rather than to impose
esses. The emphasis on quality assurance and product reli- these requirements across the entire surface of the part.
ability increases a importance of recognizing the impact The relationship between surface texture and machining
that manufacturi g processes may have on material prop- costs is discussed further in section 21.
erties. As always, in addition to these concerns and trends
the fabrication of a product or component must be accom- The application of surface integrity principles and guide-
plished within the constraints of both economics and envi- lines can increase the number of good parts nroduced or,
ronmental effects. conversely, reduce manufacturing losses. Surtace integrity
evaluations should consider the entire part processing se-
quence and emphasize the achievement of high quality in
RELATIONSHIP OF SURFACE TEXTURE the "as shipped" surface produced. The price for in-
AND SURFACE INTEGRITY attention to surface integrity can be premature component
failure or loss of reliability.
Traditionally, surface texture (roughness, waviness and
lay) has been accepted as the criterion which controls the
quality of a surface. Direct relationships are widely as- QUALITY ASSURANCE
sumed to exist between surface roughness and fatigue
strength as well as other properties. Ample data have now Surface technol,-gy ranks with dimensional configuration
been accumulated to indicate that surface texture is only and tolerance as visual evidence of quality. Deterioration
part of the consideration. Metallurgical and other altera- of surface quality with time or with number of parts pro-
tions below the surface also have a major influence on ma- duced is a handy clue to deteriorating tooL; or proces' set-
terial performance. This becomes particularly important tings. A 10-percent rule of thumb has been found to be a
where high stresses or severe environments are encoun- practical limit within which normal manufacturing oper-
tered by the workpiece. ations can be conducted without jeopardizing surface qual-

M
18-3
18.1 Introduction to Surface Technology
ity. This rule states that if surface roughness increases by questions should be raised as to the control status of the
10 percent (in microinches Ra or rms) or if any one of the process. If two o," more parameters are "adjusted" by 10
operating parameters has been reset or "adjusted" by plus percent or more, the process is no longer controlled and
or minus 10 percent from the planned values, immediate should be shut down until corrective action is effective.

Surface Texture Surface Integrity

(exterior effects) (interior effects)

Surface texture Microstructural transformations

* B46.1-1978 standards Recrystallization
* roughness Intergranular attack
lay Heat-affected zone
Macro effects Microcracks
laps, tears Hardness alterations
* pits Plastic deformation
e imoerfections ;Residual stresses
Material inhomogenities
Geometry
* tolerances

Altered material layers

i maBase material
Simulated
section

Figure 18.1-1 Surface technology effects.

I
I
I
Process Material
Energies Properties
Mechanical Tensile
Electrical Surface Effects Ductility
Thermal Roughness Hardness
Chemical Residual Stresses
Cracks
Phase Changes

Mechanical Properties
High Cycle Fatigue Low Cycle Fatigue
Stress Rupture Stress Corrosion

Component Reliability

Figure l.1-2 Interaction of processes with materials.

18-4
 -7.. . . ."'/

Surface Texture 18.2

INTRODUCTION
The surfaces produced by machining generally are irregu-
lar and complex. Despite this, the majority of machined
parts can satisfactorily perform their functions with gen-
eral, uncomplicated surface texture specifications. Many Measured profile
machining processes can meet these general surface tex- / (by instrumentation or other means)
ture requirements with ordinary process control and a min-
imum of quality control. Dimensional checks and visual ex- ''

amimation for macro imperfections usually are sufficient.

When surface roughness requirements exceed about 63 mi- o
croinches Ba 11.6 pinl most companies will use a visual No al profile
check rather than a measurement of the roughness profile. (as specified on a drawing)
Often the visual check is aided by using sets of sample
roughness specimens. Any more exacting specifications for
most surfaces would serve no practical purpose and would
result in needless expense. Figure 18.2-1 Surface texture profile. (Based on
ANSI B46.1-1978)
Parts that are highly engineered, heavily stressed or sub-
jected to unusual environments usually have more specific
and detailed surface quality requirements. Tolerance re-
quirements for these parts may also need to be closely al-
lied to the roughness allowed. For some of these parts, his-
tory or testing has demonstrated a direct relationship
between performance and surface texture. Quality control
tc measure surface texture is, therefore, necessary for these Flaw
parts. The following are examples of parts that require en-
hanced surface texture specifications in order to improve
fatigue strength. corrosion resistance, cleanliness, appear-
ance. coatability, sealing or product performance:
1. Antifriction bearings and airfoils ay
2. Objects operating in corrosive c,,vironments
3. Food preparation devices
4. Telescope lense, plug gages and rolling mill rolls
5. Journal bearings
6. Painted or coated surfaces Typical traversing-
7. Sealing surfaces or friction clamped assemblies length

Parts that are critically stressed, product-life-limiting or

safety controlling, or those specific areas on such parts, W
should have additional specifications that include surface spacing-
integrity considerations, as described in section 18.3.

SURFACE TEXTURE DEFINED

Surface texture is the repetitive or random deviations from /
the nominal surface which form the three-dimensional sur- height
face topography. A variety of mechanical, electronic and
optical devices are available to measure these deviations
by sampling the profile of the workpiece. Figure 18.2-1 Roughness
shows a comparison between the measured and the nomi- arithmetic /
nal profiles for a given surface. average -

American National Standard ANSI B46.1-1978 describes,

standardizes and calls out acceptable measuring instru-
mentation for surface texture.' (Internationally. ISO R468 s un
compares in content.) According to the standard, surface Valleys spacing
texture includes four elements-roughness, waviness, Jay Vs
and flaws. Figure 18.2-2 shows these characteristics in re- Roughness sampling
lation to a unidirectional lay surface, length or cutoff

'ANSI B46.1-1978. -Surface Texture" (which includes ANSI Y14.36-1978

"Surface Texture Symbols*) should ht available to and be read by everyone Fure 1 2-2 Pictorial display of unidirectional
concerned with specifying or measuring surface texture Copies are avail-
able from the American Society of Mechanical Engineers, United Engineer- lay surface characteristics. (Based on ANSI
ing Center. 345 East 47th Strect, New York, NY 10017. B46.1--1978)

18-5
18.2 Surface Texture
Definitions for the four elements of surface texture are as table 18.2-1). The difference is usually much less than the
follows: point-to-point variations on any given machined surface.
Roughness consists of the finer irregularities which Max. waviness height Max. waviness
generally result from the inherent action of the produc- MaxaXR width
tion process. These include transverse feed marks and Max. Ra-- 63 0.002-2
other irregularities within the limits of the sampling 3
Mm. Ra ------i:2/7U003 - Cutoff
length. _ J 0.015 . Lay
Waviness includes all irregularities whose spacing is "\\ -Max. roughness
greater than the roughness sampling length and less spacing
than the waviness sampling length. Waviness may re-
sult from machine or work deflections, chatter, vibra-
tion, heat treatment or cutting tool runout. Roughness \/Surface may be produced by any method
may be considered superimposed on a "wavy" surface. 7/Material removal by machining is required
Lay is the direction of the predominant surface pat- matorial must be provided for that purpose
tern, ordinarily determined by the production method 0.o01 IV Material removal allowance in inches
used. (or millimeters)
Flaws are unintentional irregularities which occur at 9 Material removal prohibited
one place or at relatively infrequent or widely varying
intervals on the surface. Flaws include cracks, blow
holes, inclusions, checks, ridges, scratches, etc. Unless Figure 18.2-3 Surface texture symbols used for
otherwise specified, the effect of flaws shall not be in- drawings or specifications. In this example, all val-
cluded in the roughness average measurements. Where ues are in inches except R, values, which are in mi-
flaws are to be restricted or controlled, a special note croinches (millionths of an inch). Metric values (mil-
as to the method of inspection should be included on limeters and micrometers, respectively) are used on
the drawing or in the specifications. metric drawings. (Based on ANSI Y1 4.36-1978)

Surface finish is a colloquial term widely used to denote the

general quality of a surface. Surface finish is not specifi- TABLE 18.2-1 Ratio of Root Mean Square Roughness to
cally tied to the texture or characteristic pattern of the sur- Arithmetic Average Roughness Values
face, nor is it tied to specific roughness values; however, a
"good" finish implies low roughness values and vice versa. Root mean square roughness: R,
The term surface finish is not as precisely defined as are Arithmetic average roughness: Ro
the terminologies used in the American National Standard. Theoretical ratio of sine waves,
nor is it necessarily expressed numerically. RfR&" 1.11
Actual ratios of R,/R. for
various processes:
turning 1.17 to 1.26
SURFACE TEXTURE SYMBOLS milling grinding
surface 1.16 to 1.40
1.22 to 1.27
The description and specification of surface texture is ac- plunge grinding 1.26 to 1.28
complished by means of symbols and conventions as pre- soft honing 1.29 to 1.48
sented in the ANSI Standard Y14.36-1978 (almost in com- hard honing 1.50 to 2.10
plete agreement with ISO 1302). The symbol used to electrical discharge machining 1.24 to 1.27
designate surface roughness is the check mark with a hon- shot peening 1.24 to 1.28
zontal extension as shown in figure 18.2-3. Roughness, Practical
Rq/Ro: first approximation of
which is the most commonly used surface parameter, is for most processes 1.25
specified by placing the height rating in microinches (one for honing 1.45
microinch = 0.000001 inch) or micrometers (one microme-
ter = 0.000001 meter) to the left of the check mark. If SOURCE: J. Peters; P. Vanherck; and M.Sastrodinoto. Assessment of sur-
ihere is a maximum and a minimum rating, the two num- face typology analysis techniques. Annals of the CIRP 28/2, 1979.
bers are placed one above the other. Roughness is defined
as the arithmetic average (AA) deviation of the surface ex-
pressed in microinches from a mean line or centerline (see The roughness width (or sampling) cutoff is the greatest
figures 18.2-2 and 18.2-4). R. is a symbol for roughness spacing of repetitive surface irregularities to be included in
that has been adopted internationally. Surface roughness is the measurement of the average roughness height (figure
still sometimes displayed with the symbols AA, or CLA or 18.2-2). It is specified in inches and is placed below the
c.l.a. Many instruments still in use employ an average de- horizontal extensicn of the check mark. A waviness height
viation from the roughness centerline which is the root specification is rated in inches as the peak-to-valley dis-
mean square (rms), also expressed in microinches (Rq). tance; and waviness spacing or width, also rated in inches,
While still used fiequently, rms actually has been obsolete is the spacing of successive peaks oz valleys (figure 18.2-2).
since about 1950. Roughness measuring instruments cali- Waviness height and waviness width values are placed
brated in rms read approximately 25 percent higher on a above the horizontal extension of the check mark. The
given surface than those instruments calibrated for Ra (see symbol designating the lay is placed under the extension of 4

18-6
 Surface Texture 18.2

Ra Rq Rt Rmax Rtm
Ra is the universally recognized parameter of
roughness. It is the arithmetic mean of the depar- Ft is the maximum peak-to-valley height within the
tures y of the profile from the mean line. It is nor- assessment length. Rmax is the maximum peak-to-
mally determined as the mean results of several valley height within a sampling length L. But be-
consecutive sampling lengths L cause the value can be greatly affected by a spurious
scratch or particle of dirt on the surface, it is more
Rq is the corresponding rms parameter. usual to use the average (Rtm) of five consecutive
sampling lengths.
I '! I I max
1 a
mr~ ma Rma RMaX 4 I

I I I
L-w=--L- L---1- L--',.=- 1-- ;;I I -- 1 -- L---JO--LJ.- L 21
/. Assessment length -- 4
Ra=- I yJ1,d.R tn Rmax, + Rmax, + Rmax 3 + Rmax
4 + Rmax_

L o
Rtm /5 Rmax i
Rq " 'J (x)dx
L oI

Rp Rpm
Rp is the maximum profile height from the mean line
within the sampling length. Rpm is the mean value
of Rp determined over 5 sampling lengths.
P2 R IR a I
P I PS I P4

Ten-Point Height is the average distance between , II V V V I r I V I

the five highest peaks and the five deepest valleys I
within the sampling length and measured perpen- I-L-4,- L--+- L-4--L+--L-
dicular to it. Rp,+ Rp2 + Rp + Rp4 + Rp i-
7-Rpm =1/5 Rp,

Peak count is the number of peak/valley pairs per

inch projecting through a band of width b centered
about the mean line.
L
(R,+R s R 7sR R- ) 1 count 1 count 1count
5

++ R, Rt + R~3 +R)-(R +R Mean line

Figure 18.2-4 Pome commonly used surface texture symbols and their definitions. (Based on ANSI
B46. 1-1978)

18-7
18.2 Surface Texture
the chlck mark. This symbol indicates the direction of the describe surfaces produced by some of the nontraditional
lay relative to the nominal surface. Figure 18.2-5 explains machining operations. The surface texture symbol also can
the various symbols used to designate lay. The pitted non- designate the extent of material removal desired-from
directional or protuberant designation of lay. P. is useful to none to any amount, as shown in figure 18.2-3.

Lay Example Showing Photographs

Sym- Meaning ameof
Direction of Tool Marks xp
bol- Meaning
bol Examples

Lay approximately par- - --

- allel to the line repre-

- senting the surface to .
which ,the symbol is =
applied.

Lay approximately per-

pendicular to the line i -
representing the surface
to which the symbol is
applied.

Lay anglular in both di-

X rections to line repre-
senting the surface to
which the symbol is -
applied. I

MLay multidirectional.

C Lay approximately circu-

lar relative to the center *
of the surface to which
the symbol is applied. I
Lay approximately radial
relative to the center of
the surface to which the
symbol is applied.

Lay particulate, non-di- . nR. i

rectional, or protuberant.

Figure 18.2-5 Lay symbols for surface texture designation. (Based on ANSI Y14.36-1978)

18-8
 Surface Texture 18.2

SURFACE TEXTURE MEASUREMENT

The most prevalent measuring technique for surface tex-
ture empioys a mechanical-electronic device whose readout
indicates the roughness of the surface profile taken during
the passage of a small radius stylus over a short straight
line path on the surface. The most common diamond stylus
has a 0.0004 inch 110 nml radius and usually is used with a
0.030 inch 10.8 mml cutoff width The total stylus travel is
usually 20 to 60 times the cu;,off width with the electronic
circuitry continuously averaging the readings over the set
cutoff width. These instruments can read average rough-
ness. R... peak count or other roughness designations de-
pending on the particular instrument design.

It should be kept in mind that electronic surface measuring AVNA&AAA V

devices generally indicate the roughness but do not in-
dicate the physical character of the surface. Several sur-
faces can. in effect, be quite different in appearance and
still yield similar roughness values, as shown in figure r
18 2-6. One approach to more exactly describing the sur-
face roughness is the microtopographic map. as shown in
figure 18.2-7. These maps are made by successive, closely
spaced stylus generated traces. A still more detailed exam-
ination is sometimes made using the scanning electron mi-
croscope (SEM). The series of views with SEM shown in
figure 18.2-8 utilizes increasing magnificaions of 20X. Figure 18.2-6 Sketches of cross-sections of sur-
200X. IOOOX. 2000X and 5000X which are t-isv to relate faces greatly different in character but having ap-
to the view with a IOX hand-held magnifier. proximately the same surface finish level.

Figure 18.2-7 Microtopographic map of Blanchard-ground surface of stainless steel. 200X in X-Y
plane, 2000X in Z direction (Courtesy of Gould Inc.)

18-9
18.2 Surface Texture

21X X - P00bOMOXi

Figure 18.2-8 Scanning electron microscope (SEM) views taken at a 550 angle of a typical surface of
17-4 PH stainless steel produced by electrochemical machining (ECM). Arithmetic average roughness
(R..) was 29 microinches [0.74 jan], and maximum peak-to-valley roughness height (Rt) was 152 micro-
inches [3.86 Lim].

18-10__
 Surface Texture 18.2
SURFACE TEXTURE PRODUCED BY THE processing operation to produce a specific surface rough-
MACHINING PROCESS ness depends on many factors. In turning, for example, the
surface roughness is geometrically related to the nose
To a large degree the surface texture produced by a mate- radius of the tool and the feed per revolution. For surface
rial removal process is characteristic for that particular grinding, the final surface depends on the type of grinding
process. The range of roughnesses typically obtained for a wheel, the method of wheel dressing. the wheel speed, the
variety of manufacturing processes is shown in figure table speed. cross feed and down feed. and the grinding
18.2-9. This chart also indicates that it is possible to ex- fluid. For electrical discharge machining (EDM), the
ceed the usual range under unusual or specially controlled roughness level is related directly to the individual spark
conditions. discharge energy level. A change in any of the process op-
erating parameters may have a significant effect on the fi.
The selection of surface texture values involves more than nal surface produced.
merely designating a particular process. The ability of a

Roughness average. Ra - microinches,. in [micrometers, pm]

2000 1000 500 250 125 63 32 16 8 4 2 1 0.5

PROCESS [50] (251 [12.51 [631 (3.21 (1.6] [0.801 (0.40] [0.20) [0,1010] 05] (0025] [00121
Flame cutting //.I ./!
i Snagging ~Sawing 71/-//
Planing, shaping //.I I Iz/ ,--/.I

Drilling "//! //
Chemical millng vli //.

Elect discharge mach.

Milling typical of t p l Average'ppi
Broaching produced b m r i e . m
Reaming i/1. ///
Electron beam ;-///.-
~~~~~~Laser' 'h-'-- /
E!ectrochemical "//""// //k//
Boring. t
t.
Barrel finishing //, // ,/.,i-,/-
5ZZ,/
Electrolytic grinding,/,,,/;

Roller burnishing /// /I.

Grinding W///.,//.
-" // ///

Electropolisn"'i,,/// i/l,/ll'

Polishing Z,/,-I '/ , ,-,,,, ,,,,,

Lapping /// //,//J
Superfinishing ///.'// '///
Sand casting ?// ,/,/
HOt rolling I/ '/,,
Forging //t /

Perm mold casting /J/ "//

Investment casting,-// /z ,.-..,
Extruding i/l ///,Iti
Cold rolling, drawing /,// ,//zz"V,,
,
Die casting i//. ///

The ranges shown above are typical of the processes listed. I Average application
Higher or lower values may be obtained under special conditions. Less frequent application

Figure 18.2-9 Surface roughness produced by common production methods. (From ANSI
B46.1-1978).

18-11
18.2 Surface Texture
MACHINING COST AND SURFACE Each application must be evaluated on its own merit.
TEXTURE Table 18.2-2, if used with discretion. may serve as a guide
to the surface roughness values that may be necessary
The cost of producing a machined surface increases with where machine work must be held to close tolerance for
increasing requirements for finer finishes. Certain machin- other reasons than merely surface texture. It must be fur-
ing operations. such as rough turning and milling, are nec- ther realized that the practical control of tolerance is also
essary to shape a component to its required dimensions. influenced by the size of the part, the overall size of the sur-
Additional operations to refine the surface are needed only face being cut. and the material removal operations in-
to permit the surface to perform functions which it could volved. A chart showing how attainable dimensional tolei-
not otherwise perform. A surface roughness of 63 micro- ances tend to vary as a function of part size is shown in
inches 11.6 Lml or coarser can be obtained at a reasonable figure 18.2-11.
cost by general roughing and semi-finishing operations.
The relationship of surface texture to the cost of machining
is discussed further in section 21.

DIMENSIONAL TOLERANCE VERSUS

SURFACE TEXTURE
There is a direct relationship between the dimensional tol-
erance of a part and its permissible surface roughness since TABLE 18.2-2 Guide to Surface Roughness Values for
the roughness measurement involves the average linear de- Close Tolerance Machine Work
viation of the actual surface from the nominal surface de-
fined by the dimension. If the deviations induced by the sur- DIMENSIONAL TOLERANCES SURFACE ROUGHNESS
face roughness exceed those permitted by the dimensionalt
tolerance, the dimension will be subject to an uncertainty in "tin
beyond the tolerance, as shown in figure 18.2-10. On most __ _ _

surfaces the total profile height is approximately four times Below 0,0002 Below 8 A29
the measured (arithmetic a,", age) roughness. When meas- 0.0002 to 0.0005 A 6 to 16
urements are made on a diameter of a part. this value 0.0005to0.0010 t 18to32
would be doubled. It follows that the roughness value on a 0.0010 to 0.0020 5 32 to 63 0Zo4
diameter should not exceed one-eighth the dimensional tol- 0.0020 to 0100 A 5 63 to 250 A
erance on the diameter if useful dimensional controls are to
be maintained.

Average
Roughness roughness Profile
centerline height height

L SURFACE TEXTURE AND QUALTY

Unceraintv ASSURANCE
- ize Quality assurance for the surfaces produced by material re-
measuremert moval processes should include assessment of the surface
roughness and all other surface texture factors. This does
not imply that the effect of scratches, tool marks, sharp
corners and other geometric considerations can be over-
looked. It is well established that all of these elements can
Roughness Average Profile produce stress concentrations that can lead to premature
centerline roughness height fatigue failures. Historically, surface roughness has been
height the prime criterion for surface quality and a guide to ac-
ceptable fatigue strength. Some recent data indicate that
Figure 18.2-10 Uncertainty in size measurement for some alloys surface roughness is not the critical crite-
in relation to surface roughness parameters for a rion for high cycle fatigue strength. Section 18.3 discusses
cylindrical surface. (From ANSI B46.1-1978). this matter in greater detail.

18-12
 Surface Texture 18.2
10-' _ _

8 -izzz

1000

S 4
00

U 2 _____
000

10-3 1

10--1

0.1 0.5 1.0102

D~iameter or length. in

Figure 18.2-11 General effect of part size on manufacturing tolerances. (Adapted from Manufacturing
planning and estimating handbook. New York: McGraw-Hill, 1963, p. 20-23)

18-13
18.2 Surface Texture
PREFERRED ROUGHNESS VALUES practical to place undue emphasis on achieving a specific
roughness number. To minimize the variety of drawing
With all the factors that can influence the generation of a callouts. the American National Standards Institute in the
surface roughness value, with the dearth of data linking a standard, ANSI Y14.36-1978, promotes the use of pre-
specific roughness value to the function performed by a spe- ferred values for average roughess (Rj). roughness cutoff
cific surface. and with the variability introduced by the length and maximum waviness height. These values are
minute sample used in most measuring techniques, it is im- listed in table 18.2-3.

TABLE 18.2-3 Preferred Values for Arithmetic Average Roughness (R), Cutoff
Length, and Maximum Waviness Height
ARITHMETIC AVERAGE STANDARD ROUGHNESS MAXIMUM WAVINESS I
ROUGHNESS (Ro) SAMPLING LENGTH "EIGHTI

ltin in in-

0.5 0.003 0.00002

1 __0.010 0.00003
20 0.030 0.00005
3 0.1 0.00008
4 0.3 0.0001
5 1. 0.0002
6 ____ 0.0003
8* 00005
10 0.0008
13 0.001
16* 0.002
20 0.003
25 0.005
321 0.008
40 0.010
50 0.015
63* 0.020
80 0.030
100 _
!25"
160
200
320
250*

400
600*
800
1000 =

SOURCE: ANSI Y14.36-1978.

ORecommended
'When no value is specified, the value of 0 030 inch [0.8 mini applies.

18-14
 Surface Texture 18.2
THEORETICAL ROUGHNESS PRODUCED roughness is a function of the tool radius and the feed per
BY MILLING CUTTERS AND BY LATHE revolution. The similarity between the roughness determi-
nations for the Type-B and Type-C configurations for both
TOOLS the turning tools and the milling cutters results in identical
It is possible to calculate the theoretical surface roughness sets of theoretical roughness values for each tool type in
produced by face milling cutters in a milling operation and each operation Hence. the table of theoretical values of R.
by lathe tools in turning. The theoretical surface roughness and R, values for the Type-B tooth in milling (table 18.2-9)
is important because it represents the best finish that can1 applies equally to the Type-B tool in turning. Similarly, the
be obtained with a sharp tool. The actual surface rough- values in tables 18.2-10 through 18.2-19 for the Type-C
ness usually will be poorer than this because built-up edge tooth in milling apply equally to the Type-C tool 'n turning.
is present. A series of graphs depicts the arithmetic average surface

For face milling, the cutter tooth can be classified2 accord- roughness for the various tool configurations as follows:
ig to one of the following common configurations: Type A: Zero-radius face milling cutter: figure
Type A: Zero nose radius 181-14
Type B: Round Type B: Round tool; figure 18.2-15
Type C: Nose radius, end cutting edge angle and side Type C: Tool containing a nose radius plus end cut-
cutting edge angle ting edge angle; figures 18.2-16. 18.2-17. and
18.2-18
These configurations are shown in figure 18.2-12. For-
mulas have been developed which determine the arithmetic As previously mentioned. the actual surface roughness gen-
average roughness. R,, and the peak-to-valley roughness erally will be poorer than that calculated from geometric
height. Rt. for these configurations. 3 considerations such as shown in tables 18.2-4 through
18.2-19. (The theoretical calculations all assume that the
The theoretical surface roughn.ss produced by a Type-A cutting conditions are such that the tool profile is dupli-
tooth in face milling is a function of the side cutting edge cated exactly in the workpiece surface.) During the process
angle (SCEA). the end cutting edge angle (ECEA) and the of chip formation, a built-up edge or plastically deformed
feed per tooth. Calculated values of R. and R, for this tooth material may be produced at the cutting edge. Most of this
configuration are contained in tables 18.2-4 through buift-up edge breaks off and flows away with the chip.
18.2-8. However. part of this built-up edge can remain welded to
the finished workpiece surface and adds to the surface
The theoretical roughness produced by the round Type-B roughness. as shown in figure 18.2-19. The presence of a
tooth in milling is a function of the tooth radius and the built-up edge can increase the surface roughness by a fac-
feed per tooth. Table 18.2-9 contains calculated values of tor of 1.2 to 2.5. The added roughness. or the amount of
R. and Rt for this configuration. built-up edge. is a function of the cutting tool material and
the work material. The amount of built-up edge present on
The Type-C tooth produces theoretical roughness values the surface can be minimized by using higher cutting
which are a function of the nose radius, the ECEA and the speeds and by using chemically active cutting fluids. Addi-
feed per tooth. Values R. and Rt that were calculated for tional factors which can add to the surface roughness in-
this configuration are given in tables 18.2-10 through clude chatter, vibration and tool wear.
18.2-19.
Special tool shapes can create finer- or micro-finishes. A
For turning operations. lathe tools can be characterized as -wiper- blade, figure 18.2-20. is one such tool shape used.
either Type B or Type C (see figure 18.2-13). For common Its broad. convex face reduces feed marks. Normally only
Type-C tools, the theoretical surface roughness is deter- one wiper blade is required in multiblade stiling cutters-
mined by the nose radius, the ECEA and the feed per revo- Higher cutting speeds do not appear to reduce the effi-
lution. When a round Type-B tool is used. theoretical ciency of wiper blades.

-Tyc,A. B and C tools are the sm designations used by G. R. Dickimnn

in his paper. -A sm ve of factors affecting surface fris." Poodir. In-
stitution oMechanicatine4mw 182 (Part 3K. 1968): 135-147.
'H. L. Fircheand J. T. Efrod. -Surface finish as a function of tool gometry
and feed-A theoretical approac Microtenic2S (April 1771): 175-17&

18-15
18.2 Surface Texture

B)

R Tool radius F-

Feed per
revolution

~Feed per
Feed per tooth revolution

Feed per
tooth

Feed Side cutting / radius edge angle

per [eg nl
tooth Nose
radius

End cutting edge angle

t Figure 18.2-13 Surfaces produced by turning
.. with the types of tools used ir, the theoretical sur-
" face finish calculations.
SCEA
Side cutting
edge angle
"Corner angle in face mills

Figure 18.2-12 Surface produced by face milling

with the types of tools used in the theoretical sur-
face finish calculations.

18-16
 Surface Texture 18.2
TABLE 18.2-4 THEORETICAL Values for Arithmetic-Average Roughness (Ra) and Maximum Peak-to-Valley Rough-
ness Height (Rt) for Milling-Tool Type A

ZERO NOSE RADIUS SCEA=0 o

FEED 10 1 20 30 40 50 6 T 70 8
PER
T O OT H
ECEA I
"i
ECEA Fi ECEA
14"
. . ' ;- -
I ECEA RH,--
11, -
i,
_| ECEA i
[ R-
: -" -- '-
ECEA
11, "-- l,-.. . R,
ECEA. iI.....,l .
ECEA
i , . .. "

inmicroinches

D01M, 41 17 87 35 13 52 17 70 22 87 26 105 31 123t 35 1,1

1002 87 35 17 70 26 105 35 140 44 175 53 210 61 2,46 70 281
11103 13 52 26 105 39 157 52 210 66 262 79 315 92 368 105 122)

0001 17 70 35 140 52 210 70 280 87 350 105 420 123 491 I 1.11 562
005 22 87 4.1 175 66 262 8/ 350 109 437 131 526 153 6I 176 7(3
r
0W6 2f; 10 52 210 79 314 105 420 131 525 158. 631 1841 73/ 211 843

0007 31 12? 61 244 92 367 122 489 153 612 184 736 215 859 246 984
0008 35 1.10. 70 279 105 419 140 559 175 700 210 841 246 982 231 11241
o000 39 157 79 314 118 472 157 629 197 787. 236 946. 276 1105 316 1265

)10 4,1 175 87 349 131 524 175 699 219 875 263 1051 307 1228, 351 1405
o012 52 209 105 419 157 629 210 839 262 1050 315 1261 368 1473 422 1686
001.1 61 214 122 489. 183 734 245 979 306 1225 368 1471 430 1719 492 1968

0 16 10 279 140 559 210 839 2N0 1119 350 1400 420 1582 491 1965 562. 2240
1018 79 314 157 629 236 943 315 1259 394 1575 473 1892 553 2210 632 2530
0J020 87 349 175 698 262 1048 350 1399 437 1750 526 2102 614 2456 703 2811

0 025 109 436 218 873 328 1310 437 1748 547 2187, 657 2628 767 307O 878 3514
0 030 131 524 262 1048 393 1572 524 2098 656 2625 788 3153 921 368.1 105. 1216
0035 153 611 306 1222 459 1834 612 2447 766 3062 920 3679 1074 4297 1230 4919

0 4( 175 698 349 1397 524 2096 699 2797 875 3500 1051 4204 1228 4911 1405 5622
04 , 196 785 393 1571 590 2358 787 3147 984 3937 1182 4730 1381 55-15 1581 6324
0050 218 873. 437 1746. 655 2620 874 3496 1094 4374 1314 5255 1535 6139 1757. 7027

mm micrometers
0.020 0.09 0.35 0.17 0.70 0.26 1.0 0.35 1.4 0.44 1.7 0.53 2.1 0.61 2.5 0.70 2.8
0.040 0.17 0,70 0.35 1.4 0.52 21 0.70 2.8 0.87 3.5 1.1 4.2 1,2 4.9 1.4 5.6
0.060 1.0 0026
052 2.1 0.79 &1 1.0 4.2 1.3 5.2 1.6 6.3 1.8 7.4 2.1 8.4
0.080 0 . ,0.70-. 2.8 1.0 42 1:4 . 5.8 1.7 7.0 2.1 8.4 2.5 9.8 2.8 11.
0.100
0,12 ,:",
: "1t.3
;'.11 -
5.2
63,
1.7
2, 11
7.0.4 2.2
2.11
8.7
10,
2.6
3.2
11.
13.
3.1
3.7
12,
Is.
3.5
4.2
14.
17.

0.140 0"' 14 1.24. 1.8 73' 2.4 9.8 3.1 12. 3.7 15. 4.3 17. 4.9 20.
0.100 07,,0 2.1 8.4 2.8 11. 3.5 14. 4.2 17. 4.9 20. 5.6 22.
03180 rt.. "1"3 24 9.4 3.1 13. 3.9. 16. 4.7 19." 55 22. 6.3 25.
0.2002' 1 0. 3.5 14. 4.4 17. 5.3' 21, 6.1 25. 7.0 28.
O. r ,..",t" .2 4 33 1,L 4.4 17. 5.5 22. 46.8 26., 7.7 31. 8.8 35.
.3I.: U2
6. "5.2 21. 6.6 26. 7.1, ;''.32. 92 37. 11. 42.
0360 :4 1:" i , ,0,'
4' st 1s, 6.1 " 4. 7.7 31. 9.2 37. 11. 43. 12. 49.
0.400 1. 7,7. 3. 1 5.2' 21. 7.0 X6. 07 35. 11. 42. 12. 49. 14. 56.
0450. to 7 l,"Is' W S111., 24. 7.9 31. 98 39. 12. 47. 14. 55. 16. 63.

00 22 8S In, 21 8 2 3
6. 11. 44. . 13. 53. 15. 61. 18. 70.
0.U - .. 2i.. 7 31. 10. '4. 13... 52. 16. 63. 18. 74 21. 84.
S- 9.1 '24 ' 37.'12. 15. 81, 18. .74- 21. 86. 25. 98.

"'2 4 , 14.:; , 70.. 21., ,. 84. 25. 96. 28. 112.

; :
1.000 ' ? IL
...... , 70. 22.- j 6.. 26. '--105. 31. 123., 35. 141.
1100 ____. a&__ "_ a7. 12A__l.
*, 3________. 147. 42. 169.

Best Available Copy

18-17
18.2 -Surface Texture
TABLE 10.2-5 THEORETICAL Values !or Arithmetic-Average Roughness (R, ) and Maximum Peak-to-Valley Rouch-
ness Height (RI) for Milling-Tool Type A

ZERO NOSE RADIUS SCEA=15

FEED 10 20 30 40 5 6 1 70 80
PER ECEA ECEA ECEA ECEA ECEA ECEA ECEA ECEA

rmcroinchus

0.1
,3)0 I ' 3 5? 1/ 9 8 2 10? 30 119 34.
88 21:5
'
ti / 3, I/ 63 26 103 jI 1 '31'
, 1/1 51 20.1 ,59 2;8

1: 5 : l (A '3" Y, 'I :I ;0 3W/ 102. 401,

1i/ 61 'l 138 50 .,/ '1; :2' 85 3.12 02 40J, 11) I

,/5 5 42
0'' H/ -1:1 113 ,5 !,8 386 343 30/ 427 1283 511 119. 594. 169. 1;/
) 16 101 52 208 8 310 103 413 123 513 153 613 178 713 203 3313.

)00, 0 122 61 ?42 96 362 i128I 480 150. 598 179 716 208 832 237, 918
)(08 '0, 139 69 277 103 413 137 548 71 68, 204 Q18, 238 951, 271. 1084
!001) 3,1 156 /8 311 116 465 5 6'S 192 769 230 920 267 1070 305 1219

'0) 4i
3 17, 86 346 129 51/ i2l 686 214 055 256. 1022 297. 1188 339 1354.
,,1 '? A3.8 103 415 155 620 206 824 256 1026. 307 122i 357. 1425 406. 1625
,101.1 h1 2-13 121 484 181 724 "40 961 299 1197 358 1431 416 1664. 474 1883

0 69 278 138 554 2271 827 2/" 1098 342 1368 409 1636 475 1902. 542 2167.
'018 /8 313 156 623 233 9130 :.38 1236 385 1539 460 1840 535 2140. 609 2.138
' 02' 81 34/ 1/3 892 258 1034 343 '3/3 421 1710 511 2045 594 2j77 677 2/09

0:2" 10 13.1 210 86- 323 1292 13"3 171, 534 2137. 639 2,53,6 /43 2972 841 3386
. 11,3 521 ?,' 1')38 3,84"' 1550 515 2059 641. 2565 767 3067 8Y2 3Z6 1016 4063
16:
111:35 b08 303 21!1 452 1409 f31 2402 748 2992 894 3578 1040 4161 1185. 4740

f):) 174 695 3-16 1314 517 267 6r. 2746 855 3419 1022 4089 1189 4755 1354 518.
03.15 195 782 389 1557 581 2326 ,,2 3089 962 3847 1150 4600 133/ 5349 1524 6095
03)3,0 217 869 432 1730 646 2584 858 3432 1069 4274 1278 5111 1486 5944 1693 6772.

mm : micrometers . . .

0.020 0.35
0.09 0.17 0.89 026 , ID 0.34, A 0.43 0.51 io,'0.59 .4.72A 0 2.7
0.040 .'60
7 10 41: 12 4A 1A 5.4
0.060 0.26 1.0 0.52 2.1 0.8 31 10 4I 13 1 1,5 ' '.i7~' '2.0' &1
0.080~~~0.147
0.35 0.61 1.4 0.69
1, i.
.4M -+4l+ +63I0 j t,:" 0.1417 :'- + &
" '2b 9, 2.7: 11.
0.100 0.43 1.7 0.86 3.5.' .1. 5.2 1.7 &9 2.1 ,'8 2A~ 3.4.: _14.
0.120 0.52 2.1' 1.0 ' 4.2 :1 4.2'.) .2,; 2. 3.V
M I ',4.1 16,
2 ,.0
.5 '241,,2 1 S 1. ' .'
040 0.61 ,2.4 .1.2 J3. A' .72" 2A'"9 3. W1,j, _ 1

0.180 J.69 2.8 I.A 5.51 U T 4 fli) 14'

3.1 l' 4A Ai

0.200
0.180 0.87
0.78 3.5
3.1 1.71 &13 ~.S
AA v.
.,5-18
-1.2 *'4 1 *52 2 68' 27.
24.
02 011 43 2.2 8.6 1. 4.3~ -I M
e.~ '5 A
7,, 1Mr 8. 34.
0.50 1.7 8. 2.5 14. '. ,1:~
040 2.0 528 3.9 10. r" W af8> ~ ~ Y'5S i.
'10 1:
42~6

0100 2 6 1 5.2 43 15 W4.~ 4L 12:. 41.

8.00 2.5 14. 6.9 2..' ~ 41 -a At, 108.20%

18-8 Bst Av4ailjable COPY

 - Surface Texture 18.2
TABLE 18.2-6 THEORETICAL Values for Arithmetic-Average Roughness (Ra) and Maximum Peak-to-Valley Rough-
ness Height (RI) for Milling-Tool Type A

ZERO NOSE RADIUS SCEA=300

FEED
_E__CE
10 20
ECEA
1 30
ECEA
40
EE EA
50
ECEA
60
ECEA
70
ECEA 80
TOOTH iI, ',it,K1
" o,,, 1{, ,, I, , . -6,
in microinches

0001 13 i 86 34 13 99 20 11 3 .
0' (002
1110
8;G ' 1 63 7 ~ ' 1 3 . 16, I 67c 03a 2?7:7
I~)t' ',? 71'/ 1111 3- , . 32 K 2:0 7,4. 237" 3. 34-1 i17 3i,

004 s . J t, 2'J
W?'7 5' .:3 99 3IJ6 1t6 14 I 13V.
000. ;' 6, .[3 171 .1
" 33 416;
J10 496 :40 7," I61A
0001, 2 10 4 3
'1 5 "1 4"' ' 3 1 .. 46 14 !. 32 1' 7,0

01)0)/ 301 1:11 60 "1VI i'2,U 14j b 1 m2

008 { J3!
'5 1138 ,1,/ [ 14 ' 4,.' ''-
134 470
630 4'
1i,. 3
0t1' 13
io
19 %94
3 j .1J
">9 '117 7'03 1041

?
(J()1
0 4J I/ 817 1-. ": 5,. IhO
: 8 6 2'8 8,11 46 991 .7 1 47

001? 5?" 20/ 103 411 13 .'. i 837 24 39Y9 21' 11 j 344 1376 9,
0014 60 4 11 4,, 178 "2 735 -J,1 291 166 34, 13B74115",6 455 '1

01j(16 b,9 :t 177 648 14 .

8i, iJ '3> ' 33a 343 3"> 15:6 459 1535 5-1
,20
)8
0 ( 18 31' 1'4 616 '2: 03 :.. 12'1 375 14119 .4); 1184 Sit ',j4 5.o 7..
(201
01 8l 34t, i/1 668, .4 I. , . j44 416 1666 49' 1932 67i 213 O .t>

1026 '8 4j. 214 '-,' 319 '772 I4: "6-U 621 .'082 t19 2477 71" .'>6 8'? .,'>
1030 i1.1
! '' 257
5 .', 382 ' ',4 2u': 625
.' 24115 141 2973 860 3440 .
0035 161 '
6,1 00 1i.98 445 1 :,0 - 2352 /.9 :916 l;" 3458 ! 4,13
,3 1
0040 1i3 b91 342 13t.9 6,' -. '> 26 8 33 331 991 3964 1147 456 1300 00

0046 194 385

"> 1540 572 z.3 '5 3026 9., 3748 1115 4459 1l"J 6160 1462 '13,60
0050 216 864 1112
W;' 636 z>3
- .
,4, 33b1 1341 4164 1239 4955 1433 5733 1676 6600
mm micrometers
0.020 0.09 0.35 0.17 0.66 025' 10 0.34 1.3 0.42 1.7 0.50 20 0.57 23 0.65 2.6
0.040 0.17 0.69 0.34 1.4 0.51 2.0 0.67 2.7 0.83 3.3 - 0.99 40 1.1 4.6 1.3 5.2
0.060 0.26 1.C 0.51 2.1 0.76 3.1 1.0 40 1.2 5.0 1.5 5.9 1.7 6.9 1.9 7.8

0.0680 0.35 1.4 0.68 2.7 1.0 4.1 1.3 5.4 1.7 6.7 2.0 7.9 2.3 9.2 2.6 10.
0.100 0.43 1.7 0.86 3.4 1.3 5.1 1.7 6.7 2.1 1.3 2.5 9.9 2.9 11. 3.2 13.
0.120 0.52 2.1 1.0. 4.1 1.5 61 2.0 6.1.- 2.5 10.0 30 12. 3.4 14. 3.9 16.
0.140 ,0j,0 2.4 12 4.8 1.8 7.1 24 94 2.9 12. 3.5 14. 4.0 16. 4.5 16.
O10.6 2.8 1.4'' S.5 20 II 2.7 11. 3.3 13. 4.0 14. 4.' 1& 5.2. 21.
0.180 0.78 3.1 1.5 6 23 #2 3.0 12 3.7 15. 4.5 U. $2 ,21. 5.8 23
0.200 0.86 . 1.7 &6.' 25 M10. 4 13. 42 17 .0 "20. 5.7 23. 5.5 26.
0.250 1.1 4.3 '.1 1,6 342 4.- 17. &2 21. 6.2 25. .7.2 29. . 32.
0= 13 5.2 2.6 -10. $51&6 . SJ 2. 6.2 ' 2 7As 0.1 34. 9.7 39
0350, 1.5 8.-0 U 12t 45 1. 10, . 73 2. 47. 3S. 10- 40. J1. 45.
0.400 1.7 .9 34 1. 5.1 2-. &.7 27. 8-3 .1 . t". 40 11. 46,. 13. 5z
1.9 .3.9 15. 5.7 t3. 7. 30. t9.4 .37. ji. 45. 13. 52. 15. 58.

0.500 2.2 &.8 4.3 17.*i\, &4'r ~ 8.4 34. 110. '~411 1?- 50 1%4. W57 16 6.'
o.600 2. 1. 5.1 21. . 40. .12. 15 " 69. 1. 78.-.
30812.
I000 . 4.-.-" L9-3&% 2. . .. 15. ,5.- 17. 69., 20. . 26&.. -91..
0.100 3.5 14 U68 27 t 41. a1 54. 1"'67. 20. 79. 23. 92. 26. .104.

-. 1200 5 I... 1 51.. 20 .. '2&. 81. 3 1.'19.3 W -392''15.

18-19
18.2 Surface Texture
TABLE 18.2-7 THEORETICAL Values for Arithmetic-Average Roughness (Ra) and Maximum Peak-to-Valley Rough-
ness Height (Rt) for Milling-Tool Type A

ZERO NOSE RADIUS SCEA=45 0

FEED 10 20 30 40 50 6 70 80
PER ECEA ECEA ECEA E ECEA CEA
TO O TH _I_ _ il_, , Ht R, A,_R, lAo [I,
in microinches

(01 43 17. 84 34 12. 50 16 65 20 80 21. 95. 27. 109 31 123.

0 002 86 34 17 67. 25 100 33. 131. 40. 161. 48. 190. 55. 219. 62. 246,
0 003 13 51 25 101 37 149 49 196 60. 241 71, 285. 82. 328. 92. 370.

0004 17 69 34 135. 50 199. 65 261. 80 322. 95. 380. 109. 437. 123, 493.
0.005 21 86 42. 169. 62. 249 82. 327 101. 402. 119. 476. 137. 547. 154. 616.
(006 26 103 51. 202. 75 299 98 392. 121. 483. 143. 571. 164. 656. 185. 739.

0007 30 120 59 236. 87 349 114. 457. 141, 563. 166. 666. 191. 766. 216. 863.
0 008 34 137 67 270. 100. 398. 131. 523. 161. 644. 190. 761. 219. 875. 24,6. 986.
0009 39 154 76. 304. 112. 448 147. 588. 181. 724. 214. 856. 246. 984. 277. 1109.

0010 43 172 84 337. 124 498 163, 654. 201. 805. 238 951. 273. 1094. 308. 1232.
0012 51 206. 101 405. 149 598 196. 784 241. 965. 285. 1141. 328. 1312. 370. 1479.
C014 60 240. 118 472 174. 637. 229. 915. 282. 1126 333. 1332. 383. 1531. 431. 1725.

0 016 69 274. 135 540. 199 797 261. 1046. 322. 1287. 380. 1522. 437. 1750. 493. 1972.
0018 77 309 152 607 224. 896. 294. 1176. 362. 1448. 428. 1712. 492. 1968. 555. 2218.
0020 86 343. 169. 679 249 996. 327. 1307 402. 1609. 476. 1902. 547. 2187, 616 2464.

0025 107 429 211 844 311. 1245. 408 1b34. 503. 2011. 594. 2378 683. 2734. 770. 3081.
0030 129 515 253 1012 373 1494 490 1961. 603 2414 713. 2853. 820 3281 924. 3697.
)035 150 600 295 1181 436. 1743 572 2287. 704. 2816. 832 3329. 957. 3828. 1078. 4313.

0 040 172 686. 337. 1350 498. 1992 654. 2614. 805. 3218 951. 3804. 1094. 4374. 1232. 4929.
r 045 193 772 380. 1518 560 2241 735. 2941 905. 3620 1070. 4280. 1230. 4921. 1386. 5545.
C(150 214 858. 422 1687. 622 2490 817. 3268. 1006. 4023. 1189. 4755. 1367. 5468. 1540. 6161.

mm micrometers
0.020 0.09 034 0.17 067 025 1.00 0.33 1.3 0.40 1.6 0.48 1.9 0.55 2.2 0.62 , 2.5
0.040 0.17 0.69 0.34 1.3 0.50 2.0 0.65 2.6 0.80 3.2 0.95 3.8. 1.1 4.4 1.2 4.9
0.060 0,26 1.0 0.51 2.0 0.75 3.0 0.98 3.9 1.2 4.8 1.4 5.7 1.6 - 6.6 1.8 7.4

0.080 0.34 1.4 0.67 2.7 1.00 4.0 1.3 5.2 1.6 6.4 1.9 '7.6 2.2 8.7 2.5 . 9.9
0.100 0.43 1.7 0.84 3.4 1.2 5.0 1.6 6.5 2.0 8.0 2.4 , 9.5 2.7 11. '3.1 12..
0.120 0.51 2.1 1.0 4.0 1.5 6.0 2.0 7.8. 2.4 9.7 2.9 -, 11. .3.3 '13. '3.7 15

0.140 0.60 2.4 1.2 4.7 1.7 7.0 2.3 9.1 2.5 11. 3.3 13. 3.8 .. 15. '4.3 17.
0.160 0.69 2.7 1.3 5.4 2.0 8.0 2.6 16.' 3.2 13. 3.8 . 15. 4.4 , 17, 4.9 . 20.
0.180 0.77 3.1 1.5 6.1 2.2 9.0 2.9 12. 3,6 14. 4.3 17. '3 :4.9 20 5.5 22.
0.200 0.86 3.4 1.7 6.7 2.5, 10.0 3.3 , 13. -4.0 16. 4.8 .19. 5.5 .22., 6.2
0.250 1.1 4.3 2.1 8.4 3.1 12. 4.1 . 16. 5.0 20. 5.9, ' 24., 6.8 27. 77 31.
0.300 1.3 5.1 2.5 10. 3.7 15. 4.9 20. 6.0 24. 7.1 . 8.2 ':"33. 9.2 '37.,
0.350 1.5 6.0 3.0 12. 4.4 17. 5.7 23. 7.0 28. 8.3 ,33. 9.6 38.. 11.. 43.
0.400 1.7 6.9 3.4 13. 5.0 20. 6.5 26. 8.0 32. 9.5' 38. , 11.' 44" 12. .49,
0.450 1.9 7,7 3.8 15. 5.6 22. 7.4 29. 9.1 38. 11. 43. 12. " 49. 14 . , ,55.
0o 2.1 8.6 4.2 17. 6.2 25. 8.2 33. 10. 40. 12. 48. 14 55". 15 '
'
0.600 2.6 10. 5.1 20. 7.5 30. 9.8 39. 12.- 48., 14:. 57. 16. '66. 18.'-:,74.
0.700 3.0- 12. . 5.9 24. 8.7 35. 11. .4V , 14. '58." 17 87, 19. 77. -22.'. l'8
0800 3.4 14. . 6.7 27. 10.0 40. 13.. ,..2 16. 64. 19." r6 22 . 57 25 9-.4.
:g
1.000 4.3, 17. 8.4 34.,' 12.. 50. 16. 65.., 20:. 80. 24., " 95. 27, 109. 31. ,
1.200 5.1 21. 10. 40. 15. 60. 20. 7. 24. 97 29 14 31 37

18-20
 Surface Texture 18.2
TABLE 18.2-8 THEORETICAL Values for Arithmetic-Average Roughness (R,) and Maximum Peak-to-Valley Rough-
ness Height (Rt) for Milling-Tool Type A

ZERO NOSE RADIUS SCEA=60 0

FEED 10 20 30 40 50 60 7 8
PER ECEA ECEA ECEA ECEA ECEA ECEA ECEA ECEA
TOOTH ll 1I3 R II, It R, R. R, R. R , R, R,
in microinches

(1001 42 17 82 33 12. 48 16 62 19. 76. 22 89 25 101 28 113.

0002 85 34 16 66 24 96 31. 125 38 152 44 178 51. 203 57 226.
((0(3 13 51 25 99 36 144 47 187 57 228 67. 267 76 304. 85 339.

(100.1 17 68 33 132. 48, 192 62 249 76 304 89. 356 101 405 113 452
0005 21 85 41 165 60 240 78 312 95 380 111. 445 127 506 141 565
00016 25 102 49 198 72 288 94 374. 114 456 133 534 152 608 170 678

( 007 30 119 58 231, 84 336 109 437. 133. 532 156. 622 177 709 198 791
0008 34 136 66 263. 96. 384 125 499 152. 608 178. 711 203 810 226 904
0009 38. 152. 74 296. 108. 432. 140 561 171 684 200 800 228 911. 254 1017

(010 42. 169 82. 329 120 480 156 624. 190 760 222. 889 253 1013. 283 1130
0012 51 203 99 395 144 577 181 748 228 912. 267. 1067 304 1215. 339 1356.
0014 59. 237 115 461 168 673 218 873 266 1064 311 1245. 354. 1418 396 1582.

0016 68. 271. 132 527 192 769 249 998 304 1216. 356. 1423 405 1620. 452. 1808.
0018 76 305. 148 593. 216. 865 281 1123. 342. 1368 400 1601 456 1823 509 2034
0020 85. 339. 165 659. 240. 961 312 1247 380. 1520 445. 1778. 506 2025 565 2261.

0025 106. 424. 206 823 300 1201 390 1559. 475 1899 556 2223 633 2531 706 2826
0030 127 508. 247. 988 360 1441 468 1871. 570 2279 667 2668. 759 3038 848 3391
0035 148 593. 288. 1153 420 1682 546 2183 665. 2659 778 3112. 886 3544 989 3956

0040 169 678. 329. 1317. 480. 1922. 624 2495 760 3039. 889. 3557. 1013 4050. 1130 4521
0.045 191. 762. 370. 1482. 541 2162. 702 2807 855 3419. 1000. 4001. 1139 4556. 1272 5086
0.050 212. 847. 412. 1646. 601. 2402 780 3119. 950. 379S. 1111 4446. 1266 5063. 1413. 5651

mm micrometers
0.020 0.08 0.34 0.16 0.66 0.24 0.96 0.31 1.2 0.38 1.5 0.44 1.8 0.51 2.0 0.57 2.3
0.040 0.17 0.68 0.33 1.3. 0.48 1.9 0.62 2.5 0.76 3.0 0.89 3.6 1.0 4.1 1.1 4,5
0.060 0.25 1.0 0,49 2.0 0.72 2.9 0.9A 3.7 1.1 4.6 1.3 5.3 1.5 6.1 1.7 6.8
0,080 0.34 11.4 0.66 2.6 '0.96 3.8 1.2 5.0 1.5 6.1 1.8 7.1 2.0 8.1 2.3 9.0
0.100 0.42 1.7 0.82 3. 1.2 4.8 1.6 6.2 1.9 7.6 2.2 8.9 2.5 10. 2.8 11.
0.120 0.51, 2.0 0.99 4.0 1.4 5.8 1.9 7.5 2.3 9.1 2.7. 11. 3.0 12. 3.4 14.
0.140 0.59 2.4 1.2 4.6 1.7 67 2.2 8.7 2.7 11. 3.1 12. 3.5 .14. 4.0 16.
0.160 0.68,, 27 1.3 5.3 1.9 7.7 2.5 10.0, 3.0 12. 3.6 14. 4.1 16. 4.5 18.
0.180 0.76 3.0 1.5, 5.9 2.2 8.6 2.8 11. 3.4 14. 4.0 16. 4.6 18. 5.1 20.

0.200 0,85 3.4 1.6 6.6 2.4 9.6 3.1 12. 3.8 15. 4.4. 18. 5.1 20. 5.7 23.
0.250 1.1 4.2 2,1 -8.2 3.0 12. 3.9 . 16. 4.7 19. 5.6 22. "6.3 25. 7.1 28.
0.300 1.3 5.1 2.5 0.9 , 3.6 14. 4.7 19. 5.7 23. 6.7 . 27. 7.6 30. 8.5 34.

0.350. 15 6.9 2.9 12.', . 4.2 17. 5.. 22. 6.6 27. 7.3 31. 89 35. 9.9 40..
0.400 ,.1.7. 68 3.3 13. 4h' 6.2 , 25. 7.6 30. 8.9 36. 10. 41. 11. 45.
0.450 1.9 76 . 7 1 5.4 !22. -7.0 . .28. 8.5 34. -10. 40. 11. 46. 13. 51.
0.500 .1. 8.5 4' 16., 81 24.,-11 '.8
:31,. .5 38. 1,,.44. 13. 51.- 14. 57.
.937. '1,... 5
I
0600 2.51,0i 49 ;2 -',7.2 29.' 9.4 ' 37. :11. 46. 13. 53 15. .'61. 17.: 68.
0.700 3.1 12, 58
&a ; 34. 11. 44. .,1& 53. 16. 62. 1. 71.,, 20. 79.
0.800 34 , 14.: 6.6 2& '9.6,38. 12. 50. 15. 61., 18. 71.,. 20. 81, 23. 90.
1.000 17
42 iio . I ,4
'4 16. 62.' 19. 76. 22. 89.' 25. 101. 28.- 113.-
1.200 5.1 209 l). 14. 58. 19. 75.' 23., 91. 27. 107... 30. 122. 34. '136.,

18-21
18.2 Surface Texture
TABLE 18.2-9 THEORETICAL Values for Arithmetic-Average Roughness (R,) and Maximum Pcak-to-Valley
Roughness Height (Rt) for Turning or Milling-Tool Type B

FEED/REV.
ITurning! DIAMETER
Or
[Millig)
FFEW/TOOTH 0.25 in 0.375 In 1,0.50 In j0.625 In 10.75 in 1.0 in j1.25 in 1.5 in
__ mm 10 mm 12mm j 16mm [ 20 mm 25mm 32mmin 40 mm
~R,
R fl 1, ~ R, JR. 18, 18,,fR: R 1, R.- R, I8 RI 18 1,
i In microinches

0 00 i 031 10 0 16 061 0 12 0 1 0 '0 040 1008 033 1008 025 J005 020 005 0 17
i)Ju. 10 40 U075 27 S;, 2J 040 6 1 032 13 02 10 0 20 080 OIC0 067
0003 23 90 16 66 12 4 090J 36 0,90 301 060 23 0 4: 18 040 1

0N:4 1 16 27 11 2 o '7 64 15 '3 10 0 0s0 32 2 70 27

005S 64 25 43 !7 32 13 26 10 2?2 93 17 63 1 15 50 1
0 006 92 36 162 24146 1P 37 14 37 1 23A 90 1 72 15 601

()0i1"i3 49 84 33 63 25 5J '10 4 1X 3? 2 26 98 25 82
660LI 16 64 11 43 82 32 6 55S 21 42 16 35 13 30 11
0009 1 8 1 4~ 41 83 32 70 27 S52 2IN 4? 16 37 14

0010c 26 100 17 67 13 t~o 10 40 86 33 E64 25 52 210 4. 17.

0012 37 144 25 96 18 72 15 58 12 48 93 36 7.4 29 63 24.
00141 50 196 34 131 25 98 20 78 17 65 13 49 10 39 8.5 33

0 01 66 256 44 171 33 13 26 102 22 85 16 64 13 51. 11 43.

0 01?, 83 324 55 216 4? 16? 33 130 28 108. 21 81 17 65. 14 54
0020 103 401 68 267 51 2-10 41 160 34 133. 16 100 21 80 17 67

0 025 161 627 107 417 80 313_ 64 250 53 208 40. 156 32 125 27. 104.
0030 232 903 154 601 116 456- 1 92 360 77 300 58 225 46 180. 39. 150.
0 035 316 1241 210 81d 157- E13 126 490 105 409 79 306 63 245 52. 204

0043 413 1613 274 1070 206 K0 164 641 137 534 103 400 82 320 68 267
0045 523 2042 347 1355 260 15 2G8 811 173 676 130 507 104 405 87. 338.
00U50 647 2526 429 1674 321 1253 257 1002 214 834 160 625 128 5W0. 107. 417.

0060 935 3653 619 2416 463 18&07 370 1443. 308 1202. 231 901 185 720 154 600
0070 1278 500 844 3296 631 2462 5-04 1966 420 1637 315 1227 252 981 210 817.
008,0 1677 6573 1105 4316 825 3221 659 2571 549 2139, 411 1603 329. 1281 274 1067.

0090 21h~ 8381 1402 5480 1046 408,3 835 3257 695. 2710. 520 2029. 416. 1622 347. 1351.
0 100 2654 10436 1736 6790 1293 5051 11032 4026, 1858 3348 1643 2506 1514 2003, 1428, 1669.

mm
orno~~~~~0.1
0.610om u~ M u ts s 00
0.04 . _O01. 0.015 Mtm 'Im0 -44 oilU~?4
0.060 00

0.100 on0 .021 0ON '025 II-1111,

0.120 012J 0&45 01M 0.3,'w W04 l 0

0.140 0.6 0.61 I13~ OM 1~~

0i* 01
0.160 0.21 01 0.16,.t W 26
0.180 '021 1.0. ~ .0*~ C2>
A~O , ~;i 0.20D

02M,~ OM 2.0 '1A0 IAJ ~

.16iIV -.

28~11~2~ 117i
0100sD 5. JA %o1
18.. 1~ 1.

i~IT- 1 471 1 1.3~

54

Best5Avilbl CoptyO
 Surface Texture 18.2
TABLE 18.2-10 THEORETICAL Values for Arithmetic-Average Roughness (R,,) and Maximum Peak-to-Valley Rough-
ness Height (Rt) for Turning or Milling-Tool Type C

TOOL NOSE RADIUS = 0.016 In [0.20 mm]

FIE V Iurngf 30 50 1 60 100 150 30 1 40 1 450

Or ECEA ECEA_ _.ECEA, ECEA ECEA ECEA ECEA ECEA
IMilingi1'y
f1[EO.TOOIH l'1 jI,
microinches

(10 1 2 1 s0 2 80 2 1 80 21 80 ,1 80 2 1 80 21 ,( 1 80
002 2 1) 2 2Q 82 3 8? 32 82 32 82 32 82 32 82 32
0 003 1 63 19 , 19 ,2 13 '2 19 72 19 72 19 72 V)

00,14 ,7 9! 32 21 33 33 129 33 129 33 129 33 129 33 129

I) ''i 134 41 174 30 18, 52 202 52 202 52 202 52 202 52 202
U0 4/ 12 2 ,8 251 :3 290 75 2'91 75 291 ,.5 201 75 91

1 .' 87 .,.U i0I 366 102 398 102 398 102 398 102 3M18
t S01'8 3, 1i, V,2 1017 390 i: 488 133 522 133 522 133 5211 133 5,T
i '93 1ii 41) '2.7 4613 15) '94 169 1,9 169 663 169 663 169 663

o ji '10UH I3 !11 460 14," 38 191 I05 209 804 210 823 210 823 210 823
0 012 112 ..
4
i 1t,6 1 I 19 692 255 937 295 1114 305 1200 305 1200 305 1200
3,Y14 3 ,0 : 2 748 231 831 322 1179 388 1444 421 1659 421 1659 421 1659

)16 133 39)94 239 H," dO 1014 391) 1430 485 1i92 557 2206 557 2207 557 2207
0118 181 ('63 ."16 10.1 319 1180 4601 1689 585 2154 716 2817 718 2858 718 2858
[)0
010 204 173 :114 11;1 33 1349 531 I'53 688 2528 891 3470 904 3627 904 3627

(0 S2 !fX1t 409 1')37 477 1181 114 263? 955 3508 1389 5271 1492 5937 1509 613T
U.
10 1 3 ' 1 911 592 )214 4033 3347 1233 4540 1945 7286 2224 8678 2314 9277

mm micrometers

0DZ, 0.06 025 0.06 0.25 0Z.0 0.25' 0.06 ,02' 0.06 0.25 0.06. 0.25 0.06 0.25 0.06 0.25
0"040 0.23 0356 0.26 ON' 0.26 10 0.26 1,0V 1026 1.0 '026-- 1.0 0.25 1.0 0,26 1.0
o. .. 0.43 1.6 0.54:' 2.0 17 2.1 0.58 13 0.58 '2.3 0.58 , 2.3 0.58 2.3 0.58 2.3
tp
* _0.63 23 0.6 31 0.1 34 10 10 , 4.0 1.0 4.0 1.0 40
.1.106 0,85: 3.1 1.2 4.4 1. 4.6 16.
14 D S .4 164 8,4
11. 1i 65.4 1.6 6.4
391 2.4 9.' 2.4 9.2 2.4 9.2
0'140 1.3 41 19 6J."' 2-1""'
i t g- 10.7 3.2 It 3,2 '13 3.2 13. 3.2 13.
00 5.6 2.2 , 83 2i 1.4 3.5 - 1'" 4..2 17. 4.2 17, 4.2 1.
1 26 . i 4.1 . &D 19.' 54 2 5.4. 21,. 54-. 21.

4 :.4: ~..0'
3 is.! 4J3i8 6.6 .fiY!A
'7 .11 27.
6.8 6.8 27.;
j25 9.6" 'l9'iA 4 17 66 -24. I31;
8.5%' '1"'4. 44. 11. .44.
"41 ... 5A" . 4..V'4j' d .66. 16 66, '17. 67.
'44.304.-37 ~'"'22 ~ 8. . 4 S~ -21. 71 23. 92. 24. 96.

18-23
18.2 Surface Texture
TABLE 16.2-11 THEORETICAL Values for Arithmetic-Average Roughness (R.) and Maximum Peak-to-Valley Rough-
! '. M.
ness Hc h! I%,) ,r , n
,.... ..

TOOL NOSE RADIUS = 0.031 In [0.40 mm]

FEED EvMIlurnl
Or
3
ECEA
50
ECEA
60
ECEA
100
ECEA
150
ECEA ECEA
30 [ 400
ECEA
450
ECEA
FEED,
T0O11IMInoI I__i__ R R, _ R, Ro R, _R _ _, R, Ho

in microinches
001 10 4.0 1.0 40 1.0 4.0 10 40 10 40 1.0 40 1.0 4,0 10 40
() 00 41 16 41 16 4.1 15 41 16 41 16. 4.1 16. 4.1 16. 1.1 16
(1003 03 36 93 36 93 36 93 36 93 36 93 36 93 36 9.3 36

0 004 16 63 16 64 16 64 16 64. 16 64. 16 64. 16 64. 16. 64.

0005 2t 93. 26 100 26. 100 26 100 26. 100 26. 100 26, 100. 26. 100.
0 006 3.1 125. 37, 144. 37. 145 37 145. 37. 145 37 145 37. 145. 37. 145

0001 43 15C, 50 191. 50. 196 51 197 51. 197 51. 197. 51. 197. 51. 197.
0008 53. 194 64 242 66 253. 66 257. 66. 257 66 257 66. 257. 66 257
0009 63 230 79 294 82. 312 84 326 84 326. 84. 326 84. 326. 84. 326

0010 73 268 94 349. 100. 373 103 403. 103 403. 103 403 103 403. 103. 403.
0012 94 344 126. 462 136. 503. 149 579 149 582. 149. 582 149. 582. 149 582
0014 115. 423 159. 581 174. 639 202 771. 204. 795 204. 795 204. 795 204. 795.

0 016 136 503 192 704 213 7_1. 259. 975. 267. 1043. 267. 1043 267. 1043 267 1043.
0)018 158 585 226 830 253 927 319. 1189 329. 1318 339 1326 339. 1326. 339 1326.
0020 180. 669 2Cl 959. 294 1076. 381. 1410. 417 1609 420. 1646, 420 1646. 420 1646.

0025 236 881. 350. 1291. 398. 1463 543. 1992. 636 2389. 665. 2613. 665. 2613. 665. 2613
003 293 1099 441 1634. 506 1865 711. 2607 873 3232 972. 3842 972 3842 972. 3842.
0035 351 1321. 534. 1985 615 2277 885. 3247 1120. 4124 1348. 5320. 1350 5370 1350 5370.

0040 409 1545. 628. 2343. 726 2b98 1063. 3906 1377. 5055. 1783. 6940 1808. 7253 1808. 7253.
0045 468. 1772 723. 2706 839 3127. 1244. 4583. 1640. 6020. 2263. 8684, 2355. 9456 2360. 9581.
0050 527. 2001. 819. 3074 953. 3562. 1429. 5274 1910. 7015. 2778. 10542, 2983. 11874. 3018. 12273.

0060 646. 2465 1013 3821 1185 4447 1805 6693 2466. 9080. 3889. 14572, 4447. 17356. 4629. 18554.

mm micrometers
0.020 0.0, 0.13 0.03 0.13 0.03 0.13 0.03 0.13 0.03 0,13 0.03 0.13 0.0 0.13 0.03. 0.13
0,040 0.13 0.50 0.13 0.50 0.13 0.50 0.13,_- 0.50 0.13 0.50 0.A3 .. 0.50 "0.13 0.50 ''1.13 0.50
0.060 0.28 1.1 0.29 1.1 0.29 1.1 0.29 '1.i :'0.29, 1.1 :0.29."1: '.1': '1 29
"0.29 :' 11'

0.080 0.46 1.7 0.51 2.0 "0.51 2.0 0.5' .2.0 '0.51 512.0
5011 " '0.5 2.0.
0.100 0.65 2.4 0.79 3.0 0.80 3.1 .80... 3.1 .0.6,, 31 ' 0, ,' 3.1 o ' "0.80-
0.120 0.85 3.1 1.1 4.0 1.1 4.3 1.2 -- 1.. -12.-,,
4.5 . 1,2 A4..5 1.2 .5 . l'

0.140 1.1 3.9 1.4 5.1 1.5 5.5' .1.6 , 6.2 '1.6 .52 16." &2- " .6J. 23 1
0.160 1.3 4.6 1.7 6.3 1.9 6.9 2.1. 8.0 2.1 '8 .1 ' .. 1-. 2. . " 8A' 2.18.1
1
0.180 1.5 5.4 2.0 7.5 2.2 8.2 2.6 9.9 2.6 10. 2.6 0. 2.6 10. 2.6 10.
0.200 1.7 6.2 2.4 8.7 2.6 9.6 3.2 12.. 3.2 13. 3.2:,, 3. " . ' ,13. 3.2:' 13.
0.25C 2.2 8.3 3.2 12. 3.6 13. 4.7 17. 5.1 20. 5. 20. 5 20.'.' &.1. 20.
0300 2.8 10. 4.1 15. 4.7 17. 6.3 23. 7.2 27 ,.4 29A'-,
." 7 14 29.
0.35..4..5.0 19. 5.7 21. 7915-
0.400 3.9 15. 5.9 22. .8 25." 9.6 :3& 12. .44 14. .. 54. 14, " , 14- ,4
0.450 4.5 17. 6.9 26. 7.9 29. 11. .4. 1.. 5 7 ~6.2
69 (74
0.500 5.1 19. 7.8 29. 9.0 34.. 13. ii
17;. 6:2' 22. 85_ 2M 8S- 2,-
0.600 8.3 24. 9.7 36. 11. 22... 82 31.' :120. 3 r
.. .... ffi13...,*
0700 7.5 28. 1 4.4. 14. 51. 21. 78. 2.. 102
215 42e. 46 _4"l.,

18-24
 Surface Texture 18.2
TABLE 18.2-12 THEORETICAL Values for Arithmetic-Average Roughness (Ra) and Maximum Peak-to-Valley Rough-
ness Height (Rt) for Turning or Milling-Tool Type C

TOOL NOSE RADIUS =0.047 In (0.60 mm]

I11I ';A fE LFiA Et3EA 17 F(,F

mrcrorrrches

0001 069 27 069 27 069 27 069 2.3 069 27 069 27 069 27 069 27
0002 27 11 27 11 27 11 27 11 27 11. 27 11 27 11 11 27 11
0003 62 24 62 24 62 24 62 24 62 24 62 24 62 24 62 24.

0004 11 43 11 43 11 43 11 43 11 43 11. 43 11 43 11 43
0005 17 67 17 67 17 67 17 67 17 67. 17 67 17 67 17 67
0006 25 94 25 96 215 96. 25 96 25 96 25 96 25 96 25 96

0007 33 124. 34 131 34 131 34 131 34 131 34 131 34 131 34 131

0008 42 155 44. 171 44 171 44 171 44 171, 44 171 44 17(1 44 171.
0009 51 188 56 216 56 217 56 217 56 217 56 217 56 217 56 2,17

0010 60 222 68 26 3 69 268 69 268 69 268. 69 268 69 268 69 268.

0012 80 291 96 362 99 37-9 99 38( 99 38b 99 386 99 386 99 336
0014 99 364 126 468 132 4958 135 526 135. 526 135 526 135 526 135 526
0016 120 439 157 579 167 1514 176 689 176 689 17-6 68. 16 68 16 69

0018 141 516 189 694 204 754 1224 869. 2214 874 224 874. 224 874 224 874
0020 162 594 222 812 242 590 275 1059 277 1081 277 1081 277 1981 277 1081

0 025 215 796 305 1119 339 1243 418 1568 135 169)9 435 1700 435 1700 435 1700
0030 270 1003 392 ,439 441 1614 572 2115 626 2413 630 2469. 630 2469 630 2469
0035 326 1215 480 1768 545 1999 732 2691 840 3182 864 3395 864 3395 864 3395

0 N0 382 1430 570 2i26 651 2393 898 3291 1070 3996 1140 4489 1140 4489 1140. 4469
0045 439 1649 662 2451 758 2797 1067 3911 1309 4848 1459 5764, 1459 5764 1459 5764
0050 497 1870. 754 2801 867 3208 1240 4546 1555 5733. 1824 7214 1824 7237 1824 7237.

0060 613 2318 942 3514 1 90 4&47 1594 5860 2065 7583 2674 10410 2712 10880 2712. 10880
00,10 731 2773 1132 4242 1316 4907 1958 7218 2594 9523 3647 13937 3834 15357 3852 15670
0080 850 3233 1325 4982. 1545 '7&W 2330 8613 3140 11540 4707 17759 5163 20406 5270 21344

0090 969 3697 1520 5732 1777 6.671 2708 10040 3699 13621 5834 21858 6671 26034 6943 27831

0.020 .0Z 0.06 0.02 -ONS v.02' -,am 7 :O.an -on cm8 *a,
0 0.04.2 6~ 0.02 ~0.08
00000. 0.10111 t@.337_LiIMh 11140.._13 0.33 040S amJ 0.3
tU 0.0.033
0.060 Oil. '0.75A 0.19 '0375 31. 1Sm 0.19,0" on 0.19 on7 0.1 @75 6.3M.5 19 07
PJ408 0_ '13T .3 13 O - .3, ON 43034, 1.3
0.100 0Sz'.1.t -0.5 am'.L 0.4 1.3 -US .L3 6.61t
0.61 OM7 .19t 3ti)7 D' I.7
0.120 - 0609 2 6! 0.37 -'jr W7 117 34' 0.7'.7 3 7 3.0
-q
0.160 .&, 1. 13.1 14. 1k-~ 1.1, 4., 4
0.10 '..' -,4.0 ,3i< 4_2 1.4 14' 4.4 t4 .1. SIA ., 1A ,~5A, I ' 5.4
0.18 7 1.3 1A ivi L4 1- 41 1.7> G65 1' 'U <1.71- 61
0200M~ 5. S; 1ay, 22 2~ '$M
A OSA_~ 12 $A 22 &
2-0,, 7. 21 Wl, IV 4l ,t 3A ',4.
-. 4 3A4.. 13.
0.3WSS 4.3 -4.9 4.9

4.48-5.
 18.2 $urface Texture
TABLE 18.2-13 THEORETICAL Values for Arithmetic-Average Roughness (Ra) and Maximum Peak-to-Valley Rough-
ness Height (R1) for Turning or Milling-Tool Type C

TOOL NOSE RADIUS = 0.063 in [0.80 mm]

FEE2IO[V
rurnij 1 30 50*1 i ~ I io 0 0 5

Imling
FE/OrT _CE ECEA I CE ECEA IECEA ECEA I ECEA jEE
IEEDIfill
Mifing H, P, k H R, K, , H H 0 H, H, H

microinches

[
p

01 51 201 051 20 [ '21 20 0 51 2 0l 051 20 051 201 051 20 051 20

8 211 8011 50 21 0 21 80 21 8021 8 21 0
403
I 4 o i 6 i3 6 13 46 83 46 18 46 18 46 18
82 --2 82 "2I 2 32 82 32 82 32 82 32 82 32
1
13 5. 0 ' 0 1 0 13 50 13 50 13 50 13 s0
Or!1 ~ 7 0 7 1 3 72 18 72 12 !28 721 18 72

j8> 3O 24 9 i>' 96 25 98 25 98 98
9825 98
IA 120 I 2 50'
1 33 128 33 128 33 128 33 128 33 128
4
41 1; 0 2 16? 4? 1652 42 1Q2 42 162 42 162 42 162
5. ~0~ ~
0 ~191 -f 1K 20 200
01 51 202 1 0
A12I 0j 7 287 74 09 74 283 74 289 74 289 74 289 74 289
4 t:7 3' Y
130 382 11 391, 101 393 101 39j3 101 3393 101 393 101 393

) " !:j' 33 16 28 .8,3 10j1 5,r,4 132 514 132 514 132 514 132 514 132 514
16 126 461 158 588 CA- E23 17 651 167 651 167 651 16-1 651 167 651
00 146 531 188 69 7 199 746. 6 805 206 805 206 WS5 206 805 206 805

193 "2 a 93
9b8 191 107,2 023 1251 323 1263 323 1263 323 1263 323 1263
zK
"1 92" I 05" 1-263 a 87 1418 459 174.2 467 1827 467 1827 467 1827 467 1821,
Y0
305 i31 3 1 596 4M6 17 '996 2266 639 2492 639 25(9 639 2500 639 2500

',4 360u 133i52 1917 St87 2151 "t i 28 17 833 3213 839 3286 839 326,6 839 3286
4
1 i'54? b10 2246 691 2534 921 j390 1045 397/6 1058 4190 10D68 4190 1068 4190
O 5 47 17F,2 730 2581 796 292"5 I1,35 3'82 1270 4774 132? 5218 1327 5218 1327 5218

1f
066 2193 8 62 3214t6 111 3727' 142? 5210 1743 6458 1941 7671 1941 7671 11941 7671,
3070 M0 2641 1067 3958 1230 4552 1769 5489 2239 8240 2692 1D622 2696 10719 2696 10719
AO4, 817 3090J 1255 4E684 1452 5314 2125 7308 2751 1010? 3560 13860 3609 14477 3609 14477

0090 935 3544 1445 5410 1678 6251 2487 9161 3278 12032 4519 17345 4 700 18876 4710 19119
0 100 1053 4002 11637 6146 1906 7121 12856 10543 13818 14021 15549 21056 15954. 23705 6C23 24495

mm ,nm~~;.

*:6fiS f.66
#ls 0.02- ,',0.0
0000 0.U038 MZ4 -S 4 1 'o
0,00 oz -10 02i s< 02 .
0.w0 0.30 1.5,0A t&- I0'M ;'. 1.6' 0*.- : 1

Otir, IJ 'C58 2.3

0.12 "S
1 0,79 p .1.
3

0.1600.93.
.& '4
0.140<
62i
.0116-2.
0.74 2 t 3.
Best0
Av4.ilbl
. X-Copy"A. 1. 5,
 I

Surface Texture 18.2

TABLE 18.2-14 THEORETICAL Values for Arithmetic-Average Roughness (R,) and Maximum Peak-to-Valley Rough-

ness Height (Rt) for Turning or Milling-Tool Type C

TOOL NOSE RADIUS = 0.125 in [1.2 mm]

F11 REVITurnogl 30 50 60 100 150 300 400 450

Or . EA ECEA ECE
FEED [Milling
TOOTH4 -
ECEA ECEA ECE
_ _ 1 44 4
ECEEA
j"_ 4414,
C
-II, 4,-- 14' 4
in microinche5

0001 G :4i26 I 0 6 10 '26 10 026 10 026 10 02; 6 06 1

0002 , 40 10 4b 10 40 U .0 10 40 10 40 10 444 10 ,4)
0 003 9,0 Jft '3 4 ') 23 90 23 Qi1 23 (10 3 0444

u004 4 I , 4' 16 41 It, 41 16 41 16 41 16 4 1 1 41 14;

00005 6.1 ' , ' , 4 .5 4 25 6 4 2> 64 25l 64 ?5 ;. 1 2
0'00 f, 2 ' , ' , 6 '42 34 9i 3( 9 "2 J 6t . ' 3

0)Y)/ 3 4 ,' 13 , 4I
49 1.A 44 I] 49 13 49 13 49 13 49
0 M96 6 .,4 1o 44 F 64 T6 64 16 64 16 64 16 (i. 16 6.
00j) 21 81 21 8 21 81 21 81 21 81 21 81 24 81

1)010 .'. 1(14) r, . *. l t.. '4 100 26 100 26 1042 26 100 26 100
0 012 ," 144 4 144 .,' 144 37 144 37 144 37 144 37 14 37 14.1
0014 ' ;141; F' 196 50 1io 50 196 50 196 50 196 50 196 50 196.
0016 W) 252 tk 256 66 256 66 256 66 256 66 256 6) 256 66 256
{>4018 341
W; d3 324 83 324 8 3324 83 324 83 324 83 324 83 32.
0020 99 3};? 1423 401 103 431 103 401 103 401 103 401 103 401 103 401

0025 145 534 160 621 161 627 161 627 161 627 161 627 161 627 161 627
U 430 192 l)b 228 864 231 895 232 903 232 903 232 903 232 903 232 903
0035 242 885 301 1122 311 1185 316 1231 316 1231 316 1231 316 1231 316 1231
0040 2,' 1070 377 1394 398 1492 413 1610 413 1610 413 1610 411 1610 413 1610
0)045 'I4 1259 45 1675 488 1812 523 2040 52:3 2042 523 2042 523 2042 5213 20.1)
041St) 3' 1453 36 1965 581 2144 645 2501 641 2526 647 2526 64! 2526 61/ 2526

0 060 502 1850 /01 2567 7;3 2835 912 3484 935 3653 935 3653 935 3653 935 3653
0070 610 '258 871 3191 971 3557 1213 4533 1277 4984 1278 5(WO 12/8 5000 1218 5000
0080 720 2673 1044 3834 1174 4.303 1523 5635 1667 6426 1677 6573 1677 6573 1677 6513

0090 831 3096 1221 4491 1381 5068 1843 6781 2091 7951 2135 8381 2135 8381 2135 8381.
0 100 944 3525 1399 5161 1592 5850 2170 7963 2539 9547 2654 10436 2654 10436 2654 10136

mm micrometem
0.2 1 0.01 04 0.01 0.04 0.01 0.04 0.01, 0.04 0.01 0.04 0.01 0.04 0.01 0.04 0,01 0.04
0.o40 0.04 0.17 0.4 0.17 0.04 0.17 0.04' 0.17 0.04 0.17 0.04.i 0.17 004 0.17 .0,04 0.17
01060 0.1 0.36 0.10 *. 0.10 o36 0. 0.36 0.10 o.1 0.10 0.6 0.10"" 0.38 0.10 0.38
0.0w, 0.17 0.8 0.17 0.6 W.17 0. 017 0.67 0.17' 0.87 0.17 . 0.67, 0.17 .0.67 0.17. 0.67
0.A00. , .271027 1 7 1.0 02 1. 0271, .2,. 1A.0 0.27 '10
'Or 027 '1.0 0.27 '.
0.120o- . 0 .5 o0.'
IO Is 0.31 1. 036 1.5 o5 1.5., 3A,1017
03111,0U0
1.5 .39 0.87,
.9: 3A
1.5
0.140, 0.52, 2.0:, 0.52 2.0 0.52 2.0 0.52 ' .2 2.0 0152 2.0 052 2.0 0.52' 2.0
0.10, 0.66 2. 061' 2.7 21:'.6 0M ' " 2.7 0.66 2.71 0.6 2.7 0.661 2.7.
0.180 0.85 3.' 0.8 34 7 ' 3A 037 ' .
0 0)'
87 3 1 0.67 :3.4' 0.67 . 3I4
0. 1.0 3.6 11 2 .; 1.1
4 14.2 1.1
12 42~ 11 14 ll 4
02 . . . 64- 17 6 2' 11' 4.2- 1.1 '4. 1,1 6,521.
2 7Y% :2A U"' 23- 9.3 ':.A . 9.429k
'.42.4 24:9. 9A'

4 04806~
, 1. '& 4.7. 17-. 5~ '19. 5.4 '21 5.5,"1 -21,. ':.
:i <5,5,>.1 55. 1

0. " 4.00 Is 7.
5 32. .73 -21. .5 4:r68 k 17 .7,-6 '71 36."
k
0" 7.1z' 2.L T3. '29. '4 7i?~5/ .7 2

%1

Best Available Copy ,

1 l 27 --
 '._ . vr'p' e rex.,re
TABLE 18.2-15 rHEORETICAL Values for Arithmetic-Average Roughness (RO) and Maximum Peak-to-Valley Rough-
for Turning or Milling-Tool Type C
ness Height (Fit;

TOOL NOSE RADIUS = 0,188 In [1.6 mm]

o
q IlllV
irlg3 0 s 610 0 15 . 30 0 40 0 45 0
ECEA ECEA ECEA ECEA ECEA ECEA ECEA ECEA
-
, ,,
t
M ,,, ' ... :
4,O' 44
, 4., 44....44-t
44, - 4,,. ... ...4 ,, 44 - -4--
-4- . .-i......_
,.

microinches

'f ('' 04 006 067 00b 067 044b 0467 03 067 006 067 00f 0 (7
00
41l
' r
/ ' HI 02
1 2 012 :7 414,2 2/ 062 21 162 217 042 2/

003 hi 1') 010 14') 1 P, I 4,4 I 1

640 If, 44i4 4 4344

4 ., 11 :1i 21 11 21 11, 27 41 21 1 2/ 11
, I0, ' / 11 ,t 17 43 1 43 1. .13 1/ 4:4 17 43 It
00)444, f4.' 2 4 24 62 2,4 62 2.4 462 24 62 24 62 2,4 62 24.

'04 1 41., 34 1 .1 33: 84 .4 4. :13 44, 3: 8.1 33 444 33 44 33

(4044 ' U'
.1 4:3 11 4:3 11 4 43 43 11t 43 14. 43 11 13
!y; '4 54 141 54 14 54 1.4 5. 14 54 141 51 14 54

1''4014
0 )
4),' (it I4 6I
G U. I // 07 11 6/ II Of./ 61
'4440
1 ') ' '11 96 241 44 25 446 25 96 25 341 25 91 25, 96
( 14 .34 '3 1 34 131 34 131 34 131. 34, 131 34 131 34 131 34, 131.

(116 , '/' 44 171 ,44 171 44 111 4,4 171 4,4 171 44 171 44 1/1
0448 4, '4 '1 , 216 55 21 55 216 55. 216. 55 216 55 21 55 216.
''4410 'I f;' fil. 2b/ 68 267. 68 267. 68 267. 68 267 68 2b7 66 267.
H41?' it, lo, 114' 41/ 10/ 417 41 417 107 417 107 417 107 417 107 .1417
1410 1111 'Y,.l . 601 154 601 154 601 154 601 154 604 4414 601 154 601
IO.I4 1 . 4
41 :11 817 210 818 240 BIB 210 818 20 818 210 BIB, 210. 4IB.

.0,10 .4' 13H, )., 1050 214 1069 214 1070 274 1070. 2/4 1070 274 1070 274, 1070
045 '}4' 405 41 1296 347 1343 341 1355. 347 1355. 347. 1355 347. 1355. 347. 1355.
)440
o1 4.l4l 14:3', 11.4 4552 426 1630 429 1674. 429 1674 429 1674 429 1674. 429. 1674.

1060 44)) ,01 5,', 2090 596 2238. 619 2416 619 2416. 619 2416. 619 2416 619. 2416.
(14/0 ',11 444' 7031 2656 778 288? 8.41 3287. 844. 3296 844 3296 844 3296 844 3296.
344)o 41, 217, 46 3244 966 3556 1099 4230. 1105 4316 105 4316 105 4316 1405, 4316

H54444 / 2 1/ 1444'),
0)', :380 444) 4253 13/1 52243 1402 5480. 1402 5480 140?. 5480 1442 5480
40100 'i 3181 1 44/2
12,? 1357 4970 1669 6265, 1736 0786 1/36 6790. 1736 6790. 1/36 6790

mm micrometers
0.020 001 003 0.01 0.030.01 0.03 0.01 0.03 0.01 0.03 0.01 0.03 0.01 0.03 0.1 0.03
0,040 0.03 0.13 0.03 0.130.03 0.13 0.03 0.13 0.03 0.13 0.03 0.13 0.03 0.13 0.W 0.13
0.060 0.07 0,28 0.07 0.280,07 0,28 0.07 0,28 0.07 0.28 0.07 0.28' 0,07 0.26 0.07 0.28
0.060 0.13 0.50 0.13 0.500.13 0.50 0.13 0.50 0.13 0.50 0.13 0.50 0.13 0.50 0.13 0.50
0.100 0.20 0.78 0.20 0.780.20 0.78 0.20 0.78 0.20 0.78 0.20 0.78 0.20 0,78 0.20 0.78
0,12C 0.29 1.1 0.29 1.1 0.2
"3 1.1 0.2 1,1 029 1.1. 0.29 1.1 0.29 1, 0.29 ,1.1
0,"0 0.39 1.5 0.39 1.5 0.39 1.5. 039 ,1i 0.39 1.5 0.39 15 ,0.39, .5 0.39 ..1.5
0,160 0.51 2,0 01 2.0 01 2.0: 0.51 2.0 0.51 2.0 01 2.0 011 2.0. 0.51 2.0'
0.180 0.05 2.5 0.65 2.5' A5 2.5' 0.85 .23 0.5 2.5' 0.05" 2.5 0.65, '2." 0.85 2.5'
0.200 0.80 3.1 0.80 3.1 0.80 3.1- 0.80 3.1 0.80 3.1. 0.80 3.1 0.80 3.1 0.80 3.1
3
0,250 12 4.8 1.3 4.9 1.3 4.9' 13 49 11 49 1.3'. 4.9 '1.3. 4,.9 13 4.0
0.300 1.7 6.2 1.8 7.0 18 7.0 1.8 70 1.8 7.0 1.8 "":7.0 1. .7.0 1.8 70
0.350 2.1 7.9 2.4 o.4 2.5 9.6 2. 9. 2.5 9.6 2.5 9.6 2.5 9. 2. 9.6
0.400 2.6 9.6 3.1 12. 3.2 12.. 3.2 13. 3.2 13. 3.2 13 3.2 ' 13.- 3.2 ,. 13.
0.450 ..1 11. 3.9 14, '15;4.0 '4.1 16.' 4.1' 16. 4.1 1:' -4.1 i,1.' 4.1 _:16.
'.

0.500
0.600 3.6
4.5 13.
17. 4.6 1' 4. :18.
6.2 '23.,2.: .67 '2.';.. 73,
20..
5.0., -'.2
7.3 ,2" 0
5.0, 20.
7.3 28.9
5.0
o ,..28, .,' U
7.3 7.3
, , 20. % 5.0
''
228,'; 3 .'202.,
77.3 1'-
Y.'
0,700 5.7 21. 7.8 ,29.- 8. 32.. 9.8 384, 99 9.9.30,- 9-0.9,9 -3.
080.8 25. 9.5 ' 6 : 11. '39."" .' 13, 8 13. 51, 13. 51 13 "' 81 ! 13.'1' '514
1.000 8.9 33. 13. 48. ,, 53. 19, i9. 20.. 79. . ,80. 20., .'*' 20.
1.200 42. 16. : . 19. 89 25
'21.
. 92.1, 29. 109 30. 117. L30. 117.- ." :, 117.

1.50 . 55. 22. 81. 26. 92. 1.

'.' 43 159. 47. 187,' 47.:, 18 77'. 187,
339., : 31w:' 88 361'
36.
47," 1.'34." 94 .. _ 20.
68, 87.
1, M.
2.000
2500
20.
287
77.
100.
31.
41,
116.
153.
"
71 , 282. 347,. 130. 516. 45":. . .146., 93

18-28
 - Surface Texture 18.2
TABLE 18.2-16 THEORETICAL Values for Arithmetic -Average Roughness (R,,) and Maximum Peak-to-Valley
Roughness Height (RI) lor Turning or Milling-Tool Typo c

TOOL NOSE RADIUS = 0.250 In [2.4 mm] ____

rr.[O/HEV. 11urnftg)
or
30S
ECEA ECEA __
6
ECEA __
J 100
ECEAi,
300
.. iECEA ,,__ hECEA
15 1
(E EA
400 J 450
CE
FI ________1 I ___ ___ ji _ _ _ _ I, ii, iI,, if
01 mlcrolnches
000 1 0,13 0.50 0,13 0.50 013 0,50 0.13 0,50 0.13 0.L0 0A1 0,50 0.13 050 0.13 0i.50
00011 0.51 20 051 20 051 2.0 051 2.0 0.51 2.0 0.51 20 0.51 M. 0.51 2,0
0003 12 45 12 45 1.2 4.5 1.2 4.5 1.2 4,5 112 4.5 t? 4.5 1.2 4.5
0,004 2.A 80 ?.1 110 2.1 8.0 2.1 8.0 2.1 80 2.A 8.0 2.1 8.0 2,1 11.0
000 32 13 3.2 13. 3.2 13. 3.2 13. 32 13 3.2 13. 32 13. 3.? 13
0 00N 4.63 III 406 18 4.63 18. 4.613 8, 4.0 1$, 4.8 18. '113 18 4.6 in.
0)001 633 25 13:i , 6'1.3 25 133 25, 1.3 25. 0.3 25. 13 25. 13.3 25.
0081 II 32. 82 311 8.2 32 8.2 32. 8.2 32, 82 32. 8.2 32. 8.2 32.
00019 10 41. 10. 41, 10 41. 10. 41. 10. 41, 10. 41. 10 41. I0. 41,
0010 111 so, 13 50 13 50. 13. 50. 13. 50. 13. 50. 13. 50. 13. 50.
0 012 18. 7?. 18 72. 18 72. 18. 72. 18. 72. 18. 72. 18. 72, 18. 72.
0014 25 98, 25 98. 25 981. 25. 08. 25. 08. 25. 98. 25, 98. 25. 9)3.
010 it 33 128 33, 128 33r 128 33, 128. 33. 128. 33. 128. 33. 128. 33. 128.
1)1)18 42. 1032 42. 162 42 1132 42. 18?. 42, 1032. 42. 162 42. 1132. 42. 1132.
011110) 51. M11. 51 200. 5I. 200. 51 200. 51I 200
5. 200.
51, . 200.
5 01
0025 80. 113. 80 313. 80 313. 80. 313. 80. 31. 80. 313. 80. 313. 80. 313.
01331 115. 4463, 116G 450. 1113 450. 116. 450. 110. 450. 116, 450. 1113. 450. 1113. 450.
0OX)' (55 59). 15/. 013. 1 013 W,7 1313 157. 11. 151. 613. 157. 013. 157. 013.
0040 198 744. 12013 801. 206. 801 206 801. 2013. 801. 206. 801.r 2013. 801. 2013. 80).
004." N43 903 260 1014 20. 10 15 20 0. 15,S 200 1015. 20,130. OI 20, 0 15,I 2130. 1015.
(000 289 10138. 321. 1242 321. 125:4, 321 1253 321. 1253. 321. 1253 32t 1253. 321. 1253.
0001)O 385. 1411. 455. 1728. 462. 1790. 403. 1807. 403, 1807. 403. 1807, 403 1807. 463. 1807,
00/0 483 1169. 001, 2245 622. 2370 031. 2402. 031. 2462. 631. 2402. 631. 2462. 631. 2402.
01.030 584. 2130. 754. 2187 79(5r2984. 825. 3221 825. 3221. 825. 3221. 825. 3221. 825. 3221.
0.000 081. 2519. 911, 3350. 97/6 3624. 1046 4081. 1040. 4083. 1040. 4083. 1040. 4083. 1040, 4083.
0)100 /91, 2900. 1072, 3931. 116?. 4288. 1201. 5002. 1293. 5051. 1203. 5051, 1293, 5051. 11203. 5051.
mm micrometers
0.020 0.01 0,02 0.01 0.02 0.01 0.02 0.01 0.02 0.01 0.02 . 0.01 0.02 0.01 0.02 0.01 . 0,02
0,0.40 0.02 0,08 0.02 0.08 0.02. 0.08 0.02 0.06 .0.02 0.08 0.02 'O006 0.02, 0.08 0.02 0,08
0,060 0obb 0.10 0,05 0.19 0.05 Up19 0,0o. 0.19 - 0.05 0.19 0,051 "0.19 0.5 0.19. 0.05 0.19
0.080 0.09 OW~ 0.09 0.33 0.090 .3 0.0
CAP 0.33 0.9X 0.33 0.09 '0.33 0.9 0.33 0.09' 0,33
0.100 0,13 0.52 0.13 0.52 0.13 0.52 '0.13 ' 0.52 0.13 0.52 0.13 0.52 06 0.13,3 052
0.120 0.19 0.75 .0.19 0.15 0.19 0.75 0,19 0.75 0,119. 0.75 0.19 0.75 0.194 0.75 0.19 0,75
0,140 0.26 1.0 0.26 1.0 0.26 1.0 0.26 1.0 0,2 1.0, 02 0.20.2
At 1.0 .26 , 11.0
0.160 0.34 1.3 0.34 1.3 0.34 1.3 0.34 ~1.3 .0,34 1.3 0,34,, ".13 ,~0.3 1.3 0.34. 1.3

0.180 0A3 1.7 0A3 1.1' 0A3, '1.7 0OA3 .,O A3 .7' 0,43~1,7, 0.43' 1.7',' A3 . 1,7
0.200 0.53 .2.1 0.53 '2.1 0.53 ' 2.1' 0.53 $2.1, OM3 ~ 2.1 0.53... 2.1 0.53. 2.1 0.53., 2.1.
0.250 , 0.84 3.3 0.84 3. O.84'. 3.3 3 ,4 3 4 '.4 3.3 '084 3.3, 0.84- 3.3
0.30 240 1.2.7
1 47 12 :4 '.7' ' 47*., :1.2 '47 12 47 ' 4.7'
2
0.3501.5 61 1.6 6.4 .~.GA. t.0 , J.GA f \ 64 .116 'i64 1.6 6A4 1.K .
0.400 . 2.0 7.6 .2.1 2 8.3 12.1, 11; 241' , 3 ~ 3 . '21' 8. 2.1 8.3 2.1 8.3
0.450 2.5 .3 2.7 1, 2.7. ill z7? 1, . 7 . 217 11, 2.% 'r,11. 2.7, . 1.
0.500 .0 I11.'. 3.3 13. 3.3 ,13.., 33i." N13.', 3. '13, 3.3 13, 313t 13. 3.3.: j','At"
0.600 3.9 14. 4.7 18, ,, '4.8 19, 48~.3 , 19., .8 1 8 19 48 - 9
0.700 4.9' 18, 8.24. 23. GA. .24:1 G'.0 I 20, 6. 26. 6.6 ' 26. '6 M 6' - 26.

2.000 1.
21.200 W
25.
2i.
.
3?i;
93. 1
t,~
436
44;I
1
1
,k ':13* 53.
,'
13,
5*
531
5jj'26. 5,
283 63 59120.31 89' 35

18-29
18.2 -Surface Texture
TABLE 18.2-17 THEORETICAL Values for Arithmetic-Average Roughness (Ra) and Maximum Peak-to-Valley
Roughness Height (R) for Turning or Milling-Tool Type C

TOOL NOSE RADIUS = 3.0 mm

FErD
FV. ITurning 38 50 60 100 150 300 400 450
Or ECEA ECEA ECEA ECEA ECEA ECEA ECEA ECEA
FEEDT00TH fl R,
RMilling, R . R. R, R R, R R, R, H, R. R,

mm micrometers

0.020 0.01 0.02 0.01 0.02 0.01 0.02 0.01 0.02 0.01 0.02 .0.01 0.02 0.01 0.02 0.01 0.02
0.040 0.02 0.07 0.02 0.07 0.02 0.07 0.02 0.07 0.02 0.07 0.02 0.07 0.02 0.07 0.02 0.07
0060 0.04 0.15 0.04 0.15 0.04 0.15 0.04 0.15 0.04 0.15 0.04 0.15 0.04 0.15 0.04 0.15

0.080 0.07 027 0.07 027 0.07 027 0.07 0.27 0.07 027 0.07 0.27 0.07 0.27 0.07 0.27
0.100 0.11 0.42 0.11 0.42 0.11 0.42 0.11 042 0.11 0.42 0.11 0.42 0.11 0.42 0.11 0.42
0.120 0.15 0.60 0.15 0.60 0.15 0.60 0.15 0.60 0.15 0.60 0.15 0.60 0.15 0.60 0.15 0.60

0.140 0.21 0.82 0.21 0.82 021 0.2 0.21 0.82 0.21 0.82 0.21 0.82 0.21 0.82 0.21 0.82
0.160 0.27 1.1 027 1.1 027 1.1 027 1.1 027 1.1 0.27 1.1 . 0.27 1.1 0.27 .1.1
0.180 0.35 1.4 0.35 1.4 0.35 1.4 0.35 1.4 0.35 1.4 0.35 1.4 0.35 1.4 0.35 1.4

0.200 0.43 1.7 0.43 1.7 0.43 1.7 0.43 1.7 0.43 1.7 0.43 1.7 0.43 1.7 0.43 1.7
0.250 0.67 2.6 0.67 2.6 0.67 2.6 0.67 . 2.6 0.67 2.6 0.67 2.6 0.67 2.6 0.67 2.6
0.300 0.96 3.8 0.96 3.8 0.6 3.5 0. a3.8 0.96 3.8 0.96 3.8 0.96 3.8 0.96 3.8

0350 1.3 5.1 1.3 5.1 1.3 5.1 1.3 5.1 1.3 5.1 1.3 51 1.3 5.1 1.3 5.1
0.400 1.7 6.5 1.7 6.7 1.7 6.7 1.7 6.7 1.7 6.7 1.7 6.7 1.7 6.7 1.7 6.7
0.450 ?.1 8.0 2.2 6.4 2.2 8.4 2.2 .4 2.2 8.4 2.2 8A 2.2 8.4 2.2 8.4

0.500 2.6 9.6 27 10. 2.7 10. 2.7 10. 2.7 10. 2.7 10. 2.7 10. 2.7 10.
0.600 3.5 13. 3.9 15. 33 .15. 3.9 15. 3.9 15. 3.9 15. 3.9 15. 3.9 15.
0700 4.4 16. 5.2 20. 5.2 20. 5.3 20. 5.3 20. 5-3 20, 53" 20. 5.3 20.
"
0.800 5.4 20. 6.6 25. 6.1 26. 6.9 27. 6.9 27. 6.9 27. 6.9 27. 6.9 27.
1.000 7.4 27. 9.7 36. 10. 36. 11. 42. 11. *42. 11. 42. 11. 42. 11. 42..
1.200 9.5 35. 13. 47. 14. 51. 15. go. 16. 61. 16. 61. 16. 61. 16. 61.

1.500 13. 47. 18. 65. 20. 72. 24. 90. 24. 95. 24. 95. 24. 95. 24. 95.
2.000 18. 68. 26. 97. 30. 109. 39. 144. 43. 136. 44. i72. 44. 172. 44. 172.
2.500 24. 69. 35. 131, 40.. 148. 55. 20. 66. 246., 69,.., 273. . _69.: . 273.. 69.,. 273.

18-30
 = Surface Texture 18.2
TABLE 18.2-18 THEORETICAL Values for Arithmetic-Average Roughness (Ra) and Maximum Peak-to-Valley
Roughness Height (Rt) for Turning or Milling-Tool Type C

TOOL NOSE RADIUS = 5.0 mm

I ~ FEED.
REV.
fTurningj 3 50
-
0 5 0 0 5
Or ECEA ECEA I~ 10 I 10 0E4 5

ECEA ECEA ECEA EC EA EC ECEA

FEED
mm
FEAA
TOOTH . -- t" K.,
micrometers
j 1.
HIhngI H R;L ., H,

0.020 0,01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01
00.40 0.01 0.04 0.01 0.04 0.01 0.04 0.01 0.04 0.01 0.04 0.01 0.04 0.01 0.04 0.01 0.04
0.060 0.02 0.09 0.02 0.9 0.02 O.9 0.02 0.09 0.02 0.09 0.02 0.09 0.02 0.09 (.02 0.09
0,080 004 0.16 0.04 0.16 0.04 0.16 0.04 0.16 0.04 0.16 0.04 0.16 0.04 0.16 0.01 0.16
0.100 0.06 0.25 0.06 0.25 0.CS 0.25 0.06 0.25 0.06 0.25 0.06 025 0.06 0.25 0.06 0.25
0.120 0.09 0.36 0.09 0.36 0.09 0.36 0.09 036 0.09 0.36 0.09 036 0.09 0.36 0.09 0.36
0.140 0.13 0.49 0.13 0.49 0.13 0.49 0.13 0.49 0.13 0.49 0.13 0.49 0.13 0.49 0.13 0.49
0.160 0.16 0.64 0.16 0.64 0.16 0.64 0.16 0.64 0.16 0.64 0.16 0.64 0.16 0.64 0.15 0.64
0.180 0.21 0.81 0.21 0.8 021 0.81 0.21 0.81 0.21 0.81 0.21 0.81 0.21 0.81 0.21 0.81
0.200 0.26 1.0 0.26 1.0 026 1.0 026 1.0 026 1.0 0.26 1.0 0.26 1.0 0.26 1.0
0.250 1.40 1.6 0.40 1.6 0.40 1.6 0.40 1.6 0.40 1.6 0.40 1.6 0.40 1.6 0.40 1.6
0300 0.58 2.3 0.58 2.3 056 2.3 0.58 2.3 0.58 23 0.58 2.3 0.58 2.3 0.58 2.3
0350 0.79 3.1 0.79 3.1 0.79 3.1 0.79 3.1 0.79 3.1 0.79 3.1 0.79. 3.1 0.79 3.1
0.400 10 4.0 1.0 40 1.0 4.0 1.0 4.0 1.0 4.0 1.0 4.0 1.0 4.0 1.0 4.0
0.450 1.3 5.1 1.3 5.1 13 5.1 1.3 5.1 1.3 5.1 1.3 5.1 1.3 5.1 1.3 5.1
0.500 1.6 6.3 1.6 6.3 16 63 1.6 6.3 1.6 63 1.6 6.3 1.6 6.3 1.6 6.3
0.600 2.3 8.9 2.3 9.0 2.3 9.0 2.3 9.0 2.3 9.0 -.
3 9.0 2.3 9.0 21 9.0
0700 3.1 12. 3.1 12. 3.1 12. 3.1 12. 3.1 12. 3.1 12. 3.1 12. 3.1 i2.
0.800 4.0 15. 4.1 1& 4.1 16. 4.1 16. 4.1 16. 4.1 16 4.1 16. 4.1 16.
1.000 5.8 21, 6.4 25. 6.4 25. 6.4 25. 6.4 25. 6.4 25. 6.4 25. 6.4 25.
1,200 7.7 28. 9.1 35. 92 36 9.3 36. 9.3 36. 9.3 36. 9.3 36. 9.3 36.
1.500 11. 39. 14. 50. 14. 53. 14. 57. 14. 57.. 14. 57. 14. 57. 14. 57.
2.000 16. 58. 21. 79. 23 86. 26. 100. 26. 101. 26. 101. 26. 101. 26. 101.
2.50 21. 78. 30. 109 33. 121 40. 150. 41. 159. 41. 159. 41. 159. 41. 119.

18-31
18.2 Sutf ace Texture
TABLE 18.2-19 THEORETICAL Values for Arithmetic-Average Roughness (Ra) and Maximum Peak-to-Valley
Roughness Height (R) for Turning or Milling-Tool Type C

TOOL NOSE RADIUS = 10.0 mm

FEED/RFV.
[TurningJ 30 50 1 6- 100 150 300 400 450
Or ECEA ECEA ECEA ECEA ECEA ECEA ECEA ECEA
FEED/TOOTH
(Millingi -R . H. R, R-
0 R,, k, R, R, , 0, ] Ro R, R ,

mm micrometers
0.020 0.00 0.01 0.00 0.01 0.00 001 0.00 0.01 0.00 0.01 0.00 0.01 0.00 0.01 0.00 0.01
0.040 0.01 0.02 0.01 0.02 0.01 0.02 0.01 0.02 0.01 . 0.02 0.01 0.02 0.01 0.02 0.01 0.02
0.060 0.02 0.05 0.02 0.05 0.02 0.05 0.02 0.05 0.02 0.05 0.02 0.05 0.02 0.05 0.02 0.05

0.080 0.03 0.08 0.03 0.08 0.03 0.08 0.03 0.08 0.03 0.08 0.03 0.08 0.03 0.08 0.03 0.08
0.100 0.03 0.13 0.03 0.13 0.03 0.13 0.03 0.13 0.03 0.13 0.03 0.13 0.03 0.13 0.03 0.13
0.120 0.05 0.18 0.05 0.18 0.05 0.18 0.05 0.18 0.05 0.18 0.05 0.18 0.05 0.18 0.05 0.18

0.140 0.07 0.25 0.07 0.25 0.07 025 0.07 025 0.07 0.25 0.07 0.25 0.07 0.25 0.07 0.25
0.160 0.08 0.32 0.08 0.32 0.06 0.32 0.06 0.32 0.08 0.32 0.08 0.32 0.08 0.32 0.08 "0.32
0.180 0.11 0.41 0.11 0.41 0.11 0.41 0.11 0.41 0.11 0.41 0.11 0.41 011 0.41 0.11 0.41

0.200 0.13 0.50 0.13 0.50 0.13 0.50 0.13 0.50 0.13 0.50 0.13 0.50 0.13 0.50 0.13 0.50
0.250 0.20 0.78 0.20 0.78 0.20 0.78 0.20 0.78 0.20 0.78 0.20 0.78 0.20 0.78 i 0.20 0.78
0.300 0.29 1.1 0.29 1.1 0.29 1.1 0.29 1.1 0.29 1.1 0.29 1.1 0.29 1.1 0.29 1.1

0.350 0.39 15 .0.39 1.5 0.39 1.5 0.39 1.5 0.39 1.5 0.39 1.5 0.39 1.5 0.39 1.5
0.400 0.51 2.0 0.51 2.0 0.51 2.0 0.51 2.0 0.51 2.0 0.51 2.0 0.51 2.0 0.51 2.0
0.450 0.65 2.5 0.65 2.5 0.65 2.5 0.65 2.5 0.65 2.5 0.65 2.5 0.65 . 2.5 . 0.65 2.5

0.500 0.80 3.1 0.80 3.1 0.80 3.1 0.80 3.1 0.80 3.1 0.80 3.1 0.80 3.1 0.80 3.1
0.600 1.2 4.5 1.2 4.5 1.2 4.5 1.2 4.5 12 4.5 1.2 4.5 12 4.5 1.2 4.5-
0.700 1.6 6.1 1.6 6.1 1.6 6.1 1.6 6.1 1.6 6.J 1.6 6.1 1.6 6.1 1.6 6.1

0.800 2.1 8.0 2.1 8.0 2.1 8.0 2.1 8.0 2.1 8.0 2.1 8.0 2.1 8.0 2.1 8.0
1.000 3.2 13. 3.2 13. 3.2 13. 3.2 13. 3.2 13. 3.2 13. 3.2 13. 3.2 13.
1.200 4.6 18. 4.6 18. 4.6 18. 4.6 18. 4.8 18. 4.6 18. 4.6 18. 4.6 18.

1.500 7.1 27. 7.2 28. 7.2 28. 7.2 28. 7.2 28. 7.2 28. 7.2 28. 7.2 '28.
2.000 12. 43. 13. 50. 13. 50. 13. 50. 13. 50. 13. 50.. 13. 50. 13. 50.
2.500 16. 60. 20. 74. 20. 77. 20. 78. 20. 78. 20. 78. 20. 78. 1'20. 78.

18-32
 Surface Texture 18.2
1000 --7- 7-1000 125pum)

508020m

600

40

10
000

404

328(833

- -a. -
18z2 Surface Texture

1000
1000 (125 pm

400--

Tool ype 8250 (6 3 um

125 (3 2 pm]

100

so

Q1 16 10UM

48 3 4__
 Surface Texture 18.2
1000 125 )uml
1000 _____

8000

600 /500 1l25gml

400 -

200/

125 132pm]

100
80

C))

a) 32 1O89mI

Ii)L

*~20
16 104mi

0
CD 10
8 -09M

4 EE

SCEAX-
2 fOO05Mj

0001 0.005 001 005 0.1 12.54mmJ

(0.0254 min)
Feed per revolution or per tooth, in

Figure 18.2-16 Theoretical surface roughness for turning or face milling tools with a radius of 0.0156
inch [0.39 mm] and various ECEA.

18-35

-7 - ~ ~- -
18.2 Surface Texture

1000 [25 Liml

800 i

60
-- 0 500 [125pmm]
400 5

30 ECEA
250 163pm]
200

125 [3 2 Jm]

80
cc 60 i-/6
1 t m
Cr

C,

o
,.
20

16 0 4 Lim)

0
~c 10 I - . T oo l t y p e C

8 8 [029m]

4 F 4 f~ilpmJ
SCEA\*"

2 , 2 1005pm) i

0001 0005 00
0,254 mm) 1254mm)

Feed per revolution or per tooth. in

Figure 18.2-17 Theoretical surface roughness

for turning or face milling tools with a radius
inch [0.79 mm] and various ECEA. of 0.0312

18-36
 Surface Texture 18.2

1000 7- -1000 125 p m ]

450 500 [125pm]

4000
3' ECEA

I I 250 163pumJ

125 132pum]

80,

40

C)a

z 32 108pm]

10

R0pm 16
C.)E

SC)

2 2 10 05pmr]

0001 0.005 00100501[

10 254 mm]0.50 mj
24m
Feed per revolution or per tooth, in

Figure 18.2-18 Theoretical surface roughness for turning

or face milling tools with a radius of 0.0625
inch [1 .59 min] and various ECEA.

18-37
18.2 Surface Texture

Chip

. .Tool

Built-up edge on tool

Built-up edge on workpiece surface

N Workpiece surface
Tt,11"

Figure 18.2-19 Built-up edge retained on workpiece sur'ace as detrimental to good surface texture.
(Photo from A. J. Pekelharng, Annals of the CIRP 23(2): 207)

SFeed "
j Adjustable

! cam pin
Cutting X I blade
bladesb

Wiped surface
Wiperacineg.

Figure 18.2-20 Wiper blada or micro-finish blade for smoothing feed marks from face milling.

I 8-o8
 Surface Integrity 18.3

INTRODUCTION * Reduction in manufacturing scrap or rework

Deffinitions * Improved process control and quality control through in-

derstanding of effects from process control limits
The specification and manufacture of uninpaired or e.-
hanced surfaces requires an understauding of the inter- 0 Better producibility definitioi.
relationship of metallurgy, machinability and mechanical
testing. To satisfy this requirement. an encompassing dis- 9 Strengthened value analysis
cipline known as surface integrity was introduced and has
gained worldwide acceptance Surface integrity is the de- & Better defined manufacturing and/or design leeways
scripoon and control of the many possible alterations pro-
duced in a surface layer during manufacturing, including * Guidance to advanced process design or application
their effects on the material properties and the perform-
ance of the surface in service. Surface integrity is achieved 9 More disciplined process selection
by the seiection and control of manufacturing processes ac-
cording to the evaluation of the process effects on signifi-
cant engineering properties of work materials
Problems Amenable to Surface Integrity Discipline
For highly stressed, critically loaded or specially engi- Before applying surface integrity technology, or.e must first
neered surfaces, surface integrity is an added requirement. decide whether a surface integrity problem actually exists
It is the assessment of the overall engineering quality of a The control of surface integrity generally adds cost to the
surface
tions. It and
joins its ability totolerances
dimensions, perform required service
and surface func-
texture as manufacturing process; therefore, surface integrity should
not be a consideration unles- a problem exists or
may be
an essential specification for highl, engineered components considered as a possibility. Surface .ntegrity must be con-
in order for them to satisfy modern concerns with safety,
prodct
product reliabisityv and liferliaiityandlifecyce
cycle cots.sidered
costs. in the mani-racture of highly stressed components
used in applications involving human safety, high cost. and
',nac loading is recognized as an important factor in predictable component life. If a surface integrity problem
lxists, enarnic then the pertinent surface characteristics and the af-
the design of many engineering structures in all t.,pes of ap- fected engineer ing properties of the material must be mon-
plications. Where dynamic loading " is present- operating ~torel. Some examples of the types of problems for which :
stresses frequently are limited by the fatigue characteristics
of the Stulctural material to be used. Service histories and the application of surface integrity principles can be helpful
failure analyses of dynamically loaded components illus- are Ps folwiows:
trate clearly that fatigue fail-ires often initiate at or just be overheating or burning. g-inding burns on high strength
low the surface of a component. Thus. it may be concluded aohai for burninggerndingbur on gs rg
that fatigue behavior is sensitive to surface conditions. alos freaing gearecylindegu, bear-
Also. in considering stress corrosion resistance, it is recog- i
nized that the surface condition of a component is a pri- c
mary factor in determining susceptibility to attack and pos- or filres
sible subsequent part failure.

While all manufacturing processes may have significant ef- * distortion and loss of dimensional quality, particularly in-
fects on the workpiece material and its properties. he bulk thin components
of cui of
,:, uj.z:t~ydviialedata
,viiable d rrelates
s to conventional
o n anddo
non- residualstreses lowering fatigue endurance strength
traditional materirl removal processes.
residual stresses combined with severe environments
leading w early stress corrosion failures
Benefits from the Application of Surface Integrity
Practices * reduction in fatigue strength from metallurgically altered
The disciplined use of surface integrity rractice3 for the surfaces: fbr example. untempered or overtempered mar-
manufacture of surfaces which are highly stressed and/or tensite. recast or resolidifed areas from thermal
critically loaded can yield significant benefits as follows: processes

" Enhanced component integrity with resultant increase in 0 metallurgicalor mechanical alterationsproduced as a re-
safety and service life and decrease in maintenance costs sult of excessvely high removal rates or process energy

Better understanding of the effects of manufacturing a thin sectiors of co:.ponents operating at high stress
process parameters as they relate to reliability ol levels
components
* applications where life or safety reliabilityconcerns are
" Decreased costs achieved by limiting surface integrity particularly stringent
processing only to highly stressed surfaces and simulta-
neously relaxing costly specification requirements for * holes with high depth-to-diameterratioswhere maintain-
generating the other sarfaces of a conponent !, drill sharpness may be difficult

18-39
18.3 Surface Integrity
* high temperatures and high temperature gradients

* plastic deformation or mechanical strain

* chemical reactions or absorption on nascent machined

surfaces
100 in k * excessive electrical currents

0 excessive energy densities during processing

The subsurface altered material zones can be grouped by

the principal energy modes that produce them. as shown in
table 18.3-1. Table 18.3-2 lists alterations that have been
observed in several classes of materials as a result of vari-
ous machining processes.

TABLE 18.3-1 Altered Material Zones by Principal

Energy Mode

MECHANICAL:
" Plastic deformations (as result of hot or cold working)
" Tears and laps and crevice-like defects (associated with -built-
up edge" produced in machining)
" Hardness alterations
* Cracks (macroscopic and microscopic)
" Residual stress distribution in surface layer
" Processing inclusions introduced
* Plastically deformed debris as a result of grinding
" Voids, pits, burrs or foreign material inclusions in surface
Figure 18.3-1 Failure in grinding of a carburized
BC2 rr n-r 2,n2bse., of...
tep .... su3..ace= froteg
-
e;............. a...METALLURGICAL:
rity from leading edge dullness on plunge gear e Transformation of phases
grinding. Ultraviolet light photograph of fluorescent 9 Grain -'ize and distribution
penetrant indications found during inspection after * Precipitate size and distribution
3
grinding. (G. Bellows ) o Foreign inclusions in material
* Twinning
* Recrystallization
e Untempered martensite (UTM) or overtempered martensite
(OTM)
* Resolutioning or austenite reverson
A practical balance must be found between over-con-
trolling the manufacturing process with its attendant costs CHEMICAL:
and unneeded benefits and under-controlling with its pos- Interranularattack(IGA)
sible decrease in quality, increase in scrapped components. 0 Intergranular corrosion (IGC)
or loss of reliability. Good application of surface integrity a Intergranular oxidation (IGO)
practices can result in cost improvement and quality en- * Preferential dissolution of microconstituents
hancement by insisting on greater surface quality only on * Contamination
surface areas where needed and relaxing specifications for * Embrittlement-by chemical absorption of elements such as
ti-e bulk of the component surfaces. hydrogen, chlorine. etc.
* Pits or selective etch
# Corrosion
ALTERED MATERIAL ZONES (AMZ) * Stress corrosion
Surface integrity is concerned primarily with the host of ef- THERMAL:
fLcts a manufacturing process produces below the visible * Heat-affected zone (HAZ)
surface. The -;ubsurface characteristics occur in various Recast or redeposited materiall
layers or zones. The subsurface altered material zones o Resolidified material
(AMZ) can be as simple as a stress condition different from 9 Splattered partic;es or remelted metal deposited on surfari-
that in the bcdy of the material or as complex as a micro-
structure change interlaced with intergranular attack ELECTRICAL:
(IGA). Chanoes can be caused by chemical. thermal. elec- e Conductivity change
trical. or mcchanical energy and may affect both the phys- e Magnetic change
ical and tht; metallurgical properties of the material. The e Resistive heating or overheating
principal causes of alterations to a surface during material
removal operations are as follows: SOURCE: G. Beflows and 0. N. Ttshier.

18-40
 Surface Integrity 18.3
TABLE 18.3-2 Summary of Possible Surface Alterations Resulting From Various Metal Removal Processes

ICONVENTIONAL METAL REMOVAL METHODS NONTRADITIONAL REMOVAL METHODS

MATERIAL
Milling, Drilling, or Turning
1GldnGrni
__________

Eum j ECM CHM

Steels-____ __

Nonhardenable A, RA, R. F%, A,

1018 .PD.

__________
I PD PCK.
C
R___ I SE.
IGA 1
Srz.
IGA

Hardenable A. R, R. R. l A
4340 PD, PD, MCK' SE. ISE.
D6ac L&T MCK' AC. IGA IGA
MCK' . U7'M.I
uTM. OTM OTIAI

Tool Steel R, A, R, Ft. R.

D2 PD, PD, MCK. I SE. SE.
L&T MCK. RC. IGA jIGA
PACK. UTM. UTM.
UTM. OTM OTM
___________ OTM _ _ _ _ _ _ _

Staialess (n'artensitic) R. R. A. R. RA
410 1PD. PD. MCK. SE. S5E.
L&T PACK. RC.J IGA JIGA
IIUTM.
PCK. UTM,
OTM *OTW
UTM.I

Stainless (austenitic)
302
R.
PD.
RR.
PD PACK.
R.
SE,
1R. SE.
L&T IRC IGA IGA
Precipitation hardeniiq R. . R, A.. IR.
17-4 PH 1D.
I PD, PACK SE. SE,
L &T. OA RC. IGA IGA
___ ___ __OA __ _ OA ___I
Maraging (18% Ni) R. R. A. Ij R R.
20GaeP.PD. AC SE, E
L5~af
PD. RS G G
RS. OA OA
.S

I
_________OA .
Nickel and Cobalt Base Alloyb:
Aene 41 jPD. PD. MCK, SE.SE
HS 31 L & T. MCK RC IGA IIGA
lIJ-1 00 MCI'_____ ______ _____

ritanium Alloy:
Ti-6A1-4V
IPD.
R, R.
PD.
A.
MCI'E
R. . S

Refractory Alloys: I& C CIA ____

TZM R. R...R.A
L .MCK MCI' SE. ISA

Tungsten (pressed and sintered) AR. .G RC.

SOURCE: M.Feld, J. F. Kahles and J, T.Cammeft"

________________II ______I IGA jIGA
K.ey R - Poughness G: surface UTM - Untempered martensite
PD - Plastic deformation and plastically deformed debdvs OTM - Overlenipered mart ensite
L &T- Laps and tears and crevice-lks defects OA - Over aging
MCK - Microcra.zks AS - Resolutien or austunite reversion
SE - Selective etch RC - Rezast. respattered metal, or vapor deposited metal
IGA - Intergranular attack

18-41
18.3 Surface integrity
AMZ DefintijUns Low stmss surface is ore containing a resid-
ual stress less than 20 ksi 1138 MPal or 10
Cracks are narrow ruptures or separations percent of tensile strength. whichever IS
that aiter the continuity of a surface- They greater, at depths below the surface greatr
are usually tight and characerized by sharp than 0.001 inch 10.025 mm. Sometii. _
edges or sharp changes in direction with called a stress-fret surface.
depth-to-width ratio of 4:1 or greater and
discernible with the unaided eye or with Metallurgical transformationsare those " -
lox or less magnification. "
crostructural changes resulting
from exter-
Micrecracks are those cracks requiring nal influences. They include rec*,stz:,iza-
gr rsateth ose10 racksion
foreqirng tion. all, depletion. chemical reactions.
greater than IlOX niagnification for discernl- a"o eatllay-
nent. as sho-vn in figures 18.3-2 and and re.--mdified or redeposited or recast
183-4 ers. Figure 18.3-7 shows an example oi
metallurgical transformation

Craters sire surface depressions with rough

edges. approximately round oi oval and Microcracks-See 'racks.
shallow, usually with a depth-to-width ratio
of 1,.;s than 4:1. This term is frequently ap-
plied to the impressions left by the individ- Pits are sallow depressions resembling a
ual spark discharges in electrical discharge small crater with rounded edges aid !ass
machining (EDM). as shown in figure than 4:1 depth-to-width ratio. Also describes
18.3-3. but is also used to describe massive a specialized form of localized or selective
depressions resulting from short circuit acci- etching or corrosior that results in holes or
dents in EDM or ECM. See also Pits. pockets le't by the mechanical removal of
small particles or inclusions from the sur-
face. Pits also a e the result of dents frcn
Hardness alterations are changes in hard- the impingement of foreign particles against
ness of a surface layer as a result of hea. "he surface. Pits sometimes are associated
mechanical deformation or chemical change from efectrochemical ction into regions
during processing. (Alteraticns of less than slightly removed from the high current den-
=2 points Rockwell C or equivalent from sity regions. See figure 18.3-8. See a':so
the hardness of the bulk of the material are Craters.
not considered significant.) (See also figure
18.3-15.)
Plastic deformation is a microstructural
change as a result of exceeding the yield
Heat-affected zones (HAZ) are those por- point of the material and generally includes
tions of a material not melted. yet subjected
to sffiientthemalenery
to sufficient thermal energy tto proucemi-creased
produce mi- elongation
hardness. grain
of the See figure 18.3-19. and in-
structure
crostructural alterations or microhardness
alterations, as shown in figure 18.3-4.
Recry's:allizatiop is the formation of new.
in te sufacestrain-free gra.;i or crystal structure from
laver of an object and may be either foreign -
that existing in the material prior to process-
e oing. usually as a result of plastic deforma-
or a part of the normal composition of the tion and subsequent heating or from a phase
material, as shown in figure 18.3-4 change occurring during heating. See figare
18.3-10.
Intergranularattack (IGA) is a form of cor-
rosion or attack in which preferential reac-
tions are concentrated at the surface grain Recast materialis a gcneral term applied to
boundaries, usually in the form of sharp surfaces that have at some point in the proc-
notches or discontinuities. as shown in fig- essing become mot,, and then rt-solidified.
ure 18.3-5. These effects are sometimes Frequently includes a conglomerate mixture
supplemented by intergranular oxidation of redeposited or remelted material, as
(IGO) derived from exposure to elevated shown in figure 18.3-11.
temperatures or intergranular corrosion
(IGC)de-ivec from exposure to active chree- Redepositedmaterialis that material, which
ical reagents. .-. in the material removal process. is removed
from the surface in a molten state, and then
Laps, folds or seams are defects in a surface prior to solidification is reattached to the
from continued plastic working of over- surface. This is sometimes called splattered_
lapping surfaces, as shown in figure 18.3-6. metal ail! is also shown in figare 18.3-11.

i8-42
 Surface Integrity 18.3
Rem elted or resolidified n. ,erialis that por--______________________
tion of the surface which during the metal
removal process become molten. but if not
removed from the surface prior to resolidifi- -70001 in

cation. See figure 18.3-11. I-

Resi-Jual st resr-s are those stresses which ,
influences (forces, therimal gradients. or ex-
ternal energy) have been removed. See fig-
ure 18.3-16.
ielective stch is a form of in-process corro-
s-oii or attack in which preferential reac- Figure 18.3-4 Example of heat-affected zone.
tions are concentrated within and through r'iii Laset machining of Inconel Alloy !8 (solution
the grains or conceptrated on certain con- treated and agr=J). i000X. 'ote epitaxial growth of
stituents i-I the bast- material. See figure grains nucleating from base metal grains. Also
18-3-12. shows microcracks and an inclusion (Surface in-
Splattcred mitW-Sce Redeposited mna'erial tegrity Encyclopedia')
and figure 18.3-11.

ON o
0 -

F ;ure 18.3-2 Example )t micror-ack froi. grind- Figure 18.3-5 Example of intel-granular attack,
ing of Lidimet 700C. 250X. (Surface Inte~grity En- ECM of Waspaloy (aged. 40 R-). iOOOX. (W. P. Kos-
cyclopedia') ter et als)

- C

Figure 18.3-3 Example of craters. EDM of ffnc-nel Figure 18.3-4 Example of l3p, fold and tears. Drill-
Alloy 718 (solution treated and aged). SEM at 40 ing of 4340 steel (quenched and tempered. 50 Rc),
and 215X. (Sujrface integrity Encyclopedia') IODOX perpendicular to lay.

18-43
 18.3 Surface Integrity

Figure 18.3-7 Example of metallurgical transfor-

mation. Reformed alpha case crystals of Ti-6AI-4V
during grinding, 1000X. Note also the plastic defor-
mation, Figure 18.3-9 Example of plastic deformation.
Conventional turning of Inconel Alloy 718 (solution
treated and aged) with dull tool, 500X, approx-
imately 0.0036-inch deep. (Surface Integrity Encyclo-
pedial)

0.001
in

0.0002 in
Pit

0.001 0.
in

Figure 18.3-8 Example of pit from grinding of Figure18.3-10 Example of recrystallization. Re-
Rene 80 (solution treated). Top, surface view at crystallized layer from age heat treatment following
40X; bottom, section at 1000X. (Surface Integrity En- grinding of Rene 80, 1000X. (Surface Integrity En-
cyclopedia)) cyclopedia')

18-44

w
-_- -'- - - -_ -- - - -- - - - -- - -- - - =-- - _
 Surface Integrity 18.3
The standarddata set provides more in-depth data for more
IL critical applications. It includes the results from the min-
imum data set along with residual stress (or distortion) pro-
files and high cycle fatigue screening tests. as outlined in
table 18.3-4. Generally. the standard data set has informa-
o- tion at two or more diverse levels of process intensity to
o represent finishing and roughing (or abusive) machining
conditions. Figure 18.3-13 is an example of the standard
data set produced in grinding of 4340 steel, quenched and
tempered to 50 Re.

The extended data set provides data gathered from statist-

ically designed fatigue programs and yields data suitable
for detailed designing. It also includes specialized data
such as stress corrosion life with specific types of environ-
mental exposures. Components of the extended data set
Figure 18.3-11 Example of recast, redeposited are given in table 18.3-5.
and splattered material. EDM of 4340 steel
(quenched and tempered 50 Rc), 1000X. Note un-
derlying untempered martensite in the 0.002 inch-
deep heat-affected zone. (W. P. Koster et al8)

TABLE 18.3-3 Minimum Surface Integrity Data Set

1. Surface texture
* roughness measurement (per ANSI B46.1-1978) or
microtopographic map (figure 18.2-7, section :8.2)
* lay designation or photo
2. Macrostructure (lOX or less)
- macrocracks or surface imperfections (pits, laps. etc.)
* occasionally includes scanning electron microscope
(SEM) series of photos at increasing magnifications
(recommended series 20, 200, 1000, and 2000X)
(figure 18.2-8. section 18.2)
-_ macroetch indications (e.g., fluorescent penetrant or
magnetic flux or similar)
3. Microstructure (cross section examination at 1000X preferred)
* microcracks
* plastic deformation (section parallel to lay suggested)
Figure 18.3-12 Example of selective etching. * phasetransformations
Chemical machining of Inconel Alloy 718C (solution * intergranular attack
treated
ete a and aged, 40 Rc), 1000X. (W. P. Koster * micro defects (laps, inclusions, etc.)
n built-up edge or deposits of debris
et a18) recast layers
* selective etching
* metallurgical transformations
4. Microhardness alterations
* heat-affected zones

SOURCE: G. Bellows and D.N.Tishler.m

EVALUATION TECHNIQUES
TABLE 18.3-4 Standard Surface Integrity Data Set
Experimental procedures have been developed to provide
three increasingly deeper levels of surface integrity eval- 1. Minimum data set
uation. The minimum data set is the least expensive ap- 2. Residual stress profile-or ;.Miurtlon measurements
proach and should be considered only as a screening test 3. Fatigue tests (screening only-recommend using full-reverse
for the analysis of surface effects. It is essentially metal- bending at room temperature using tapered area flat spec-
lographic information supplemented with microhardness imens with results to 10' cycles)
and surface texture measui ements. Table 18.3-3 describes
the components of the minimum data set. SOURCE: G.Bellows and D.N.Tishler.

18-45
18.3 Surface integrity

-0001
odi
E
X.-0.0

0,002- 0.002

LOW STRESS CONDITIONS - No visible surface ABUSIVE CONDITIONS - A total heat affected zone
alterations in microstructure were detected, of 0013 inch was produced The white layer shown
above is 65 RC and appioximately 0.001-0002 inch
deep but in some sections was up toO0 005 inch deep.
MICROHARONESS 10 RESIDUAL STRESS FATIGUE
ar I
70 110 F~e F 1-110-\IF-I-
G 80
- -,_-....-Low stress
-- ~Low
stress I AuivE 12 0

~~~-Abusive
600 i li:l z r : 0
0 j140j~jj 10 0 0
00 000 008 0d
Depth
surfacein
bennl

sutace, TABLE 18.3at5 Suran Itert Dat Se

1. Standard data set

2. Fatigue tests-statistical data to establish design data
3. Stress corrosion tests at selected environmental conditions
4. Additional mechanical testing
e tensile
e stress rupture
*Creep
*specialized: friction, wear, sealing, bearing performance
*fracture toughness
*low cycle fatigue
*elevated or cryogenic temperature
*crack propagation
*surface chemistry
SOURCE: G. Bellows and 0. N.Thler)"

18-46
 Surface Integrity 18.3
Process Intensities and Surface Integrity
Processes are usually operated over a range of intensities.
The roughing and finishing modes are one reflection of
these differing intensities or energy densities. From a sur-
face integrity and quality assurance standpoint, it is neces-
sary to consider the change in surface effects over the full
range of energy levels expected to be used. These data can
then be used to establish reasonable quality control limits.
This range of process intensity 'evels is often implied in the
machining terminology that indicates increasingly intense
processing, such as the following-
" low stress surface
" finish machining (or "gentle")

" conventional (or -standard')

* roughing (or "off standard")

* abusive (or accidental conditions)

Figure 18.3-14 A 1-1/4 inch diameter metal-
The surface integrity of components produced with rough- lographic mount prepared by the vacuum epoxy
ing or off-standard operating conditions is frequently less method. The white layer contains aluminum oxide
than that produced under standard conditions. The stand- pellets. (M.Field, J. F. Kahles, and J. T. Cammettl 2)
ard surface integrity data set evaluations should include at
least two levels of process intensity. It should be empha-
sized that ultimately abusive and gentle processing can be
differentiated only by mechanical testing (fatigue, stress
corrosion, etc.) and/or service performance.

Metallographlc Sectioning and Special Preparation

Techniques
Microscopic examination is an important and inexpensive
means for rapid initial surface integrity evaluation. How-
ever, special metallographic techniques are necessary for
studying surface phenomena. Surface microstructure alter-
ations are generally very shallow, usually of the order of
0.001 to 0.003 inch 10.025 to 0.076 mml.Under very abu- -

sive conditions, alterations as deep as 0.005 to 0.015 inch

10.127 to 0.38 mml have been noted. Often significant mi- Microhardness Determinations
crostructure alterations, microcracks, or flaws as shallow Microhardness determinations can be made on the pre-
as 0.0001 inch 10.0025 mm in depth are developed during viously described metallurgical mounts using a micro-
material removal processing. Thus, it is necessary to em- hardness tester with either a Knoop or a Vickers indenter.
ploy sectioning, mounting and other metallographic tech- Microhardness studies are important for identifying the
niques which do not alter or destroy the pertinent surface possible overall effects of heat-affected zones caused by
and which maintain high edge retention. One successful specific material removal operations. Examples of surface
technique consists of the application of vacuum epoxy effects revealed by microhardness variations include the
mounting as outlined in table 18.3-6 and shown in figure following:
18.3-14. It should be noted that the frequently employed

I
edge retention technique of plating can alter some of the * areas of untempered or overtempered martensite
surface effects that might
be present.
Various types of microscopy are available for the eval-
uation of surface metallurgy including optical microscopy, * cchemical
softening
softeningsotie
(sometimesasnite
associated with chemical
scanning electron microscopy (SEM), and transmission machining or electrochemical machining)
electron microscopy (TEM). Optical microscopy is the
least expensive and the most widely applicable method. It a heat-affected zones
is advisable to examine metallurgical mounts first in the
unetched condition, thereby accentuating the profile, mi- 9 plastic deformation or work hardened zones
crocracks, inclusions, voids, and crevice-like defects. After
etching, specimens are reexamined for microstructural Figure 18.3-15 illustrates some of the types of hardness al-
identification and grain boundary conditions. terations observed.

18-47
18.3 Surface Integrity
TABLE 18.3-6 Mounting Technique and Metallographic Preparation for Edge Retention

1. Samples are sectioned from the workpiece in a manner which leads to the least oossible distortion or burring.
Bandsawing or hacksawing is preferred. A minimum oi 0.030 inch [0.76 mm] is then removed from the cut
surface using a 120-grit silicon carbide paper on a low-speed polisher.
2. Copper molds (or tubes), 1'Ainches [31.8 mm] inside diameter by 2 inches (70 mml high, are placed on a
pallet approximately 5 inches (125 mm] in diameter. The inner surface of the molds and surface of the pallet
are previously sprayed with a silicone releasing agent.
3. Afte, placing a metallurgical specimen in a mold, a mixture of epoxy resin, hardener, and pelletized aluminum
oxide, sufficient to produce a layer of '%to % inch [6.4 to 9.5 mm] in depth, is poured over the specimen. The
ratio of resin to hardener is 4 to 1.The amount of pellets added is in the range of 10 to 15 grams. The hard-
ness or abrasive level of the pelletized material used (low, medium, or high fired) is strictly a function of the
alloy to be prepared and its hardness cheracteristics.
4. The pallet containing the molds is placed in a vacuum chamber (at a vacuum of 1 x 10-1 to 1 x 10-' torr) in
order to degas the mixture. thereby improving the adherence of the epoxy and pellets to the surface of the
specimn. When v;gorous bubbling of the mixture decreases after vacuum impregnation, sufficient resin and
hardener (4to 1 ratio) is added to produce a mount approximately 1inch [25 mm] high.
5. The mounts are cured at a temperatur - not greaier than 70F [21(C] for approximately 10 hours. Casting of
the mounts is accomplished during the latter portion of the laboratory workday so that curing occurs over-

6. After curing, they are placed in an oven at a temperature of 150OF [660C] for a period of one hour after which
they are removed from the molds.
7. Approximately 0.020 inch [0.50 mm] of stock is then removed from the as-mounted metal surface on a posi-
tive positioning automatic polishing unit, using the side of a 1-by-13-inch [25 x 330 mm] aluminum oxide 320-
grit grinding wheel as the grinding medium. Water is used as a coolant.
8. Subsequent rough grinding is performed wet on silicon carbide papers or equivalent ranging from 240 to 600
9. For steels and nickel- and cobalt-base superalloys. the intermediate polish is performed on an automatic pol-
isher using a polishing cloth with a soft nap texture and 6-micrometer diamond paste. The final polish is
achieved using deep nap or pile cloth similar to billiard cloth with a suspension of 0.1 micrometer or finer
aluminum oxide inwater.
Titanium and refractory alloys require an etch-polish cycle (using a slurry of hydrogen peroxide, water, and
0.1 micrometer or finer aluminum oxide) which is accomplished between a diamond polish and a final polish
procedure. The final polish for titanium and refractory alloys is accomplished oo, a vibratory polisher using a
deep pile cloth with a suspension of 0.1 micrometer or finer aluminum oxide in water.
10. Samples are etched by swabbing. Examples of some typical etchants used are given below:
Mate:.nl Etchant
Steels 2%HNO3 and 98% Denatured Anhydrous Alcohol
Nickel Base Alloys 100 ml HCI, 5 g CuCI 2,2H20, and
100 ml Denatured Anhydrous Alcohol
Titanium Alloys 2%HF and 98% H2O or
2%HF. 3% HNO3. and 95% H20
SOURCE: L.R.Gatto and T.D.DLullo.a

50 j " 1
Recast layer

S45
/ material hardneSS'f
SBase mtra
/D
M 40 - -When determining the microhardness using a Knoop in-
[1oftened denter, a 100-gram load is generally employed. W'th this
Softened zone load and carefully performed readings, accurate hardness
readings can be made to within 0.001 inch 10.025 mi of
3,5 ' the surface without producing edge yielding. Surface hard-
0 oo02 0,004 0006 0.008 ( 020 ness readings to within 0.0005 inch 10.0127 mml of th- sur-
Depth beneath surface, in face may be made using 25- to 50-gram loads, but extreme
care must be taken even with these light loads. It is recom-
Figure 18.3-15 Microhardness traverses on mended that if the light load is used, hardness readings also
Inconel Alloy 718 (solution treated and aged) from a be taken at a considerable distance from the edge and com-
variety of machining processes. Key: A, roughing pared with 100- and 500-gram load Knoop readings.
EDM and shot p3ening; B, gentle ECM and glass Knoop readings are generally converted to Rockwell C
bead peen; C, gentle grinding; D,ECM; E,EDM.(G. readings for a ready appreciation of the hardness relation-
Bellows and D. N. Tishler)4) ships which exist near and below the affected surface layer.

18-48

7777
 Surface Integrity 18.3
Residual Stress Determination
The use of X-ray diffraction for measuring residual stress
Distortion may occur in the manufacture of components
as has by and large superseded the deflection test strip
a result of heat treating or material removal processes
which can leave substantial residual stresses in the method. Much smaller areas can be measured with greater
surface accuracy. Accuracy of plus or minus 5 percent can be
layers. There are several ways of determining the
residual obtained.
stress profile. The two most common are X-ra, diffraction
and layer removal-deflection techniques. Most of
the ma-
chining-induced residual stress occurs in the first 0.0005
to
0.010 inch 10.0127 to 0.254 mini below the surface.
Some
of the descriptors used in residual stress discussions
shown in figure 18.3-16. Figures 18.3-17 and 18.3-18are
il-
lustrate results of residual stress profiles determined
from
two materials and are typical of the range of effects
ob-
served. It should be noted that single surface residual
measurements can be quite misleading, stress
and a profile for the 100
first few thousandths of an inch below the surface --
is essen-
tial. The peak value and its depth below the surface
lated to the high cycle fatigue strength are re-
and magnitude of . 80 F
distortion. For example, note in figure 18.3-18 that the sur- ,
face residual stress is zero, yet substantial stress is ")
present Conventional grinding
less than 0.001 inch 10.025 mml below
the surface. -60

401 -

+ Tensile S20 a /'

" 20 Electrochemical
machining ECM

Depth below surface, / I I

,20 -
0 1012
thousandths inch
h and -inch
-20 "-
Gentle
grinding-

-40 ,.
- Compressive

Figure 18.3-16 Residual stress profile descrip-

-60
tors. Key: 1, surface residual stress-value
depth; 2, peak stress (tensile)-value at definedat zero
depth; 3, cross over-depth in thousandths ECM and shot peening
inch; 4, r -80-
peak stress (compressive)-value at defined depth; .2
5, depth of residual stress-depth below the surface
where stress declines to and
20,000 psi or an inconsequentialremains less than
value or less than PL -10-
E
10% of tersHeiI strength. (G. Bellows"3) 0

-120

-140 - - - - -

2 Carefully measured distortion on strip test specimens as

shown in figures 18.3-19 and 18.3-20 can also be used as -160 0 0 0_..
0.002 0.004 0.006 0.008 .
0.010 0.012
an overall residual stress indicator. In these measurements
the initially flat and unstressed blank, figure 18.3-19, has
Depth beneath surface, in
one
The surface
distortionmachined
after theby thecutprocess being investigated.
test is measured in the fixture
shown in figure 18.3-20. The distortion variation with Figure 18.3-17 Residual stress produced
dif- in
Inconel Alloy 718 (solution treated andeaged)
ferent process intensities is illustrated in the grinding by
D6ac as shown in figure 18.3-21. of several machining processes. (G. Bellows and D. N.
Tishler14)

18-49
18.3 Surface Integrity
120 I 0,0001 inch indicator

100' Grinding Conditions

Gentle Convent. Abusive
-
\ Wheel A46HV A46KV A46MV LoaigDmaeflet
Deflctio
Specim~en
8080 l~
l
Wheel speeci.
fpm 2000 6000 6000
pins rmetstop,
/ma
Ik' Down feed.
60 inch/pass ',S'0001 0002 LJ

U) Gri:nding Suit Sol. oil Dry

40 -.\Conventional -35icgaeent-
grind -gh 3. inhgg 1
(0.0157) .-
~1 201
Co /I
IL 4~
I~~0.055911
Abusive grind Figure 18.3-20 Deflection measurement fixture.
(M.Field, J. F.Kahles and J.T.Cammet?)
(0

S-20
cle Electropolish -

grind 1(00030)
r -40 (0.0040)1t -

I Abusive
C-60 I grind + shot peen
E (0.0352)

I
-

-80 -Wheel grade: 32A 46K MVE

Crossfeed: 0.050 inch/pass
-100 1
Nuiesin parentheses indicate
-Table speed: 40 fpm
DetI fct:000i
specimen distortion in3-5-inch gage length, in Specimen size: 0.070 x 3/4 x 4-1/4 in
-120 * 0.035 -Grinding fluid: soluble oil (1:20) -1
0 0.002 0.004 0.006 0.008 0.010 0.012
Depth below surface, in
20.030 - ____ nohps
Figure 18.3-18 Residual surface stress ira 4340 0)/as 0.0
steel (quenched and tempered, 50 Rc) produced by CO dwtedownfeed
Cn
surface grinding. (M. Field, J. F Kahles, and J. T. M
Cammettl 2)0.2

0.1
0
0)0.001 inch/pass M
C downfeed
- Amount of stock 000.010--
- removed in test cut

cT0.005 Low stress

0.060-inch thickness dwfe
after test cut 0
2000 4000 6000
Bot0sde Wheel speed, fpm
Figure 18.3-21 Change in deflection versus wheel
Figure 18.3-19 Distortion and residual stress test speed for surface grinding D6ac steel (quenched
specimen. (M. Field, J. F. Kahles and J. T. Cam- and tempered, 56 Rc). Effect of down feed. (M.
mettl 2) Field. W. P. Koster and J. B. Kohlsts)

18-50
 Surface Integrity 18.3
Fatigue Strength Testing temperatures. For the simple screening tests that are part
It is well established that variations in material removal of the standard data set, however, it is sufficient to collate
operations can produce great differences in the mechanical or compare results from room temperature, full-reverse
performance of the workpiece material. Fatigue strength is cantilever bending high cycle fatigue tests. the setup for
perhaps the most sensitive property. The extensive range which is shown in figure 18.3-23. A test specimen that pro-
of precess influence on high cycle fatigue strength is shown duces repeatable results and exposes an ample test surface
in table 18.3-7 for Ti-5A1-2.5Sn alloy and in table 18.3-8 to the test stress level is shown in figure 18.3-24. The re-
for Inconel Alloy 718. High cycle and low cycle fatigue sults are frequently displayed on an S-N (stress versus num-
strengths are dynamic properties that are surface depend- ber of cycles to failure) curve. figure 18.3-25. or in a bar
ent and are linked on a simple continuum for AF 95 (Rene graph using the stress level at 107 cycles as representative
95) in figure 18.3-22. Similar effects are found at elevated of the endurace strength.

TABLE 18.3-7 Comparative High Cycle Fatigue Strengths and Surface Roughnesses of
TI-SAi-2.SSn Alloy (formerly A110 Alloy) from Several Processes
PROCESS FATIGUE STRENGTH* SURFACE ROUGHNESS
ksi 14n R.

Ultrasonic machining (US[ 1) 98 20

Conventional slab milling (-.4L) 86 6to8 f
Chemical machining plus vacuum - -

anneal (CHM) 77 30 to 40
Shot peened (CPE)l 76 __
As rolled 61
Chemical machining (CHM) 59 30 to 40
Conventional traverse grinding (CGS) 53 16 to 18
Conventional longitudinal grinding (CGS) 52 31 16 to 18
Electrical discharge machining (EDM) 22 30 to 40

SOURCE: Data from R.J. Rooney."

*Room temperature, 10' cycles full-reverse bending.
* P28 steel shot; 0.010 to 0.012 A2 Almen level.

TABLE 18.3-8 Effect of Machining and Peening on Fatigue Strength of

Inconel 718 (Solution Treated and Aged 44 Rj)
OPERATION FATIGUE STRENGTH*
ksi - Percent of
gentle grind

Gentle surface grinding 60 100

Conventional surface grinding 24 40
Gentle turning 60 100
Abusive turning 60 100
Standard ECM 39 65
Off-standard ECM 39 65
Standard ECM plus Peen 78 130
Off-standard ECM plus Peen 67 112
Finish EDM 22 37
Rough EDM 22 37
Finish EDM plus Peen 66 110
Rough EDM plus Peen 75 125
Electropolishing (ELP) 42 70
ELP plus Peen 78 130
LRoom temperature. 10' cycles full-reverse bending.

18-51
18.3 Surface Integrity
300---
2830 - ---

260 - - ~LCF HCF Condition

rn 0 0 EDM &Peen -- -
'220 -3 -D
0
'C

00
ci)I

U160' 0 0 O 0

Cycles
failur t
Fiu1. 2 Eapeo ihccead o yl aiu teghcntnu nts aafo lc
trEa dicag8ahnn0fA 5 Rn 5 t10~.(.Belw n .P otr

:3_

20-5
 Surface Integrity 18.3
Section AA

+LWpeen this area

0246 -25

Note 8 0iin
187e rneiahe

~~~~3 hoAlowsresgrn

2. AbsvArnadrtme

40 050-
.
(40 11

1121
5 0005to495-n)

Noe
diesin ininche untrpre

Figure 18.3-25 S-Niue hpeihncycle faigue test dat rou

to 4340steel (quecedand tem-
pred.5sc. (M. Field, J. F. Kahies and J. T. Cammettl )

A Lowstres grin
1406 a o tesgidadrtme
o Absivegrid
retmpe an
120 Esimate
~~=Lo-t.---r gridq enuac limit-~--~----
-~~~1- s-i--
18.3 Surface Integrity
Surface Roughness and Fatigue Strength the endurance strength of particular material and process
In the testing of several alloys, it has been observed that combinations. Caution must be exercised before drawing
surface roughness is not the critical factor that it has tradi- general conclusions from the limited data available at this
tionally been assumed to be. It appears that the effects of time concerning surface roughness and surface integrity
roughness can be overshadowed by the effects of residual interrelationships.
stresises. the presence of metallurgically changed phases.
plastically deformed surfaces or other effects. As indicated Stress Corrosion Cracking
in figure 18.3-26. the gently ground surfaces on 4340 steel The two surface integrity effects having the most direct
produced the best high cycle fatigue strengths. Notice. bearing on design and application considerations are fa-
however, that inothetheatwor
case wee
fator of abusively ground surfaces big ong and andstress
applcation ccracking
rain propensity.
refa-
other factors were at work wihinthe ang ofsurace
within the range of surface tigue strength
The former lends itself to corrosion
a fairly simple comparison as
roughnesses tried. and all roughnesses developed the same he frer len itelf To atfai mple comparison, as
65 ksi 1448
milling MPal fatigue strength.
of Ti-6AI-6V-2Sn and in theObserve also that
face turning in the
of Inconel has already
simple been noted
evaluation The latter
procedure is more that
has evolved complex
yieldsand no
corm-
Alloy 718. the fatigue strength did not vary with surface parable data. The number of possible combinations of ma-
rougi8ess. terials. processes. metallurgical states. energy levels. serv-
roughess.ice stresses, environmental fluids or gases is beyond
Further studies of the effects of surface roughness on fa- counting. Therefore. each application should be analyzed
tigue strength have been made in which the data represent for its own situation and evaluated by carefully structured
conditions where residual stresses from the machining testing.
process were essentially zero. Figure 18.3-27 shows the
differences among three materials that range from prac- Combined Effects
tically no effect from surface roughness (Inconel Alloy 718) It is rare that the dynamic properties results can be attri-
to a substantial effect (the two titanium alloys). For alloys buted to a single surface integrity effect. such as residual
where surface roughness has little or no effect on fatigue stress. finish, hardness. etc. One of the more pronounced
strength. a considerable potential for cost reduction exists. relationships which has been observed exists between the
peak residual stress value and the fatigue endurance
In analyzing surface roughness. it is not implied that the ef- strength. as demonstrated in figure 18.3-28. The tri-axis
fect of scratches, tool marks. sharp corners and other geo- graph. figure 18.3-29, illustrates the relationships among
metric considerations can be overlooked. The effect of fatigue endurance strength. residual stress and surface
these factors as producers of stress concentrations leading roughness for Inconel Alloy 718. These results are for spe-
to premature fatigue failure is well established. cific materials and process combinations, and other com-
binations may demonstrate different relationships. Caution
In summary. an important point to consider is to test and should be taken not to draw general conclusions from the
evaluate the influence of finish and other factors affecting limited data available.

ISurface roughnessl
pinRa a
4340 (Q& T. 50 R) 8 - _ 117
longitudinal
surface grinding 127 ioc
4340 (0 & T. 50 Rc) 111
transverse 58
surface grinding 128 185 S

4340(o & T. 5ORc) 29 6

tongitudinal 65
surface grinding 97 65

Ti-6-6-2 (STA. 42 Rc) 13 13212

end milling (end cut) 55 82
125 88

Inconel 718 (STA, 44Rc) 25 60 Gentles

enl
turning (facing)
118 60Abusive
Inconel 718 (STA. 44 Rc) 76 6
turning (facing)60 0 2C 40 60 880 10
100 10
120

Endurance limit. ksi

Figure 18.3-26 Summary of high cycle fatigue strengths-surface roughness study. Fatigue strength
in fu.i-reverse bending at 107 cycles at room temperature. (W. P.Ko.tCer et at) 4

1 5

185
 Surface Integrity 18.3
60 1401-
50
130-

- Ii---
40 - -- -. Inconel 718
S ~~120-*
30 .
_______ _ _____ ~,j110 - - - -
u-20Ti-A-2Sn-4Zr-2Moa
0__ to100
1 10 100 10000

Surface roughness - minl Ra 90

Figure 18.3-27 Fatigue strength versus surface E: 80 -

roughness with negligible residual surface stress 7

(full-reverse bending at 107 cycles at room temper- a, -M- .
ature). (G. Bellows and W. P. Koster",)I

60 -- - - ~

Figure 1.28Correlation betweenpekrsd

ual stress and fatigue strength in 4340 steel at vari-

ous levels of grinding intensity. Flat tapered speci-
mens were tested in full-reverse bending. (W. P.
Koster" )

____ urfacFrauigeu inRa it i

__ _ _
lowssiua

_ _
arresd W.P.Kote

_
-10-- 118_ 20
_ _ _ _ _ _
6 -0+00-2
_ _ _io
14
18.3 Surface Integrity

GENERAL GUIDELINES 9 New or indeterminate

ing stress, temperature, environmental
conditions
and atmosphere.
includ-
surface integrity ef-
There is an increasing awareness that
fects can significantly impact product integrity, longevity 9 Requirements for designs which approach more com-
and reliability. Specific data on every material and process plete utilization of material properties.
combination are not available. Reliable data must also con-
sider the several processing intensities that may be used * Manufacturing requirements calling for use of material
and the several metallurgical states that may be presented removal processes, such as rough conventional machin-
for processing. Until more data can be accumulated, re- ing, heavy grinding, EDM and laser beam machining,
liance must l~e placed on sets of guidelines. Detailed data which characteristically cause surface alternations.
supporting the guidelines are contained in the references.
Basically, each level of processing intensity for each manu-
facturing process has a distinct set of surface integrity ef- Guldrlines for Material Removal Processes in
fects when it is applied to a specific metallurgical state of a General
, orkpiece material. While most of the surface integrity investigations to date
have involved material removal processes, this does not
Precautions in Use of Guidelines mean that forming, joining, coating or other processes are
The following guidelines can only serve as general or start- exempt from surface integrity considerations. It only in-
ing recommendations. Data and experience gathered to dicates that insufficient data are available for these
date indicate that these practices lead to the production of processes.
unimpaired or enhanced surfaces. However, knowledge of Some general guidelines tor all material removal processes
the surface technology at this time is such that general rec- are as follows:
ommendations are not always applicable to all specific sur-
face integrity situations. For highly critical or highly 1. Thorough component or product testing is one of the
stressed surfaces, it is mandatory to make specific individ- best assurances for and checks of surface integrity.
ual evaluations. The tests should be run with surfaces produced by the
Surface integrity control generally results in increased complete and exact sequence of production operations.
costs and decreased production rates. Therefore, surface
integrity practices should be implemented only where a def- 2. cal
Apply surfacestressed
or highly integrity requirements
zones only to the
of the component part.criti-
Do
inite need exists. Process parameters which enhance sur-
face integrity should be af lied selectively to critical parts not apply "all over".
or critical areas of given parts to help minimize costs. 3. Highly stressed areas of critical components should be

The guidelines are intended primarily for processes used in evaluated carefully to assess the impact of the full se
quence of processes that generate the "as-shipped"
producing the final or finished surface of a workpiece. It is face. The control of the sequence of processes is as sur-
ir
important to know the depth of surface alterations pro-
duced during the roughing or prior operations so that ade- portant to surface integrity as is the selection and
quate provision can be made for removing any damaged maintenance of the process operating parameters.
layers. In maintaining surface integrity, the sequence of op- 4. Control of the material metallurgical state is as impor-
erations is as important as the specific processing level. tant as control of the process parameters.

Ample recognition .mustbe given to the necessity for relent- 5. Material inhomogeneities or anomalies (sometimes
less process control once the desired surface integrity proc-
essing parameters have been selected. Equal consideration even those within specification limits) caa have com-
for control of the metallurgical state and condition of the ponent integrity effects as serious as the surface integ-
material being presented for processing is essential. rity effects from different process intensities.

6. Designers, shop sup-rvisors, and quality control and

process engineers must be educated and trained in or-
der to increase their appreciation of the magnitude of
Key Indicators of Need for Surface Integrity Control surface integrity effects from manufacturing processes,
" Hazards to life and/or the possibility of high economic
property loss. 7. The surface integrity from processes other than mate-
rial removal or machining processes should also be
* Distortion in thin parts. evaluated.

" Cracking in processing or in service. 8. Thefsurface integrity effects from conventional ma-
chining are of the same magnjtude as those from non-
" Short service life. traditional machining.

* Requirements for manufacturing parts using sensitive al- 9. Metallographic sections at high magnification, taken
loys, such as high strength steels, nickel and cobalt base parallel and perpendicular to the lay pattern, provide
high temperature alloys, titanium alloys, beryllium, and an effective early alert to potential surface integrity
refractory alloys. problems.

18-56
 Surface Integrity 18.3

10. Post-processing treatments, such as heat treatment, ing of holes. Other plants give short courses on how to in-
shot peenling, roller burnishing, low stress grinding, spect for rehardened and overteniPered inartensite in the
etc., may offset some, but not necessarily all. of the manufacture of high strength steel components.
otherwise detrimental surface integrity effects. Specifying Surface Integrity Qnality
11. Hand-controlled operations have a tendency to pro- Overspecification or too extensive use of surface integrity
duce variability in surface effects and should be consid- quality specifications can significantly increase manufac-
ered suspect. turing costs. Component part drawings should call for the
surfa'e integrity controls only on the areas or zones that
12. Low piocess en.ergy intensities and low material re- are highly stressed or critical in preference to notes calling
moval rates are characteristic of most, but not all, ma- out "apply all over". Good value engineering and coordina-
terial removal processes which provide acceptable sur- tion with manufacturing personnel will produce design de-
face integrity, tails with the best component integrity.

13. Rigid, high quality machine tools and fixtures are Manufacturing Engineering
desirable. Carefully integrated machine, operation and inspection
planning will improve the surface integrity results and con-
14. Cutting fluids should be fresh or well controlled and tain the manufacturing costs. Simple metallographic exam-
carefully, completely and quickly removed from the ination of test pieces can provide a preview of the surface
workpiece when the operation is completed. integrity results to be expected during production. These
checks can prevent expensive and time consuming sur-
15. Deburring of all machined edges is desirable. prises during initial production.

16. Parts stored for extended periods should be covered Maintaining Operating Parameters
with a protective coating to prevent corrosion. Particular attention should be given to the necessity for
maintaining specified operating paraineters. Machine oper-
ators should be thoroughly trained to follow the proper
Comparison of Altered Material Zones from procedures outlined by manufacturing engineering. All pa-
Material Removal Processes rameters for material removal should be specified by nianu-
Examination of several thousand section photomicro- facturing engineering. For chip renloval operations, these
graphs of surfaces generated by a wide variety of material include tool material, tool geometry, cutting speed, feed,
removal processes has provided data for table 18.3-9, a cutting fluid, and tool life (maximum nurber of parts per
summary of the depth of surface integrity effects. These tool grind). Similarly, appropriate parameters must be set
data sh'w the maximum depth of alterations observed to up for operations such as grinding, ]2DM and ECM. Ma-
date for two particular operating levels of each listed proc- chinists should be informed as to the reason and necessity
ess. The two process intensity levels displayed represent (a) for maintaining good surface integrity and surface quality
finishing, "gentle" or low stress conditions or (b) roughing, and should be made aware that it is not currently possible
"off-standard" or "abusive" conditions. The former repre- to guarantee maintenance of surface integrity by final part
sent what might be expected from well controlled, good inspection. Management needs to be ever alert to the de-
surface integrity operations, while the latter represents sire on the part of operators to try 'just one more notch" on
high intensity or even accidental conditions, such as a de- the control. Without requalification, this relaxation of
layed application of coolants. The data cover the full range standards may result in loss of surface integrity.
of material types.
Quality Audits
Since no instrument can measure the surface integrity pro-
Implementing Surface Integrity Programs duced, reliance is frequently placed on process control.
The following cteps are. -,commended for instituting an in- Good quality control practice includes randomly spaced,
house surface integrity program: periodic audits of the operating conditions actually being
used as compared to the preplanned values. Some Corn-
Education and Training panies use the manufacturing engineer most knowl-
Manufacturing and product engineering personnel are gen- edgeable in a process to conduct the audit.
erally not sufficiently acquainted with the many types of
surface alterations which can be produced during material Guidelines and Specifications
removal operations. Product or design engineers generally The guideline concept has been used by some organizations
do not realize that high temperatures prevail in conven- to assist in the implementation of surface integrity process-
tional machining at the workpiece-tool interface, while ing. Booklets can be designed to fit the specific needs of a
manufacturing people often do not realize the extent to company, division, or department. Guidelines are partic-
which metallurgical changes occur and how seriously they ularly useful prior to the development of practical and
lower mechanical properties. This situation points out the meaningful specifications.
advisability of educational efforts to help increase general
cognizance of the importance of surface integrity control. Preparation of processing specifications is highly recom-
In addition to general educational programs, sp. cific train- mended for critical parts. In fact, some of the aerospace
ing is required for machine operators and quality control producers have written detailed manufacturing specifica-
personnel. Some companies, for example, require qual- tions incorporating machining parameters and procedures
ification of personnel in order to perform drilling and ream- in an effort to maintain surface integrity. These specifica-

18-57
18.3 Surface Integrity
TABLE 18.3-9 Comparison of Depth of Surface Integrity Effects Observed in Material Removal Processes
PROPERTY
AND
II MAXIMUM OBSERVED DEPTH OF EFFECT*
inch
TYPE OF EFFECT CONDITIONE
.. m....
I
Turning Electro- Electro- Electrical Laser
or Chemical chemical chemical Discharge Beam
Milling Drilling Grinding Machining Machining Grinding Machining Machining
MECHANICAL ALTERED MATERIAL ZONES

Plastic deformation (PD) finishing' 0.0017 0.0008 0.0003 1

roughing# 0.0030 0.0047 0.0035 =
!;rfin~s~-71 '0.07K I190fO0K9
O02jP - s* **

Plastically deformed finishing 0.0005 =

debris (PDI) roughing *=* 0.0013 ===

Hardness alteration' finishing 0.0005 0.0010 0.0015 0.0010 0.0014 0.0007 0.0010 -
roughing 0.0050 0.0200 0.0100 0.0031 0.0020 0.0015 0.0080

-05 - !WVMt O3&

[0.1= ZOW5,
Microcracks or finishing 0.0005 0.0005 0.0005 0.0003 0.0000 0.0005 0.0006
Macrocracks roughing 0.0015 0.0015 0.0090 ' 0.0015 0.0010 0.0070 0.0040
, . W. .- .- . .. . -_I_ - ,_-- ., _

Residual stress* finishing 0.0060 - 0.0005 0.0010 0.0000 0.0000 0.0020 0.0002
roughing 0.0140 - 0.0125 0.0010 0.0000 0.0000 0.0030 -
24o* - -W - I 71 Th- _=
________________fsa M~___M W=~hbg
13rw ~U2i
METALLURGICAL ALTERED MATERIAL ZONES
Rectystallization finishing - - 0.005 1 -'
roughing - - -

Intergranular attack (IGA) finishing ** " = 0.0003 0.0003 0.000 " i

roughing 0.0060 0.0015 -

Selective etch, pits, finishing 0.0004 - 0.0002 0.0006 0.0004 0.0001 0.0005
protuberances roughing 0.0010 0.3000 0.0004 0.0015 0.0025 0.0005 0.0016

Metallurgical
transformations
_ _ _ _ _
finishing
roughing
0!=
0.0004
0.0030
-
0.0015 0.0005
0.0200=_ EPP MI
0.0060 -
MI0.0000
"0.0002
00001
0.0003
0.0006
0.0050 _
0.0006
0.0015

Heat-affected zone(HAZ) finishing 0.0001 - 0.0007 0 *0 0.0006 0.0006

or Recast layers roughing 0.0010 0.0030 0.0125 " ' 0.0050 0.0015

SOURCE: G,Bellows and W.P.Koster.' $Depth to point where residual stress becomes and remains less than 20
NOTE: Adash (-) in the table indicates no or insufficient data. ksl [138 MPa] or 10%of tensile strength, whichever is greator.
A triple asterisk (***) in the table indicates no occurrences or not 'Finishing, "gentle" or low stress conditions.
expected. t Roughing, "off-stapdard" or abusive conditions
*Normal to the surface.
'Depth to point where hardness becomes less than 2 points R,(or equiv-
alent) of bulk material hardness (hardness converted from Knoop micro-
hardness measurements).

18-58
 Surface Integrity 18.3
tions, even though widely used in subcontract work, are These data emphasize the importance of the machining
generally considered proprietary and under the control of process; however, equal consideration should be2 given to
the prime contractor. It is suggested that the manufac- the metallurgical state of the workpiece material.
turing or engineering departments of the large producers
be contacted directly concerning the availability of their
speciicatons.Specific Guidelines and Data for MECHANICAL
specifications. Material Removal Processes
Testing Specific Applications Conventional mechanical machining surface integrity
Thorough component or product testing is one of the best guidelines have been developed principally from data get'-
assurances for checking of 3urface integrity. Tests should erated by single- or multiple-point tools operated in the
be conducted on surfaces of parts that have completed the turning, milling (end, peripheral or face) or drilling mode.
full sequence of processing steps. While metallographic ex- Table 18 3-10 combines and summarizes the surface integ-
amination and some nondestructive tests can be helpful rity data observed from all of these. Figures 18.3-30
and can reveal clues to the surface integrity, the most criti- through 18.3-44 illustrate both good and poor surface con-
cal applications should preferably be supported by specific ditions as seen in cross section, high magnification photo*
specialized testing where the test conditions reflect the ex- micrographs. Figures 18.3-45 and 18.3-46 show residual
pected operating environment, stress profiles found from the surface inward a few
thousandths of an inch perpendicular to the surface. Fig-
ures 18.3-47 and 18.3-48 compare the high cycle fatigue
strengths of a variety of materials. These strengths are the
SPECIFIC GUIDELINES values at 107 cycles of failure from full-reverse bending
cantilever tests run on tapered section specimens at room
While several thousand bits of data have been used to de- temperature. The reference base or "handbook" value in
velop specific surface integrity guidelines, only the sum- most cases was data generated from low-stress-ground
mary tabulations or statements are included in this hand- specimens or hand-polished specimens. Other mechanical
b-Dk.1 These summaries are accompanied by a material removal illustrations are figures 18.3-6, 18.3-7,
representative selection of specific data to illustrate the 18.3-9 and 18.3-26.
types of effects observed.
Conventional machining processes
have been used so long
The guidelines aic organized and presented according to that it is easy to forget that they are characterized by me-
the process groups that follow: chanical plastic deformation, regular lay patterns and
somtimc zubstantial heat affects from too forceful a pas-
* Mechanical Processes, including milling, turning and sage of the cutter point over the surface. The degree of
drilling dullness of the tool is a major factor in determining the sur-
face effects. With the approach of the end of the tool life,
* Abrasive Processes, including grinding, sanding and low extensive roughness, tears, laps, or deposited built-up edge
stress grinding can result in abused surfaces. (See section 18.2, figure
18.2-19.)
" Electrical Processes, including electrochemical machin-
ing and electrochemical grinding Surface integrity data for the mechanical nontraditional
processes are not extensive and should be investigated in
Thermal Processes, including electrical discharge critical applications using techniques suggested previously.
machining, laser beam machining and electron beam Generally the low energy levels and gentle material re-
machining moval rates result in a minimum of altered material zones.

" Chemical Processes, including chemical machining and

photochemical machining Chip Cutting Process Guidelines that Promote Good
Surface Integrity Results
For each process group, the following information is pro- 1. Sharp tools are essential for establishing surface integ-
vided: rity in turning, milling, and similar single-point tool
cutting processes. Plastic flow is frequently present
Depth of surface integrity effects observed and dull tools can produce laps, tears and roughness
which can be initiating sites for fatigue failure.
* Photomicrographs of good and poor surfaces
2. Maximum flank wearlands should be limited to 0.005
* Representative residual stress data to 0.008 inch 10.127 ta 0.203 mm). This is the point at
which the wearland becomes visible to the naked eye.
fatigue strength values for several materials
e High cycle 3. Cutting paramleters should be selected which provide
* Minimum or standard data sets where available long tool life in order to assist in keeping tools sharp.

* Comments by major material groups 4. Form cutters tend to produce surface damage more
readily than do finishing tools which generate a form.
9 Comments on special situations
5. The heat from the passage of a cutting tool, especially
o List of guidelines a dull one, can produce metallurgical transformations.
L4

18-59 1
7=-
18.3 Surface Integrity
6. Evidence of burning on the surface should initiate a as to do everything pcssible to provide a low rate of tool
check of the depth, which can extend to 0.010 inch wear. All tools should be inspected after grinding to insure
10.254 mini. that previous wear. chipping, galling. etc., have been cor-
rected to meet tool specifications. After grinding, the cut-
7. Residual stresses from dull cutting tools are frequently ting edges of all tools should be protected to prevent acci-
compressive, below the surface. dental damage from transit or handling. Tools should be
double checked by the machine tool operator for obvious
8. Sharp drills should be used to help avoid serious sur- defects.
face layer alterations.
Sharp tools help establish surface integrity in turning
9. Dwelling during drilling should be avoided; galling, and milling. For chip removal operations, as for grinding
torn or discolored su:faces should be cause for rejec- operations, it is important to produce a surface which has a
tion or correction. minimum or preferably an absence of surface alterations;
that is, the surface layers should be similar to the base ma-
10, Drill fixturing rigidity is desirable. terial below the surface.

11. Deburring is imperative on both the entr nce and the For turning and milling, there are two very important steps
exit of holes. which will improve surface integrity. First, select machin-
12. Drilled and reamed holes should be chamfered on both ing conditions which will give long tool life and produce
good surface finish. Second. machinc with sharp touls.
the exit and the entrance. Sharp tools minimize distortion and generally lead to better
13. Reaming stock allowances should be contioiied, control or
turning during
ilgmachining. The
iie maximum
ghudb flank wear when
o prxmtl .0
tunnrmilling should be limited to approximately 0.005
to 0.008 inch 10.127 to 0.203 mm. A good rule of thumb is
14. A maximum number of holes per reamer should be to remove the tool when the wearland becomes visible to
specified and maintained despite the visual appearance the naked eye since the aforementioned wearland is just
of reamer. barely visible to the naked eye. Dull tools develop high
compressive stresses which cause distortion, and very often
15. Hand feeding of straight reamed holes should be they produce tears, laps and metallurgical alterations of
avoided. the surface, including untempered and overtempered mar-
tensite in steels. For turning most alloys, carbide tools tend
16. Alignment, tool geometry and tool condition are impor- to have the lowest wear rate and at the same time make it
tant controls in hand reaming. possible to meet reasonable production rates. Indexable
carbide tools, in particular, should be used whenever pos-
17. Finish boring operations should maintain roughness sible. This expedites the changing of cutting edges when
limits and avoid laps and tears. Only very small wear- ever tool wear reaches its specified limit.
lands can be tolerated with about 0.005 inch (0.127
mini as a limit. One finish pass per cutting edge is a fre- In order to determine machining conditions which will pro-
vide long tool life. it is necessary to refer to tool life data for
specific materials and material removal operations. Refer-
18. Honing is an excellent finishing operation for devel- ences
eci 33trthrough 66lsupply
data
data forretol
tool maeratol geom
materials, tool geom-
oping surface integrity. etry, feeds, depth of cut, cutting fluids, etc., for the purpose
of achieving long tool life. If tool life data are not available,
checked. Old fluids should be checked because old the material closest in characteristics to the actual work
w.uokpieces mre aiedyematerial can be used for initial consideration of the machin-
fluids often corrode workpieces more rapidly. ing parameters. In addition, it is recommended that tool life
20. Finish roughness values should not ser 'e as the only data between
ship be studiedmachining
carefully parameters
in order to and
develop
tool the
life.relation-
In this
criteria for development of fatigue strength. si ewe ahnn aaeesadto ie nti
way, one can get an idea of the effects of changes in speeds,
feeds, tool materials, etc., on tool life and be in a better po-
Special Comments Concerning Surface Integrity sition to decide on departures from the recommended ma-
Practices for Chip Cutting Processes chining parameters.

Rigid, high quality machine tools are essential. They Any evidence of burning as a result of a tool or cutter
must be designed with the ranges of speeds and feeds nec- breakdown should be reported to supervision. Care must
essary to meet surface integrity requirements. See com- be taken to remove sufficient stock after tool breakdown to
ments below on the need for selecting speeds and feeds completely remove the effects of the burning which may ex-
which give long tool life. tend as much as 0.005 to 0.010 inch 10.127 to 0.254 mini
below the machined surface.
Cutting tools should be inspected carefully prior to
use. Cutting tools must be carefully ground, and the most There is a tendency for more surface damage to occur
rigid tool design should be employed. For example, stub when a long cutting edge produces the final surface. This
length drills should be used instead of a jobber's length -situation usually occurs when turning to a shoulder or
wherever possible. Cobalt or premium grade high speed when milling a radius into a component. The use of espe-
steel should be used wherever carbide is not applicable so cially sharp cutters for finishing is desirable in order to min-

1f

18-60
 Surface Integrity 18.3
imize the alterations. For turning, whenever possible a In addition, it may be advisable to provide for alignment of
shoulder or large radius should be generated by the finish- the reamer to insure accuracy during the hand reaming
ing tool rather than being formed by the long cutting edge operation.
of a forming tool.
Double ream all straight holes 5/16 inch 17.9 mini or larger
Sharp drills should be used to avoid serious surface al- with a minimum metal removal of 3/64 inch 11.2 mml on
terations. Holes in highly stressed components should be the diameter. On smaller holes, the minimum metal re-
free of tears, laps, and untempered or overtempered mar- moval should be 1/64 inch 10.40 mini on the diameter. The
tensite. To minimize defects, the wearland on drills should operator should visually check the reamer for sharpness af-
be limited to 0.005 to 0.008 inch (0.127 to 0.203 mini. ter each operation. At the first sign of chipping, localized
Wherever possible, all hand feeding during drilling should wear or average flank wear beyond specification, the
be avoided. When drilling assemblies, a rigid machine tool reamer should be replaced, and the hole should be in-
or gantry type drill should be employed in preference to spected. Also, regardless of the hole and reamer condition,
portable drilling equipment. Dwelling should also be a maximum number of holes should be specified for reamer
avoided because it produces damage and may even friction replacement. Each reamed hole should be carefully in-
weld the drill to the workpiece. The operator should vis- spected for surface roughness, galling, smearing, scratches,
ually check the hole and drill after each operation. If aver- etc. The entrance and exit of all holes should be carefully
age or localized wear exceeds specifications, the drill deburred and chamfered.
should be replaced. If abnormal conditions develop in the
hole, it should be marked and inspected thoroughly before Deburring and chamfering should be used to remove
assembly. Galling, torn surfaces, or discoloration from all sharp edges. Drilled and reamed holes should be
overheating are causes for rejection. When a drill wears ex- countersunk or chamfered at the entrance and exit to re-
cessively or actually breaks during the drilling of sensitive move the entire burr because sharp edges and burrs are
alloys, the operator should notify appropriate personnel so common sources of component failure. To countersink, use
that remedial steps can be taken. Accidents of this type in- power feed units if possible and use a countersink which
dicate that machining conditions have not been selected completely avoids chattering. Generally, low spindle
and/or used properly. Coolant-fed drills may help minimize speeds are desirable and chamfering tools should be kept
surface damage, but no supporting data are available, sharp. The operator should visually inspect the tool after
each cut, and it should be replaced if there is any visual evi-
Proper drill fixturing assists in minimizing damage dence of wear.
or
during drilling. When drilling holes 1/4 inch 16.4 minI ac- The breaking of edges or radiusing may be done by abra
myedneyar-
larger, a drill fixture or bushing should be used. Where Thbraigoedsoraiun
largeriaydrillitfixtureor bshing should be usedWhe ac- sive deburring using a low speed, po'ver hand drill. When
cessibility permits. a drill backup should be used to min- cafrn
chamfering a part, iiu
at a minimum off000ic 024mn
0.010 inch 10.254 mini
imize burring, chamfer is advisable. The break edges and chamfers
should be carefully examined for compliance with surface
Finishing of drilled holes is imperative. The entrance roughness requirements. This is especially important on
and exit of all holes should be carefully deburred and chain- the entrance and exit of holes where fatigue failures have a
fered. All holes should be finish reamed after drilling when- tendency to originate. The chamfers should be carefully
ever possible to insure better surface finish and surface in- blended into the adjacent surfaces.
tegrity. (See comments that follow.)
Honing is an excellent fizishing operation for devel-
Bushing clearance is needed on deep holes. For holes oping surface integrity. Honing is usually used only when
with depths 3 times the diameter, or more, ample clearance finish requirements or tolerances are too close for practical
should be provided between the drill bushing and the work- use of other finishing operations such as reaming, grinding,
piece for the chips to flow. etc. A multi-stone head is preferred; heads with steel shoes
and/or steel wipers are not recommended. Honing pro-
Special precautions should be taken when reaming duces less surface deformation and fewer surface integrity
holes in sensitive alloys. Since reaming often serves as a effects than any other conventional mechanical hole-finish-
final hole finishing operation, all machining parameters ing process.
must be controlled. Stock allowances must also be con-
trolled. Power feeding of power driven machines should be Boring may be used as a finish machining operation If
employed for reaming of straight holes. When using power roughness is within the manufacturing engineering
driven machines for tapered holes, hand feeding is per- limits. When boring, extra precautions should be taken in
missible, but power feeding is preferred. Hand reaming of the preparation of the cutting edge to provide extremely
tapered holes using a tap wrench may be permissible after low surface roughness values. The tool wearland in finish
power reaming. If hand reaming is performed, special at- boring should be limited to 0.005 inch 10.127 mini, but of.
tention should be given to the selection of tool material, the ten it should be far less than this in order to achieve the de-
reamer geometry, and the accuracy in grinding the reamer. sired accuracy and surface roughness.

18-61
18.3 Surface Integrity

Figure 18.3-30 Built-up edge from face milling 4340 steel (quenched and tempered, 50 Rc). Machin-
ing operations such as turning, drl'i 'g, e....tc.,
ecpeciay under Door machin'-g conditions, are
likely to produce surfaces with a built-up edge. This photomicrograph shows that portion of the built-up
edge which was left on the workpiece. Fracture analyses of failed parts have shown that cracks associ-
ated with the built-up edge have served as origins of the fracture.

0.001 in

GENiLE MILLING ABUSIVE MILLING

Surface roughness: Surface roughness:
Perpendicular to lay: 28 min Ra Perpendicular to lay: 39 min Ra
Parallel to lay: 38 /jin Ra Parallel to lay: 32 pin Ra
Figure 18.3-31 Surface characteristics of Ti-6AI-6V-2Sn (solution treated and aged, 42 Rc) produced
by peripheral end milling Orientation: longitudinal r urface sections perpendicular to lay. Slight evi-
dence of distortion c n be seen on the gently millet tople. Very pronounced alterations are associ-
ated with abusive milling. A maximum hardness loss of 8 points Rc and a total affected depth of 0.004
inch carn be attributed to abusive milling. Approximately 6 points Rc surface hardness loss was meas-
ured on the gently milled samp!es. In this case, however, the effect was much shallower, not exceeding
0.002 inch. Indicated hardness data on the photomicrographs are Rc values converted from Knoop
hardness measurements. Surface roughness measurements are averages of readings made on all
specimens from each group. (W. P. Koster et al9)

18-62
 Surface Integrity 18.3

1000X Abusive Conditions - an overheated white layer about 1000X

Gentle Conditions - a slight white layer is
visible but without detected microhardness 0 0004-inch deep and a plastically deformed layer totaling
change. 0 0015-inch deep are visible. Microhardness measurements
show a total affected zone 0.003-inch deep
soI
I -L
I Gentlet
Abusie
cc 40--------------------

30 -
3- White surface layer

20 1-
0 0010 0020 0030
Ucpth iieatn surface. in

Figure 18.3-32 Surface characteristics of Ti-6AI-4V (aged, 33 Rc) produced by face milling. (Surface
Integrity Encyclopedia )

IN

Built-up edge produced by sharp Tearout of untempered martensite in flat

tool. Note microcrack originating surface produced by dull tool.
at base of edge.

Figure 18.3-33 Surfaces produced by carbide face milling 4340 steel (quenched and tempered, 40
Rc). (M. Field. W. P. Koster and J. B. KohlsIs)

18-63
18.3 Surface integrity

ABUSIVE CONDITIONS -Photoniicrographs at 1000X (left) and 250X (right) showing white rehardened patches of martensite. The interval
the patches corresponds to the feed of the cutting tool. Thin zones of
70 - - -of
IL - Gentle
Abusive
overtempered rfartensite 0 001-inch deep with hardness as low as 46 RC
are found beneath each patch.
cc..... 60
;ehardened patches

4 00 0020 0030

Depth beneath surface. in

Figure 18.3-34 Surface rharacteristics of 4340 steel (quenched and tempered, 52 Rc) produced by
face milling. (M.Field, W. P. Koster and J. 3. Kohls' 5 )

- ~~~~~~~~
in ~~~0001
_____________________

Flat surface. dutl tool.

Flat surface sharp tool. Surface band of untempered martensite (60-65 Rc)
No surface atteration and darkened overtempered martensite band.

0.001 in

Transient surface, sharp tool. Transient surface, dull tool.

Thin disturbed surface layer Characteristics similar to above
(untempered martensite). but with less tempering effect.

Figure 18.3-35 Surfaces produced by carbide face milling M~ac (quenched and tempered. 48 Rc). (M.
Field, W. P. Koster and J. B. Kohls's)

18-64
 I

Surface !ntegrity 18.3

28.5X 1450X

0.00025 in

2850X 7100X
Figure 18.3-36 Turning Inconel Alloy 718 (solution treated and aged) with sharp tungsten carbide
showing anomaly areas of smeared metal, material pull-outs and microchatter. Views at successively
greater magnification from scanning electron microscope taken at 150 from perpendicular. Plastically
leformed surfaces as seen in figure 18.3-37. (G. Bellows' 7 )

CMi

_19
4

Deepest plastic deformation, 0.002 Deepest plastic deformation, 0.0014

inch with sharp tool. inch with dull tool.

- x-

' Z4-
Worst spot with sharp tungsten carbide. Note Worst plastic deformation, 0.0012 inch, plus
built-up edge and lap. torn metal, with dull tool.

Figure 18.3-37 Surfaces produced by turning Inconel Alloy 718 (solution treated and aged) with sharp
and dull tungsten carbide tools. Sharp tool had 0.005-inch wearland and dull tool had 0.013 inch. Sur-
face roughness was 63 microinches R. in both cases. (G.Bellows')

18-65

m '
it
" - I
18.3 Surface Integrity
Clean surfaces - no laps or tears 50 MICROHARDNESS

S48
.44 inB N =
0.001 i

-40f ,

-t ~ ~ 2 1.5 4 8 1 6
0.O~hn
(Depth - beneath surface. thousandths inch
N..RATIUA STREGT
.~~ 100--~~ ag dl
s6o
60 WC - -

_ ~ix
.~-40

with~Dpt
specimens
lowstessgrun thousBellowsin)

0.0.00 in

, r7- M~ ~ 100 -A , u1

C 60 WC6
. -, sharp
7o). T

40 orCB

Figure 18.3-39 Drling oe-Alloy2n R1

soig taklerevicndaedstmmnlyr sfund intedriled and
reame oles.in Leformatheectionswn isarburr to woriec surfce. Burseln
wth hage eneshonaode
n
resp onsblessfor ppecie dcns(G Bofaigstrnt1nseesadi itnulos

-*4 uoi i

Hole1wall
 Surface Integrity 18.3

Sharp drill. 750X Dull drill. 750X

Thin zone of plastic deformation at the surface. Thin uniform00 layer of untempered martensite.

Sharp drill. 750X Dull drill. 750X

No surface alteration. Plastic deformation and extensive cracking.

Dull drill. 750X Dull drill. 750X

Untempered martensite (62 Rc )plus surface cracking. Extensive laps and tears.

Figure 18.3-40 Surfaces produced by drilling 4340 steel. Top two photos represent carbide drilling
4340 (quenched and tempered, 54 Rc); remaining photos represent high speed steel drilling 4340
(quenched and tempered, 48 Rc). (M. Field. W. P. Koster and J. B.Kohls's)

18-67
18.3 Surface Integrity

WW.-

Gentle conditions - very thin trace of Abusive conditions - an overaged or resolutioned layer
cold work may be seen on the surface. 0.001-inch deep at 37 Rc is found on the surface. Total
50OX affected deoth is approximately 0.002 inch. 50oX
.. l ..L_ _ _L
U) 50 Gentle
01T--
' ' e s Ol u t iOn e
d - - busive
- i
30 layer _ If] j
U "-.u1U U.uLO 0.030
Depth beneath surface, in

Figure 18.3-41 Surface chatacteristics of 18% nickel maraging steel Grade 250 (aged, 52 Rc) pro-
duced by driiling. (M. Field, W. P. Koster and J. B. KohlslS)

0001 in

Sharp reamer. Dull r a er. 75OX

No surface alteration. Built-up edge resulting in surface tear.

Dull reamer. 750X

Short tears plus thin film of surface deformation.

Figure 18.3-42 Surfaces produced by high speed steel power taper reaming 4340 steel (quenched
and tempered, 40 Rc). (M. Field. W. P. Koster and J. B. Kohls's)

18-68

- - _____
 Surface Integrity 18.3

C
C 0C

R 01
0

T0

JExit
Exit
Burr condition produced 75OX Burr condition produced 75OX
by sharp reamer.
by dull reamer.
Figure 18.3-43 Surfaces produced by high speed Steel power
taper reaming 4340 steel (quenched
and tempered, 48 Rc). (M.Field. W. P. Koster and J. B. Kohis
Is)

18-69
18,3 Surface Integrity

I V 0.010 in

Exit burr 0.002 to 0.004 inch high.

Exit burr - 0.015 to 0.017 inch high.

~~K);~j: 7\~0f+01 in__

'~44 N,

0.00045 Plastic deformation 0.0012 inch Plastic deformation and

0.0001 inch smeared metal.

INITIAL BROACHING PASS LAST PASS, #254

0
a:
ci)

0 _

30 - 4
-25-
0.5 0.75 1 1.5 2 4 8 16
Depth beneath surface, thoutandths inch

Figure 18.3-44 Broaching of Inconel Alloy 718 (solution treated and aged) with T15 high speed steel
tools. Wearland increased to 0.006 to 0.007 inch during 254 cuts for a total of 158 inches of cut. Micro-
hardness traverse taken after 254 passes. (Surface Integrity Encyclopedia)M

18-70
 Surface Integrity 18.3

Cutter. 4 inch dia single-tooth face mill

with C-6 carbide
Axial rake. 00 Corner angle: 450
C 100 -- Radial rake'-15 Clearance- 8
o. End cutting edge angle: 50
C Cutting speed: 180 fpm
50 Feed per tooth' 0.005 in
Depth of cut: 0.040 in
U; Cutting fluid. none
.- t" I
0 \' , ()0 in wearlandII

0
n- o 6.008 inwearland
100

0.016 in wearland
,i..

0
-150
0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009
Depth below surface, in

Figure 18.3-45 Effect of tool wear on residual stress in milled surface, face milling of 4340 steel (52
Rc). Note that the amount of residual compressive stress produced in this specimen is related to the
tool sharpness. The worn tool produced a deeper compressive layer. (W. P. Koster and J. B. Kohisls)

80 CUTTER: 4 inch dia.. 6 inch long 12 tooth.

C-2 (883) carbide
AR. 150 Relief- 100
RR: 00
60 Feed per tooth- 0 004 in
in
Depth of cut: 0 030

. .0 ABUSIVE CONDITIONS
U, 40 Cutting speed: 150 tpm
a - Tool wear 0.015 to 0 020 in
Cutting fluid: dry
-GENTLE CONDITION -
20
Cutting speed 100004fpm
in
Tool wear 0 to 0
!,l

Cuthng fluid Hocut #237 (1"30)

01
U)
0D 0

T -20
E Orientation: longitudinal mill. Stress profiles
o L-40 , I parallel to lay. i
9
0 0.002 0.004 0.006 0.008 0.010

Depth below surface, in

Figure 18.3-46 Residual surface stress profiles of Ti-6AI-6V-2Sn (solution treated and aged, 42 Rc)
produced by peripheral end milling. (W. P. Koster and J. B. Kohlsl8)

18-71
18.3 Surface Integrity
Peripheral
Cutting I
Ti-6AI-4V 66 Gentle
Beta rolled 32Rc 62 Abusive

T-A- -2Sn _ _-__j 73 N7 Low stress

STA,42 Rc n45 1 65 grinding

Ti-6A1-2Sn-4Zr-2Mo 82
STA, 36 Rc 47 68

End Cutting T 6
82 @ 13 p in roughness
Ti-6AI-6V-2Sn 82 @ 55 pin roughness
STA, 42 Rc i 82 @ 125 j in roughness

Ti-1A1-4V 64
Beta rolled 32 Rc 77

Ti-6A 1-4V 73
Anneal, 32-34 Rc 64
AISI 4340 - 85 102
0 & T. 50 Rc| 1

4340 Mod. 163

Q &T, 53 Rc 63

Grade 300 S%Ni 1057__123

Maraging steel
54 Rc 120

Rene 41 4775
STA, 40 Rc

17-4 PH 7V98
43 Rc 4
42
Mar-M509
as cast, 29 R c 4

1 9 H4 il
424
Alum 7075-T7351
77 R 8 9

17 V24 Carbide mills

0 20 40 60 80 100 120
Fatigue strength at 10' cycles, ksi
(toom temperature, full-reverse bending)

Figure 18.3-47 Summary of high cycle fatigue strength-end milling.

18-72

- ~
 Surface Integrity 18.3

60O
Inconel 718, 60 @ 25 pin roughness
STA, 44 Rc 60 @ 58 p in roughness
60 @ 118 p in roughness
i60 @ 76 pin roughness

17-4 PH, 75 61 gin roughness

STA, 29 Rc 70 @ 126 pin roughness
44 @ 500 pin roughness V198

403 Stainless steel, 50 @ 55 pin roughness

STA, 25 Rc 51 @ 118 pin roughness
38500 pin roughness

Ti-6A i-4V, 66
Annealed, 32-34 R c 71

Rene 41. -71

STA, 40 R c 5

Almiu, 7Gentle
7075-T7351, 7I
77 RB
775-731 14 V 24 AbIusive
Low stress grinding

Rene 95, HIP. with CBN tools 164V7

R5 . H. with WC tools 54
_________I-I _________ _________ ________i _______

0 20 40 60 80 100 120

Fatigue strength at 10" cycles, ksi

Figure 18.3-48 Summary of high cycle fatigue strength-face turning.

18-73
18.3 Surface Integrity
TABLE 18.3-10 Surface Integrity Effects Observed in Mechanical Material Removal Processes
FINISHING, ROUGHING,
PROPERTY "GENTLE" OR "OFF-STANDARD"
AND LOW STRESS OR ABUSIVE
TYPE OF EFFECT CONDITIONS CONDITIONS

Surface roughness, pin R. in R. "

Average range 8
to A-to 125 -. c
63 250
Less frequent range 1
to to to S's
125 1,00
Mechanical altered mater;al zones: inch* inch*
Plastic deformation (PD) 0.0017 -4 As 0.0047
Plastically deformed debris (PD1) 0** .- *
Hardness alteration't.0010 u 0.0200
Microcracks or Macrocracks 0.0005 1 0.0015
Residual stresst 0.0060 - 0.0140

Metallurgical altered material zones: inch* m t inch*

Recrystallization
lntergranular attack (IGA)
Selective etch, pits, protuberances 0.0004 0.0010
Metallurgical transformations 0.0015 0.0200
Heat-affected zone (HAZ) or Recast layer 0.0001 0.0030

High cycle fatigue (HCF): percent percent

Variation from "handbook" values at room
temperature# -50 to + 22 -48 to + 2

SOURCE: G. Bellows and J. B.Kohls."

NOTE: Adash (-) in the table indicates no or Insufficient data. A triple asterisk (*) in the table indicates no occurrences or
not expected.
'Maximum observed depth normal to the surface.
'Depth to point where hardness becomes less than t 2 points R,(or equivalent) of bulk material hardness (hardness converted
from Knoop microhardness measurements).
'Depth to point where residual stress becomes and remains less than 20 ksi [138 MPa] or 10% of tensile strength, whichever is
greater.
I
'Handbook values from HCF testing frequently are generated from specimens that have been processed using low stress
grinding, hand or gentle machine polishing or occasionally electropolishing. For 'his table, "handbook" values represent HCF
strength values generated from low-stress-ground specimens (with their minor amount of retained but enhancing compressive
residual stress). The values are the 10' cycle strengths from full-reverse bending tests at room temperature.

Specific Guidelines and Data for ABRASIVE and alloys studied to date. Titanium alloys are the most
Material Removal Processes drastically affected by grinding variables, although some
The heat in the workpiece surface resulting from the use of cast nickel base materials are close behind. The ferrous
any of the varieties of abrasive machining is the principal materials, except the high strength varieties, are less sensi-
ingredient affecting surface integrity. The amount of heat is tive to grinding variables than these other alloys groups,
proportional to the intensity with which the process is ap- although very significant losses in fatigue strength are asso-
plied. The degree of surface effects is a function of the ther- ciated with both conventional and rough grinding levels of
mal properties of the workpiece material and its metallur- intensity. Even shallow, isolated spots of untempered or
gical response to the heating k1",,. Residual stress and the overtempered martensite can be detrimental to fatigue en-
attendant distortion can be .oblems, as can smeared durance strength. Hand sanding or deburring operations
metal or the debris from plastic deformation. need strict control to reduce the human variables that can
influence surface reliability. Abrasive cutoff operations are 1
particularly susceptible to surface damage. Table 18.3-11
Grinding produces the greatest ange of fatigue endurance summarizes the surface integrity effects observed during
sensitivity among the several material removal processes the examination of several thousand pieces of data.
a2
18-74
I
 Surface Integrity 18.3
The charts and guidelines that follow have baselines the 11. Hand grinding of sensitive alloys should be dis-
same as those for the mechanical material removal proc- couraged, unless done under very careful control.
esses. Figures 18.3-49 through 18.3-54 illustrate good and
poor surface effects from grinding. Figure 18.3-55 shows 12. Stict instructions and controls over power hand sand-
typical microhardness alterations, and figures 18.3-56 to ers should be maintained.
18.3-61 show variations of the residual stress or distortion
patterns. High cycle fatigue responses are charted in fig. 13. Abrasive cutoff frequently has a harsh and deep sur-
ares 18.3-62 and 18.3-63. Other grinding illustrations are face effect, and these altered layers should be removed
figures 18.3-1, 18.3-2. 18.3-8, 18.3-10, 18.3-13, 18.3-15, by more gentle processes.
18.3-17, 18.3-18. 18.3-21. 18.3-25, 18.3-26. and 18.3-28.
14. Surface X-ray residual stress measurements can be
Abrasive Process Guidelines that Promote Good misleading. A full profile is best, or enough checks
Surface Integrity Results should be made below the surface to correct for pene- Ai
1. Low stress grinding techniques can reduce distortion tration of the X-rays and the slope of the profile.
and surface damage. Frequent coarse dressings of 15 Good dressing action on the grinding wheel is pro-
softer grade wheels, lower infeeds and reduced grind- moted by cleanliness and sharpness of the dressing
ing wheel speeds with lubricating-type cutting fluids tool. Pauses or dwells in the dressing tool action can
are the principal elements of low stress grinding. A dull the wheel surface, particularly with the roll form,
shallow depth of low value tensile or compressive re- crush roll or form block dressing tools.
sidual stress can be attained.

2. Highar work material speeds can aid both product. ity Special Comments Concerning Surface Integrity
and surface integrity. Lower wheel surface speeds aid Practices for Abrasive Machining Processes
su;face integrity without sacrificing productivity. Reduce grinding distortion and surface damage by us-
ing 'low stress" conditions during finish grinding.
3. Frequent coarse dressing of grinding wheels can re-
duce surface damage by keeping the wheels open and Conventional finish grinding practices should be replaced
sharp, thus helping to reduce temperatures at the by low stress grinding procedures in order to minimize
wheel-workpiece interface, grinding distortion and to reduce the possibility of produc-
ing extensive surface metallurgical alterations and crack-
4. Modifications to established low stress grinding pro- ing. Low stress grinding procedures are described in table
cedures should not be attempted unless testing con- 18.3-12. Some of the metallurgical alterations caused by
firms that they can be tolerated, abusive grinding do not produce cracking immediately, but
they develop conditions leading to delayed cracking, which
5. If low stress grinding is specified for finishing oper- may occur later "on the shelf' or prematurely in service,
ations, then conventional grinding can be used to thereby seriously complicating inspection practices. Low
within 0.010 inch 10.254 mml of the finished size, pro- stress grinding in comparison with conventional practices
vided that the work materials are not sensitive to employs softer grade grinding wheels, reduced grinding
cracking. wheel speeds, reduced infeed rates, and chemically active
cutting fluids. Low stress conditions should be used for re-
6. Lubricating-type fluids and coolants should have a co- moving the last 0.010 inch 0.254 min. See tables 18.3-13
pious and positively directed flow and should be to18.3-17.
checked for their chemical action on the specific mate-
rial being ground. Modification of low stress grinding procedures should
not be attemped unless service experience or testing
7. Conventional grinding conditions should not be used programs in the shop and/or laboratory confirm that
for finish grinding of highly sensitive alloys such as compromises can be tolerated. For certain type parts
high strength steels, high temperature nickel and co- made of sensitive alloys, no compromises should be permit-
bait base alloys, and titanium or molybdenum alloys, ted in the specification of low stress grinding parameters.
Experience has shown that it is sometimes possible to relax
8. The heat-affected zones from rough grinding can be low shuess procedures in order to accommodate equipment
much deeper than the surface discolorations might in- limitations or to increase production rates. Table 18.3-17
dicate. Microhardness traverses can generally detect is an example of a set of grinding conditions, case A, which
the depth of surface alterations. produced scrap as a result of grinding cracks in the fir-tree
section of IN-100 turbine blades. Substitution conditions,
9. High stress grinding of martensitic steels can create case B, are essentially low stress except for the infeed. Ex-
untempered mqrtensitic zones with overtempered mar- perience had indicated that in this instance an infeed as
tensitic zones below them, both of which will limit fa- high as 0.002 inch 10.050 m]l could be tolerated.
tigue strength.
An almost identical cracking problem was encountered in
10. Crack detection tests should be made when rough the production of Inconel Alloy 713C turbine blades. This
grinding materials. Existing surface cracks can propa- problem was also solved by implementation of the recom-
gate ahead of the grinding when finishing some ther- mendations shown for case B of table 18.3-17. Parts made
mally sensitive materials. Low stress grinding should of cast HS-31 and cast WI-52 have also cracked in conven-
be used to remove more than the altered material tional grinding. Because of these experiences and tha lack
zones from any prior conventional grinding operation. of other data, it is suggested that all cast nickel and cast

18-75
18.3 Surface Integrity
cobalt base high temperature alloys be processed using low quenched and tempered steels, OTM is frequently pro-
stress grinding conditions for the highly stressed or criti- duced under the UTM. Even if the UTM is removed by
cally loaded surfaces. gentle grinding, the fatigue strength is still reduced 25 to
30 percent. This indicates that overtempered martensite
If low stree grix~dfng is required for finish grinding, may be as important as untempered martensite in in-
then conventional grinding can be used to within 0.010 fluencing fatigue strength.
inch 10.254 mini of finish size if the materials being
ground are not sensitive to cracking. During conven- Conventional grinding conditions should not be em-
tional grinding, metallurgical alterations, including ployed for either roughing or finishing alloys wh.ch
stresses. are usually confined to within approximately are ultra-sensitive to the grinding process. From expe-
0.005 inch 10.127 mini of the surface or less, This makes it rience, certain alloys have been found to crack easily dur-
possible to remove most of the stock by conventional prac- ing conventional grinding. For such alloys, it is likely that
tices and then finish grind using low stress methois. How- the cracks created will not be eliminated by finish grinding.
ever crack detection tests should be made to see that con- The high temperature nickel and cobalt bas,- cast alloys
ventional grinding of the material in question does not (such as IN-100, Inconel Alloy 713C. M.R-M509. HS-31,
create cracks of greater depth. Stock allowances of the or- WI-52, Udimet 500, Udimet 700. inconel Alloy 738, etc.),
der of 0.010 inch 10.254 mml or greater. if necessary, are in contrast with the wrought nickel and cobalt base high
sugge;ted to compensate for location inaccuracies in hold- temperature alloys, are examples of alloys which should
ing fixtures. never be ground conventionally. See table 18.3-17 for a
specific case history involving cracking of a cast nickel
Finish grinding of critical and/or highly stressed sur- base high temperature alloy. Metals and alloys which are
faces of sensitive alloys exposed to high service brittle, such as beryllium and tungsten, tend to respond
stresses should be performed using low stress grinding similarly.
instead of conventional grinding. Some high perform- Frequent dressing of grinding wheels can reduce sur-
ance, high strength alloys are also sensitive to the thermal face damage by keeping the wheels open and sharp,
shocks accompanying grinding. A partial list of these alloys thus helping to reduce temperatures at the wheel-
is as follows: workpiece interface. Automatic dressing and wheel com-
High Strength Steels, Wrought pensation contribute to the ecenomic feasibility of frequent
4340 or 4340 Mod. at 40-54 Re dressing. Crush dressing and diamond roll dressing can
300M or D6ac at 48-56 Re also be used to minimize the cost of frequent dressing.
Maraging
HP94-45 Steels Cutting fluids, properly applied, help promote surface
integrity. In order to get fluid to the wheel-workpiece in-
High Temperature Nickel and Cobalt Base Alloys, terface, position the fluid nozzle as close to the wheel as
Wrought possib!e. A general rule of thumb, regarding the quantity of
Rene 41 fluid needed, is to use at least two gallons of fluid per horse-
Rene 80 power per minute.
Udimet 700
AF 95 (Rene 95) Hand grinding of sensitive alloys should be dis-
Waspaloy couraged. The inherent lack of control has been respon-
AF2-1DA sible for creating many surface defects.
Inconel Alloy 718
Rene 125 Abrasive cutoff requires special surface integrity con-
Titanium Alloys, Wrought siderations. Abrasive cutoff operatio-: generally cause
Ti-6A1-4V deeper surface alterations than grinding, sometimes as
Ti-hAI-2.5Sn much as 0.050 inch 11.27 mini, and capability for min-
Ti-6A1-25Sn-4Zr-2Mo imizing damage from cutoff operations varies from plant to
Ti-6AI-6V-2M plant. It is recommended, therefor!!. that when abrasive
cutoff is used that steps be taken to determine the extent of
Table 18.3-18 and figure 18.3-62 provide high cycle, room disturbed layers
the subsequent andbyproper stock allowances be made
for cleanup suitable machining. Also, the en-
temperature fatigue data showing the adverse effects of for su t ceanup b e an ina ls the en
abusive and of conventional grinding compared with gentle tresutnsrace sube exie e the tmr
or low stress grinding for several classes of aerospace te gt e
materials.

Fatigue str- igth reduction of martensitic steels as a result Controls for hand power sanders should be main-
of abusive grinding has been determined to be approx- tained. Test data reported in figure 18.3-63 show that
imately equal, regardless of the quantity of untempered good fatigue results can be obtained for such alloys as 4340
martensite (UTM) or overtempered martensite (OTM) pre- at 50 Re and Ti-6AI-4V provided that controlled conditions
sent. Traces of UTM or OTM as well as 0.004-inch 10.10 are maintained. The conditions are as follows:
mini deep layers were associated with the same fatigue
strength reduction, figure 18.3-25. Reduction of the fatigue Use a low belt speed (2000 feet per minute 110 m/sl
strength was found to be about 30 to 35 percent. For maximum, for example).

18-76
 Surface Integrity 18.3
Use a flexible (rubber) support for sanding disks or Adjustment of the grinding conditions can sub-
belts. stantially alter the surface conditions. When it is not
possible or practical to control one of the operating param-
Use an abrasive grit generally no coarser than 80. and eters to low stress values, alteration of all of the other pa-
use coolant if feasible. rameters to the best values can frequently achieve the de-
sired surface quality, as shown in figure 18.3-64.
At present, the relatively new high speed grinding
processes should not be used for finishing of highly
stressed structural parts unless an extended data set is
developed. Presently, insufficient mechanical property
data are available to justify the recommendation of high
speed grinding for critical parts even though increased pro-
duction rates are attainable. High speed grinding increases
the difficulty of the effective application of the grinding
fluid, especially on complex parts, thereby making it more
difficult to avoid surface damage from overheating.

Abrasive processing and especially finish grinding

must be accomplished under strict process control
when employed for the manufacture of aerospace com-
ponents. Tests have shown that uncontrolled abusive as
well as conventional grinding can decrease substantially
the low and high cycle fatigue strengths at room and at ele-
vated temperatures for titanium alloys, nickel base high
temperature alloys and high strength steels. In addition to
the room temperature high cycle fatigue data shown in
table 18.3-18 and figure 18.3-62, data have been devel-
oped for elevated temperature high cycle fatigue and for
low cycle fatigue. Tests on AF 95 (Rene 95) show that at
100OF 1538C the endurance limit (107 cycles, full-reverse
bending) is lowered from 98 ksi 1676 MPal for gentle grind-
ing to 48 ksi 1331 MPal for abusive grinding. Low cycle fa-
tigue properties are affected adversely by abusive grinding,
as shown in table 18.3-19. Infeed: 0.010 in/min
Surface roughness: 11 rms 1000X

g f4 0 ( .. -

Figure 18.3-49 Surface produced by abusive Infeed: 4.9 in/mp

grinding of 4340 steel (50 Rc). The thin white mar- Sufc ognss 6 m 00
tensitic layer in the photomicrograph is often found Sraeruhes 6 m 00
in the surfaces of hardened alloy steels after grind-
ing. It has been found that even isolated patches of Figure 18.3-50 Surfaces produced by plunge
untempered or overtempered martensite as thin as grinding 4340 steel (45 Rc). Grinding Whael:
0.0002 inch can reduce fatigue strength of high 32A54MVBEX113. Wheel Speed: 11,500 fpm. (M.
strength steels as much as 35% to 40%. Field9)

17 I

18-77 m
18.3 Surface integrity

Coo

:
* C o

0 (.

a)'-

0
C)w
(00 0 0 -%
C: 0 CY

E Co

000-0
-~ C
Cm :60 0
CLSo a) 00
C>

4)0 C
C C C .. C ")
oo < ) o

cr0 00.C C
.C .C
.T .- 0(wG 'D a .
- 0. 00 C
OCD U) > 4) -
0 0 0 CIL
o 0 V- 0
z 0 C Eo~.
CD
0) 0 6 o
C
-;
0) 0

0 0

ID 0

0 -V0
0 CC 0

S
C COO 0
05
0w, 2s-
8 0 HCCO 0 _H-

-0 20
-0C
L
:3 0

CL.

Ln - .

Cm
>

M -U
18-7M
 Surface Integrity 18.3

0 0 C

A ~A
Q)0
CD

cc0 t

CLC

oC

00
0,,x
.0.C)0 ::3
U0)
CcV~

CL 0

42 coo0

0
C)

'F t-S

C.D

=0 )

-D0~- 0) CL

an -_

A87

____________________________________
18.3 Surface Integrity

-~ ~ -U---0.001 in
V!V2I

7 '~

-7

41
V
Ln. _
1-2

-
1

Abusively ground -no subsequent heat treatment,

100__

Abusively ground -heat treated, after grinding, at 20000 F for one

vacuum. Recrystallized layer at surface.

Figure 18.3-53 Recrystallization resulting from abusive grinding

of HS-31 alloy.

18-80
 Surface Integrity 18.3

V0

. 0 0
0
-
C
0

CC)
CL
ww - -i7E E
0

C
00

C)0

40
~ ~ ~ ' n o .I
2~@
- ' -o
~C

r 0 .
0
0 0 0

CL
0CC
0

0 '00
> 4

C.2
41 -o

MRES a
0C~.
cc- 00
.00

-0 00

0 40

00

18081
18.3 Surface integrity
60 1 1120
Un empered zone I I I
Low tres gridingWheel
j Wheel grade. A46KBV
speed 6000 fpm
Cr Table spetd 60 fpm
'6I Crossfeed 0040 n~.hpaso
stress grinding 80 - Depthi ol grind. 00.0 inch
0High
.g ~ IGrinding llu'dl soluble oil (140)
M 0 1Specimen size u ,j60 x 314 x 4-114 in
M4 60-
400
Ivremee
zoe
4C 000 inch/pass
zones_
Ovremee 00 inh/s

0 0.001 0.002 0.003 0.004 0.005 0.006 a: 20 t-

Depth below surface, in

FIgure 18.3-55 Typical hardness alteration tra-T 2

verses of subsurfaces as a result of grinding 4340
steel (quenched and tempered. 53 Rc) at low stressu40- 1
and high stress levels. (G. Bellows"3) a o002 0.004 0.006 0.008 0.010 0.012
Depth below surface, in

Figure 18.3-S7 Effect of downfeed on residual

stress in ground surface at 4340 steel (52 Rc). It
should be noted that high residual tensile stresses
are reduced by grinding at lower wheel speeds and
at iower downfeeds. The corresponding distortions
(measured at the center of a 0.060 inch by 3/4 inch
by 4-1/4 inch specimen) are shown in figures
18.3-59 and 18.3-60. (M. Field, W.P. Koster and
J. B.Kohlsts)j

Wheel grade:A46K8SV
wheel speed: wee below
100 Downfeed: 0.002 inch/pass
Table speed: GGfpm
Crossfeed: 0.040 inch/pas
60 So Deth of grind:O.010 in
.2 Grnding fluid: soluble oil (1.40)
uin Ra Ispecimensize: 0.060 x314 x4-1/4 in
S40 -p 5
65 in Ra--.-
127 luin Ra .....

- - ~ 40 -

I I I

ca C 0

0 0.002 0.004 0.006 0.006 0.00 0.012

C) Depth below surface, in

-60 - -Figure 18.3-5$ Effect of wheel speed on residual

0 0.002 0.004 0.006 0.008 0.010 0.012 stress In ground surface 4340 steel (52 Rc). It
Depth below surface, in should be noted that high residual tensile stresses
are reduced by grinding at lower wheel speeds and
Figure 18.3-56 Residual stress profiles of 4340 at lower downfeeds. The corresponding distortions
steel (quenched and tempered, 50 Rc) for various (measured at the center of a 0.060 inch by 3/4 inch
values of surface roughness. Stress profiles and by 4-1/4 inch speimen) are shown In figuresa
grinding lay parallel to longitudinal axis of speci- 18.3-59 and 18.3-60. (M. Field, W.P. Koster and
mens. (G.Bellows' 3) J. B. Kohls's) M

18-82
 Surface Integrity 18.3

0035 Wheel grade- A46K8V 0 Wheel'grade:

refd 00X4618V
CRCrst 1-04ichpasCrossfeed0 040 inch/pa
aw003 Table --d: 60 ipi 8.030 Table speed: 60 fpm
C Dow ..eed: see below i ownfeed- 0002 inch/Pass
Depth of grind: 0 010 in IDpho rn 00i
~' 025pecien ize: 07 X 34 X4-V/4 in Cownfeed cjC 005Specimen size 0.070 x 3/4 x414i
002 inch/pass 02
C 0
I I C Soluble oil(1:40)
-5 0.015
CC,/emulsion
I I I ~ 005
0.0 t~ACnemiical
U 0010 oo.v /0
C I inch/pa.zS -
o I If 0 1 Sulfurie i

20D0 4000 6000 2OD 41 6O

Wheel speed. fpm Wheel speed. fpm

Figure 18.3-59 Effect of downfeed on change in Figure 18.3-61 Effect of grinding fluid on change
deflection versus wheel speed when surface grind- in deflection versus wheel speed when surface
ing 4340 steel (52 R@). Note the low distortion pro- grinding 4340 Steel (52 Rc). Distortion is minimized
ducedi by low wheel speed and low stress down- by use of low wheel speeds and also by using sulfu-
feed. A typical low stress downfeed calls for carefulrienl.M.ildW.PKstradJ .ohs)
control in removal of the last 0.010 inch in finishing.
The first 0.008 inch is taken at 0.0005 inch/pass
and the last 0.002 inch at 0.0002 inch/pass. Resid-
ual stress values for these tests are shown on fig-
ures 18.3-57 and 18.3-58. (M. Field, W. P. Koster
and J. B. KohisIs)

Downlsed: 0.002 inchtpass

Crossfeed: 0-040 inch/pass
Table speed: 60 pm
Depth of grind: OD10 in
0 Gninding fluid: soluble oil (1:40) 0
ZE ODMSpcinsize: 0.070 x3,4 x4-1/4 in

- 0.040

;-.t I I/ -

0-010 0

2000 4000 6DO0

Wheel speed. fpm

Figure 18.3-60 Effect of wheel grade on change

in deflection versus wheel speed when surface
grinding 4340 steel (52 Rz). Note that low wheel
speeds and soft wheals tend to minimize distortion.
Residual stress values for these tests are shown on
figures 18.3-57 and 18.3-58. (M. Feld. W. P. Koster
and J. B. Kohls-s)

18-83
13.3 Surface Integrity

AISI 4340
0 & T, 50 R c -117@8uin roughness
1 10@ 65 pin roughness
(longitudinal grind) l0 127pMin roughness
AISI 4340 120@ 1. pn roughness
T, 50 Rc 185 100@ 58 in roughness
AISI 4340 9 pin roughness
o & T,,50 Rc 65@ 64 m roughness
(longitudinal grind) 65 @9 7p in roughness
AISI 4340
Q & T, 50 R
c
4340 Mod . 1122
o & T, 53 Rc
Grade 300 105
maraging steel
STA, 54 R c 85
17-4 PH steel 42 198
4
3 Rc 8
Ti-6A1-4V 54
beta rolled, 32 Rc 14

Ti-6A I-2Sn-4Zr-2Mo 68
STA, 36 Rc
Ti-6A[-6V-2Sn - .=-=-
..--'30
30. 65
STA, 42 Rc
Inconel 718 60
STA, 44 Rc 24
Rene 41 152
STA, 40 Rc
Rene 80 42
STA, 40 R C ,
ST plus grind plus age 32-36
AF95 (Rene 95) 24
STA, 50 Rc 26
Low stress
AF2-1DA 170 or gentle
STA, 46 Rc 20

MAR-M509 42 Conventional
as cast, 29 Rc 24
7075 Aluminum 24 High stress
9 or rough
T7351, 77 RB

0 20 40 60 80 100 120 140

Fatigue strength @ 101 cycles, ksi
(room temperature, full reverse bending)

Figure 18.3-62 Summary of high cycle fatigue strength-surface traveise grinding.

18-84

____
-
____
_ ___
- ~~ ~ _
-~-~--
__
-= - -------
___ ____ S
 r

!SurfaceIntegrity 18.3
I I I I }
AISI 4340 Q&T, 50 Re
I I I I ,
4340 Mod O&T, 53 R, , 105

Grade 300 maraging steel 85

STA, 54 Rc 85
Ti-6A1-4V, beta rolled, 32 Rc 67

Ti-6AI-6V-2Sn STA, 42 Rc 67
I I
17- Gentle
Abusive
Low stress
grinding

0 20 40 60 80 100 120 140

Fatigue strength @ 107 cycles, ksi
(room temperature. full reverse bending)
Figure 18.3-63 Summary of high cycle fatigue strength-hand sanding. Controlled hand grinding or
hand sending generally results in fatigue strength levels only ;lightly lower than those produced by
gentle or low stress grinding. With one exception, the materials budied were not sensitive to variations
in hand sanding processes over the range studied. (G Bellows and W. P Koster16)

SURFACE SECTION

1/4 in 0.0005 in
lO00X icoox
HIGH STRESST
Fine dress, dry,, 6000 fpm
I

CONVENTIONAL
Fine dress, oil, 4800 fpm

_CONVENTIONAL
Coarse dress, oil, 4800 fpm

LOW STRESS
Coarse dress, oil, 2000 fpm
Figure 18.3-64 Effect of different grinding intensities. Left, ultraviolet photographs of fluorescent pen-
etrant inspections of the four surfaces of a bar of cast nickel base alloy ground under four different con-
ditions of surface grinding. Right, corresponding section photomicrographs at 1000X. These photos re-
veal the presence of cracks and pull-out. The low-stress-ground surface is free of microcracks. (Surface
Integrity Encyclopedia')

18-85
M
18.3 Surface Integrity
TABLE 18.3-11 Surface Integrity Effects Observed In Abrasive Material Removal Processes
FINISHING, ROUGHING,
PROPERTY "GENTLE" OR "OFF-STANDARD"
AND LOW STRESS OR ABUSIVE
TYPE OF EFFECT CONDITIONS CONDITIONS

Surface roughness: onR. lainnR.

Average range 4 32

Less frequent range 1 8

to to
125 250

Mechanical altered material zones: inch* inch

Plastic deformation (PD) 0.0003 0.0035

Plastically deformed debris (PD2) 0.0005 0.0013
Hardness alteration' 0.0015 0.0100
Microcracks or Macrocracks 0.0005 0.0090
Residual stress' 0.0005 0.0125

Metallurgical altared material zones:inhic*

Recrystallization 000
lntergranular attack (IGA)
Selective etch, pits, protuberances 0.0002 0.0004
Metallurgical transformations0.05.06
Heat-affected zone (HAZ) or Recast layer 0.0007 000

High cycle fatigue (HCF). percent percent

Variation from "handbook" values at room

temperature# 0 to + 62 -95 to 0

SOURCE: G.Bellows and J.B.Kohs.'*

NOTE: A dash (-) In the table indicates no or insufficient data Atriple asterisk (*'*) in the table indicates no occurrences or
not expected.
*Maximum observed depth normal to the surface.
'Depth to point where hardness becomes less than t2 points R,(or equivalent) of bulk material hardness (hardness converted
from Knoop microhardness measurements).
sDepth to point where residual stress becomes and remains less than 20 ksi [138 MPa] or 10% of tensile strength, whichever is
greater.
$Handbook values from HCF testing frequently are generated from specimens that have been processed using low stress
grinding, hand or gentle machine polishing or occasionally electropolishing For this tab!e, "handbook" values represent HCF
strength values generated from low-stress-ground specimens (with their minor amount of ratalnad but enhancing compressive
residual stress) The values are the 10' cycle strengths from full-reverse bending tests at room temperature.

18-86
 Surface Integrity 18.3
TABLE 18.3-12 Low Stress Grinding Procedures

GRIN'ING STEELS AND NICKEL BASE

PARAMETERS HIGH TEMPERATURE ALLOYS

English L Englsh

WheelA4HC6V
Wheel speed 2500 to 3000 fpm* - - 2000 to 3000 fpm*
Do%-wnfeed per 0.0002 to 0.0005 -- 0.0002 to 0 0005
pass inch'tinch'
Table speed 40 to 100 fpml - 40 to 100 fpml
,;rossfeed per 0 040 to 0 050 - 0.040 to 0.050
pass inch inch
Grinding fluid Highly sulfurized See section 16.3.

, TRAVERSE CYLINDRICAL GRINDING

Wheel A601V C60HV

Whe': speed 2500 to 3000 fpm* 2000 to 3000 fpm*
Infeed per pass 0.0002 to 0.0005 0.0002 to 0.0005
inch' inch*
Work speed 70 to 100 fpm* 70 to 100 fpm$
Grinding fluid Highly sulfurized Se ction 16.3,
oil Codes81 and 83-

NOTE, For a wide variety of metals (including high strength steels, high 'Downfeeds or infeeds in the range of 0 0002 to 0.0005 inch per pass
temperature alloys, titanium and refractory alloys), low stress grinding [0 005 to 0.013 mm/pass] have been found satisfactory for steels, nickel
practices develop very low residual tensile stresses. In some materials the base high temperature alloys, and titanium alloys. A typical feed schedule
residual stress produced near the suface is actually in compression in- calls for removing the last 0.010 inch [0.254 mm] of stock as follows. re-
stead of tension. move 0.008 inch [0 2 mm at 0.0005 inch per prss [0 013 mm/pass] and
*Low stress grinding requires wheel speeds lower than the conventional remove the last 0.002 Inch [0 05 mm] at 0 0002 inch per pass [0.005 mm!
6000 feet per minute [30 meters per second]. In order to apply low stress pass].
grinding, It would be preferable to have a variable speed grinder. Since :Increased work speeds even above those indicated are considered to be
most grinding machines do not have wheel speed control, it is necessary advantageous toward improving surface integrity.
to add a variable speed drive or make pulley modifications

2 I

18-87
18.3 Surface Integrity
TABLE 18.3-13 Process Parameter Guidelines for Low
Stress Grinding Results

PROCESS PARAMETERS GUIDELINES

1 Grinding wheel Frequent ano coarse to maintain

dressing technique shdrpness Mantain sharpness
of drassing tool. Avoid dwell in
using crush, roll, or single-point
dressing tools.
2. Wheel speed Low, under 3,500 fpm [18 m/s].
3. Downfeed (or infeed) 0.0002 to 0.0005 inch/pass [0.005
rate to 0.013 mm/pass) with
programmed reduction from
conventional rates.
4. Grinding fluid Oil-base fluid is preferred.
5. Wheel classification Soft grade (G, H or I*).
Open structure (6 or more).
Grain size (60 or coarser).
6, Table (workpiece) High, 50 fpm [15 m/min] and up
speed Crossfeed is preferred to plunge
motion.
7. Grinding fluid Adequate to high fluid flow.
flow control Assure placement of fluid
between wheel and workpiece.
Flow controlling nozzle design.
Reduce air film on wheel.

SOURCE: G. Bellows.,$
NOTE- Process parameter guidelines are listed in descending order of sig-
nificance to low residual stress generation in the workpiece surface. A ma-
chine and setup with good rigidity, freedom from vibration or chatter and
well maintained with fine cleanliness are also an aid to grinding perform-
ance
*Cylindrical grinding frequently requires use of harder wheels (with J
grade prevalent): however, the other parameters must be selected to com-
pensate for this extra hardness.

TABLE 18.3-14 Typical Infeed Schedule for Attaining Low Stress Surfaces by Grinding
I INFEED RATE

Ruh STEPj WORKPIECE STOCK REMOVAL*

Rough Grinding From raw material dimension to up to 0.002t
within 0.010 inch [0.25 mini of
Dress wheel desired final dimension

Semi-finish Grinding From 0.010 inch [0.25 mm] to 0.0003to

0.001 inch [0.025 mm] of final 0.0006
size
Dress wheel Optional
Finish Grinding From 0.001 inch [0.025 mm] to 0.0001 to
(to low stress levels) final size 0.0002
Optional:
at final size, with continued 2 to 4 spark-out passes
application -,fgrinding fluid

SOURCE: G.Bellows.'"
*Data applies to the radius for cylindrical grinding and to the depth for surface grinding.
'This roughing rate should be such that roughness, tears, cracks, or microcracks In the surface are of lesser magnitude than
the material remaining to be removed by the finishing and semi-finishing cuts.

18-88
 Surface Integrity 18.3
TABLE 18.3-15 Influence of LSG Parameters on Production Rates
RANKING DIRECT INFLUENCE MINOR INFLUENCE NO INFLUE!.CE
IN INFLUENCE ON MATERIAL ON PRODUCTIVITY ON PRODUCTION
ON RESIDUAL REMOVAL RATE AND RATE
STRESS PRODUCTION TIME
1 (most) Dressing
2 Wheel speed*
3 Infeed rate

4 Lubricant
5 Wheel grade
6 Table speed
7 Machine type and quality
8 Rigidity of setup
9 (least) Coolant nozzle design

SOURCE: G Bellows."
NOTE: It is possible to achieve the "best of both worlds"--high surface integrity and good productivity-it a
careful selection among the LSG parameters ismade.
*At very low sheel speeds, a wheel acts like asofter wheel and needs more frequent dressing and thereby has a
minor influence or production rates.

TABLE 18.3-16 Low Stress Grinding Troubleshooter

Checklist
1. Check that planned machine settings are being used.
2. Iswheel grade correct?
3. Check for correctness and freshness of wheel dressing.
4. Check for changes in workplece material or its metallurgical
state.
5. Are set values of feed and speed being attained and is infeed
program of reductions being followed?
6. Isgrinding fluid correct, clean and inserted properly?
7. Check fixtures and machine rigidity.
8. Isworkpiece clean and initially free from cracks?
9. Check inspection techniques

SOURCE G. Bellows"
4i

TABLE 18.3-17 Grinding Parameters for IN-100 Turbine Blades (Case A

resulted in cracks; Case B resulted in no cracks)

GRINDING CASE A CASE B

PARAMETERS (Cracks) (No Cracks)
Wheel 38A10018VBE 38A8018VBE
Wheel speed 5,500 fpm 2,800 fpm
Table speed 20 fpm 20 fpm
Infeed per pass 0.004 inch 0.002 inch
Fluid Sulfo-chlorinated oil Highly sulfurized oil
Grinding cycle Rough: 0.060 inch at 0.004 Dress: feed 0.060 inch at
inch/pass, dress. Leave 0.002 inch/pass;
0.100 inch/side for
finish operation. Dress: feed 0.060 inch at
0.002 inch/pass;
Finish; 0.012 inch from
finish size (3 passes at Dress: feed 0.010 inch at
0.004 inch/pass; 0.002 inch/pass to
2 sparkout passes). finish size.

18-89
77-
18.3 Surface Integrity
TABLE 18.3-18 Fatigue Strength Variation from Different Grinding Conditions

MATERIAL Low Stress Conventlonql Abusive

Grinding Grinding Grinding

High Strength Steels:

4340 (0& T, 50 Rj 102 70 . 70 z483 62 -=427
4340 Mod (0 & T, 53 Rj) 12 _ 4_6_4 62 47
Maraging steel, 300 Grade (STA, 54 Rj) 105 ~7247 82 -U- 5 -5B

High Temperature Nickel Base Alloys:

Inconel Alloy 718 (STA, 44 Rj) 60 44 2
AF 95 (STA, 50 Rj) 5 17 2 . 6 19
AF2-1 DA (STA, 46 Rj) 70 __ 2 7 -2
Rene 80 (STA, 40 Rj42 90 1 12 16 1 -

Titanium Alloys:
Ti-6A1-4V (Beta rolled. 32 Rj 62 713 9
Ti-6A[k6V-2Sn (STA, 42 Rj 5 .4 0)0 0 18
Ti-6A1-2Sn-4Zr-2Mo (STA, 36 Rj 68 40 17 11 10 6

*Room temperature. 101 cycies full-reverse bending

TABLE 18.3-19 Low Cycle Fatigue Test Data From Surface-Ground Materials

MATERIAL. CONDITION AT 20,000 CYCLES*

4340 Gentle surface gfind 165 z3"9_

(0 & T, 50 Rj) Abusive surface grind 142_____

Ti-6A1-4V Gentle surface grind 92

(Beta rolled, 32 Rj) Abusive surface grind 71 ____

Inconel alloy 718 Gentle surface grind 160

(STA, 44 Rj) Abus~ve surface grind 127 __

Rene 80 Gentle surface grind 55 ___

(STA, 40 Rj) Abusive surface grind 45

'At room temperature.

18-90
 Surface Integrity 18.3
Spn-cific Guidelines and Data for ELECTRICAL 7. Contact between the electrolyte and workpiece with-
Matarial Removal Processes out current flow should be minimized.
The nolecule by molecule dissolution of the electrically
conductive workpiece in electrochemical machining 8. Localized overheating of the workpiece as a result of
(ECM) is a forceless material removal that introduces no poor connections or short circuits should be carefully
residual stresses into the workpiece. The surface texture is examined for the extent of any damage. Removal of
smooth, has no lay pattern, and can approach a metal- the surface discoloration is insufficient, as demon-
lograph-polish caliber even to revealing individual grain strated in figure 18.3-75.
patterns. The absence of beneficial residual stress and/or
cold working in the surface frequently results in high cycle 9. Careful and complete rinsing of the electrolyte from
fatigue strengths less than that produced with conven- the workniece is essential. Ultrasonic agitation of the
tionally prepared surfaces. If nceded. the addition of a post- cleaning bath is helpful.
ECM process such as shot peening or rolling can add a
beneficial compressive residual stress. Some slight soft- 10. Selective etching, excessive roughness, intergranular
ening of the surface has been observed in some alloy- attack or pitting are evidences of less than optimum
electrolyte combinations. The key to good ECM surfaces is operating conditions or tooling practices. These condi-
a careful match of the electrolyte composition with the tions can occur on surfaces subjected to low current
metallurgical state of the workpiece material plus careful density in the presence of the electrolyte or in areas ad-
control of the operating parameters, especially the current jacent to the main electrode cutting face.
density. Selective etching, intergranular attack (IGA) or
pitting may occur in the low current density areas adjacent 11. Room temperature fatigue endurance strength is gen-
to the main electrode high current density areas. Static ma- erally lower as compared to that of low stress conven-
terial properties have not been found to be affected bytionally ground specimens and represents the unblem-
ECM. Hydrogen embrittlement has also not been attri- ished or unaffected material properties state. The lack
buted to ECM (the hydrogen ions form at the cathode and of any residual stress in electrochemically machined
are in the molecular state before reaching the anodic work- surfaces can account for the differences observed in fa-
piece surface). tigue strength.

The charts and guidelines that follow have baselines the 12. The use of a post-ECM shot peening or rolling treat-
same as those for the mechanical material removal proc- ment may be desirable to enhance component fatigue
esses. Figures 18.3-65 to 18.3-73 illustrate good or poor
surface effects from the electrochemical processes. Micro- 1c
hardness examples are shown in figures 18.3-67. 18.3-71
and 18.3-72. and residual stress patterns are shown in fig- in material composition can influence the surface qual-
ures 18.3-66 and 18.3-72. High cycle fatigue strength sum-
mary data are shown
summry
srfaein ffigure
te 18.3-74. Table 18.3-20
itegityeffctsobsrve is a
duing 114. Some surface softening will occur in many, but not all.
the examination of several thousand pieces of data. Other
18.-1.illustrations
electrical machining are figures 18.3-5.
nd183-7.15. . An increase in roughness of the ECM surface can be a
18.3-15. and 18.3-1 7. significant alert to the departure from optimum or pre- i
planned operating conditions.

Electrical Process Guidelines that Promote Good 16. Hydrogen embrittlement is not attributable to CM.
Surface Integrity Results Special Comments Concerning Surface Integrity
1. Surface roughness standards should be -e .d Practices for Electrical Machining Processes
when applying ECM because ECM produces unusual
surface textures with no ly pattern. High current densities produce improved finishes and
high material removal rates. In sharp contrast to conven-
2. Well controlled ECM does not induce any stresses into tional machining, ECM finishes improve with the higher
the surface. material removal rates that accompany high current den-
sities in the main electrode working gap. Rates of electrode
3. High current densities are desirable in the cutting gap advance of 0.001 to 0.005 inch per second 10.025 to 0.127
for good finishes and rapid metal removal. mm/sl and current densities of 500 to 1500 amperes per
square inch 178 to 232 A/cm2Jlare frequent. The upper limit
4., The current density in the workpiece should be care- for current densities is usually the internal, resistive heat-
fully planned to prevent overheating in the material. ing in the workpiece. Inaccuracies or distorting forces can
accompany this internal heating. Poor electrical con-
5. Relentless process controls should be supplemented nections or clamps can produce highly localized hot spots
with periodic metallographic checks from representa- that can involve temperatures to the point that micro-
tive surfaces. structural alteration occurs, as shown in figure 18.3-75.
6. The work material heat treat state should be precisely Surface roughness can be a quality control guideline.
known and controlled to assure the best repeatability The usual fine ECM finish, if tracked or plotted, sequen-
of ECM surfaces. cially and frequently can be a good quality control tech-

18-91
18.3 Surface Integrity
nique. A gradually changing roughness usually accom- Accidental short circuits should be carefully examined
panies a slow change in ECM operating parameters; for for subsurface damage. Modern short circuit protection
example rising sludge content, electrolyte temperature de- devices have rapid enough action to protect surfaces from
cline, etc. A sudden change in roughness frequently can be severe damage (and in some cases show only barely detect-
traced to a change in the metallurgical state of the work- able pin pricks). Older, slower devices have been known to
piece material: for example, a new lot of stock. produce microcracking as deep as 0.10 inch 12.54 mml.
Careful examination, removal of damaged areas or rework-
Areas of low current density should be suspects for in- ing can protect the workpiece surface integrity. Occasion-
tergranular attack or selective etching. At increasing ally, overheated areas will show only as a light surface dis-
distances from the principal electrode cutting face, the volt- coloration. While the appearance is easily restored, cases
age, current and current density all decline and with them have been recorded of nuggets of metallurgically altered
the cutting rates. At specific low values, pitting, inter- material of considerable extent. Figure 18.3-75 illustrates
granular attack. selective etching or anodic films can oc- one such nugget that occurred from overheating a Ti-6AI-
cur. Insulation of the sides of the electrode can concentrate 4V alloy by concentrating the current flow under a con-
the electrolytic action. Masks on the workpiece surface are nector as a result of a loose adjacent connector.
only partially effective in reducing these undesirable effects
because a groove of removed material will frequently ap-
pear at the edge of such masks. These stray etching areas
usually have so little material removal activity that dimen- ECM produces unblemished surfaces. With the lack of
sional problems are nonexistent and the cosmetic appear- mechanical contact with the workpiece, the gentle mole-
apce effects can be confined to the anodic film or "blush" cule-by-molecule dissolution of the material, and the min-
that is readily removed. ute surface chemistry effects, ECM produces a nearly un-
blemished surface. From the standpoint of assessment of
Random pitting in workpiece surfaces adjacent to the pure, uncontaminated or unaffected material proper-
ECM'd areas can result from material anomalies. Occa- ties. specimens prepared by well controlled ECM are unex-
sionally groups or single pits will afoear on the workpiece celled. Even polishing with worn crocus cloth can have
in areas adjacent to the ECM'd area. The pitted areas have measurable impact on high cycle fatigue values.
been exposed to low current density from free flowing elec-
trolyte or electrified mists. The electrolytic action concen-
trates in the anomalies in the work material, thus gener-
ating a pit or ring- shaped depression (around a less Mechanical material removal action in electro-
conductive inhomogeneity in the material). Some use has chemical grinding (ECG) should be controlled to min-
been made of this selective cutting tendency as an in- imum values. The abrasive action of the electrically con-
spection aid to assess the surface uniformity of material ductive wheel used in ECG is intended for removal of the
stock, anodic films formed on workpiece surfaces. It is not used
for significant material removal. The principal material re-
Control of the metallurgical state of the work material moval action is still electrolytic, Too heavy abrasive action
is needed. The proper selection of electrolyte, current den- can result in short circuits, abrasive burns or too much re-
sity and the other operating parameters must include con- sidual stress, as in conventional grinding. Less than 5 per-
sideration of the heat treat or metallurgical state of the ma- cent, and frequently as little as 1 percent. of the material
terial. While electrolytic machining will continue at almost removed comes from the mechanical action. One rule of
the same rate regardless of the material hardness, the pres- thumb states that no more than two light scratches from
ence or absence of IGA can depend on the heat treat state. abrasive action should be seen in each square inch of sur-
Many alloys will be free of IGA when ECM'd in the hard- face. The primary purpose of the abrasive action is to pro-
ened state: some, however, must be ECMd in the annealed vide a clean nascent surface so that the electrolytic action
state to be free of IGA. A simple metallographic section of can proceed at the most rapid pace consistent with over-
a test piece or coupon is good quality assurance. For ex- heating the workpiece. wheel or electrolyte. With good
ample, the massive IGA shown in figure 18.3-68 dis- electrolyte flow control and good operating parameters.
appeared completely when the M252 alloy was electro- ECG will result in stress free and unexcelled surface integ-
chemically machined in the annealed state. rity, as is demonstrated in figure 18.3-73.

18-92
 Surface integrity 18.3

08

2 4

-a20-- ~

-40
0 0.002 0.004 0.03 0.008 0.010
Depth beneath surface, in

Figure 18.3-66 Typical residual stress profile

from
ECM (17-4 PH). (G.Bellows and J. B.Kohls2o)

0 38**
C)

0 34*-
- 32
Figure 18.3-65 Typical surface characteristics 0.5 075 11.5 2 4 8
of 16
17-4 PH producad by electrochemical machining.
Top. SEM of surface at 45' and 1000X; bottom, Depth beneath surface, thousandths inch
section at 1000X. Surface roughness is 29 micro-
inches R.; Rt = 152 microinches. (Surface Integrity
Encyclopedia]) Figure 18.3-67 Typical microhardness traverse
from ECMV showing surface softening or Rebinder
effect (17-4 PH). (G.Bellows and J. B. Kohls2O)

18-93
18.3 Surface Integrity

STANDARD
OFF STANDARD

Minimal IGA
0.0003 in
Udimet 500

_0
_1 ORR 0
"-:i , , _Pits or
selective etch
U0.0015 in

Udimet 500

Massive IGA
._ 0.002 in
CY Aged M252

Figure 18.3-68 Comparison of surface

sections of "standard" and "off-standard"
machining of several nickel alloys. (G. Bellows2) electrochemical

ZI33Rc

__
0

Co----___

Figure 18.3-69 E;ectrochemical machining

of cast Rene 41 (aged, 47 Rc). Photomicrograph
surface having a pronounced tendency shows a
toward intergranular attack during an
terations, such as shown, are difficult ECM process. Surface al-
to detect, but they are detrimental and
the use of proper process parameters can be avoided through
and exacting control of ECM conditions.
(W. P. Koster et alS)

18-94
- -- -- ~ - ---- ---- --
 Surface integrity 18.3

II Surface
Ol1in

Section

15
10

Talysurf CLA 9.6 iin Ra

002i
Figure 18.3-70 ECM of Ti-6A1-4V (beta processed).
trace of well performed ECM with NaCI electrolyte. Surface view at 5X, section at lOO)OX and stylus
(Surface Integrity Encyc;opedial)

0A~
7~

M - -

5 -w

Getl rnonedmcr-Abusive
oniios-
scopic roughening and tendency toward conditions - pronounced surface roughening
intergranular attack plus slight surface plus moderate surface hardness loss. -

Surface roughness 40W juin Ra

hardness loss. IOGOX
Surface roughness 40 wn Ra 100OX

r-rGent-le

0 0-004 0008 0012 V 0.020

Depth beneath surface. in
=Figure
18.3-71 Surface characteristics of type 410
stainless steel (annealed, 89 Re) produced
ECM. (W. P. Koster et aiB) by

18-95
18.3 Surface Integrity
- - so lCROHARDNESS
S45a

35 -

Depth2 beneath
-~- 0 4 surface.
6 thousandths
8 10
inch 12

S10
a.ypical processing paa eessufc og i
s2
43 gjin Ra Minor subsurface softening plus a fyp-
ical surface etching.'

__,

000 2f 4_ 6 8 1 1

STGU STENT

___Da

Ci C

18-39
 Surface Integrity 18.3
MATERIAL 3j
321 stainless steel
________________________________
403 stainless steel1 7
54_______68____

1 198- 122
300M. 0 & T, 52 Rc I 7
___64_ 105
Grade 250 maraging steel 1_____
38! 60 671
Ti-6AI-4V. STA. 36 Rc max--
'47 72
Ti-6A I-6V-2Sn. STA. 42 RcI
Inconel alloy 718. STA. 44 Rc
41145 52
Rene 41. STA. 40 Rc72 8
17-4 PH. STA. 43 Rc
1 35 145i
Mar M509
1 1 44 J57 75
Rene 95. STA.50~R283 42
Rene 80. STA, 40 Rc VVntec &ereo
1 55 6365 -handbook- values by
AF2-1DA. STA. 46 Rc low stress grinding
I I I ~ Range observed to date
0 20 40 60 80 100
Fatigue strength at 10- cycles. ksi
(room temperature. full reverse bending)

Figure 18.3-74 Summary of high cycle fatigue strengths from electrochemical machining. Note: In the
observed ranges. the lower values most generally represent the "off-standard" operating conditions,
while the upper values are representative of "standard" or preplanned conditions.

F. -2

~ ~~A~~-3!e -M.056 in

Figure 18.3-75 Metallurgical alteration below the ECM surface of Ti-6A1-4V caused by current con-
centration under an electrical connection adjacent to a poor (or high resistance) electrical connection.
40X. (G.Bellows2 l)

18-97
18.3 Surface Integrity
TABLE 18.3-20 Surface Integrity Effects Observed In Electrical Material Removal Processes
FiNISHING, ROUGHING,
PROPERTY "GENTLE" OR "OFF-STANDARD"
AND LOW STRESS OR ABUSIVE
TYPE OF EFFECT CONDITIONS CONDITIONS

Surface roughness: pin R. - pin Ra 4-R,

Average range 8 0 63 1.6
to to
32 2506.
Less frequent range 2 m05 8
to to
125 V 2 500

Mechanical altered material zones: inch* incho m

Plastic deformation (PD) 7"
Plastically deformed debris (PDI)
Hardness alteration' 0.0014 n 0.0020 .
Microcracks or Macrocracks 0.0003 O38 0.0015 O 3
Residual stresst 0 0

Metallurgical altered material zones: inch* NOW tn

Recrystallization -
Intergranular attack (IGA) 0.0003 -OWN 0.0015 I
Selective etch, pits, protuberan"es 0.0004 0.0025 1-
Metallurgical transformations - -
Heat-affected zone (HAZ) or Recast layer - _

High cycle fatigue (HCF,: percent percent.

Variation from "handbook" values at room
temperatures' + 6 to -33 -20 to -45

SOURCE: G.Bellows and J.B Kohls."*

NOTE: A dash (-) in the table indicates no or iqsufficient data.
*Maximum observed depth normal to the surface.
'Depth to point where hardness becomes less than :2 points R,(or equivalent) of bulk material has (hardness converted from
Knoop microhardnesc measurements).
$D,pth to point where residual stress becomes and remains less than 20 ksl [138 MPa] or 10% of tensile strAn:,ih, whichever is -
greater.
2Handbook values from HCF testing frequently are generated from specimens that have been processed using low stress
grlnding, hand or gentle machine polishing or occasionally electropolishing. For this table, "handbook" values represent HCF
strength values generated from l1w-stress-ground specimens (with their minor amount of retained but enhancing compressive
residual stress). The values are the 10' cycle strengths from full-reverse bending tests at room temperature.
; Short circuit accidents have caused microcracking as deep as 0.10 inch [0.25 mm].

Specific Guidelines and Data for THERMAL The shallow thermal impact of these processes is accom-
Material Removal Processes panied by the very rapid quench rate from the heat sink of P
The therial material removal processes utilize a variety of the bulk of the material. These transient thermal waves
heat sources to melt, vaporize or sublime the workpiece produce a recast and/or resolidified layer(s) on the surface
surface. The rate of material removal is a function of the with a heat-affected zone (HAZ) below the recast layer(s).
energy density which can vary from 100 watts per square Lightly attached splatter and globules appear at higher
inch 115 5 w/cm2l with plasma arc or electrical discharge energy levels. Figure 18.3-78 illustrates most of the effects
machining 2(EDM) to 3 x 1010 watts per square inch 10.47 x found. The thickness of the recast layers increases with an
1010 w/cm for laser machining. The surface texture re- increase in the material removal rate, as shown in figure
flects the impingement of the heat source and the molten 18.3-79. When EDM is well controlled only a few ten
state that occurred, as is shown in figures 18.3-3 ane thousandths inch of recast is found, as shown in figure
18.3-76. Surface roughness measurements of reasonable 18.3-80. The recast layer has a heat-affected zone immedi-
accuracy can be made on these surfaces if stylus traces are ately beneath it and of a thickness approximately the same
averaged over several readings taken in different direc- as the maximum recast. Figure 18.3-81 shows typical mi-
tions. Roughness increases with increase in process energy crohardness traverses with the much harder recast and the
level vh;,;h is directly proportional to the material removal usually softened zone below.
rate, as shown in figure 18.3-77.

18-98
 Surface Integrity 18.3
Since most of the thermal machining data has been gener- 11. Microholes (those less than one millimeter in diameter)
ated using EDM, the temptation to extend these data to produced by thermal processes may not be detrimental
other thermal processes should be resisted The signifi- to fatigue endurance strength A check by facture me-
cantly different energy rates of laser, for ex,,nple, produce chanics of the critical hole size for a specific material is
significantly different effects, as demonstrated in figure desirable.
18.3-4. The charts and guidelines that follow have base-
lines the same as those for the mechanical material re- 12. Ou; thin components, high current densities may over-
moval processes. Figure, 18.3-76 to 15.3-92 illustrate heat the workpiece.
good or poor surface effects from thermal material removal
processes. Microhardness example- are shown in figures 13. Thorough cleaning to remove lielectric fluids, beads
18.3-81, 18 3-82, 18 3-84, 18.3-86, 18 3-87, and 18.3-89 and vapor residue is desirable.
and typical residual stress patterns in figures 18.3-88 and
18.3-89. A summary of high cycle fatigue strengths from 14. The microcracks per inch of cross section can be a
EDM is contained in figure 18.3-94 and table 18 3-22 valuable clue to the relative thermal sensitivity of ma-
Table 18 3-21 is a summary of the surface integrity effects terials. table 18.3-23.
observed during the examination of several thousand
pieces of data. Other thermal material removal illustra- Special Comments Concerning Surface Integrity
tions are figures 18.3-3, 18 3-4, 18.3-11, and 18.3-15. Practices for Thermal Machining Processes
Whenever EDM is used in the manufacture of highly
stressed structural parts, the heat affected layer which
Thermal Process Guidelines that Promote Good is produced should be removed or given a remedial
Surface Integrity Results post treatment. The altered surface layer(s) which is pro-
duced during EDM lowers fatigue strength of alloys signifi-
1. The surface texture is composed of a random array of cantly. The altered layer consists of a recast layer with or
overlapping craters or cusps, sometimes with macro- without microcracks. some of which may extend into the
cracks at the roughing level of processing, as shown in base metal, plus metallurgical alterations such as rehard
figures 18.3-3 and 18.3-76. ened and tempered layers. heat-affected zones, intel-
granular precipitates, etc. Concern over the lowered fa-
2. Surface roughness standards should be reassessed tigue strength is in reference to highly stressed structures.
when using these processes because they produce un- For many tool and die applications, the altered layer has
usual surface textures with no lay patterns and require not caused problems. and the. e have been reports of im-
different methods of checking. proved die life in speial applications. Generally. during 0

3. The prior metallurgical condition of the workpiece is

EDM roughing, the layer showing microstructural I
changes, including a melted and resolidified layer. is less
as important to generating surface quality as is the se- than 0.005-inch 10.127 mml deep; while during EDM finish-
lection of operating parameters. ing, it is less than 0.001 inch 10.025 minI.

4. Careful monitoring of the preselected operating param- The detrimental high cycle fatigue effects of the surface al-
eters is necessary. Some older types of equipment do terations caused by EDM are shown in comparison with
not maintain their initial settings throughout a long low stress grinding in table 18.3-22 and figure 18.3-94.
day or run.
Post treatment to restore fatigue strength is recom-
5. The depth of thf heat-affected zone (HAZ) or recast mended to follow EDM of critical or highly stressed
structure on the surface is aporoximately proportional surfaces. Since all alloys examined to date show a signifi-
to the magnitude of the energy impinging on that sur- cant decline in fatigue strength when their surfaces are pro-
face It is always present to some degree. duced by EDM, it is necessary to apply a modifying post-
EDM process in order to restore the surface integrity.
6. The HAZ can induce hardness variations and a sub- There are seve-al effective processes to accomplish resto-
stantial tensile residual stress in the surface layers. ration or even enhancement. It is recommended that a spe-
cial surface integrity evaluation be made for critically
7. The depth of the H AZ below the recast layers is ap- loaded surfaces. The evaluation should be made on test
proximately equal to the depth of the maximum recast. workpieces or coupons to which the full sequence of oper-
The recast layer in EDM can be controlled precisely ations generating the "as-shipped" surface has been ap-
and is usually only a few ten-thousandths inch thick. plied. Among the frequently used post-treatment processes
are the following:
8. Fati,ue strength is frequently severely reduced by the
HA-,(s). 9 removal of layers by low stress grinding

9. Highly stressed or critical surfaces should have the * removal of layers by chemical imachining
HAZ produced by thermal material removal processes
removed or modified by a post-processing treatment. 0 addition of a metallurgical type coating

10. Removal of the altered material zones (AMZ) may not

be necessary if component or laboratory tests shown
that design requirements are being satisf-d.
* reheat treatment

* application of shot leening

II
18-99
18.3 Surface Integrity
See figure 18.3-93 and the Specific Giiidrdines for Post- the microcracking seen in the recast layers from EDM or
Treatment Processes. other thermal machining methods is either to" reject the
processes or apply a drawing note to finish by mechanical
The thermal nature of these processes always produces means if such a process is used. This approach is costly,
a recast and underlying heat-affected zone (HAZ) on eliminates useful alternatives and ignores the altered mate-
the surface being machined. The intensity of the process rial zones from mechanical processing (see milling "recast."
energy does affect the amount of recast and microcracking figure 18.3-34). A more fruitful approach is to apply sur-
However, the thermal sensitivity or chemical complexit." -f face integrity evaluations only to those areas of a work-
the alloy can also affect the microcracking propensit' ,- piece that are fatigue or stress corrosion or critically lim-
ing a constant EDM energy level, the number of i ited in some manner peculiar to the specific applications.
cracks per inch was measured on several nickel a. Concentrated effort to improve these areas by the method
Table 18 3-23 shows the increasing rate of microcrack p- used for their generation or by the application of post-proc-
pearances as the complexity of the alloy increases. These essing treatments is eminently worthy to produce the best
values are the count found in an examination at 1OOX of 2 surface and component integrity. It is for these areas that
inches 150 mini of EDM cut surface. the decision must be made to remove or to modify EDM.
For all other less critical or noncritical surfaces, specifica-
This same study found no significant surface effects differ- tions can be relaxed with the potential for considerable
ences between cast and rolled states of Hastelloy Alloy X cost improvements. These less critical areas are usually
or Rene 41 when processed using EDM It is probable that several times as extensive as the critical areas.
the energy density in EDM is such as to overwhelm the dif-
ferences in the energy state between casting and rolling in The recast layer is not a crack propogation barrier.
these alloys. Many section photomicrographs will sl.jw microcracks

The degree of microcracking can be a valuable comparison only in the recast layer. It is wrong to assume that the
technique to assess the relative thermal sensitivity of sharp metallurgical structural change at the interface be-
alloys, tween the recast and the base metal will act as a barrier for
the propagation of microcracks. The single metallographic
Laser beam machining (LBM) develops surfaces show- section is too small a sample to assure that no microcrack
ing the effects of melting and vaporization. Applica- extends deeper than the recast, and no data are available
tions for LBM are not yet common. Recently, however, on such microcrack propagation characteristics.
LBM with oxygen assi.t has been investigated for cutting
instead of shearing various alloys including titanium. Also, Very minor fatigue strength differences exist between
LBM has been used for the production of small holes. finishing and roughing EDM. Finishing and roughing
Wherever LBM is used in manufacturing highly stressed EDM are characterized by a wide difference in surface
structural members, it should be remembered that in the roughness levels (50 to 200 microinches Ra 11.25 to 5.0 Am
application of this method the surface is subjected to melt- RaJ) and wide differences in recast layer thicknesses
ing and vaporization. Indications are that such surfaces (0.0002 to 0.005 inch 10.005 to 0.127 i..ml). High cycle fa-
should be removed or modified. It becomes difficult, how- tigue strength, however, is nearly the same for finishing as
ever, to apply secondary processing to parts containing for roughing EDM, as shown in figures 18.3-93 and
very small diameter holes or narrow slots. As a first step, it 18.3-94. The roughness values are not as significant as it
is suggested that critical parts made by electron beam ma- has classically been assumed to be. Not only the recast
chining and laser beam machining be tested to see if sur- layer but also the underlying heat affected zone can be det-
face alterations lower the critical mechanical properties. rimental. For critically loaded surfaces, it is desirable to re-
move the HAZ or to modify the surface preparation or to
The concern for EDM recast should be confined only to conduct extensive testing to Assess the reliability of the sur-
critically loaded surfaces. Too frequently the reaction to face generated for particular applications.

18-100
 Surface Integrity 18.3
-7-- -T-
0 050 in 0 010 in

0.005 in 0.002 in

Figure 18.3-76 Scanning electron microscope photomicrographs at successively greater magnifica-

tions of finish electrical discharge machining of Inconel Alloy 718 (solution treated and aged). Views
taken at 840 to the surface. Surface roughness is 62 microinches R0. (Surface Integrity Encyclopedia')

1000

500

250 [6 3/pm C_, ___

Ca

50

25..
0.005 0.01 0.02 0 05 0.1 0.2 0.5 1.0 2.0
[16.4 cm3/hrJ
Material removal rate, in'/hr

Figure 18.3-77 Approximate relation of surface roughness to material rei oval rate for electrical dis-
charge machining. (G. Bellows and J. B Kohls2o)

18-101
18.3 Surface integrity

SpatrBlow hole Globules Resolidified .

globules Heat-Affected -
Delamination Microcracks Redeposited Zone (HAZ)

Figure 18.3-78 Recast surface with types of alterations and their descriptors (Hastelloy Alloy X at
300X). (G.Bellows and J B Kohls2O)

50

Cu

0.0

cc
a)

005010.02 0 0 %. . . .

:5;~8- 1--21a

0.2_ - --
 Surface Integrity 18.3

c Recast StructureAbsv

I 5)C 40

0 0010 0020 003C

Depth beneath surface. in

Figure 18.3-81 Typical microhardness traverse
Figure 18.3-80 Typical well controlled EDM on EDM surface of Inconel Alloy 718 (solution
re- treated and aged). (G Bellows and J B KohS2O)
cast and heat-affected zone (0.0002 inch pre-
dominant recast from EDM of Udimet 700). (Surface
Integrity Encyclopedtat))

0.001 in
Finishing conditions -a thin discon-
tinuous recast ayer 00~1to002inch Roughing conditions.-.a band of cracked recast
metat
and underlying layers of untempered and
deep was produced on the surface overtem-
pered martensite were formed The total heat-affected
10DOX depth was approximatu.y 0 005 inch
1000X
70 -Recast structure
o--Untempered martensite
SC
0 I

C
Overtempered martensite
'2 50
Finishing
40 / Roughing
0 0010 0020 03
Depth beneath surface, in
Figure 18.3-82 Surface characteristics of type
D2 tool steel (quenched and tempered, 61
duced by EDM. Ac) pro-

18-i103
18.3 Surface Integrity

x
Figure 18.3-83 Surface characteristics of tung-
sten carbide (883) produced by EDM. (Surface In-
tegrity Encyclopedia')

0001 in

Finishing conditions - discontinuous patch- Roughing conditions - globs of recast metal

es of recast metal plus a thin layer of rehard- (62 Rc) are spattered on awhite layerof rehard-
ened martensite (0 0001 inch) are seen No ened martensite totaling 0 003 inch deep, also
hardness change was detected f00OX at 62 Rc An overtemperedzoneassoft as46Rc
70 Ris found beneath the surface Total depth of
Recast metal --- Finishing layer affected approaches 0 010 inch 1000X
09 While layer Roughing

so

40
0 001C 0020 0030
Depth beneath surface. in

Figure 18.3-84 Surface characteristics of 4340 steel (quenched and tempered, 50 Rc) produced by
electrical discharge machining.
11

18-104 i
 Surface Integrity 18.3
0 002 in _

150 000, in

Stylus trace 162 pin Ra. 1000 tp in-peak to valley

SEM at 450 1250 X

Predominate recast 0 00013 in Maximum recast 0 00124 i

Figure 18.3-85 Typical surface characteristics of rolled Hastelloy Alloy X from "normal" EDM. (Sur-
face Integrity Encyclopedia')

Finishing conditions - a discontinuous Roughing conditions -a recast layer approximately

recast layer averaging 0 0002-inch deep 0.0005-inch deep plus a heat-affected microstructure
was produced on this surface. 1000X averaging 0001-inch deep. both frequently cracked,
were produced on the surface Microhardness measure-
60 ast s'tructure - Finishing ments indicate a total heat-affected depth of 0 005-inch.
Rougfring 100OX
C 0

W ffected
a n
40

0 0010 0020 0030

Depth beneath surface. in

Figure 18.3-86 Surface characteristics of Waspaloy (aged, 40 Rc) produced by EDM. (W. P. Koster
8
et a1)

18-105
18.3 Surface !ntegrity
_ __ _ 140 1
0 00 n 2 FINISHING ROUGHING
~7 O~in12 ~ Frequency. kc 260 16
~ ~ ~Amperes 1 4-5
-4'~ Capacitance. mifd 0 2
If100 jVoltage 70 80

Finishing. 89 in Ra. 8...95 in range 0 I I -.i Finish EDMV

Recast 0 0003 inch avg. 0 0005 inch max 80
1,i
W -Rough 2DM

A oil- 1
.4fU)
00 i

40--

Recas 02ic a.S 00 00n -nhag

Q 20

0 0 0.002 0.004 0.006 0.008 0.10

Depth below surface, in

MC
I ~j~ Figure 18.3-88 Residual surface stress profiles in
AF 95 (Rene 95) (solution tree 4ed and aged, 50 RC)
uiFinishing produced by EDM. See also f-gure 18.3-93. (W. P.
- - -Koster and J. B. Kohls' 8)
4 -
.Rouhing

0.5 1 2 51 0 20
Depth beneath surface, thousandths inch

Figure 18.3-87 Surface characteristics of nickel

alloy AF2-1 DA (solution treated and aged) pro-
duced by EDM. (Surface Integrity Encyclopedia])

18-106
 Surface integrity 18.3

~- 001in -F 4~
~-0001 in

a Finishing -thin recast layer averaging 0 0004

ich. Some surface softening Surface roughness b Roughing variable recast layer averaging
62 Oin Ra 0 00053 i-ch. max of 0 0009 inch Sub-surface
softening toO0 004-inch depth Surface roughness
MICROHARONESS 206 gin Ra
RESIDUAL STRESS
~50 - b T._j 10
FATIGUE STRENGTH
545 100
a
C40 80
'235
C a6 a bo au 606
40 400
X0 4 6___ 10 12_0_b
E_4_ 20 22
Depth beneath surface. thousandths inch S-20

-40 Number of cycles

Depth beneath surface. thousandths inch

Figure 18.3-89 Surface integrity standard dpta

set of EDM of Inconel Alloy 718 (solution treated
aged). Note that thin layers of recast (or the HAZ) and
many times as thick. In this alloy, the reduction can bE' *trimental to fatigue strength as layers
is 63% from , handbook" high cycle fatigue strength
of 60 ksi. (W. P. Koster et a[9)

_V

T
0 .00045 h07
18.3 Surface Integrity

- 4 .
-. 3

,k..

Figure 18.3-91 Surface characteristics of hole in Inconel

Alloy 718 produced by LBM showing worst
microcrack observed, 0.0008-inch long. Predominant
recast 0,0007 inch, maximum recast 0.0029 inch.
Note epitaxial growth in deposite ,dyer nucleated on
base metal grains. (Surface Integrity Encyclo-
pedia')

0.016 in

Figure 18.3-92 Surface characteristics of hole drilled

in Rene 80 (solution treated and aged) with ruby
laser. Note the two distinct recast layers from vapor deposited
during the two laser pulses.

18-108
 Surface Integrity 18.3
140 -- FATIGUE SURFACE
- - -CONDITION STRENGTH ROUGHNESS

12 41111 MllimFinish EDM -Peen 115 45

Z Rough EDM -Peen 110 130
le
'6; 100 -
C0

80 Gentle grind 75 13
ca

<~ 60

40 Fiih80 0s
I -t Rough EDM 35 200+
105 108

Cycles to failure

Figure 18.3-93 High cycle fatigue characteristics of AF 95 (Rerne 95) (solution treated and aged, 50
Rc) produced by EDM. Mode: cantilever bending, zero mean stress, temperature 75 0F. See also figure
18.3-88. Note that finish EDM has about the same reduction in fatigue strength as rough EDM as com-
pared to gentle low stress grinding. Note also the recovery and enhancement of fatigue strength With a
post-EDM shot peen treatment. (W. P. Koster and J. B. Kohisl")

MATERIAL i F ] Ii
410 stainless steel. 0 &T. 32 Rc 1__40 62
Ti-5AI-2.S Sn 21I
Ti-6A1-4V, STA. 32-34 Rc 24V4

Ti-6A1-4V. Beta I11.STA. 39 Rc 10 177

Commercially pure titanium '30 7
17-4 PH. STA. 45 R, 22
7
1 -4 PH. STA.43 Rc 3
Inconel alloy 718. S. A. 4 RC 22
Inconel alloy 718. ST. 33 Ra 12
2917 60 v4
Mar-M509. as cast 29 Rc 1I435g

Rena 41. STA. 40 R0

_T 3017 52 1
Range observed to date
Reference baseline or
52 handbook-' values by
Rene 80, STA. 40 Rc 26low stress grinding
Rene 80 with resolution & age 32 42
351
Rene 95 (AF95). STA. 50 Rc 40
4 V75
417

AF2~1DA. STA. 46R 20C 6 00

C355 cast aluminum, as cast E 7 121
Fatigue strength at 10' cycles. list
(room temperature, full reverse bending)

FRgure 18.3-94 Summary of high cycle fatigue strength from electrical discharge machining.

18-109
18.3 Surface Integrity
TABLE 18.3-21 Surface Integrity Effects Observed In Thermal Material Removal Processes
S FINISHING, ROUGHING,

PROPERTY "GENTLE" OR "OFF-STANDARD"

AND LOW STRESS OR ABUSIVE
TYPE OF EFFECT J CONDITIONS CONDITIONS

Surface roughness: Fin R. inR.

Average range 32
to 1 125
to
125 500

Less frequent range 2 1, ' 32

to to
250 -,e 1.000

Mechanical altered material zones: inch* inch*

elstic deformation (PD) )
Plastically deformed debris (PD * *
Hardness alteration' 0.0011 0.0080
Microcracks or Macrocracks 0.0003 0.0070
Residual stress: 0.0020 0.0030

Metallurgical altered material zones: inch*

Recrystallization
Intergranular attack (IGA)
Selective etch, pits, protuberances
Metallurgical transformations - -
Heat-affected zone (HAZ) or Recast layer 0.0006 0.0050

High cycle fatigue (HCF): percent percent

Variation from "handbook" values at room
temperature, -17 to -96 -48 to

SOURCE: G.Bellows and J.B.Kohls."

NOTE: A dash (-) inthe table indicates no or insufficient data. Atmple asterisk (1**) inthe table indicates no occurrences or
not expected.
-Maximum observed depth normal to the surface.
'Depth to point where hardness becomes less than 2 points k,, (or equivalent) of bulk material has (hardness converted from
Knoop mlcrohardness measurements).
'Depth to point where residual stress becomes and remains less than 20 ksl [138 MPa] or 10% of tensile strzngth, whichever is
greater.
'Handbook values from HCF testing frequently are generated from specmsns that have been processed using low stress
grinding, hand or gentle machine polishing or occasionally electropolishng. For this table, "handbook" values represent HCF
strength values generated from low-stress-ground specimens (with their minor amount of retained but enhancing compressive
residual stress). The values are the 10" cycle strengths from full-reverse bending tests at room temperature.

TABLE 18.3-22 Fatigue Strength Comparison for

Materials Processed Using EDM or Low Stress Grinding TABLE 18.3-23 Cracking Sensitivity of Nickel Alloys
FATIGUE STRENG from EM
Gentle or EDM
ItNUMBER OF
MATERIAL Low Stress (Finishing MATERIAL MICROCRAC;S
Grinding Conditions) PER INCH [25 mm]9

Hastelloy X (least sensitive) 1.0

Inconel 71e (STA, 44 Rj 60 2 Rene 41 1.5
AF 95 (STA. 50 R 75 Rene77
Ran 80 3.5
Rene 80 (STA. 40 R,) 2Rena 120 (most sensitive) 4.6
AF2-1 DA (STA, 46 R) 70 SOURCE: G.Bellows.w observedi Intwo incesm (50 mitlimetem] of cross
~ ~
NOTE:~~~~~~ ~ ~RomtmeaueuinntdohrieNumber of microcracks
section after the specimen was electrical discharge machined at a normal
*10' cycles full-reverse bending. level equivalent to amaterial removal rate of 0.18 to 0.27 in'/hour.
At1000IF(538-C]. Observations were made at a magnification of 1000X.

18-110
 Surface Integrity 18.3
Specific Guidelines and Data for CHEMICAL 4. Surface roughness variations during processing can be
Material Removal Processes a good indicator of changes in the processing condi-
The chemical family of material removal processes is char- tions. or a change in the metallurgical state of the
acterized by an absence of stress introduced into the work- work material.
piece as a result of the process. The gentle chemical action
of dissolution. molecule-by-molecule or grain-face by grain- 5. Careful rinsing of the solutions from the finished work-
face, is typically smooth: however, very smooth surfaces piece is essential.
(32 microinches Ra or less [0.8 pn R. or lessil are slightly
roughened, while rough surfaces (125 microinches R, or 6. The control of the metallurgical and heat treat state of
more 13.2 pn R. or morel) are usually smoothed. The uni- the work material is as essential as the control of the
formity and fineness of the grain structure in the original process parameters.
workpiece is a principal factor in the final roughness. A 7 Selective etching, intergranular attack and pitting can
slight softening of the surface sometimes attributed to the rslt f rooffistana tsch as hig et-
Rebinder effect* is frequently. but not always. found, as result from off-standard conditions such as high et-
demonstrated in figure 18.3-100. Surface discontinuities, chant temperatures, incomplete stirring. depleted or
such as a weld joint, frequently result in different surface unbalanced solutions or contaminated solutions, and
texture and cutting rates. variations in the metallurgical state of the work
material.
Achieving good surface integrity from the chemical mate-
rial removal processes begins with a careful matching of 8. Weld areas tsually show a different rate of cutting than
the reagents to the metallurgical state and composition of the base material and an increase in surface rough-
the work material. Proper process control, particularly the hess.
chemical bath freshness. -isessential. 9. Steel, titanium and nickel base alloys which are sus-

Selective etching, pitting or IGA can occur with improper ceptible to hydrogen embrittlement should have a post
reagents or overly contaminated or stagnant chemicals. heat treatment of a few hours at a temperature of
Hydrogen absorption and possible embrittlement can occur about 3750 to 4009F 1191 0 to 204'C). Treatment should
with some alloys of steel. titanium or nickel. Post-process- be applied immediately after chemical processing.
ing bakes are recommended for this condition. 10. Room-temperature, high cycle fatigue strength gener-

Static mechanical properties have not been found to be ef- ally is lower when compared to conventionally pre-
fected by chemica; machining (CHM). The absence of ben- pared, low-stress-ground specimens. This is probably
eficial compressive residual stress from chemical machin- caused by the absence of residual surface stresses.
ing has the effect of reducing the high cycle fatigue strength
when com pared to conventionally prepared test specimens. 11. The use of post treatments to add a compressively
stressed surface layer may be desirable for enhancing a

The charts and guidelines that follow have baselines the component's fatigue strength.
same as those for the mechanical material removal proc-
esses. Figures 18.3-12 and 18.3-95 through 18.3-100 ills- 12. A test coupon for metallurgical evaluation should be
trate some of the good and poor surface effects from chem- made at least at 90- to 180-day inte als, or whenever
ical material removal processes. A summary of the high
cycle fatigue strengths from chemical machining and elec-
tropolishing (ELP) is shown in figure 18.3-101. Table 13. For quality assurance, a deviation of one operating pa-
18.3-24 is a summary of the surface integrity effects oh- rameter by more than 10 percent from the preplanned
served during the examination of several hundred pieces of value should be cause for alarm and checking. If more
data. than one parameter has deviated by more than 10 per-
cent, the operation should be shut down until correc-
Chemical Process Guidelines that Promote Good tions have returned the process to a controlled state.
Surface Integrity Results
1. Chemical machining does not induce any significant
stress in the machined surfaces. Special Comments Concerning Surface Integrity
Practices for Chemical Machinig Processes
2. Surface roughness standards should be reassessed
when applying CHM because CHM produces surfaces Special cognizance should be taken of the surface soft-
with unusual textures and no lay pattern. ening that occurs in CHM and ECM of aerospace mate-
rials. Microhardness studies on aerospace alloys have
3. The chemical reagents must be matched to the ex- shown that chemical machining and electrochemical ma-
pected metallurgical state of Ohe work material. chining8 produce a soft layer in a majority of the aerospace
alloys. Hardness reductions for chemical machining and
electrochemical machining range from 3 to 6 Rockwell C
points to a depth of 0.001 inch 10.025 ram for hemical
machining and 0.002 inch 10.050 mini for elec-ochemical
machining. Shot peening or other suitable post processing
The Rebinder effect is the modest softeniag of su:Uce z of an objec should be used on such surfaces to enhance mechanical
upon applicauon of secteid chemical sO'uio-.s that vy with ti material properties. This surface soft.ning is sometimes labeled the
of the object.' Rebinder effect.
18-111 i
18.3 Surface Integrity
Surface integrity evaluations should be made when for example, is very sensitive to the heat treat state of the
chemical (CHM) and electrochemical (ECM) processes material. Material removal is -t the rate of 0.0005 inch per
are used for finishing critical parts. The fatigue strength minute 10.0127 mm/minI, and :he surface roughens slightly
of surfaces produced by controlled chemical and electro- when in the full solution-treated state. When aged, how-
chemical processes has often been found to be low,-r than ever. massive IGA appears. Figure 18.3-99 illustrates the
that produced by some of the more commonly ':sed mate- differences. These differences occur with ider.*ical process-
ria! removal processes. This is generally attributed to the ing parameters. The material quenching rate is the princi-
unworked, stress-free surface produced by processes such pal variable. The best chemical machining of Rene 4 oc-
as electrochemical machining (ECM). electropolishing curs when the material is in a fine-grained structure with
(ELP), and chemical machining (CHA.). There is evidence the best uniformity. The quick quench in hot rolling, plus
that processes such as milling and polishing may some- the well-worked structure of thin (under 0.100 inch 12.54
times provide beneficial fatigue resistance as a result of mml) zheet stock yields the best material condition for
cold working or compressive residual stresses; therefore chemical machining. Increased thickness and slower
when substituting CHM for other machining processes, it quench rates tend to produce increased roughness and
may be necessary to add post-processing operations such slower material removal rates. The aged condition usually
as steel shot or glass bead peening or mechanical polishing, produces a surface that is rough (150 to 400 microinches
Some companies require neening of all chemically or elec- Ra 13.75 to 10 /n Ral) and filled with IGA. In the worst
trochemically machined surfac-s of highly stressed struc- case, a film forms on the surface exposed to the chemicals,
tural parts. inhibiting the action. This film must be mechanically re-
moved before chemical machining can be continue4
Heat treat state is a principal factor in good chemical
machining results. The chemical machining of Rene 41,

--

Figure18.3-95 Unblemished surface section of

cast Ti-5AI-2.5Sn (A110 alloy) produced by well
controlled chemical machining, 250X. (Surface ,.
tegrity Encyclopedia')

18-112
 Surface Integrity 18.3

20 X 100 X 200 X

0001 in

1000 X 2000 X

Fiy,.re 18.3-96 Surface texture of chemically machined Rene 41. SEM photos at 20, 100, 200, 1000,
and 2000X taken at 840 to surface. Surface roughness 500 microinches R, from off-standard condi-
22
tions. (G. Bellows )

0001 in

Gentlc conditions. No visible surface effects Abusive conditions Slight surface roughening plus indicated
othr than shallow hardness loss. hardness loss less than 0 002-inch deep.
Surface roughness 35 min Ra Surface roughness 120,uin R a

., wG entle
35I.,- --. Abusive

30f
25 j i
0 0004 0008 0012 0020
Depth beneath surface, in

Figure 18.3-97 Surface characteristics of 4340 steel (annealed, 31-36 Rc) produced by CHM.

18-113
18.3 Surface integrity

Surface roughness 45 uin Ra 1000X 65-80 pin Ra 1COox

Gentle conditions Abusive conditions
Very slight surface roughening Moderate surface roughening;
tendency toward unleveling

40 Gnl

S35

30 LL1.LL
Abusive

0 0004 0008 0012 0016

Depth beneath surface, in

Figure 18.3-98 Surface characteristics of 17-4 PH stainless steel produced by OHM. (W. P Koster
et a18)

(A) (B)

__ -'=~~0 001 in~

Typical surface roughness 50 to 60 Pin Ra. Off-standard surface roughness, 100 to130)jinlRa. Note, both inter-
granular attack and selective etch.

Figure 18.3-99 Comparison of surfaces of Rene 41 (45 Rc) when chemically machined in (A) solution
23
treated state and (B)solution treated and aged state. (G.Bellows )

18-114

SR
 Surface Integrity 18.3

50- ____ _ _ __ _ _

45 -

C)

C1

30 7 1 1.5 2 4816

Depth beneath surface, thousandths inch

Figure 18.3-100 Rebinder (softening) effect on chemically machined Rene 41 (solution treated and
aged), surface roughness 190 to 290 microinches R,.(G.Bellows2 3 )

MATERIAL
CHM
AZ9lC mnagnesium alloy 1r 15 r3 Range observed to date
X2020 aiununurr 31;32/2
L71 li~inu-coperally 1 23Reference baseline or "handbook" values
L7 lmu-opraly1 V 23by love stress grinding or milling
DTO 687 aluminum-zinc alloy 12 14 1-~
70754T7351 aluminum alloy. 77 Ra 18 V 4
Al 1 AT titanium alloy (T.-5AI-2 5 Sni,59 6
Ti-6A1-4 V-bela rolled 31-33 Ac 45 51 62
To-6A!-4V, annealed 32-34 Re 4212 54
S97 steel 14 V7
.RS130, 1%CrMo ferrous alloy ---- T--- 3-t :4
RS140 3% crMoV ferrous ailoy 57 4 )Z 6 170
H50. 5%crMov ferrous alloy X/4 172
17-4 PH. STA, 43 Ac 60 98
Rene 41. STA. 40 Ac 33 36 52
ELF
305 stainless steel. hot rolled 25M 22733
AISI 4340. 0 & T. 50 RIc 90 102
Inconel 718 alloy, STA. 44 RC 142 eo I
F1
Inconel 718 alloy, ST. 98 Re. age after
machiningI
28
....1.....J-1.... 7
-t-

0 20 40 80 80 100

Fatigue strength at 10 1cycles (room temperature, unnotched bending). ksi

Figure 18.3-101 Summary of high cycle fatigue strength from chemical machining (CH-M) and electro-
polishing (ELP). (G.Bellows 23)

18-115
18.3 Surface Integrity
TABLE 18.3-24 Surface Integrity Effects Observed in Chemical Material Removal Processes
FINISHING, ROUGHING,
PROPERTY "GENTLE" OR "OFF-STANDARC"
AND LOW STRESS OR ABUSIVE
TYPE OF EFFECT CONDITIONS CONDITIONS

Surface roughness: pn R. R1 ,in R.

j-- F_ nR
Average range 63 - -1 125 3
to to to t
250 3 5Z00
So2.o
Less frequent range 8 0.2 _f06E 63
tto o _ to 7j.
500 2 500 ;25E

Mechanical altered material zones, inch* _ - inch- mm*-

Plastic deformation (PD) *
Plastically deformed debris (PDI)
Hardness alteration' 0.0010 0025 0.0031 009
Microcracks or Macrocracks--- -
Residual stress$ 0.0010 0.0?5-- 0.0010 g 0,5 -

Metallurgical altered material zones: inch* inch* - !

Recrystallization "'' - -- .- -- "-
Intergranular attack (IGA) 010003 M 1008- 0.0060 W
Selective etch, pits, protuberances 0.0006 0I5=* 0.0015 O03&
Metallurgical transformations -
Heat-affected zone (HAZ) or Recast layer = *- - "=*

High cycle fatigue (HCF): percent percent

Variation from "handbook" values at room
temperature + 18 to -39 -22 to -37

SOURCE: G. Bellows and J. B. Kohis

NOTE: A dash (-) in the table indicates no or insufficient data. A triple asterisk (***) in the table indicates no occurrences or
not expected.
*Maximum observed depth normal to the surface.
'Depth to point where hardness becomes less than =2 points R (or equivalent) of bulk material has (hardness converted from
Knoop microhardness measurements).
$Depth to point where residual stress becomes and remains less than 20 ksi [138 MPa] or 10% of tensile strength, whichever is
greater.
'Handbook values from HCF testing frequently are generated from specimens that have been processed using low stress
grinding, hand or gentle machine polishing or occasionally electropolishing. For this table. "'handbook" values represent HCF
strength values generated from low-stress-ground specimens (with their minor amount of retained but enhancing compressive
residual stress). The values are the 10' cycle strengths from full-reverse bending tests at room temperature.

Specific Guidelines and Data for POST- CBN Roller burnishing

TREATMENT Processes to Aid Surface Integrity CBS Belt sanding
Finishing operations or post-treatment processing have CGH Hand grinding
long been used in manufacturing. These operations are CHM Chemical machining
used to improve the surface roughness or appearance. to CHN Honing
remove undesirable surface layers, or to enhance the bene- CPE Peening-shot, sand
ficia, compressive layers. The surface integrity produced CPG Glass bead peening
by these finishing processes. or sequence of processes. CPO Buffing
should be assessed with the same diligence as that used for CTB Abrasive barrel tumbling
the prime fabricating process. While shot peening has been CVD Chemical vapor deposition
the most extensively used post treatment, consideration ECD Electrochemical deburring
should be given to other techniqucs to achieve the desired ECP Electrochemical polishing
effects. Often, other treatments may be us.ed that result in ELP Electropolishing
less cost or greater productivity or better quality assur- HT Heat treatment
ance. Some of the effective post-treatment processes are as LSG Low stress grinding
follows: LST Laser shock treatment
USC Ultrasonic cleaning
USP Ultrasonic peening
AFM Abrasive flow machining VSR 'Vibrationstress relief
4

18-116
 Surface Integrity 18.3
Veiy gentle. low energy intensity conventional turning. 5. Peening with steel shot or sand or glass beads can be
milling or reaming can be quite effective as finishing oper- useful to add substantial beneficial ccmpressive resid-
ations: however, on stress-critical areas these processes ual stress. improve surface cleanliness and enhance fa-
should be carefully evaluated as previously detailed. Proc- tigue strength
ess and/or quality control must be rigorous and continuous
with much insistence on the use of sharp tools Chemical 6. Mechanically gentle processing can be effective with
and electrochemical processes with their absences of resid- specific evaluation of each situation
ual stress need special evaluation if it is desirable to add re-
sidual stress or cold working. 7. The benefits of shot peening can be nullified or se-
verely decreased by exposure to high local stresses or
Figure 18.3-102 shows the shot peened surface of 18% temperatures or by vibration which allows the surface
-.ckel maraging steel Grade 250. Figure 18.3-103 illus- stress to relax by plastic deformation either from creep
trtes the surface section of olution treated and aged or yielding during "post-peen" processing or during
'nconel Alloy 718 after shot peening, with off-standard operation.
ECM as the primary material removal method. Figure
18.3-103 depicts two levels of peening: level 1, using Si 10 8. The possibility that peening. burnishing, lapping and
shot of 50 to 55 Rc hardness with 300 percent coverage to similar processes can cover up. but not overcome, the
Almen strip intensity of 0.006 to 0.008 A: and level 2. existing microcracks should be assessed.
which was the same peening as level 1 except coverage
was 125 percent 9. Human variability means that hand finishing should be
avoided if possible or controlled rigorously.
Figure 18.3-104 charts the residual stress pattern induced
in solution treated and aged Inconel Alloy 718. The low- 10 It is possible to overpeen surfaces and create excessive
stress-ground specimens, 0.076 inch by 0.75 inch by 4 core stresses. microcracks, untempered martensite.
inches [approx. 2 mm by 20 mm by 100 mml, were shot laps or similar abuses.
peened with SI 10 steel shot to Almen intensity level 0.006
to 0.008 A. The residual stress profiles were prepared on 11. The junction between peened and unpeened surfaces
specimens after exposure to the indicated temperatures for should be "feathered" to avoid stress concentrations.
100 hours in a vacuum. The shot peening pattern is essen-
tially retained through 1300F 1704C1 for Inconel Alloy Special Comments Concerning Surface Integrity
718. This results in a 6 to 16 percent improvement in high Practices for Post-Treating Processes
cycle fatigue strength at 1000F 15380C. On such speci-
mens, an overpeened (that is. damaged) condition can oc- Cracks, heat-affected and other detrimental layers cre-
cur when a 0.012- to 0.014-A intensity level is used on thin ated during material removal processes should be re-
specim ns such as these. moved (or altered) from critically stressed areas of
component parts. Microstructural examination and mi-
Figure 18.3-105 summarizes the high cycle fatigue crohardness testing can frequently establish the depth of
strengths found for various materials subsequent to shot adversely altered layers and other defects. Certain critical
peening. These data are comparable to those illustrated for situations may require mechanical testing to be certain that
the material removal processes. Most of the tests were run no alterations have been produced which cannot be de-
on specimens peened to 0.006 to 0.008 A2 or 0.004 to tected by microexamination. Removal of these defective
0.006 A2 ,on the Almen strip scale with 125 to 300 percent layers by gentle processes should be accomrt hed. Some
coverage. post-treatment processes can satisfactorily alter these lay-
ers or even enhance the fatigue strength results.
Figure 18.3-106 summarizes the high cycle fatigue
strength found with several types of post-processing treat- Steel shot and glass bead peening as well as burn-
ment
Iconl Aloy 18.ishing
ononeallo. can be used to improve surface integrity. A con-
Post-Treatment Guidelines that Promote Good Surface siderable number of studies have confirmed that the fatigue
Integrity Results life determined in laboratory tests and verified by field per-
Interit Resltsformance is measurably enhanced by peening. 8 Laboratory
1. Careful washing should be employed to remove all tests have shown that shot peening is effective in sub-
traces of fluids used during machining that could con- stantially increasing high cycle and low cycle fatigue
tribute to stress corrosion. strength at both room and elevated temperatures for typi-
cal titanium alloys, high temperature alloys, and high
2. Low temperature heat treatment will remove any hy- strength steels, regardless of the type of prior material re-
drogen picked up during processing. moval processing. For example. electrical discharge ma-
chining and abusive grinding are two processes which are
3 Heat treatments following material removal are of lim- among the most detrimental to these alloy groups. But
ited usefulress. when added as a post-processing treatment, shot peening
has been shown capable of fully restoring the room and ele-
4. Abrasive tumbling can be effective for improving sur- vated temperature low cycle and high cycle fatigue
face texture and for adding a modest compressive re- strengths for these alloy groups. Since the above comments
sidual stress to aid fatigue strength. are based upon laboratory tests of specimens. component
evaluations are recommended. Peening. which puts the
surface layer into compression and cold works the surface,

18-117

; ._ .o
-- --- J-.-='. -- - - - -_ ~~
18.3 Surface Integrity
must be performed under controlled conditions Specifica- shot peening Low temperature heat treatments are helpful
tions for controlled peening should include consideration of in eliminating embrittlement for operations where hydro-
factors such as the cleanliness and surface roughness of the geii may be picked up during processing. such as in plating.
part being machined: the type. the chemistry. the geometry Elimination of hydrogen is time- and temperature-depend-
and the hardness of the shot and its fluid carrier: and peen- ent and also depends upon the alloy being treated. Steels.
ing time, intensity and coverage. Reports also indicate that for example. are often treated at about 3750 to 400F 11910
peening improves resistance to corrosion and reduction in to 204'CI ror periods of 8 hours or more.
stress corrosion susceptibility. There are indications that
cold working ot drilled holes by burnishing is also benefi- Abrasive tumbling is an effective process for improv-
cial as is roller burnishing. Some reports contain pre- ing surface properties including fatigue. This process is
cautions against overpeening in order to avoid fatigue dam- less applicable than shot peening for many of the very large
age and to reduce the possibility of masking flaws such as parts required for aerospace applications Both abrasive
fine cracks. tumbling and shot peening usually require an added polish-
ing operation when very high finish requirements must be
Evaluate the use of controlled shot peening practices satisfied. Care must be taken not to remove the thin favor-
to restore fatigue life of components processed by elec- able surface layer established by peening or tumbling.
trical, chemical, and thermal removal processes. Shot Abrasive tumbling can be used to reverse unfavorable ten-
peening has been shown to be extremely effective in im- sile stresses by inducing a compression stressed surface
proving the fatigue life of specimens processed by electro- layer.
chemical machining (ECM). electrical discharge machining
(EDM). and electropolishing (ELP).9 Component tests are
recommended to confirm the favorable trends shown in Washing procedures should be employed for critical
tests on laboratory specimens. Examples of shot peening parts and assemblies to remove all traces of cutting
improvement in the fatigue strength of specimens are fluids which may cause corrosion. Typical suspect com-
shown in table 18 3-25. pounds are sulfur compounds on aluminum and nickel base
alloys and chlorine compounds on titanium alloys-" Cur-
Post heat treatments following material removal are of rently, some companies do not allow any chlorine-contain-
limited usefulness. Stress relief treatments, used to soften ing cutting fluids to be used in processing titanium parts
hardened layers produced during grinding of steels, do not which are to be used at room or elevated temperatures.
restore the hardness of overtempered layers which are pre- Other companies use this precaution only for parts which
sent immediately below the damaged surface layers. Also, are subjected to temperatures over 500F 1260T]C. For ap-
0
heat treatment does not heal any cracks produced during plications at less than 500'F 1260 C, carefully controlled
material removal. Some companies have advised the use of washing procedures are often used to remove the chlori-
tempering operations to relieve stresses after electrical dis- nated and sulfurized cutting oils. These fluids are partic-
charge machining (EDM) of steels. Stresses may be re- ularly effective for chip removal operations such as drilling.
lieved but fatigue properties are not improved sufficiently. tapping and broaching. Since complete agreement does not
Evidence has also been presented to show that annealing exist among manufacturers regarding cutting fluid prac-
treatments following EDM on nickel base alloys, such as tices. subcontractors are obliged to follow the policies and
Rene 41. Inconel Alloy 625. Inconel Alloy 718 and Monel procedures established by the prime contractor.
Alloy K-500. seriously lower tensile strength and ductility
as a result of carbon diffusion) 0 Experience has shown that Protection of parts. Parts should not be stored for ex-
heat treatments in some cases have improved surface integ- tended periods without being carefully washed and then
rity of damaged surfaces but not nearly as effectively as covered with a coating of oil for corrosion prevention.

18-118
 Surface Integrity 18.3

UO
0

20X 200X 2000X

Figure 18.3-102 Typical surface characteristics of shot-peened Grade 250 Maraging steel. Surface
machined with ECM, then 300% coverage shot peened with S110 shot of 45 to 50 Rc hardness to Almen
level 0.004 to 0.006 A2. View by SEM at 450 at increasing magnifications of 20, 200 and 2000X. Note im-
pression bf single shot in highest magnification view. Surface roughness of 38 microinches R,. (Surface
Integrity Encyclopedia')

0.001 in

125% peen- surface roughness - 119 juin Ra 300% peen: surface roughness - 9C gin Ra

tr 5-
45 ---- ECM - 125% peen
ECMA + 300%, peen
8 40
-

0 0.004 0.008 0012 0.020

Depth beneath surface, in

Figure 18.3-103 Surface characteristics of Inconel Alloy 718 (solution treated and aged, 44 Rc) pro-
duced by ECM plus shot peening. Note roughness similar to ECM but with additional tears and cracks,
perhaps from peening. Subsurface strain lines from peening also visible. (A. P. Kosler et ale)

18-119

- ____ ~
18.3 Surface Integrity
40

d oj:- 4Ce

0
13000 F

-201
(02 00 0 Ff

-40

0)
10000
OL -60__ _

E
0

-8 11000F

No exposure
-1001 %&

-120 - - -- I

0 0.002 0.004 0.006 0.008 0.010 0.012

Depth beneath surface, in

Figure 18.3-104 Residual stress patterns in Inconel Alloy 718 (solution treated and aged) produced by
low stress grinding plus peening (0.006- to 0.008-A
24
intensity) after 100-hour exposure to various ele-
vated temperatures. (G.Bellows and R.M.Niem1 )

18-120J
 Surface Integrity 18.3
MATERIAL AND BASIC PROCESS

AISI 4340. Q&T, 50 R c CGS 11

ELP

Ti-6Al-2Sn-4Zr-2Mo, STA, 36 Rc CHM 65wih90

Hadgrind 374 Note the ranges observed to

~6 32 date generally represent
60 65tinishing processes in the upper
Inconel alloy 718, STA. 44 Rc LSG IS 70 end of the ranges and roughing
I 1 63 'levels in the basic process at
ECM - b he tower end
31 1 6 iA Reference value - no shot
EDM KM- I pening
ELP A . 5I
CTR G 1100

SI I I 1 1 610 75
17-4 PH. STA, 29 Rc CTR A J'j83

Rene 80. STA. 40 RC EDM IV 64

CGS k 50

Ti-6A1-6V-2Sn, STA, 42 Rc CGS AL8

ECM A -85

Rene 95. STA. 50 Rc EDM1

ECM 5 1
571
Turning AL= 92
Grade 250 maraging steel ECM A____ _ 100

AISI 403 stainless steel. 25 Rc Turning A t-

7075-T6 aluminum, as rolled 251A1

0 20 40 60 80 100 120 140

igue strength at 10? cycles
(room t.-; .perature, full reverse bending). ksi

Figure 18.3-105 Summary of high cycle fatigue strength of materials shot peened subsequent to basic
matertal removal process.

18-121

_7a
18.3 Surface integrity

Conventional grind + resolution & age 24L 50

Electropolish + shot peen - -k 78

EDM +stress relief kZ I

EDM + resolution & age k 38
Finish ECM -glass bead peen A

Off-standard ECM + shot peen L7

4
(125-500 ji in Ra)
Standard ECM + shot peen (16-32 ji in Ra) A_7

+ shot peen I7016

LSG
Baseline - LSG-I I -1b

M Range observed to date. 0 20 40 60 80 100

A Reference value without Fatigue strength at 10? cycles
post-processing treatment. (room temperature. full reverse bending). ksi

Figure 18.3-106 Summary of high cycle fatigue strength of Inconel Alloy 718 (solution treated and
aged) with several types of post-processing treatments. Baseline reference, or "handbook" value, from
low stress grinding (LSG).

TABLE 18.3-25 Fatigue Strength Comparisons for

Materials Processed With and Without Shot Peening

MAATERIAL FATIGUE STRENGTH*

ANlD lWhoujt With
PROCESS Ipeen Peen

KIsi ksii

AF 95 4STA.SR
15 105
ECM 5710
EDM 4 1
Low stress or Gentle grindiri_ 115-

incone; 718 (STA. 44 A.c)

ECM398SA
ELP427
Low stress or Gentle grinding 6

Ti-6AI-6V-?Sn (STA, 42 R, f
ECM
Low stress or Gentle guinding 5
K
*Ro~ohtemperature. 10'cycles furorerz* bending.

18-122
 Surface Integrity 18.3

SURFACE INTEGRITY BY MATERIALS- selection. Tables 18.3-7. 18.3-8, and 18.3-26 to 18.3-30
HIGH CYCLE FATIGUE RESULTS provide such data for a number of alloys. Caution and re-
straint should be exercised before transferring these data
It is helpful in selecting the processes to be used in fabri- to similar alloys. It has been found that each intensity level
cating a component part to compare the relative fatigue of a process will have a unique surface integrity response
stiengths from a variety of processes. Value engineering for each metallurgical state of the work material. The data
can be strengthened by use of surface integrity data to as- presented are the room temperature high cycle fatigue
sure a more complete and disciplined approach to process strength at 10- cycles taken from full-reverse bending tests.

TABLE 18.3-26 Comparative Fatigue Strengths and Surface Roughnesses of 4340

Steel (Quenched and Tempered 50 R) from Several Processes

PROCESS FATIGUE STRENGTH* SURFACE ROUGHNESS

li n R
-
Grinding:
Gentle longitudinal surface grinding 117 M - 8
Gentle longitudinal surtace grinding 110 EA t 65
Gentle longitudinal surface grinding 100 -z1 127
Gentle traverse surface grinding 120 7 11 -
Gentle traverse surface grinding 100 58 ____

Gentle traverse surface grinding 85 128

Low stress surface grinding (LSG) 102 45 M k -
Conventional surface grinding 70 40 -
Abusive grinding I 62 jE
Abusive longitudinal surface grinding 65 D
Abusive longitudinal surface grinding 65 64
97zii
Abusive longitudinal surface grinding 65 97
Low stress grinding plus shot peen 112 25
Abusive grinding plus shot peen 88-92 40-76
Gentle hand sanding 94 115
Abusive hand sanding J98 105
Abusive hand sanding plus shot -
peen 118 56

Milling: _-_

Finish end milling-end rut 65 R 75

Rough end milling-end cut 727

Chemical NTM:
Electropolishing (ELP) 1-0 15
ELP plus shot peen 96 45

- Roorrn temperiare. 10acycles fuil-reverae bending.

18-123
18.3 Surface Integrity
TABLE 18.3-27 Comparative Fatigue Strengths and' Surface Roughnesses of
Ti-6A1-4V from Several Processes
MATERIAL CONDITION IFATIGUE STRENGTH*I SURFACE ROUGHNESS
AND PROCESS _
ksi rn R.
pi-~

BETA ROLLED 32 R,

Grinding: _ i
Low stress surface grinding 62 _i__27__ 35 0.90_;;
Conventional surface grinding 12 83 I 45 R -
Abusive surface grinding j 13 906516
Gentle hand sanding j 57 -338 0
Abusive hand sanding 1 027 1 802.
Milling: I
End milling-sharp cutter 64 41 67 170~
End milling-dull cutter 77 __5184 j2.10
Peripheral milling-sharp cutter 70 4830.17
Peripheral milling-dull cutter 32 21 J 50 -3
Chemical NTM:
Standard OHM 51 352 20 D0750
Off-standard OHM 45 20165 -- 4.20

SOLUTION TREATED AND AGED

Electrical NTM:____ ______

Standard ECM I 60 -41 14 -P_3

Off-standard ECM j 40 278 165 42

ANNEALED 32-34 Rc

Grinding:_____
Low stress surface grinding 54 73k24 06
Conventional surface grinding 12 8___ 30
Abusive surface grinding 14 197M 48 2_____
Turning:.-____
Gentle turning 66 22 M __

Rough turning 71 :S490zg 34 -=0.8

Milling: __ _

Gentle end milling-end cut j73 W503 16

Rough end miling-end cut 64_____ 20
OCremics; N4TM: 59
Standard OH!; 53 18
Off-standard OHM 42 5296___ 157
Thermal NTM:
EDM 24 -15 6P

*Room temperature. 10'cycles full-reverse bending.

18-124
 Surface Integrity 18.3

TABLE 18.3-28 Comparative Fatigue Strengths and Surface Roughnesses of

Ti-6Al-2Sn-4Zr-2Mo (Solution Treated and Aged 36 Rj from Several Processes
PROESSFATIGUE STRENGTH* SURFACE ROUGHNESS

ksi gi-R

Grinding:
Low stress surface grinding (LSG) I68 4939 OV
Conventional sujrface grinding I17 117V 41 --
Abusive surface grinding 1 10 69
132
Hand grinding
LSC-plus age
Conventional surface grinding pu
50
21120
345 V
shot peen 6
Hand grinding plus stress relief j44 30
Hand grinding plus shot peen 74 f--i--

Milling:
Gentle milling-peripheral cut
Rough milling-peripheral cut {47 82
0324f
6536
j 77 1

Electrica! NTM:
Standard ECM1403-2
Off-standard ECM 25 -1225-50 SO-2O
STEM 35~
Standard ECM rplus st-=c peen '55 ___

Off-standard EOM%ptus sn-ot peen 146-50 ~145

Chemica' NTM:I
ELP s

CHM plus shot peen 65_____

*Room temperature 1 sycift %?-.-reversebending.

18-125
 M-

18.3 Surface Integrity

TABLE 18.3-29 Comparative Fatigue Strengths and Surface Roughnesses of Inconel
Alloy 718 (Solution Treated and Aged 44 R) from Several Processes
PROCESS [FATIGUE STRENGTH* I SURFACE ROUGHNESS

Grinding:
Low stress surface grinding (LSG) 60 414 15
Conventional surface grinding 24 1 26 05
Abusive surface grinding 22 70
Hand grinding 40 iis 64
LSG plus resolution and age 58 io 15
LSG plus superfinish and age 49 _3M <5
LSG plus vacuum age 74 5I 17
LSG plus shot peen 65-70
LSG plus shot peen 70
Conventional surface qrinding
plus resolution i-id age 50 .___5 26
Conventional surface grinding
plus stress relief 58
Hand grinding plus stress teliet 40 12"75 32

Turning:
Gentle face turning 60 -4 25
Gentle face turning I60 5 4
Gentle face turning j 60 _-14 188
Abusive face urning 60 4 76
Conventional turning-Borazon' CBN
tool 858BW6 39
Conventional turning-Carbide 55 _7 65 !

Electrical NTM:
Standard ECM 39-40 43
Off-standard ECM 3940 74-500 a
STEM 39 125 KA,
Standard ECM plus vacuum age 42 19
Off-standard ECM plus vacuum age 69
5
Standard ECM plus glass bead peen 78 69
Standard ECM plus shot peen 65-78 74
Off-standard ECM plus shot peen 67-75 90- 119 2

Thermal NFM
Finish EDM 22 60
Rough EDM 22 170
Finish EDM plus vacuum age 29 65 ,
Rough EDM plus vacuum age 29 165 .
Rough EDM plus resolution and age 26-38 62 175 4.40.
Rough EDM plus stress relief 25 221
Finish EDM plus glass bead peen 66 43
Rough EDM plus shot peen 75 125
-h-n ical NTM-
r,.M 40 16
ELP 40-42 76-Z90 15
ELP plus shot peen78 43
ELP plus vacuun; age 28 15

*Room temperatjre, 10' cycles full-reverse bending

18-126

C
- -- -~ ~ -7
 i

Surface Integrity 18.3

TABLE 1b.3-30 Comparative Fatigue Strengths and Surface Roughnesses of Rene 80
(Solution Treated and Aged) from Several Processes
PROCESS FATIGUE STRENGTH* SURFACE ROUGHNESS
ksi 1wpin R.

Grinding. A
Low stress grinding (LSG) 42-13 2902w-= 16 0
Conventional grinding 18 124
Abusive grinding 16 .110
Low stress grinding-finishing _
plus age heat treat 33-40 M-_7W
Low stress grinding-finishing
plus full heat treat' 35 241
Low stress grinding-finishing
plus full heat treat and shot
peen' 53-57 i365
Conventional grinding-roughing
plus age heat treat 32-35 M-241
Conventional grinding-roughing
plus full
Conventional heat treat
grinding-roughing 52
33-36 4

plus full
peen' heat treat and shot 54 - 72= -
Ultra-high speed grinding plus

vacuum heat treat LSG 40 _3

Ultra-high speed gri nding plus
shot peen 50
Electrical NTM:

fl3v
Standard ECM conditions b"dn28
Off-standard ECM conditions 28 g o c 4
Finish ECG 30
Rough ECG 30 A

Thermal N TM. '--=

Finish EDM 24-26 1W- 1 70 .. .. A
Rough EDM 22-26 121150 F
SolutNan treat plus EOM 25 1
M
a
EDM plus resolution and age 132
EDM plus
EDM with shot
recastpeen
removed by LSG

' Room temperature, 101 cycles f ull-reverse bending

34
64 23
441
VI
p

SFull heat treatment Includes aging plu,,. equivalent of brazing and coating cycles

QUALITY ASSURANCE FOR SURFACE It is advisable to become acquainted with the possible
INTEGRITY types of surface alterations which result from the com-
bination of a metal removal process with a specific mate
Quaiity control practices should be reviewed and amplified rial. Information of this type is provided in tables !8 3-2
in order to satisfy high surface quality requirements. No in- and 18.3-32. Nondestructive testing is the most desiralie
strument exists that will measure surface integrity. Proper- approach to evaluating surface integrity effects. The princi-
ties which may require investigation -n order to establish pal iondestructive testing methods for evaluating surface
surface integrity include surface texture, surface metal- integrity and subsurface characteristics are listed ir.tables
lurgy, mechanical properties, surface chemistry and other 18.3-33 and 18.3-34. Destructive ,ecnniques are also
engineering properties. Table 18.3-31 is a summary of shown in table 18.3-34 for compariso,
standard and specialized techniques generally employed for

these measurements.

18-127

-- - -X O
18.3 Surface Integrity
TABLE 18.3-31 Techniques for Surface Integrity Measurement
I I
PROPERTY , STANDARD TECHNIQUES 1 SPECIALIZED TECHNIQUES

Surface Texture S Contact (tracer point or stylus Noncontact measurements-

measurement)-Linear traverse Optical Microscopy
or area traverse Interference microscopy, et,
i Three dimensional surface profile
by combination of roughness
measurement and computer plotting
Scanning electron microscoy

Surface Metallurgy
Microstructure Metallurgical sectioning-Opticai
I Transmission electron microscopy
microscopy
Mic;ohardness Microhardness testing-Knoop or Vickers
indenter
Microcracks and Crevice-like Metallurgical sectioning-Optical Scanning electron microscopy
defects microscopy Nondestructive-Eddy Current
Nondestructive-Macroetching Ultrasonic
Penetrant inspection I etc.
etc.

Static Mechanical Properties I

Tensile strength & Ductility Tensile testing
Stress rupture & Creep I Creep testing
Residual stress X-ray diffraction
Layer removal-Curvature measurement
Stress corrosion Steels &Aluminum: Constant prestress with Stress corrosion crack propagation
alternate immersion in salt solution and testing
I air
Titanium: Specimen coated with salt or
halide and exposed to high temperature

Fracture toughness
and stress
j Fracture toughness testing

Dynamic Mechanical Properties

High cycle fatigue Bending fatigue testing, A* = Oc Axial fatigue testing, A* = 0 95
Low cycle fatigue Bending fatigue testing, A =- Axial fatigue testing, A = 0.95

Sirlace Chemistry Electron microprobe analysis Electron spectroscopy-Electron

Dissolution of the surface layer by soectroscopy for chemical analysis
chemical or electrochemical etching (ESCA)
followed by spectroscopy, spectrophoto- Auger spectroscopy
metry, etc. Ion spectroscopy-
Ion scattering spectrometry
Ion probe mass spectroscopy

Other EFngineering Properties

Friction A variety of standarl and specialized techniques have been developed to evaluate these
Wea. propertiets for specdic ~i;acaLio.-,
Fietting
Galling & Seizing
Corrosion
Reflectivity
Electrical properties
Etc.

SOURCE: M. Field, J, F.Kahles and J T.Cammett."

'A - ratio of dynamic/static stress

18-128

- - - !
 Surface Integrity 18.3
TABLE 18.3-32 Surface Hardness Changes That May Result from Various Metal Removal Processes
CONVENTIONAL PROCESSES NONTRADITIONAL PROCESSES
Milling, Drilling,
MATERIAL Turning, or Grinding j EDM ECM or CHM
Surface Hardness Surface I Hardness Surface Hardness
Alteration Change j Alteration Chance Alteration Change

Steels PD Increase RC Increase None Decrease

UTM Increase UTM Increase
OTM Decrease OTM Decrease
RS Decrease RS Decrease
OA Decrease OA I Decrease

Nickel- and PD Increase RC Increase None Decrease

Cobalt-base

Titanium alloys PD Increase RC Increase None Decrease

Refractory alloys RC I No change None Decrease

(TZM, Tungsten) ___

SOURCE: M. Field, J. F.Kahles and J. T.Cammett.'

Key: PD - Plastic deformation and plastically deformed debris
UTM - Untempered martensite
OTM - Overtempered martensite
RS - Resolution or austerte reversion
OA - Overaging
RC- Recast, resplattered metal or vapor deposited metal

18-129
18.3 Surface integrity
TABLE 18.3-33 Nondestructive Techniques for Detecting Surface Inhomogeneities In Metals

TECHNIQUE APPLICATION STATUS

1 Visual Inspection Surface defects Widely employed

2 Automatic Optical Scanning Surface defects Specialized
3 Dye Penetrant Surface defects Widely employed
4 Magnetic Particle Surface defects Widely employed
5 Acid Macroetch Crack detection Widely employed
Surface phase transformations Widely employed
Redeposited & resolidified metal Widely employed
6. Eddy Current Surface defects Widely employed
Inclusion & subsurface defects Widely employed
Surface hardness changes Specialized
Plastic de'ormation Specialized
Surface phase transformation Needs development
Subsurface fatigue Needs development
Residual stress analysis Needs development
7 Ultrasonic Pulse Echo Inclusions & subsurface defects Widely employed
Surface defects Specialized
8. Ultrasonic Velocity Residual stress analysis Specialized
Surface phase transformation Needs development
Plastic deformation Needs development
9 Ultrasonic Attenuation Recrystallization & grain growth Specialized
Residual stress analysis Needs development
10. High Frequency Ultrasonic High resolution of surface defects Specialized
11. X-Ray Radiography Subsurface defects Widely employed
12 X-Ray Diffraction Residual stress analysis Widely employed
Surface phase transformation Specialized
13. X-Ray Spectroscopy Composition changes Needs development
14. Neutron Radiography Subsurface defects Specialized
15. Gamma Radiography Subsurface defects Specialized
16 Radioactive Gas Penetrant Surface defects Needs development
Recrystallization & grain growth Needs development
Plastic deformation Needs devel-hpment
Subsurface defects Needs develupirent
17. Surface Electrical Resistance Surface defects Needs development
Surface phase tra.nsformation Needs development
18 Beta Backscatter Surface hardness changes Needs development
Plastic deformation Needs development
19. Electrochemical Potential Residual stress analysis Needs development
20. Laser P,'obe Mass Spectrometry Surface compcsition Needs development

SOURCE: M.Field, J F.Kahles and J T Cammett"

18-130

__ _ _
 Surface Integrity 18.3
TABLE 18.3-34 Testing Techniques Used To Detect and Locate Surface Inhomogeneities in Metals

METALLURGICAL -NONDESTRUCTIVE TECHNIQUES

INHOMOGENEITY Commonly Employed j Specialized Possible With Further DESTRUCTIVE TECHNIQUES
_ _Developments

Macrocracks Visual inspection Ultrasonic pulse echo Acoustic impact Optical matallography
Binocular inspection I
Magnetic particle Automatic optical I
Penetrant scanning i
Eddy current
Acid macroetch I
Microcracks Binocular inspection Ultrasonic pulse echo. Radioactive gas penetrant Optical metallography
High sensitivity fluorescent surface waves and High frequency ultrasonic Scanning electron microscopy
penetrant lamb waves Acoustic impact Transmission electron
Magnetic oarticle i Surface electrical resistance microscopy
Tears, laps & pits Visual Nithparticle
Magni.tic etch , Automatic optical
scanning Radioactive gas penetrant Optical metallography
Scanning electron microscopy

Eddy current
Penetrant

IGA & selective etch High sensitivity Macroetch

fluorescent Optical electron microscopy
penetrant Transmission electron
microscopy
Surface phase Macroetch X-Ray diffraction Ultrasonic velocity Optical metallography
transformation Magnetic particle Surface electrical resistance
(OTM, UTM, Eddy current
resolutioning, etc)
Composition changes Laser probe Wet chemical analysis
(oxidation, decarb, Mass spectrometry Electron microprobe
etc) .__ X-Ray spectroscopy i

Surface hardness
changes
Superficial hardness testing
Ultrasonic hardness testing
Eddy current
X-Ray diffraction
Beta backscatter IMtcrohardness
I
traverse

Redeposited & Macroetch Optical metallography

resolidified metal Visual inspection
Recrystallization & Ultrasonic attenuation Radioactive gas penetrant Optical metallography
grain growth _ _ I
Plastic deformation
(cold work,
hot work)
Inclusions & voids
Superficial hardness testing

Ultrasonic pulse echo shear

wave, surface wave,
Eddy current
Magnetic particle

Gamma radiography
Neutron radiography
j.Ultrasonic
Beta backscatter
Radioactive gas penetrant
velocity
Radioactive gas penetrant
Optical metallography
Microharaness traverse
_.

Optical metallography
-

and lamb wave

Penetrant I
X-Ray radiography
Eddy current
Magnetic particle,_ .

Residual stresses X-Ray diffraction Ultrasonic velocity Eddy current Pating-out

Electrochemical potential Layer removal
Ultrasonic attentuation X-R-y diffraction
Magneto-absorption

Distortion Visual inspection Metrology g b

"
SOURCE: M.FId. J. F. Kahles and J T. Cammelt

18-131
18.3 Surface Integrity
After exhausting the nondestructive testing methods. re- Specific Guidelines and Special Comments on
liance is then placed on destruct*ve testing of extra work- Quality Assurance for Surface Integrity
pieces or coupons by simulazing the process factors In
some situations. it is necessary to resort to detailed process 1. Detection of Untempered and Overtempered
parameter planning followea up by operator education and Martensite
periodic audits for compliance to the preplanned condi- Parts manufactured from martensitic high strength steel
tions Few quality assurance engineers are fully satisfied can be visually inspected after an acid etch for evidence of
with a process control approach: however, it can be effec- untempered or overtempered martensite (frequently found
tive-if production supervision exercises a relentless insist- from grinding and some forms of mechanical cutting,,. Typi-
ence ipon performaneeaccording to standards cally. untempered martensite appears white -nd over-
tempered areas appear darker than the background mate-
It is vital to surface integrity that as much attention be rial A specific etching technique for detecting grinding
placed on the quality of the material presented for process- damage in hardened steel is given in table 18.3-35
ing as is placed upon process parameter control. The met-
allurgical state will affect the final "as-shipped*"surface 2. Conventional Versus Nontraditional Processes
quality as much as the intensity level at which the process
is operated. Similarly the full sequence of operations The original surface integrity investigations concentrated
applied to a surfacc must be evaluated, and the evaluation heavily on grinding and the nontraditional material re-
must be made with the exact sequence used during moval processes like electrical discharge machining and
production. electrochemical machining. More recently. the older, con-
ventional. generally mechanical material removal proc-
The best quality assurance is the evaluation of surfaces of esses have beer, shown to have an equal range of surface in-
specific parts when exposed to the full environmental ef- tegrity effects It is vitally important that the application of
fects expected: namely, heat. chemicals. stress. vibration, surface integrity practices include an assessment of every
etc The minimum data set can provide a better evaluation, process that effects the final, as-shipped" surface.
but the extended data set is recommended for the most crit-
ically loaded or exposed surfaces. This controlled, system- 3. Suggested Experimental Programs
atic testing technique is recommended for safety critical Systematic metallurgical and mechanical testing programs
areas of component parts. for establishing and controlling surface integrity are essen-

TABLE 18.3-35 Etching Technique for Detecting Grinding Damage in Hardened Steel
OPERATION i SOLUTION USED DESCRIPTION, TIME, OR FUNCTION
Double Etch Method
(1) Etch No. 1

(2) Rinse
4 to 5%Nitric acid in water

Warm water
I
I Until black. 5 to 10 seconds.
Do not over etch.
I To remove acid
(3) R'nse Methanol (or acetone*) I To remove water
(4) Etch No. 2 5 to 10% Hydrochloric acid in I Until black smut is removed.
methanol (or acetone*) 5 to 10 seconds
(5) Rinse Running warm water i To remove acid
(6) Neutralize 2%Sodium carbonate + ITo neutralize any remaining acid
phenolpthalien indicator in
water
(7) Rinse Methanol To remove water
(8) Dry Warm air blast
(9) Oil dip Low viscocity mineral oil with rust Enhance contrast, prevent corrosion
inhibitor

Nital Etch Method

(1) Etch 5 to 10% Nitric acid in ethanol I Until contrast is evident
or me'hanol
(2) Repeat steps
5.9 above I
'
SOURCE: M Field, J. F Kahies and J T_Camrnett
NOTE: Dark areas on etched surfaces show overtempertng. light areas show rehzrdening. and uniform gray in-
dicates no injury-
14% HNO, in water for Etch No 1 used with 2% HCI in acetone for Etch No. 2 sometimes gives greater .ensi-
tivity on high carbon hardened steel. itis important that appropriate precautions be taken to avoid fire hazards.
and good ventriation must be provided

18-132
 Surface Integrity 18.3
tial for highly critical parts and have been detailed pre- and application of rust inhibitors, as outlined in table
viously. Functional testing of the final product of field test- 18 3-35
ing under actual service conditions is a desirable step for
the most critical applications c Magnetic particle inspection. penetrant inspection. ul-
trasonic testing. and eddy current techniques are recom-
4. Comparative Photomicrographs mended for detecting macrocracks. Most of the in-
Comparison of current results during production with sets spection techniques currently being used should be
of photomicrographs that display both the "standard" and fur ther refined by using more care in their application.
"off-standard" conditions to be expected are helpful. The Direct visual examination shoula be supplemented by
growing data accumulations in surface integrity encyclo- macroscopic examination at low and medium magnifi-
pedias also are useful. The Machinability Data Center has cations (5 to 20X). Some of these methods require low
the most extensive collection of this information. These levels of surface roughness on the surface being exam-
data also are useful in appraising or establishing quality mned in order to reduce background "noise- to the in-
control limits or process parameter limits strument.

5. Specifications d. X-ray diffraction methods are available to detect resid-

Several companies now have special specifications for ual surface stresses. This method may be helpful in
processing to secure the best surface integrity. These are process development as well as in spot checking of fin-
very helpful to the vendors for guidance and to quality con- ished parts. The entire residual stress profile in the sur-
trol for measurement. These special specifications should face layer can be destructively determined by X-ray dif-
be used with care and only for those portions or surfaces of fraction plus etch techniques or by a deflection-etch
a component part deemed critical. otherwise costs will rise technique
unnecessarily. Standards for surface integrity are being
prepared both by the American National Standards In- 8. Process Control Practices
stitute (ANSI) ,nd by the International Organization for Where process control is relied upon to maintain surface in-
Standardization (ISO) tegrity. deterioration of the process control can frequently
be detected by observing the change in surface finish. A
6. Accidents Which Occur During Processing Should gradual drift to rougher values can signal a gradual drift in
Be Peported to Quality Control process p -ameters. One practical rule of thumb states that
Operators should be instructed to notify supervisors of all if. as a corrective measure, any one of the operating param-
accidents or damage including all visual evidence of dam- eters of a process is reset or "adjusted" by plus or minus 10
age. Grinding burn. breaking of drills. reamers or taps in percent or more from the planned values. immediate ques-
holes, or shorting of electrodes in both electrical discharge tions should be raised as to the control status of the proc-
machining and electrochemical machining are examples of ess. If two or more pararmetc,s are "adjusted" by 10 percent
the types of mishap. which should be reprted.C.p or more. the process is out of control and should be shut
surface discoloration is not necessarily sufficient to remove down until corrective action is effective.
all of the damage which may extend several thousandths
inch below the surface. as demonsz-ated in figure 18.3-75.
In case of damage. parts should Le systematically ECONOMICS AND APPLICATIONS OF
reviewed. SURFACE INTEGRITY
7. Inspection Practices Should Be Reviewed and A frequent initial reaction to surface integrity is a concern
Amplified in order To Satisfy Surface Integrity for productivity and costs The generally gentle. low speed.
Requirements lower, -,%-levels employed in machining unimpaired or
There are several nondestructive and destructive testing enhanc -faces do increase costs and lower production
practices which are being employed to test surface condi- rates- H, --r. this is only part of the overall cost picture.
tions. Brief discussions of these practices are presented in Considerat, .i should be given to the added costs of defec-
the following: tive or scrapped parts or the cost of rework or replacement
during the course of manufacture when component parts
a. Microscopic examination including microhardness test- fail to pass quality control inspections. Subsequent to man-
ing is used on a sampling basis in order to determine the ufacture, the costs of early product failures. complaints. lia-
kind of surface layer being produced and its depth. This bility or its insurance also must be included. Many of these
method may be used to check for microcracks. pits. c- -f- can be ameliorated by attention to surface integrity
folds. tears. lams. built-up edge. intergranular attack. and its contribution to product reliability and product
sparking, etc. Since many surface alterations are shal- integrity.
low. it is essential to use good edge retention techniques
for microscopic examination. See table 18.3-6. The more disciplined approach of surface integrity can
cope with the more stringent designs that involve increas-
h The white layer or overtempered martensite produced ingly thinner sections of stronger materials. The principal
during grinding of steels can be detected by immersion saving can con.e from applying surface integrity wechniques
et,.iing using a 3 to 5 percent aqueous nitric acid solu- selectively Specific surface int-grity specifications should
tion_ The procedures used vary among producers and not be applied all over a componcint part but only to the
are quite detailed and very exacting. consisting essen- cr:tically stressed areas. Consultation with the design
tially of appropriate and specific precleaning. etching. engineer will frequently reveal that only a very small area.
and post-etching procedures. including cleaning. drying. a radii, a shoulder or a section will be exposed to high
1E
18-133 i

- r - ~----
18.3 Surface Integrity
stress or severe working environment The balance of the 5. Field. M.: Mehl. C L "and Kahles. J F. 1906. Machin-
surfaces are lightly loaded and a relaxation of specifica- ing data for numericalcontrol. AFMDC 66-1 Cincin-
tiorts can be justifled without compromising the product nati. OH: Air Force Machinability Data Center
integrity
6 Field. M.: Meh!. C. L : and
Kahles.J. F 1968 Supple-
By eliminating "ail-over"-type specifications and concentra- ment to machining data for numerical control.AFMDC
ting on specific critical areas. substantial cost reductions 68-2. Cincinnati. OH: Air Force Machinability Data
have been made Indeed. some of the "all-over" specifica- Center.
tions have been found to be carry-over from previous gener-
ations of designers with little or no data to support the spe- 7 Glaeser. W. A. 1969- Surface effects in metal deforma-
cific required levels One set of gas turbine discs of Inconel tion Technical Paper MF69-1 01. American Society of
Alloy 718 had for years been specified to have a 63-micro- Tool and Manufacturing Engineers. Dearborn. MI
inch R_ l 6 umi roughness all over. When both high cycle
and low cycle fatigue tests showed that the particular alloy 8 Koster. W. P. et al. 1970. Surface integrity of ma-
was not sensitive to roughness level (see table 18.3-29 and chined structural components. U. S. Air Force Techni-
figure 18.3-48). the roughness level was changed to 125 cal Report AFML-TR-70-1 1. Metcut Research Asso-
microinches Ra 13.1 pml on all but one critical radii which ciates Inc.. Cincinnati. OH.
was changed to 32 microinches R. 10.8 ,ml. A 7 to 12 per-
cent reduction in machining time was effected on the six 9. Koster. W. P et al. 1972. Manufacturing methods for
discs while increasing the quality assurance. The savings surface integrity of machined structura_ components.
was several hundred thousand dollars per year at the then U. S. Air Force Technical Report AFML-TR-71-258.
current level of production. Metcut Research Associates Inc.. Cincinnati. OH

10. Werner. A. R. and Olson. P. C. 1968. EDM-A metal

SELECTED SOURCES OF SURFACE removal process. Technical Paper MR68-71 0. Ameri-
INTEGRITY DATA can Society of Tool and Manufacturing Enginee-s.
Dearborn. MI.
The following References and Bibliography provide much
detailed information on specific surface integrity situations 11. Koster. W. P. 1974. Surface integrity of machined
as well as general background information. Information materials. U. S. Air Force Technical Report AFML-
may also be obtained on a continuing basis from the Ma- TR-74-60. Metcut Research Associates Inc.. Cincin-
chinability Data Center (MDC). MDC is collecting infor- nati. OH.
mation and data on surface integrity as they become avail-
able and is evaluating the data for application to the 12. Field. M.: Kahles. J. F.: and Cammett. I T 1072 A
material removal industry. These data are included in 2n review of measuring methods for surface integrity. An-
encyclopedic collection of photomicrographs, tables and nals of the CIRP21(2): 219-238.
graphs of surface integrity effects from a wide variety of
material and process combinations and are available to aid 13. Bellows. G_ 1978. Low stress grinding:ForqualiT pro-
discussions or comparisons. Specific inquiry services are duction. MDC 78-103. Cincinnati. OH: Machinabilit;
available to U.S. Government agencies and to private in- Data Center. Metcut Research Associates Inc
dustry. Inquiries should be directed to Supervisor. Techni-
cal Inquiries. Machinability Data Center, 3980 Rosslyn 14. Bellows. G. and Tishler. D. N. 1970. Impact of surface
Drive, Cincinnati. Ohio 45209: Telephone: 513-271-9510: integrity on material properties. Report TM70-975.
TWX: 810-461-2840. General Electric Company. Cincinnati. OH.

15. Field. M.: Koster. W. P.: Kohls. J. B. 1970. Machining

of high strength steels with emphasis on surface ipteg-
References rity. AFMDC 70-1. Cincinnati. OH: Air Force Ma-
1. Surface integrity encyclopedia. (Specia; unpublished chinability Data Center.
collection of data and effects from specific material-
process combinations.) Maintained for reference by the 16. Bellows. G. and Koster. W. P. 1972. Surface integ-
Machinability Data Center, Cincinnati. OH. rity-Update "72. Report TM72-384. General Electric
Company. Cincinnati. OH.
2. Influence of metallurgy on machinability. 1975. and In-
fluence of metallurgy on hole making operatons.1977. 17. Bellows. G. 1974. Surface integrity from finish turning
Metals Park. OH: American Society for Metals. of Inconel 718. Paper presented at 5th Annual Carbide
Cutting and Forming Seminar, held 25-27 June 1974.
3. Zlatin. N. and Field. M. 1971. Machinability parame- at Purdue University. West Lafayette, IN.
ters on new and selective aerospace materials. U. S.
Air Force Tcchnical Report AFML-TR-71-95. Metcut 18. Koster. W. P. and Kohls. J. B. 1972. Relation of sur-
Rusearch Associates Inc.. Cincinnati. OH. face integrity to cost and reliability of structural com-
ponents. Technical Paper IQ72-207. Society of Manu-
4. Zlatin. N. and Field. M. 1969. Machinability parame- facturing Engineers Dearborn, Mi.
ters on new and selective aerospace materials. U. S.
Air Force Technical Report AFML-TR-69-144. Met- 19. Field. M. 1974. Plastically deformed debris and built-
cut Research Associates Inc.. Cincinnati. OH. up edge produced on surfaces by chip removal and

18-13,
 Surface Integrity 18.3
abrasive machining processes. Annals of the CIRP -. 1972 Application of surface integrity to production of
23(1): 191-192. jet engines Metals Engineeringguarterly 12(4): 55-58.

20 Bellows. G. and Kohls. J B. 1976. Surface inte'-rity of _. 1972. Advanced material removal processes Techni-
nontraditicnal material removal processes. T, hnical cal Paper MRR72-02. Society of Manufacturing Engi-
Paper MRR76-12. Society of Manufacturing Engi- neers. Dearborn. MI.
neers. Dearborn. MI.
-. 1969. Surface integrity of electrochemical machining.
21- Bellows. G. 1970. Surface integrity of electrochemical Report R69AEG172. General Electric Company. Cincin-
machining. Technical Paper 70-GT-1 11. American nati. OH.
Society of Mechanical Engineers. New York. NY.
S. 1968. Impact of nonconventional material
removal
.2. Bellows. G. 1973 Surface integrity of nontraditional processes on the surface integrity of materials. Technica,
machining processes. Technical Paper IQ73-633. Paper MR68-518. American Society of Tool and Manufac-
Society of Manufacturing Engineers. Dearborn. MI. turing Engienering. Dearborn. MI.

23. Bellows. G. 1977. Chemical machining: Production _. 1968. Surface integrity guidelines. Report
with cheinistry. MDC 77-102. Cincinnati. OH: Ma- R68AEG192. General Electric Company. Cincinnati. OH.
chinability Data Center. Metcut Research Associates
Inc. Bellows. G. and Tishler. D. N. 1970. Manufacturing proc-
ess effects on surface integrity. Report TM70-976. General
24. Bellows. G. and Niemri. R. M. 1971. Surface integrity Electric Company. Cincinnati. OH.
of machined Inconel 718 alloy. Technical Paper IQ71-
239. Society of Manufacturing Engineers. Dearborn. - 1970. Surface integrity processing guidelines. Report
MI. TM 70-977. General Electric Company. Cincinnati. OH.

25. Bellows. G. --- I Tishler. D. N. 1970. Introduction to Christenson. A. L. 1961. The measurement of stress by
surface integrity. R:;port TM70-974. General Electric x-ray Information Report TR 182. Society of Automotive
Company. Cincinnati. OH. Eng.neers. New York. NY.

26. Gatto. L. R. and DiLullo. T. D. 1971. Metallographic Clorite. P. A. and Reed. E. C. 1958. Influence of various
techniques for determining surface alterations in ma- giindiz:g conditions upon resiauai stresses in titanium.
chining. Technical Paper IQ71-225. Society of Mianu- Transactionsof the ASME 80 Series B (1): 297-301. 4
facturing Engineers. Dearborn. Ml Cross. J. R. 1972. Electrochemical machin.'g. U. S. Air

21- Rooney. R. J. 1957. The effects of various machining Force Technical Report AFML-TR-72-188. Cross Techni-
processes on the reversed-bending fatigue strength of cal Sales. Cincinnati. OH.
A-11
cal OAT titanium
Report alloy sheet. U. S.
WADC-TR-57-310. Air Force
Wright Air Techni-
Devel- D7
Decneut. A. and Peters. J. 1973. Continuous measurement
opment Center. Wight-Patterson Air Force Base. OH. of residual stress in thin cylindrica; pieces using deflection-
etching techniques. In Proceedingsof the internationalcon-
28. &eiiz. .f 072. Surface integrity from electrical dis- ference on surface technolog'. pp. 262-281. Dearborn. MI:
charge machining Juer~l:,L' Report R72AEG236 Society of Manufacturing Engineers.
(not fully releas d at this time). General Electric Coin- Donachie. Jr.. M. J. and Sprague. R. A. 1968. Mechanical
pary. Cincinnati. OH. properties. residual stress and surfaces. Technical Paper
EM68-519. American Society of Tool and Manufacaturing
Engineers. Dearborn. MI. ___

Field. M. 1973. Surface integrity-A new requirement for

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Field. M. and Kahles. J. F. 1971. Review of surface integ-
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cedures for machining 300M steel and titanium aircraft Paper IQ71-226. Society of Manufaturing Engineers. Dear-
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National Aeronautics and Space Administration. 1967
Gurklis. J. A. 1965. Metal removal by electrochemical Nondestructive testing: trends and techniques. NASA
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DMIC Report 213. Defense Metals Information Center.
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Phillips. J. L_ 1967. Effect of machining on the service life
Kahles. J_ F and Field. M. 1973. Impact of surface integ- of high-strength low-alloy steels. In C,nference on machin-
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Koster. W. P. 1976. Surface integrity: An emerging crite- MI.
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Society of Manufacturing Engineers. Dearborn. MI. Schroeer. R. 1968. Research on exploratory development
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Koster. W. i.4zd Fj itz. L.j. 1970. Surface integrity in Force Technical Report AFML-TR-67-167 (Part 11). A-vin
conventional machining. Technical Paper 70-GT-100. Systems Inc... Dayton. OH.
American Society of Mechanical Engineers. New York.
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Koster. W. P.: Fritz. L. J.: and Kohls. J. B. 1971. Surface Rensselaer Polytechnic Institute. Hartford Graduate Cen-
integrity in machining of 4340 steel and Ti-6AI-4V. Techni- ter. Troy. NY.
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Dearborn. MI. Society of Automotive Engineers. 1971. Residual stress
measurement by x-ray diffraction. SAE J784a. New York.
Kroll. R.J.,: Westermann. F. E.: and Cuddeback. J.K. NY.
1970. Expansion of derivation of Stablein's equation for
calculating residual stress in a machined surface. Metcut Tarasov. L. P. 1946. Detection causes and prevention of
Research Associates Inc.. Cincinm.ti. OH. injury in ground surfaces. Transactions of American
Society for Metals 36: 389-439.
Littman. W. E. 1967. Control of residual stress in metal
surfaces. In International conference on manufacturing Tarasov. L. P.: Hyler. W. S.: and Letner. H. R. 1958. Ef-
technology. Proceed:n.gs. pp. 1303-1317 Dearborn. MI: fects of grinding direction and abrasive tumblingon the en-
American Society of Tool and Manufacturing Engineers. durance limit of hardened steel. American So, iety for Test-
ing Ma tcrials Proceedings58: 528-539.
-- 1967. The infl.jence of grinding on workpiece tech-
nology. Technical Paper MR67-593. American Society of Westermann. F. E. 1971. Determining the distortion and
Tool and Manufacturing Engineers. Dearborn. Mi. residual stresses produced by metal removal operations.
Technical Paper IQ71-224. Society of Manufacturing En-
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18-136
 SECTION 19
MACHINING GUIDELINES

19.1 General Machining Guideines.................................................. . 19-3

19.2 Guidelines for Drilling .................................................. 19-5

Introduction ............................................ ..................... .......................... 19-5
Types of Drills .......... .......................................... 19-5
Drill Geom etry ......................................................... .................................................. 19-8
Hole Sizes .............................................................. 19-8
Accuracy of Drilled Holes ... ............................................ 19-9
Tool M aterials for Drills . .............. ............ ...-................................. -...................... 19-9
Coolant Systems for Drilling .......................................... ;9-10
Thin Sheet Drilling ........................................................... 19-10
Drilling Nonmetallics ............................................... 19-10

19.3 Tool Life . ......................................... ............. ...... ....... ............... , ........................ ................. 4.9-11

19.4 Types of Machinability Data................ ............................................. 19-15

Tables of Recommended Machir.ing Conditions ...................................................... 19-15
W ide Range Machining Data ...................................................................................... . 19-15
Cost and Production Rate Determination and Analysis ............................ 19-15
Mathematical Correlation of Machining Parameters with Tool Life and
Subsequent Optimization of Cost and Production Rates ................................................ 19-15
Machinability Ratings .............................................. 19-15

19-1
 I

i~~Di'G PAI. UBLAa-cyr FliJ!ED

General Machining Guidelines 19.1

1. 'Good machining practice requires a rigid setup in addi- 6 When dimensional accuracy and surface integrity are
tion to the selection of proper cutting speed. feed. tool not critical, high speed steel tools should be removed
material, tool geometry and cutting fluid. Rigidity in it- when the wearland on the flank of the tool reaches ap-
self does not ensure a successful machining operation: proximate;y 0.060 inch 11.5 mini width. In the Lase of
however, without it. tools are subject to p-emature carbide tools, the maximum width should not be al-
failure. lowed to exceed 0.030 inch t0 75 miml. ott'erv'- ,om-
plete tool failure may occur. On componer-.s wh-re d:-
2. The machine tool must be capable of providing the ri- mensional accuracy and surface integiity are critical.
gidity required for the machining conditions used. If the tool wear must be carefully limited, see section
the Size of the machne tool is not adequate or if loosen- 18.3.
ess exists in the moving parts. such as spindle bearings
or gibs. ciitter will occur and poor tool life will result. 7. Wearland measurement is not always oossible on the
When a rigIJ setup cannot be made. the feed and, or tool: however, it is practical to instruct the operator to
depth of cut must be reduced accordingly. change tools after a predetermined number of pieces
have been machined. The number of parts to be ma-
3. Excessive tool overhang is a source of trouble in a ma- chined per tool should be set conservatively so that the
chining operation. When this condition exists, poor cutter will not fail. Occasionally by this procedure. a
tool life and surface finish result. and dimensional ac- cutter may be removed before it is dull: therefore. the
curacy is difficult to maintain. Stub-length drills should resharpening time will be short. but catastrophic fad-
be used inscead of jobbers-It ngth drills where the depth ure will have been avoided.
of hole permits. Milling cutters should be mounted as
close to the spindle as the iob will allow. The length of 8. The cutting fluid system should provide a copious flow
end mills should be kepi at a m;nmum. Climb milling of cutting fluid to the area where the chip is being
usually gives better tool life and surface finish than formed- In the case of machining operations where cut-
does conventional milling if the machine tool and setup ting fluids are used with carbide tools. a continuous
have sufficient rigidity and the feed mechanism is free flow of the cutting fluid is irrperai.tc. Interrupted or
from backlash. intermittent flow can cause thermal shock and break-

4. Misalignment
problems. such andastool runout arid
oversize cause other machining
bellmouthed holes age of the carbide tool.
problems.reasuch as oersi and butheds es - 9- The concept of good machining practice involves con-
ping and die threadiugh sideratio- of all factors associated with the machining
operati' n. Each detail-workpiece. fixturing. speed.

5. Maintenance of cutting tools must be given careful feed. tool material, tool geometry. cutting fluid. and
consideration in the development of good machining the machine tool itself-must be ,iven e~refi atten'o-
p1 actict.. One common problem is the failure to change to ensure success for the machining operation under
tools at the proper time. Tool costs become exorbitant consideration.
on those jobs where tool failure is the criterion for tool
change. Usually this approach results in excessive 10. The machinability of a wc.k material must be deter-
regrinding time or. in the case of a milling cutter. the mined in order to select the proper machining cor.di-
replacement of broken teeth with new ones. Tooth re- tions. The machinability oi a material can be defined
placemert requires considerable time in addi,:on to in terms of three major factors: surface integrity. tc-ol
regrinding time. iife. and power or force requirements.

19-3
 Guidelines for Drilling 19.2

INTRODUCTION A standard twist drill has two cutting edges. two helical
flutes, and a straight or tapered shank.
Drills are among the most wideiv used tools in the shop.
but their selection, grinding, and usage often receive the Straight shank drills have cylindrical shanks which may be
least care. A drilled hole i3 usually either a clearance hole of the same or of a different diameter than the body uf the
for a fastener or a starting point for tapping. reaming. or drill.
boring. Drilling usually can be done satisfactorily with
standard off-the-shelf twist drills. Where large quantities of Tapershank drills are preferable to the straight shank type
precision holes must be produced. certain refinements in for drilling medium and large diameter holes. The taper on
practice are necessary as follows, the shank conforms to one of the tapers in the ANSI Stand-
ard Series. Taper shank drills generally have a driving
* The drills should be machine ground in order to develop tang and are directly fitted into tapered holes in drilling
accurate geometry of the noint. machine spindles or into driving sockets.

* Point angle. web thickness. and lip clearance shoula be Double margin drills have a second pair of margins at the
suitable for the material being drilled, rear of the lands which act as steadying elements. Double
margin drills may produce more accurate holes. Their size
* The work should be properly supported and clamped range is from 1/8 to 2 inches 13.2 to 50 mml.
and the drill should be guided in a drill bushing of suit-
able fit and length. Chip breakerdrills have features built into the drill design
to preverit long. stringy chips. They have a diameter range
* Adequately powered and rigid machine tcols should be from 3/8 to 2 inches 19.5 to 50 mm).
utilized.
Atemate Drills
TYPES OF DRILLS When applications arise that cannot be inet by using a twist
drill, one of the following alternate drills can be considered:
Step Drills. figure 19.2-2
Twist Drills Subland Drills. figure 19.2-3
A tw;st drill is an end cutting tool having one or more cut- Flat Drills. figure 19.2-4
ting edges and having helical and sometimes straight flutes Spade Drills. figure 19.2-5
for the passage of chips and the admission of a cutting Core Drills. figure 19.2-6
fluid. See figure 19.2-1 and table 19.2-1 for the description Oil-Hole or Pressurized-Coolant Drills. Figure 19.2-7
and application of twist drils. Gun Drills, figure 19.2-8
Sse tables 19.2-1 through 19.2-3 for the descriptions and
applications of alternate drills.

(a) Standard Helix - 29

(b) Low Helix - 18 Figure 19.2-2 Step drills.

(c) High Helix - 40

(d) Straight Flute - "

- < Figue 192-3 Subland drills.

(e) Double Margin

() Chip Breaker )

Figure 19.2-1 Twist drills. Figure 19.2-4 Flat drills.

I
19-5
19.2 Guidelines for Drilling

TABLE 19.2-1 Characteristics of Twist, Step and Subland Drills

TWIST DRILLS STEP DRILLS SUBLAND DRILLS

Description Twist drills are the most common. Step drills have two or more diame- Subland drills are combination tools
Most of these drills are made ters produced by grinding vari- having separate lands or margins
with two helical flutes which al- ous steps on the diameter of the which extend the full length of
low the removal of chips and the drill. The steps or different diam- the flutes for each of the two or
admission of a cutting fluid to the eters are ground on the same more diameters. See figure
tip of the drill. See figure 19.2-1. land. See figure 19.2-2. 19.2-3.

Application Twist drills are used to produce the Step drills produce two or more diam- Two or more diameters can be drilled
majority of clearance holes for eters in one pass of the drill, and simultaneously. The different
fasteners and pilot holes for sub- also serve as combined drills and lands can be ground to permit
sequent reaming or tapping. countersinks, combined drills drilling and countersinking for
and counterbores, and combined fiathead screws or drilling and
drills and reamers. counterboring for socket head
screws. Two or more diameters
can be maintained constant
throughout the life of the drill
even after resharpening.

"ool High speed steel, solid carbide, or High speed steel High speed steel
Material carbide-tipped for special appli-
cations. -

Size range Standard range: 1/8 to 1-1/2 inches Standard range: 1/4 to 2 inches Standard range: 5/32 to 3/4 inch
[3 to 35 mm] [6 to 50 mm] [4 to 18mm]
Micro range: 0.0059 to 1/8 inch
[.15 to 3 mm] For special sizes, the largest diame-
Large range: 1-1/2 to 6 inches ter should be no greater than
[38 to 150 mm] twice the smallest diameter be-
cause of the variation in cutting
speeds.

----------------------------------

Figure 19.2-5 Spade drills. Figure 19.2-7 Oil-hole or pressurized-coolant

drills.

(a) 3 Flute -

Figure 19.2-8 Gun drills.

(b) 4 Flute

Figure 19.2-6 Core drills.

19;-6
 Guidelines for Drilling 19.2
TABLE 19.2-2 Characteristics of Flat, Spade and Core Drills

FLAT DRILLS SPADE DRILLS CORE DRILLS

Descrip:,on Flat drills derive their name from the A spade drill has a removable tip or Core drills are multi-fluted, and have
shape of the drill body which is bit clamped in a special holder no point, similar in design to a
flat rather than the normal round attached on the drill shank. See reamer. See figure 19.2-6.
configuration. The drills are pro- figure 19.2-5. Most holders have
duced by grinding tapered oppo- an axial hole through the shank
site flats on the drill body. The to allow the passage of cutting
flats are usually nct parallel, cre- fluid under pressure to the drill
ating a web which is thicker at point. Replacement blades cost
the shank. A slight back taper of about 1/6 as much as a twist
0.001 inch [0.025 mm] or less is drill.
ground on the drill body. See fig-
ure 19.2-4.
Application Flat drills have a low production ca- Spade drills smaller than 1-3/4 inch Core drills are used to enlarge cored,
pacity, but because of their sim- [44 mm] should be used only for forged or previously drilled
plicity in design and low cost are shallow holes, one diameter holes. They do not produce the
occasionally used for drilling deep vertical, two diameters original holes. Core drills are ex-
hard forgings and castings. deep horizonial. Do not use a tremely rigid, and because of the
center drill for starting a spade greater number of flutes (3 to 6),
drill. Use instead a short spade they can be used at higher feed
drill having the same point angle rates than twist drills.
as the drill to be started.
Tool Standard size: HSS or carbide Blade: HSS or carbide High speed steel or carbide tipped
Material Micro size: HSS Holder and shank: Alloy steel
Size Range Standard range: 3/32 to 1/2 in. Standard range: 1 to 5 inches Standard range:
[2.4 to 13 mm] [25 to 125 mm] 3 flute: 1/4 to 3/4 inch
Micro range: 0.001 to 3/32 inch Special range: 3/4 to 1 inch [6 to 18 mm]
[0.025 to 2.4 mm] [18 to 25 mm] and 5 to 15 inches 4 flute: 1/2 to 1-1/4 inches
[125 to 380 mm] [13 to 32mm]

TABLE 19.2-3 Characteristics of Oil-Hole or Pressurized-Coolant and Gun Drills

OIL-HOLE OR PRESSURIZED-COOLANT DRILLS GUN DRILLS
Description An oil-hole drill is either a twist drill or a straight fluted drill A gun drill is a special straight flute drill for producing
which has one or more continuous holes through its deep holes. It has a straight fluted tip, cutting to cen-
body and shank to permit the passage of cutting fluid ter, mounted in a tubing shank. The tips are often
under pressure. The holes can be through either the brazed to the shanks, but in the larger sizes, the tips
lands or the web of the drill. See figure 19.2-7. Chip- are keyed or pinned to the shanks for convenience in
breaking grooves are sometimes ground in the drill removal for regrinding. Both the tip and the shank al-
point to break and curl the chips to aid ejection. low for ample volume of coolant under high pressure
to reach the cutting edges and also to wash away the
chips. See figure 19.2-8.
Application Oil-hole drills
where very suitable
floodareapplications of aforcutting
making deep holes
fluid would be
Gun quire are used for
drills extremely making very deep holes that re-
close tolerance in straightness and
ineffective. Increased metal removal rates are pos- diameter.
sible in both normal and deep holes by using oil-hole
drills instead of flood cooling. Both constant pressure
and pulsating pressures from 50 to 300 psi [345 to

I
2068 kPa] are employed.
Tool High speed steel or carbide-tipped steel for special The tip is usually carbide, and the shank is alloy steel
Material applications, tubing.
Size Range Standard range: 6/32 to 1-1/2 Inches Standard range: 1/8 to 2 inches
14 tom38 mm] [3 to50 mm]

19-7
19.2 Guidelines for Drilling
DRILL GEOMETRY Straight Flute
Straight flute drills (zero helix) are especially adapted for
drilling brass and other soft or very hard metals. See figure
Drill Point 19.2-1 (d).

Point Angle
Standard drills have point angles of 118 degrees. The point Lip Clearance
angle may be increased up to 150 degrees for very hard or For most drilling, the lip clearance varies from 7 to 25 de-
tough materials. For softer materials such as aluminum or grees depending on the drill size. Smaller drills require
copper alloys, the point angle may be 90 to 100 degrees. more clearance, while larger drills require less. In general.
for harder materials, the clearance should be as small as
Double Point Angle possible to allow maximum strength to the cutting edge.
When drilling very hard or abrasive materials, double an-
gles are sometimes ground on the point to reduce chipping
of the corners of the lips. This is done by first grinding the HOLE SIZES
larger included angle (118 to 140 degrees) and then regr-
inding the smaller included angle (60 to 90 degrees) on the Micro Drilling
corners, giving the effect of a chamfer at the corner. For holes from 0.001- to 0.020-inch 10.025 to 0.5 mini di-

Thinned Web ameter, flat drills are used over this entire size range.
The central web of the drill increases in thickness toward Twist drills are used for hole sizes over 0.006 inch 10.15
point must be thinned as the drill is mml. Speeds must be much lower and feed rates higher
the shank.
ground back so as the
Hence, to prevent excessive end pressure. This than are used for larger drills so as not to produce a pow-
is usually required when the web thickness exceeds one- der that will pack in the flutes.
fifth of the drill diameter. Techniques used to reduce the Normal Drilling
web thickness include the undercut thinned point, the For holes from 0.014- to 3-inch 10.35 to 75 mini diameter,
notched point, and the crankshaft point, standard twist drills are generally used.

Radius Corner Large Holes

A radial lip twist drill has curved outer lips. These curves For holes larger than 3 inches 175 mm) in diameter, spade
allow stress to be uniformly distributed over the entire cut-
ting area. This design may produce a smoother finish in the drills, gun drills, or trepanning tools are needed.
hole and may reduce the burrs at breakthrough. This point Deep Holes
can be produced on a special machine designed for that When drilling deep holes with twist drills, the recom-
purpose or on general-purpose cutter grinding machines. mended speeds and feeds should be reduced as the holes
Spiral Point become deeper, as shown in table 19.2-4. The drill should
also be retracted periodically to clear the chips and lubri-
Reducing the point from a regular chisel edge to a spiral as te rets.
point gives the drill a better self-centering effect. The spiral cate the points.
point must be ground on a spiral-point-grinding machine.
Multiple Point and Relief Angle
Drills having points with more than one included angle and
more than one angle of relief (faceted) can be self-centering TABLE 19.2-4 Reduction of Speed and Feed for Orilling
and chip-breaking for use in hard materials. Deep Holes with Twist Drills
REDUCE REDUCE
HOLE SPEED FEED
DEPTH BY BY
drill
Helix Angle diameters
Standard Helix 3 10% 10%

A standard helix (approximately 29 degrees) high speed 4 20% 10%

steel drill is used for drilling most cast irons and steels. See 5 30% 20%
figure 19.2-1 (a). 6 35% 20%

Low Helix 8 40% 20%

Low helix drills (approximately 18 degrees) have reduced
axial rakes which facilitate the penetration of brass, plas-
tics, and other soft materials. See figure 19.2-1 (b).
High Helix
High helix drills are made with wide flutes and narrow Oil-hole drills are helpful in deep-hole drilling. Hole depths
lands, for drilling deep holes in mild ferrous and nonferrous up to 30 diameters are sometimes possible. The feed rate t
materials. The higher helix (approximately 40 degrees) re- should be reduced as the holes become deeper,as shown in
moves chips more effectively. See figure 19.2-1 (c). table 19.2-5.

19-8

-I
 Guidelines for Drilling 19,2
TABLE 19.2-5 Reduction of Feed for Deep-Hole Drilling Hole Location
wi!h Oil-Hole Drills The machine tool and the setup affect the accuracy of the
location of the hole. Approximate placement capabilities
REDUCE for three general categories of machining with respect to
DEPTH BY true location are as follows:
drill Jig borer 0.0002 inch
diameters 10.005 mml
NC drill 0.0025 inch
5to 7 10% 10.064 mml
8 to 10 20% Drill press (with bushings in drill jig) 0.002 inch
over10 30% 10.05mm
I Drill press wtithout bushing 0.015 inch
1 0.08 mm)

TOOL MATERIALS FOR DRILLS

High Speed Steel

ACCURACY OF DRILLED HOLES Several common grades such as MI. M7 and M10 IS2 and
S31 are used in the majority of drilling operations. See sec-
Accuracy of Holes Drilled with Twist Drills tion 14.2 for :omplete listing of HSS compositions.
There are two elements of hole accuracy-location and
oversize. Table 19.2-6 indicates the accuracy of holes Cobalt High Speed Steel
drilled with twist drills vith and without center-drilled Grades containing combinations of high cobalt with high
holes and drill bushings. Holes drilled without center- vanadium or high carbon such as TIS, M33. and M41
drilled holes and drill bushings tend to be bellmouthed. through M47 IS9. S11 and S121 are very useful in drilling
hard steels, titanium alloys and nickel-base alloys. The co-
balt grades usually give higher tool life or faster production
Effect of Drill Point than regular high speed steel. The cobalt grades are more
The point angle affects hole location and size. Point angles expensive and in some cases are more difficult to grind
which are -nore acute than standard point angles (smaller than the common high speed steels.
included angle) have more of a self-centering effect on the
drill. The blunter the point angle, the greater the care and
skill which must be exercised to control hole location and Surface Treated HSS Drills
size. Special point grinds, such as spiral points, also im- Various surface treatments such as cyaniding and nitriding
prove the centering effect of the drill, can be applied to high speed steel drills to increase the
hardness of the outer layer of materials. Cyanided and ni-
trided HSS drills are considered when drilling hard and
Point Grinding Faults abrasive materials which allow very short tool life of un-
Cutting lips of nonuniform length or angles will produce treated HSS drills. Flash chrome plating is used on occa-
oversize holes and excessive margin wear. Insufficient sion when drilling small-diameter holes in printed circuit
clearance will result in excessive drill thrust and will pro- boards, carbon and graphite, and some nonferrous metals.
duce excessive heating and burning of the work material Other treatments such as special polishing and black oxid-
and drill point. A too large lip clearance, leaving in- ing are used to minimize friction between the drill and the
sufficient support behind the cutting edges, results in chip- workpiece, galling of chips in the flutes, and excessive
ping and crumbling of the cutting edges. work material buildup on the drill lips.

TABLE 19.2-6 Average Accuracy of Holes Drilled with Twist Drills

DIAMETER

CONDITION 14to 34 Inch 314iol-/2kc

Oversiz Location Oversize Location Ovrsize Location

No center drlled hole-no bushing 0.003 0.007 0.006 0.008 0.008 O.O09
Center drilled hole-no bushing 0.003 0.004 0.003 0.004 0.004 0.005
Drill bushing 0.002 0.002 0.003 0.002 0.004 10.003

No center drilled hole-no bushing

Center drilled hole-no bushing
Drill bushing

19-9
19.2 Guidelines for Drilling

Carbide Drills Burrs and delamination can also be minimized by con-

Twist or straight-flute drills can be tipped with carbide cut- trolling the operation to ensure that drills are sharp at all
tiig edges ut be made of solid tungsten carbide. times.

" Carbide-tipped drills are usually preferred because they Very large assemblies of sheet material, usually aluminum.
are less expensive than solid carbide drills. Standard titanium or steel alloys, are frequently drilled in the aircraft
carbide-tipped drill diameter range is usually from 3/32 industry. The larger assembly size usually dictates the use
to 1-1/2 inches 12.4 to 38 mml. of portable drilling equipment. This equipment may be
electric- or pneumatic-powered. The drills may be hand-fed
" Solid carbide drill diameter range is from 1/16 to 1/2 when drilling aluminum alloys, but are power-fed when
inch 11.6 to 13 mmlI (or No. 80 to No. 13). drilling titanium alloys or steel.

" Applications for carbide drilling:

DRILLING NONMETALLICS
a. For steels harder than 50 Re to avoid surface damage
to the steel
Plastics
b. High production drilling on cast iron and aluminum Use low helix drills with deep-polished, large-radius flutes
to facilitate chip removal. Point angles should be 60 to 90
c. Drilling of reinforced plastics including circuit boards degrees: use 60 degrees on sheet plastics.

Some plastics produce undersize holes. To overcome this

problem, use drills 0.002- to 0.003-inch 10.05 to 0.08 mml
COOLANT SYSTEMS FOR DRILLING oversize. Before using a cutting fluid, check the possible
damaging reaction to the plastic. or use an air-cooling jet.
Flood
The most commonly used method of applying coolant to Composites
the drill is the overhead flood, where a constant stream of Composite materials containing glass, graphite. boron and
liquid is directed at the hole. Kevlar fibers are finding increasing applications in aero-
space, automotive, marine and commercial items. Bas-
ically. these materials are composed of high-'!rength fibers
Mist impregnated in a plastic matrix. These matt..als are very
Application of a mist of coolant to the drill is very useful in hard and abrasive by nature; therefore, conventional drills
situations where a recirculating coolant system would be made of both high speed steel and carbide find limited us-
impractical or impossible, such as on large sheets or air- age because their tool life is short and they tend to delami-
frames. nate the material on exiting the drilled hole.
These problems have practically eliminated the use of HSS
Oil-Hole or Pressurized-Coolant Drilling System drills and have led to the development of a family of new
This application is used often in screw machines and turret drill configurations and drilling technology utilizing both
lathes for drilling deep holes. The coolant is pumped under carbide and diamond. According to present technology, the
constant or pulsating pressure (see section 3.3). drilling of small-diameter holes, up to 3/16-inch 14.75 mml
diameter, is best performed using solid carbide drills hay-
Recent availability of relatively inexpensive pump and ro- ing a low flute helix and a smaller than normal included
tating seal equipment will permit the use of oil-hole drills in point angle. These drills have less tendency to delaminate
almost any drill press, old or new, provided that it is in rea- the material when a back-up material is impractical to use.
sonably good condition. Oil-hole or coolant-fed HSS drills
are now available in a wide range of sizes in both high For larger diameter holes, industry has turned to a wide-
speed steel and carbide-tipped styles. Oil-hole usage may, spread use of diamond-impregnated core drills. These drills
in many cases, result in increased metal removal rates over have brought vast improvements in hole quality, hole size
flood cooling for normal depth holes as well as for deep and drill life. Running at much higher speeds than conven-
holes. tional drilling speeds. diamond core drills grind the hard fi-
bers, thus eliminating fiber whiskers in the hole.

A new development in the use of diamond-impregnated

THIN SHEET DRILLING core drills employs ultrasonic vibration to produce faster
penetration rates. However used, diamond core drills do
Very thin sheets, either metallic or nonmetallic, should be have a tendency to delaminate upon exiting the hole; there-
backed up with a solid block of wood or soft steel to pre- fore, it is recommended that wherever possible the under-
vent cracking in brittle materials, deformation in metals, or side of the hole be backed up with wood, aluminum or plas-
oversize holes. The formation of burrs, both at the entrance tic. A newer family of composites composed of fibers in a tat
and the exit of the drill, is a common occurrence in drilling metal matrix, such as aluminum, are posing problems in
"sandwich" layers of sheets, and delamination of pressed drilling which require -additional process developments,
and sintered alloys may occur under heavy feeds. The use such as utilizing rotay ultrasonic core drilling, electrolytic
of a -backup minimizes both burring and delamination diamond drilling ati(flasers to produce acceptable holes.

19-10
 Tool Life 19.3
Tool life is one of the most important factors in the eval- speed are presented in figures 19.3-2 and 19.3-3. Figure
uation of machinability. Specifically. the manufacturing en- 19.3-2 shows that for tests on 8640 steel using a carbide
gineer needs to know the relation of too! life to speeds. tool. the longest tool life was obtained at 300 feet per min-
feeds and the other pertinent machining parameters. For ute 190 m/minI with a feed per revolution of 0.010 inch
production operations, tool life is usually expressed as the 10.25 mini. Figure 19.3-3 shows the tool life in cubic inches
number of pieces machined per tool grind. In m~rhinability of metal removed for the same test conditions. In this case.
testing, tool life is generally defined as the cutting time in the greatest tool life was obtained at 300 feet per minute
minutes to produce a given wearland for a set of machining 190 m/minI with a feed per revolution of 0.020 inch 10.5
conditions. This cutting time can be converted to cubic mml even though the tool life in minutes was less than that
inches of metal removed for a given depth of cut. obtained when using a feed per revolution of 0.010 inch
10.25 mml.
Turning tests usually are used for evaluating the machin-
ability of a material in terms of tool life. This operation is Once the tool life curves have been established showing the
used because of the simplicity of the cutting tool. In addi- effect of cutting speed. other tests can be run to develop the
tion. all of the machining conditions, such as speed. feed. relationships between tool life and other machining varia-
tool geometry. tool material, and cutting fluid. can be read- bles. Tool life curves on the effect of feed for a constant
ily controlled. y varying one of the machining conditions cutting speed are shown in figures 19.3-4 and 19.3-5. Tool
and keeping the others constant, it is possible to determine life versus feed is given for three different cutting speeds.
the effect of such a change on tool life. The relationships The curves in figure 19.3-4 show tool life in minutes. The
among the various machining variables are obtained in this longest tool life was obtained using a feed per revolution of
manner. 0.010 inch 10.25 mini with a cutting speed of 300 feet per
minute 190 m/minl. Figure 19.3-5 shows tool life in cubic
In a machining test such as turning, the tool is removed af- inches of metal removed. At a cutting speed of 300 feet per
ter a given amount of wear is produced on the flank of the minute 190 m/minI. tool life was greatest when using a feed
tool. The wearland is usually 0.015 or 0.030 inch 10.38 or per revolution of 0.020 inch 10.5 mini. For complete results.
0.75 mini for carbide and 0.060 inch 11.5 mini for high a three-dimensional graph of speed and feed versus tool life
speed steel. It is general practice in these tests to stop the is necessary.
machining at frequent interva!s and examine the wearland
on the tool. The time to produce the wearland is then re-
corded. A typical data sheet for turning tests is shown in Other tool life tests can be performed to evaluate the effect
figure 19.3-1. This procedure is continued until the wear- of the other machining variables, such as carbide grade.
land reaches a predetermined width, which in these tests tool geometry. and cutting fluid. Figure 19.3-6 shows a set
was 0.015 inch 10.38 minI. It should be noted that inter- of tool life curves comparing the effect of a carbide grade
mittently measured tool wear rates may not fully indicate on tool life. Tool life curves for various materials can be
rates of continuous cutting wear. Hence, wear tests should grouped on the same chart to compare the relative machin-
be run both ways. ability of each of the materials when machined under sim-
ilar conditions. A group of tool life curves for turning vari-
Initially. a tool life curve is obtained with several different ous materials is shown in figure 19.3-7.
speeds. keeping the other variables constant, thus obtain-
ing a relationship between cutting speed and tool life. The This presentation on tool life curves has dealt mainly with
recommended cutting speed for a high speed steel tool is turning tests. While turning tests are most widely used, it is
generally the one which produces a 60-minute tool life. preferable whenever possible to test using the particular
With carbide, the tool life can be much shorter. particularly machining operation in question. such as turning, milling,
if a throwaway-type tool blank is used. In this case. a 30- drilling, reaming. tapping, etc. The tool life curve is a valu-
minute tool life may be satisfactory. When a tool life curve able source of machining information: from it the tool engi-
is available for a range of cutting speeds, the tool engineer neer. designer. or planner can obtain machining conditions
can select "he cutting speed which will give him the best which will produce maximum production at a minimum
compromise between tool life and production rate. Tool life cost for the machining operation. A further discussion of
curves for various feeds which show the effect of cutting cost is presented in section 21.

aI-

19-11

7
--- --- - _ _
19.3 Tool Life

44 H+ - -- - --4

--- -- -

fil -f Ef

S0 ('EN '-.
.Wj

O.S

LLu

w ca U;

Z-I _ _ 2z_ _ 1
0 19-12
 Tool Life 19.3

50 I Tool. C-6 carbide

44I BR. 0* ECEA 50 300 -
40 ----- SR. 6* Relief 5* > 270
38. ---
- /:0.010 1pr SCEA o NR 0.040n 2.0 ,
e
":3.
d Depth
/I~ of cut 0100n i 0020iprFeed
35ee Cutting fluid Dry 0 ' 1-
EE 30 ! Wearland: 0.015 in =200--- ' - '

o 20 l . e "' t0.0ipr 5Feed

0 20 2C- 005 ipr Feed

10 _ _-__ _ _. __o_ [ 61 . .. .
100020 ,pr .,zo._ ,

,
0 Feed I "- ' - -

300 400 500 600 700 800 300 400 500 600 700 800
Cutting speed. fpm Cutting Speed. fpm

Figure 19.3-2 Effect of cutting speed on tool life Figure 19.3-3 Effect of cutting speed on tool life
for turning 8640 steel, 190 Bhn. for turning 8640 steel, 190 Bhn. See figure 19.3-2
for test conditions.

4410j. 1 3 27

300 fpm Cutting speed

_ __ _ _ _ _ _ _ _ _E 200_

"30 -t I * - - -,.."
0 " - 300fpm Cutting speed

-6 20 pm 10j0 speed
Cutting I
0 17 jsOwp~tigpe
f.
1- -- 0pm Cutting
100 speed r 50
1 --
10 z0 45 30 pm Cutin
f___
utn see
pe
10 - 800 1pm Cutting speed 0 - _

0 1 011-& - I -'

0.005 0.010 0.01 5 0.020 0 005 0 010 0.015 0 020

Fed. -0005Feed. ipr

Figure 19.3-4 Effect of feed on tool life for turning Figure 19.3-5 Effect of feed on tool life for turning
8640 steel, 190 Bhn. See figure 19.3-2 for test 8640 steel, 190 Bhn. See figure 19.3-2 for test
conditions, conditions.

19-13
 I

19.3 Tool Life

0 -Tool
Carbide (see below)
BR 0* ECEA 50
SR 60 Relief 50

SCEA- 0 NR 0 040 in
6 60
-- -eFeed
Depth, of cut 0 100 in
0 0 10 ipr
Cuiting fluid Dry Wear 0015 in

C-7 Grade carbide uring Dry Wear 0015 in

0 0 (harder more brittle grade)

40 Ef - - - - - - ~-

[ C-6 Grade carbide

(general purpose)

SI 0
200 0 1~ j -
*-

300 400 500 600 700 800

Cutting speed. fpm

Figure 19.3-6 Effect of carbide grade on tool life for turning 8640 steel, 190 Bhn. Best tool life was ob-
tained at 300 fpm using C-7 grade carbide. For a 40-minute tool life, AISI 8640 steel can be turned at
415 fpm using C-7 grade carbide, compared to 320 fpm with C-6 grade carbide.

Tool- C-6 carbide (brazed)

BR: 00 ECEA: 50
SR: 6* Relief: 5.

SCEA- 0* NR: 0_040 in

60 O-Depth of cut, 0.100 i-I
Feed: 0010 ipr
O Cutting Fluid: Dry Wear 0015 in

003
' I 1%= ./ 1020 Steel
o - Se ! / 115Bhn

20 /l 0 NN
'" I
430OSteeI 0
0 T 400 Shn~ fi
250 4 00
0 200 320 1 740
0 200 400 600 800 1000

Cutting speed. fpm

Figure 19.3-7 Effect of cutting speed on tool life for turning various materials. For a 40-minute tool life
turn the above steels at: 740 fpm for 1020 steel, 115 Bhn; 320 fpm for 8640 steel, 190 Bhn;, 250 fpm for
8640 steel, quenched and tempered to 300 Bhn; and 200 fpm for 4340 steel, quenched and tempered to
400 Bhn.
4

19-14
 Types of Machinability Data 19.4
There are various degrees of sophistication of machin- these situations, it is possible to calculate the machining
ability data available for use by industry. A general dis- conditions which provide minimum cost or maximum pro-
cussion of the types of data will be given. duction rate or maximum profit. Whenever such calcu-
lations are made, it is wise to verify the calculation by shop
trial.
Tables of Recommended Machining Conditions
This Machining Data Handbook contains the practical Machinability Ratings
starting conditions for most of the significant work mate-
rials and machining operations. It supplies the recom- There appears to be an endless desire to provide macnin-
mended feed, speed, tool material, tool geometry. and cut- ability ratings for materials. The original machinability rat-
ting fluid as well as data for determining horsepower ing index was based upon turning BI 112 steel at 180 feet
requirements for various machining operations. It also con- per minute 155 m/minI with a high speed steel tool for an
tains the most practical and readily accessible data for gen- index of 100 percent. This index was developed years ago
eral shop application, under strong influence from the Independent Research
Committee on Cutting Fluids.
Wide Range Machining Data Since inthat
bides time, high speed steels have lost ground to car-
turning. It is tempting to try to use a single numer-
Detailed machining data covering the tool life obtained un- ical value to designate the degree of difficulty (or ease) with
der a wide range of machining parameters such as speed. which a particular material can be machined. Unfortu-
feed. tool material, tool geometry. and cutting fluids are of- nately. it has been found that this machinability rating of a
ten useful in selecting a set of conditions for machining at given work material changes with the type of operation in-
lower costs or higher production rates. The detailed ma- volved and with the tool material selected. The inconsist-
chining parameters can be obtained from laboratory stud- encies and futility of applying machinability ratings can be
ies or from shop studies by varying the pertinent parame- seen in table 19.4-1.
ters and observing their effect on tool life. Data formats for
presentation of wide range machining data are shown in Machinability ratings are given for four work materials
section 21. and three operations-turning, milling and drilling. In addi-
tion. the rating is given for both high speed steel and car-
bides for the turning and milling. In machining 4340 steel.
Cost and Production Rate Determination and the rating is seen to vary from 25 to 88 depending upon the
Analysis operation and tool material.
It is possible and desirable to calculate the total cost and
production rate on any machining operation. Section 21
supplies the necessary procedures for making these calcu-
lations based on the relation of tool life to the machining TABLE 19.4-1 Mahlnablit Index Inconsistencies
parameters.
WORK MATERIAL
Mathematical Correlation of Machining Parameters 250
with Tool Ufe and Subsequent Optimization of OPERATION 4340 T-3k- 17-7 PH Maraglng
Cost and Production Rates Steel 13V-llCr Steel Stee
Attempts have been and are being made to correlate tool 3i9
4 215 8hn 170 DIm 330
life with the other pertinent machining parameters. The
usual approach is to obtain empirical data relating tool life Tamining
to speed, feed, and depth and width of cut. In some cases. HSS 25 - 32 54
these data can be put into the fairly simplified equation: Carbide 31 16 18 59
Milling
vTfadb%- = K HSS 25 16 37 74
Carbide 88 20 53 83
where: v = cutting speed Drilling
T = tool life HSS 42 17 42 92
f = feed _. -

d = depth
w = width
and n, a. b, c, and K are constants.
The application of the machinability index should be re-
Unfortunately. it has been found that most work materials stricted to very special situations where the ratings have
when machined by thevarious operations do not follow this meaningful and consistent values. Another application of
simple relationship except for restricted regions of cutting the machinability rating system involves the use o, relative
speeds and feeds. Despite this, certain combinations of machining time, an example of which is given. A more pre-
work materials and operations that obey this simple law :ise and logical approach to the selection of machining
permit one to obtain this mathematical relationship be- data is to use the data contained in the Machining Data
tween tool life and the various machining parameters. For Handbook.

19-15
 SECTION 20
GRINDING AND
ABRASIVE MACHINING

20.1 Grinding Wheels.................................................................................... 20-3

Conventional Wheels ....... ............................................................... 20-3
Cubic Boron Nitride (CBN) Grinding Wheels ................................................. 20-8
Diamond Grinding .............................................................................. 20-11

20.2 Grinding Guidelines................................................................................. 20-13

Grinding Recommendations................................................................... 20-13
Modifying Wheel Recommendations.......................................................... 20-13
Modifying Operating Conditions to Change Wheel Grade Action ......................... 20-14
Precautions...................................................................................... 2D-15

20.3 Surface Roughness and Tolerances ............................................................... 20-17

20.4 Grinding Formulas and Charts...................................................................... 20-21

20.5 Abrasive Machining................................................................................ 20-33

Vertical Spindle. Rotary Table Surface Grinding............................................. 20-33
Reciprocating Table Surface Grinding ....................................................... 20-3
Abrasive Belt Machining ....................................................................... 20-33
High-Efficiency or High-Speed Grinding...................................................... 20-34
Cylindrical Crush Dress Grinding ............................................................. 20-35
Creep Feed Grinding ........................................................................... 20-35

20-1
 I

Grinding Wheels 20.1

CONVENTIONAL WHEELS Wheel grad, requirements vary irnversely with the work-
piece hardness. Harder materials require softer'grade
Wheel Identification wheels. while softer marerials require harder-grade wheels.
Table 20.1-1 shows the standard marking system for iden- Wheel Structure
tifying grinding wheels and other bonded abrasives (per The wheel structure number i-Aicates the porosity or den-
ANSI B74.13-1977 and ISO 525-1975E)_ h of he tutr Low ubri:dctsteprst rdn
sity the wheel. numbers indicate a dense structure.

Tables 20-1-2 and 20.1-3 list the codes that are used by while high numbers indicate an.open structure.
the various grinding wheel manufacturers for alminum Wheels having an open structurt are recommended for sur-
oxide wheels and silicon carbide wheels. respectively. face grinding, while wheels having a dense structure are

Abrasive Types recommended for cylindrical. centcrless and form grinding.

Dense wheel structures art rt-commended when low sur-
The two most common abrasives used in industrial appli- face roughness values are required.
cations are aluminum oxide and silicon carbide. Aluminum
oxide is a synthetic material produced in an electric fur-
nace. Aluminum oxide abrasives have a wide variety of
properties. such as toughness and friability, which can be Of the several bond types listed in table 20.1-1. resinoid.
tailored to specific job requirements. Tough aluminum ox- rubber and vitrified are the most widely used types.
ide is used for rough grinding operations. Semifriable
aluminum oxide is a general-purpose type. White friable Vitr.,ied bonds are more brittle than resinoid bonds but are
aluminum oxide is used for tool grinding and for heat sensi- superior for holding form. Normal speeds for vitrified
tive materials, while pink friable aluminum oxide is used wheels are 6.500 or 8.500 feet per minute 133 or 43 m-sl.
for difficult-to-grind alloys. Higher speeds of 10.000 to 16-500 feet per minute 151 to 64
misl require special wheels, tested and approved for the
particular speed and machine.
Silicon carbide. also a product of the electric furnace, is
harder than alum;num oxide and is used primarily for Normal speeds for resinoid-bond wheels range from 6500
grinding nonmetallic. nonferrous and low-tensile-strength to 9.500 feet per minute 133 to 48 m/sl depending on the ac-
materials. Green friable silicon carbide is used for general- tual grading. In some cases. cutoff wheels and snagging
purpose grinding of tungsten carbide. Various combina- wheels can be run at speeds up to 16.500 feet per minute
tions of aluminum oxide and silicon carbide abrasives are 164 m/sI. In any case. the speed marked on the blotter is
available only in organic bonds-resinoid. rubber and the maximum permissible speed. Resinoid-bond wheels are
shellac. used for wet grinding and for cutoff operations.

Grain Size
Grain size influences surface roughness. stock removal Truing and Dressing
rate. chip size and corner holding ability. Surface rough-
ness depends on a number of factors. such as wheel hard- Before truing a grinding wheel, the spindle should be run
ness. structure and dressing methods. but finer-grain abra- until it is up to operating temperature Then the diamond
sives tend to produce surfaces with lower roughness truing tool should be placed at the center of the wheel and
values. fed out to the wheel edge. and then from edge to edge. A
copious flow of coolant should be directed at the wheel-tool
interface.
Wheel Grade
The grade or hardness of a wheel is a measure of the The face of the wheel must be prepared for the job it is ex-
strength of the bond holding the grains in the wheel. The pected to do by dressing. When dressing wheels for finish-
niajor factor affecting bond strength is the amount of bond ing operations. the diamond tool is fed slowly across the
holding an individual grain. Wheel grades range from A to face: when dressing wheels for roughing operations. the di-
Z in order of increasing bond content. amond tool is fed more rapidly.

20-3 ___
20.1 Grinding Wheel'

Cr).
Cc 0

ca 0 30 c

'0' 0
>- . ~ u
-
'Fa '55S1Z 2M..R' 0)

%fo* aa c a 0 aQ cc .
. cCo5P:;
UL. ).
00LL

I Cb

a.
4) 0)C 4 o q c j

0,

00

CL

LU E

ITW
.
V nN
I 0 0 0 0D
mg

all coC4
_ _ _ _ U- ~ f) 1r U D Uc

0i CD 0 00c

<'
c

Ii. cc0

I ; II N
m_-_-_-_
z04
---- cs
 Grinding Wheels 20.1
TABLE 20.1-2 Comparative Aluminum Oxide Wheel Marking Symbols
(Includes both manufacturers' prefixes and abrasive symbols)
HEAVY DUTYI
MIXTURE OF MIXTURE OF
MANUFACTURER Aluminum IREGULAR SEMI- FRIABLE ALMNM Al. Ox. &

Acme A 3XT 7XT A FA -WA CA

Bancroft NA
-8XT

ZA VA
-RA

A
- I -

--

1A 2A
-CIA

-C2A

5A 7A

Bay State 1A A 3A 9A 8A CA
-27A 25A 1 /A -GA

-33A - -iA- 16

Bendix RA -KA I A, PA I WA GA I CA
- -6A -BA -EA-

- I 31A JA -- - DA C
2A 22A A 35 48 15 CA
1-88A I -29 - 18

--- A I -- FBA AC
- - - -- FWA-
- I - - - BWA-

Blanchard --- A 5A 9A 59A CA

-- - -6A -91A

Brightboy --- ALO----

Buckeye A ZA SA A PA WA MA CA
Bullard 3A -A PA WA 6A 6TA CA
Carborundum A VA WA A BA AA DA CA
-XA -- GA -BGA-

-- - -PA FA-
-- - - SA---

Chicago TA ZA - 51A 12A 53A 50A CA

-ZX - -52A -54A-

-AZ - -55A ---

Cincinnati --- A 2A 9A 97A CA

- -- 4A -- C2A
- -- 12A - C4A
- I - - C12A

Colonial HA -- A TA 20A - 5TAC

----- 21A - 10TAC
----- 22A - 5CTA
----- 25A - lOCTA
24A 5TA-
=
- ---

-_ 26A 1OTA

de Sanno A I XA -A 7A 9A 97A CA
-YA -AT 7AT 10A JA DA
-ZA -- 8A RA 7RA PA
- - - -12A 4A-
- -- KA GA
- -- -KTA HA
- -- - - -SA-

- s -- - -PTA-

Edmar HA ZA SA A PA WA MA CA
Ferro (FMR TA ZT EA A FA 13A 2A BA
Electia) YA BZT XA -JA 36A 15A CA
-CZT - TFA WA HA DA
_ _ - - - - -LA-

Fisher M ZR -- A B AS AC
SOURCE, Grinding Wheel Institute.

20-5
20.1 Grinding Wheels
TABLE 20.1-2-Continued

I DUT HEAY MIXTURE OF MIXTURE OF

MANUFACTURER Aluminum REGULAR SEMI- FRIABLE ALUMINUM Al. Ox. &
Oxide Zirconla Sintered FRIABLE OXIDE sic

Gardner --- A 82A 80A 81A AC

- -84A - -83A -
- -87A - -85A -
- -- -- -86A -
- -- -- -88A -

- -- -- -91A -

Grier -- A 27A 28A 78A CA

- -- - - 22A--
- I - - - -29A--

Hanson TA I -
ZA
-- MA -BA

FA
RA
WA
HA
W2A
CA
AC
ITT Abrasive HA XA MA A KA WA ZA JA
- - - -PA -EA-

Jowitt &Rodgers --- G B W sw 8X

MWA 5A 54A 63A 1A 8A 2A SFA SAC
---- 11A - S11A 11AC

National JA 14A 6A A PA SA MA CA
- ZA - - BA WA - KA
- 24A - - HA - -
- 34A - -- ---

- ZMA - - LA ---
- - - - BKA --

Ney Abrasives - -- RW A WA HA CA
Norton - 66A -A 57 32 16 AC
- 68A 76A -- 38. 19
- ZF -- - 23 - A
- ZS --- -53-

-NZ-- -

Osborn 3A - 7A 2A 1A -AC

Pacific - 19A - ---- 69A -

- 20A - A 35A 50A 40A 70A
- 21A - - ---

- 22A - -- 47A 42A 71A

- -- 49A 45A 72A
- - - -- -73A

Red Hill TA ZA -A FA WA HA AC
NA XA--- --

SGL Abrasives 3A 15A - A 14A 1CA HA RA

-18A - -4A - KA EA
-20A - - ---

Universal -- 4A - A FA WA WAA CA
-QB - SA WRA FCA
-40D - RA (Ruby) EM -

- - - - EA (Em- RFA-
Raid) ______

Wat"ham A 28A 46A A - BA DA

-29A 47A - --
-48A - -- ---

21A 51A - - 2168A 25A--

- 54A - - 68A WA 14A CA
- 30A - - 11hA 24A 16A
- 49A - - - 12A-
- 53A --- 3A (Pink) -

Westfield TA -A FA 75A 7ACA

77A -73A 76A
- - 74A

20-6
 Grinding Wheels 20.1
TABLE 20.1-3 Comparative Silicon Carbide Wheel Marking Symbols
(includes both manufacturers' prefixes and abrasive symbols)
SILICON
MANUFACTURER HEAVY REGULAR SEMI- FRIABLE CARBIDE
DUTY FRIABLE MIXTURE
Acme -GO-

Bancroft C C GOC
Bay State 70 C 10
Bendix SC C GC MC
-C GO HO
Blanchard -C 90
Brightbay sic---
- S
Buckeye HO C GO CA
Carborundum TO C SO GO ROC
WO BC-
Chicago 490 - 49CG 470
-480C

Cincinnati -60 50s 7C

Colonial 0 0 GOC
de Sanno HO C -GO GCO
Ecimar HO 0 FO GO MOI
Ferro (FMR Electro) TO 0 GO RC
Fisher -C GOC
Gardner -C GO AC

Hanson HOC GC 4C
ITT Abrasive 0 C GO SO
Jowitt & Rodgers -X GOC
MWA C 30 70 30
National -C GO RC -

Ney Abrasives -C GO-

Norton 370C 390 740 ,
Osborn 30C 1
Pacific -750C 800 770C
Red Hill - C GO
SGL Abrasives - 0 70C
Univeisal - C BIC GOC
Waltham 210 0 GO LCI
-C -M0

7 Westfield -C GOC
Bullard 0 FO GO 60C

SOURCE: Grinding Wheel Institute.

207
20.1 Grinding Wheels

CUBIC BORON NITRIDE (CBN) GRINDING When grinding the superalloys, a heavy-duty, active grind-
WHEELS ing fluid, that is, sulfo-chlorinated oil or sulfo-chlorinted
soluble oil, is a must These heavy-duty grinding fluids will
also improve grinding ratios when grinding hardened steels
Applications with CBN wheels
CBN grinding wheels are recommended for alloys that are
difficult to grind with conventional abrasives: that is. steels
and cast irons with hardnesses above 50 Re and nickel Truing and Dressing
and cobalt high temperature alloys with hardnesses It is of utmost importance that a CBN wheel be properly
above 35 Re. conditioned before attempting to grind with it. Both resi-
noid-bond and vitrified-bond wheels can be trued using a
Wheel Identification rotary diamond dresser, a brake-controlled truing device or
Table 20.1-4 shows the standard marking system for dia- a metal-bonded, 100 to 180 mesh size diamond truing tool.
mond and cubic boron nitride abrasives (per ANSI B74.13- A single-point or cluster diamond should not be used. The
1977). Table 20.1-5 lists the codes that are used jy the wheel should be flooded with a copious supply of coolant
while truing.
various wheel manufacturers for these abrasives.

Bond Types After truing. resinoid-bond CBN wheels must be dressed to

open up the glazed surface left by the truing process. A con-
CBN grinding wheels are available with resinoid, vitrified ditioning stick containing approximately 200-mesh alumi-
and metal bonds. Resinoid-bond wheels produce a good fin- num oxide or silicon carbide abrasives in a soft vitrified
ish at high metal removal rates and provide fairly good bond can be used. It is best to jog the wheel and press the
wheel life. Vitrified-bond wheels are better for holding form conditioning stick into the wheel while it is slowing down.
and provide longer wheel life. Metal-bond wheels are free This removes the bond, exposing the sharp cutting edges.
cutting and give high metal removal rates. When the conditioning stick starts to wear rapidly, the

Metal-Lond, electroplated wheels contain a single layer of wheel is properly dressed. Vitrified-bond CBN wheels usu-
CBN grains and cannot be trued or dressed. Therefore, it is ally do not need to be dressed or conditioned. They can be
imperative that the spindle be running true and that all used immediately after truing.
mounting surfaces be clean and free of burrs. When these
wheels are mounted, the runout should not exceed 0.0005
inch 10.013 mm TIR in either the radial or the lateral Machine Requirements
directions. To realize maximum benefits from using CBN wheels, tie
Grit Size machine must have sufficient rigidity, horsepower and
spindle speed. Machine vibrations that can be tolerated
Because of the sharpness of CBN, it is necessary to use with conventional abrasives because of their more rapid
finer grain sizes than are used with conventional abrasives wheel breakdown will cause CBN wheels to chatter.
to obtain the same surface roughness level. Extremely fine
finishes are difficult to obtain with CBN abrasives because
there is little or no burnishing of the surface since CBN
abrasives wear so little. Surface Integrity
Because CBN wheels remain sharp longer, they produce
Grinding Fluids less heat and deformation in the workpiece, thus less resid-
Hardened steels and cast irons can be ground dry with ual stress. This permits the use of conventional speeds and
CBN wheels; however, using a grinding fluid will improve feeds on critical parts that would otherwise require "low
both the surface roughness and the wheel life. A light-duty stress- grinding procedures if conventional abrasives were
soluble oil will suffice for these materials, used.
I

20-8
 Grinding Wheels 20.1

z0 f

.0 LL LW

V m U)c a) Dco-

0 .2 a) E .

0 C

4,, o
-2 '0. >, 3: x
0
ir Q rcoP

00
o 0 0.5
o0 r- m

a o I-

LU C) X,

I.a E~ 0
a.z

C0 0 aU oc

z = 0CM C
tu 20-z

C.0 E____________________
I
20.1 Grinding Wheels

TABLE 20.1-5 Comparative Diamond and Cubic Boron Nitride Wheel Marking Symbols

MANUFACTURER CUBIC BORON NITRIDE DIAMOND

Bay State 1B (Borazon) D. 1D, 3D, 4D. 6D, 9D

Bendix B (Cubic boron nitride) D (Manufactured)

Carborundum CB (Nickel-coated resin-bond cubic D

boron nitride) MD (Manufactured)
B (uncoated cubic boron nitride) CMD (Coated manufactured)
SND (Selected natural)

Cincinnati 1BN (Metal-coated cubic boron nitride) MD (Manufactured)

2BN (Cubic boron nitride) CMD (Coated manufactured)
AMD (Coated manufactured)
EMD (Coated manufactured)
DMD (Coated manufactured)

Norton CB (Cubic boron nitride) D

SD (Manmade)
ASD (Coated manufactured)
ASDC (Coated manufactured)
AZD (Coated manufactured)

Universal BZ (Borazon) D (Natural)

CD (Coated natural)
?V10 (Manufactured)
WD (Metal coated manufactured)
DD (Metal coated manufactured)
SD (Metal coated manufactured)

Waltham BN (Borazon) MD (Manufactured)

D (Natural)
ND (Manufactured nickel coated)
CD (Manufactured copper coated)

SOURCE: Grinding Wheel Ir-stitute.

20 10
 I-

Grinding Wheels 20.1

DIAMOND GRINDING Wet grinding with diamond wheels eliminates some of the
common problems associated with dry grinding. Since
Diamond grinding technology has developed considerably workpiece temperatures are kept at a low level, the poten-
during the past 30 years with respect to both grinding tial for surface cracks or possible catastrophic cracking of
wheels with natural grit and. more recently. grinding the workpiece is greatly reduced. Dust problems also are
wheels with synthetic grit. Today. diamond wheels are eliminated. The flushing action of a copious supply of cool-
available in a large variety of mesh sizes. diamond concen- ant helps to keep the diamond wheel cutting free, thus pre-
trations, and bond types. Table 20.1-4 lists the standard venting loading of the wheel.
markings used for diamond wheels. The designations for
abrasive types used by various wheel manufacturers are
listed in table 20.1-5.

Grain types have been developed for specific grinding oper- Dry Grinding
ations and materials. More recent developments have If dry grinding is absolutely necessary, wheel speed must be
opened up new applications for diamond wheels, especially kept below 4.500 feet per minute 123 m/sl. with 3500 to
in the field of steel and carbide grinding utilizing metal- 4.000 feet per minute 118 to 20 m/sl preferable. With care
clad, diamond-grain wheels. and practice. an experienced operator can become pro-
ficient at dry grinding of hard materials such as carbide and
Diamond wheels are available in several bonds: metal, vit- ceramics. One problem associated with dry grinding is
rifled and resinoid. Each bond type provides different re- dust: therefore, adequate dust-collecting systems need to be
suits, depending on the type of grinding operation and the employed. Wheel wear will be greater than with wet grind-
material being ground. ing because softer wheels must be used to help keep the
grinding temperatures as low as possible. Although resi-
Metal-bond wheels are extremely strong, long-life wheels noid-bond wheels are recommended for dry diamond grind-
having diamonds securely held in a metal matrix. Chief ing of hard. brittle materials such as carbide, glass and ce-
uses are cutoff operations with thin wheels, offhand grind- ramics, high grinding temperatures can burn or crack the
ing. chip-breaker grinding and electrolytically assisted grinding wheel. Metal- and vitrified-bond diamond wheels.
grinding. Metal-bond wheels should always be used with a on the other hand, if run dry on hard, brittle materials may
coolant, cause cracking of the wnrkpiecc miaieriai.

Vitrified-bond wheels are diamonds bonded together with

ceramic materials. This bond type provides long wheel life
at good grinding rates. The principal applications for vitri-
fied-bond diamond wheels are surface grinding, cylindrical Machines for Grinding with Diamonds
grinding, offhand grinding and internal grinding. Diamond grinding requires a higher level of machine tool
integrity than might be required for grinding with a silicon
Resinoid-bond wheels are the most popular type because carbide or an aluminum oxide wheel. Spindles must run
they provide excellent grinding speed and relatively long true, bearings should be in good condition and good
life. A resinoid diamond wheel is ideally suited for grinding maintenance procedures should be followed.
carbide cutting tools where maximum protection from
heating and cracking are a consideration. This type of
bond is best for machine grinding operations, such as cut-
ter grinding, surface and cylindrical grinding. Resinoid
bond has excellent form holding qualities, is easily dressed, Wheel Mounting
and is most suitable for diamond wheels with formed faces. When mounting a diamond wheel, extra care should be
taken to be sure that back plates, flanges and spindles are
Wet Grinding clean, free of burrs and running true. Straight wheels
should be tightened gently between the flanges and then
Wherever possible. diamond wheels should be used wet. lightly tapped into position so that they run within 0.0005
This promotes longer wheel life, decreases workpiece sur- inch 10.013 mini TIR. The flanges should then be coin-
face roughness and reduces wheel dressing frequency. For
machines not equipped with flood coolant systems or where
the operator must observe the work at all times, the mist or
wick method can be used. The primary reason f-: recom-
mending wet grinding with diamond wheels is tlf.a. the dia- If the grinding machine has a tapered spindle nose, it is
mond itself has a relatively low thermal threshold and will common practice to mount each diamond wheel on a sepa-
"burn" at relatively low (1,100 to 1,3000 F 16000 to 7000 1) rate collet or adaptor. If left as a unit, the mounted wheel
temperatures. The heat at the crystal-work interface can and adaptor can then be removed and replaced as needed,
easily reach the low temperature range in dry grinding, and the time and abrasive lost in truing can be avoided.

20-11
 pR IG PA BL -NOT FI/LZD

Grinding Guidelines 20.2

GRINDING RECOMMENDATIONS General Guidelines

0 To remove a substantial amount of stock-wet grinding
The grinding conditions listed in section 8 of this handbook is recommended over dry grinding.
are provided as starting recommendations. These starting
conditions may have to be adjusted to reflect (1) workpiece * To remove stock faster-use a coarser grain wheel with a
characteristics. (2) requirements for the ground surface. (3) more open structure and a less friable abrdsive.
economic objcctives and (4) operational conditions. Ob-
viously. these grinding recommendations represent only an &To produce a smoother finish-use a finer grain wheel
approximation of the optimum conditions achievable by with a denser structure and a less friable abrasive. (See
testing and experimenting, table 20.3-1.)

These recommendations should handle most grinding situ- * To generate form-use a finer grain wheel with a more
ations. In a job shop. it is often necessary to avoid wheel dense structure. (See table 20.3-3.)
changes: a few general-purpose wheels usually are used to
grind almost every type of material, even if at less than * To grind large areas-use a softer grade and coarser
optimum efficiency. Where large production quantities are grain wheel.
involved, testing and modifications may be necessary to ob-
tain optimum results. To grind small areas-use a harder grade and a finer
grain wheel.
Despite the use of standard grinding wheel markings (table
20.1-1). wheels with identical markings made by various * To grind soft metals-use a harder grade and a coarser
manufacturers may vary in actual performance. Individual grain wheels.
wheel makers have their own modifications of both abra-
sive and bond which cannot be included in the data tables. * To grind hard metals-use a softer grade and a finer
Likewise. the structure number is omitted from the wheel grain wheel.
identification because its significance differs among various
makes of wheels. The structure provides chip clearance * To improve workpiece finish-dress the wheel to a fine
and is also a result of grain size and proportion of bond. finish.
The best or standard structure is usually derived for most
grain size and grade combinations as a result of experience * To minimize heat. warpage and surface damage in the
and tP-ting. The manufacturers of grinding wheels publish workpiece-maintain wheel sharpness (see section 18.3,
thti tables of wheel recommendations which include Surface Integrity).
grat, -iifications as well as structure numbers.
* If the grinding wheel breaks down "o fast-use ;i wheel
Recommi . in section 8 are predicated on average with a less friable abrasive, a harder grade and a denser
shop conditions. Deviations from such basic conditions will structure.
generally affect the manner in which grinding wheels per-
form. Some of the variables discussed later have opposing 0 If the grinding wheel glazes and burns-use a wheel with
effects and may balance each other when present con- a more friable abrasive, a softer grade and a more open
currently. Other variables can have similar effects which structure.
can be expected to work additively. An understanding of
the directions in which process variables interact with
grinding wheel performance permits modification of the
controllable variables
tion to or improve overall operating condi-
conoics.Guidelines for Surface Grinding
tions or economics.
" To minimize heat and warpage in the workpiece-use
fast tabh speeds, light downfeeds, and dress the wheel
before final size.
MODIFYING WHEEL
RECOMMENDATIONS * To improve workpiece finish-dress the wheel to a fine
The following list of guidelines are providf.d for use in mod- finish.
ying the grinding wheel recommendations provided in sec-
-n 8 to improve production or to meet the specific require- te-usingradeesofter bon.
ats of an application. No application, however, should ter-use one grade softer bond.
be so finely tuned that normal variations would affect the
output rate or the quality. The best approach is to accom-
modate any variations likely to occur. The best wheel for
any application is the one that compromises the ability to Guidelines for Surface Grinding, Vertical Spindle,
cut rapidly with the ability to hold form, maintain surface Rotary Table
roughness requirements and last longer. e To produce smoother workpiece finish and closer toler-
ances-use faster table speed, lighter downfeed and
Wheels recommended in section 8 are suitable for proper sparkout.
both rough and finish grinding in one setup. Where
two setups are used, use a wheel one grade harder for 0 To increase material removal rate-increase table speed
roughing and a wheel )ne grade softer for finishing, and downfeed rate.

20-13
20.2 Grinding Guidelines
Guidelines for Cylindrical Grinding Guidelines for Internal Grinding
" When using wheels larger than 14-inch 1356 mml diame- 0 For long bores-use softer grade wheels and wider
ter-use one grade softer bond. wheels, if possible.
" For heavier stock removal-use a faster traverse speed e For low powered machines-use softer grade wheels.
and a slowr work speed and/or increase the depth of
cut. * For light spindle machines-use softer grade wheels.

" To improve workpiece finish-use a slower traverse

speed and a faster work speed and/or decrease the depth
of cut.
" When using wider wheels-use a softer grade wheel (in- MODIFYING OPERATING CONDITIONS
feed grinding). TO CHANGE WHEEL GRADE ACTION
" When using narrower wheels-use a harder grade wheel Most grinding problems (other than those related to ma-
(infeed grinding), chine condition) arise from the action of the wheel grade (or
hardness) which is a direct function of the wheel sharpness
or wear rate. Indicators of too little wear (that is. the wheel
Guidelines for Centerless Grinding is acting hard) are: the wheel glazing, loading or not cutting
" When using wheels smaller than 20-inch 1500 mm diame- freely; workpieces with burning, heat checking (grinding
ter-use a one grade harder wheel. cracks) or out of roundness; finishes getting progressively
better (due to glazing); and finely spaced chatter marks or
" To improve workpiece finish-use a smaller angle of squealing. Indicators of too much wear (that is. the wheel is
draw and a faster regulating wheel speed. acting soft) are: the wheel breaking down too fast: work-
pieces with finishes getting progressively worse: widely
" For heavier stock removal-use a larger angle of draw spaced chatter marks; and scratches. fishtails. taper or
and a slower regulating wheel speed and grind closer to lack of accuracy.
center.
The action of the wheel grade can be altered by adjusting
" To produce roundness-grind as high above center as the other grinding conditions to achieve proper grinding ac-
possible. tion when it is not desirable or possible to change the
wheel. Table 20.2-1 contains guidelines for modifying
" To grind long bars-grind below center on a flat blade. wheel action.

TABLE 20.2-1 Guidelines for Modifying Wheel Action

OPERATION To Make Wheel Act HARDER To Make Wheel Act SOFTER

!.,iemai Decrease work rpm Increase work rpm

grinding Decrease wheel reciprocation Increase wheel reciprocation
Increase wheel rpm Decrease wheel rpm
Dress wheel at slower rate Dress wheel at faster rate

Surface Decrease table speed Increase table speed

grinding Decrease crossfeed Increase crossfeed
Increase wheel rpm Decrease wheel rpm
Dress wheel at slower rate Dress wheel at faster rate

Cylindrical Decrease traverse speed Increase traverse speed _

grinding Increase wheel rpm Decrease wheel rpm

(traverse) Dress wheel at slower rate Dress wheel at faster rate

Centerless Decrease feed wheel rpm Increase feed wheel rpm

grinding Dress grinding wheel at slower rate Dress grinding wheel at faster rate

20-14
 Grinding Guidelines 20.2
PRECAUTIONS direct the fluid so that is reaches the cutting zone. See sec-
tion 16. Cutting Fluids.

Safety
Follow all requirements for safe wheel use. Do not exceed
the maximum speed marked on the wheel or shown in
ANSI B7.1-1978, Safety Requirements for the Use, Care, Surface Integrity
andProtectionofAbrasive Wheels. See tab!e 20.2-2. To avoid damage to the ground surface in the form of
grinding burn. heat checks (grinding cracks). warpage. re-
sidual stress or other surface alterations, see section 10.4.
Cutting Fluids Low Stress Grinding. for proper grinding procedures. Also
Use the proper cutting fluid. use the proper flow rates. and see section 18.3. Surface Integrity.

20-154
20.2 Grinding Guidelines
TABLE 20.2-2 Standard Maximumn Wheel Speeds_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

I MAXIMUM WHEEL SPEED. fpm

FICATION' YE FWEL INORGANIC BONDS ORGANIC BONDS
NUMBER LOW Medium High LOW Medium High
_________________________ Strength LStrength Strength Strength IStrength IStrength
Type I1-Straight Wheels-except classifications
6.7,9,10.11.12.13 and 14 below.1
iType 40-Taper Side Wheels
I
ITypes 5. 7.20.21.22,23.24.25.26
1 Reesd Dovetailed and/or relieved wheels. 5.500 6.0 650 650 800 9.0
(Except Classification 7 and 14 below.)6.0 650 650
IType 12-Dish Wheels
iType 13-Saucer Wheels
Types 16.17.18.19-Cones and Plugs
2
________
Typeinserted
2-Cylinder Wheels
nut and including
projecting plate mounted.
stud-Segments_____I____ 5.000 5.500 J6.000
_____________
5.000 I 6.000 7.000
____

3(For Fixed Base Machines) 4.500 5000 6.000 6.000 7.500 8.500
Type 6-Straight S' e Cups
jType 1-Flaring Cups____ ___ _________I

Cup Shape Snagging WheelsI

4(For Portable Machines) 4,500 5.500 6.500 6.000 8.000 9.500
Type 6-Straight Side Cups
Type 11 -Flaring Cups________1
Abrasive Dics: Plate MountedI
5 Inserted Nut and Projecting Stud: Solid or 5.500 6.000 1 6.500 5.500 7.000 8.500
Reinforced Wheels Type 1I
I Max. Dia. 4" NAI NA NA 9.500 12.500 16.000
Max. Thickness 1/4" ____

Max.Ti. I sl/V NA -NA NA 9.500 12.500 14.200

6f All Other Diameters and Thicknesses NA NA NA 9.500 12.500 - 12,500
Reinforced Wheels-Types; 27 and 28
Max. Dia. 9" -NA NA NA 9.500 12-500 14.200
Max. Thickness 3/8" 1____ _____________

____ Max. Ola. 9"--Over 3/8" Thick NA NA NA NA 9.500 11.000

Type 1 Whees for Bench and Pedestal Grinders
7 Types 1 and 5for Surface Grinders only in sizes 5.500 6.325 6.600 6.500 8.000 9.500
7" dia. up to 2" thick an~d up to 2" hole ___ ___

8" dia. upto 2" thick and up to 2" hole 5.5W0 6.325 7.550 6.500 8.000 9.500
Diamond and Cubic Boron Nitride Wheels NA NA 6.500 NA NA 9.500
8 Exceptions- 1. Metal Bond NA NA 12.000 NA NA NA
2. Steel Centered Cutting-off Wheels NA NA 16.000 NA NA 16.000
9 Cutting-off Wheels Type 1 and 27A N A N .0 2O 42
-Larger tVan 16" dia.. Including Reinforced Organic N A N .0 200 1.9
Cufting-off Wheels Type 1 and 27A
10 16" dia.. and Smaller-including Reinforced NA NA NA 9.500 12.000 16.00
______ OrganicII
11 Threal aind Flute Grinding Wheels 8,000 10.000 12.000 8.000 1000 12.000
12 Crankshaft and Camshaft Grinding Wheels 5.500 8.000 8.500' 6.0 8.000 9.500
Type 1 Snagging Wheels 16" diamneter and

J
13larger. Organic bond including reinforced: NA NA NA NA NA 12.500
Used on swing frame grinders, designed
for this speed ______ __ I___

I
Used on semi-automatic snagging grinders. NA NA NA I NA NA 16.500
deefgned for this speed

14 Internal Wheels-:Type I and 5 5.500 8.000 8.300 6.500 5.500 9500

Mounted Wheels foiiain)I NA 1_NA 1000 -0A -
_______ (See stadard NAr NAmi10.000s
SOURCE: ANSI B7.1-1978. p.65 type play a part in the overall strength of an abrasive wheel specifiction.
NOTE:. Abrasive wheels are produced in a wide range of specifications to Therefore, the maximum allowabl operating speeds vary depending on
perform sastisfictorin a wide range of grinding appktations. As a gen- the strength of the wheelq. It asfor this reason that speeds St.Own are listed
era[ ride, hard matera requires a soft grade whee and soft material is incolumns labieled Low. Medium, and High Strength.
best ground by a hard grade_ whel.flferent wheel grades have different -Nrarndrd shape.
strengths, harder grade wheals are geerally Stonger tha softer grade 'Casfcto 6 excludes cutoff wheels.
wheels, alfthough other ingredients Such as grit size. structure and bond -

20-16
 Surface Roughness and Tolerances 20.3
SURFACE ROUGHNESS is limited by the maximum allowable raijius at the botton
of the thread. This radius is usually given in terms of rcot
The grain size of a grinding wheel will determine the ap- width, which is the distance between the points of tangency
proximate surface roughness that can be obtained on the of the arc and the sides of the teeth. The root width varies
workpiece. as given in table 20.3-1. The structure of the inversely with the number of threads per inch for metric
wheel and the dressing procedure will also affect the sur- pitch): the greater the number of threads per inch. the
face roughness to some degree. A finer-grain-size wheel will smaller the maximum allowable root width.
usually produce surfaces with lower roughness values at
some sacrifice of stock removal capability. To alter the wheel recommendations in section 8.14. table
20.3-4 may bz used as a guide for selecting the coarsest al-
Obtaining surf, -e roughness values of less th in 10 to 15 lowable grain size for a thread grinding wheel. If a particu-
microinches R. 10.25 :o 0.38 pml requires special attention lar standard calls for a narrower root width, the grain size
to work speeds and crossfeed or traverse rates. Very must be chosen for the maximum allowable root width. An-
smooth surfaces require abrasive grain sizes of 220 and other factor to be considered is the quality of the finish.
finer. Where a very low surface roughness value is required on
threads of relatively coarse pitch. it is advisab!e to use a
finer grain wheel than would be necessary to hold the
TOLERANCES proper root width.
The tolerances achievable with various grinding oper-
ations are given in table 20.3-2. The production tolerances
can be held without difficulty: however, larger tolerances TABLE 20.3-1 Grinding Wheel Grain Sizes for
where acceptable will be more economical. The precision Producing Various Surface Roughnesss
tolerances can be held with care but will be more costly.
GRAIN SURFACE R NESS
SIZE
Form Requirements
Grinding of forms and fillets usually requires the use of 80 pin
grain size and finer wheels, as indicated in table 20.3-3.
46 32
54 20 to 32
Thread Grinding Requirements 60 15to2o
In conventional grinding, the standard practice is to use the 80 10 to 15
coarsest practical grain size for fastest stock removal. In 120 a to 10
thread grinding, however, the coarsest practical grain size _

I 20-17 -

V -+ _ __
20.3 Surface Roughness and Tolerances
TABLE 20.3-2 Production and Precision Grinding Tolerances
TOLERANCES (Plus or Minus)
GRINDING
OPERATION inch .n-h M

Production Precision e

CYLINDRICAL GRINDING =
Diameters 000025 0.00001 0064k
Shoulders
Shoulder to Shoulder 0.00025 0.0005 O.0064 00
Traverse Grinding to a Shoulder 0.002 0.001 0 0
Corners and Radii
External Corners Sharp Sharp
Internal Corner Radii 0.005 0.0025 0 03
Spherical Sections (oscillating grinders)
Diameters 0.00015
Location of Centers 0.001 .....
CENTERLESS GRINDING
Diameters and Parallelism 0.0001 0.000025
Roundness 0000012 fe' w
Concentricity of Stepped Diameters 0.00025 0.0001 " *40
THREAD GRINDING
Lead Error (inch per inch) 0.00025 0.00001 '6
Pitch Diameter 0.0005 0.0002 0 00
Roundness 0.00025 004
Concentricity (thread form with OD) 0.0005
Grooves (width) 0.001
SURFACE GRINDING
Reciprocating Table Grinder
Flatness 0.0002 0,00015
Thickness 0.0003 0.00015
Rotary Table Grinder _

Flatnes3 0 0002 0.0001 . w. 0=--

Paralle'sm 0.0002 0.00005 00
Thickness 0.001 0.0002 ,0
INTERNAL GRINDING
Holes (using automatic sizing devices) 0.00025 0.00005 0 . 0,0013
Face Runout (squareness of shoulder to bore) 0.00025 0.00005
SOURCE. Adapted from H E.Trucks, Designing for economical production, Dearborn, MI. Society of Manufacturing Engineers, 1974, p.34.

I
TABLE 20.3-3 Grinding Wheel Grain Sizes for the
Radius of Forms or Fillets

GRAIN MINIMUM RADIUS

SIZE inch _

80 0.010
120 0.007 C
180 0.007
220 0.004
280
320
500
0.003
0.0020-5
0.001
0.7
i

20-18
 Surface Roughness and Tolerances 20.3
TABLE 20.3-4 Coarsest Allowable Grain Sizes for Thread Grinding Wheels
AMERICAN STANDARD COARSEST ALLOWABLE -jFI500TRIAL METRICT &
UNIFIED THREADS GRAIN SIZE - T HREAD

Threads Root Width Vitrified Resinoid - iitht

Per Inch in Wheels Wheels - r-r--

80 0.0016 240 220 0.350

72 0.0017 240 220
64 0.0019 220 180 . .....
- (0.0020) 220 180 0405
56 0.0022 220 180 00, 0 __56
- (0.0024) 220 180 01- 0.0_62
48 0.0026 220 180
44 0.0028 220 180 2Z2
- (0.0029) 220 180 50O6 0.7
40 0.0031 220 180
36 0.0034 180 180 wn4
- (0.0035) 180 180 0.7 0,088
32 0.0039 180 150 M 0100
28 0.0045 150 120
- (0.0049) 150 120 00 0.
24 0.0052 150 120
- (0.0061) 120 120 e I 015 _
20 0.0062 120 120 -1k
18 0.0069 120 100
- 0.0074 120 100
16 0.0078 120 100 M ___
- 00086 120 100 7 0,21
14 0.0089 100 100
13 0.0096 100 90
- 0.0100 100 90 0.250 a
12 0.0104 90 90
11 0.0113 90 90
- (0.0123) 90 90 0.31
10 0.0125 90 90 ____

9 0.0139 90 80
(0.01 48) 90 800.7M
6 0.0156 80 80 ,
- (0.0172) 80 80 0,438
7 0.0178 80 80 _ .
- (0.0197) 80 80 t 0 W A
6 0.0208 80 80
- (0.0221) 80 80 0
- (0.0246) 80 70 0. 25
5 0.0250 80 70
- (0.0271) 80 70 0.6
4.5 0.0278 80 70
- (0.0295) 80 70 .0.7M
4 0.0312 70 70

SOURCE: Adapted from Thread Grinding, 18th Edition, 1963, published by Norton Company.
NOTES: Pitch = 1 + number of threads per inch.
Root width - 0.125 x Pitch.
*Also ,pplies to British Standard ISO Metric Threads.

20-19
 PRECEDING PAM BLANK-NOT FILLE

Grinding Formulas and Charts 20.4

Shop equations and data for determining pertinent infor- Figure 20 4-4 Alignment chart for determining
ination on various types of grinding operations are given in metal removal rate and horsepower
tables 20.4-1 through 20.4-4 and figures 20.4-1 through required at motor: traverse grinding
20 4-7 as follows: (reciprocating table) for horizontal
and vertical spindle surface grinding.
Table 20.4-1 Definitions of symbols used in grind-
ing formulas and sketches, English
units. Figure20.4-5 Alignment chart for determining
metal removal rate and horsepower
Table 20.4-2 Definitions of symbols used in grind- required at motor: plunge grinding
ing formulas, Metric units. (reciprocating table) for horizontal
and vertical spindle surface grinding.
Figure 20.4-1 Sketches of various grinding oper-
ations Figure 20.4-6 Alignment chart for determining
metal removal rate and horsepower
Table 20.4-3 Grinding formulas, English units. required at motor: traverse grinding
for centertype cylindrical, centerless
Table 20.4-4 Grinding formulas, Metric units. and internal grinding.
Figure 20.4-2 Unit power for surface traverse
grinding: horizontal spindle-recipro- Figure 20.4-7 Alignment chart for determining
cating table. metal removal rate and horsepower
required at motor: plunge grinding
Figure 20 4-3 Unic power for centertype cylindrical for centertype cylindrical, centerless
plunge grinding, and internal grinding.

20-21
20.4 Grinding Formulas and Charts
TABLE 20.4-1 Definitions of Symbois Used in Grinding TABLE 20.4-2 Definitions of Symbols Used in Grinding
Formulas and Sketches, English Units Formulas and Sketches, Metric Units

a = Depti of grind, inches per pass a = Depth of grind, millimeters per pass
at = Total depth of grind, inches at = Total depth of grind, millimeters
b = Width of cut in plunge grinding, inches b = Width of cut in plunge grind;ng, millimeters
b Crossfeed, inches per pass b = Crossfeed, millimeters per pass
b -- Original width of grinding wheel, inches b, = Original width of grinding wheel, millimeters
b. = Width of workpiece, inches b. = Width of workpiece, millimeters
do = OD of grinding whec', inches (velical spindle surface d. = OD of grinding wheel, millimeters(vertical spindle
grinder) surface grinder)
IDof grinding wheel. inches (vertical spndle urface d, I.) of grinding wheel, millimeters (vertical spindle surface
grinder) grinder)
dr = Regulating wheel diameter, inches (for centerless d, = Regulating wheel dtameter, millimeters (for centerless
grinding) grinding)
do = Initial grinding wheel diameter, inches grinding
d Initial grinding wheel diameter, millimeters
d,2 = Final grir ding wheel dqmeter, inches J,2 Final grinding wheel diameter, millimeters
d, Average diameter of workpiece path on rotary table, dt Average diameter of workpieca path or. rotary table,
inches (vertical spindle surface grinder) millimeters (vertical spindle surface grinder)
d.t = Original work diameter, inches d, = Original work diameter, millimeters
d 2 = Final work diame:z-J, inches
E = Efficiency of grinding wheel drive d,2 = Final work diameter, millimeters
ft = Table traverse feed rate or throughfeed of work in E = Efficiency of grinding wheel drive
centerless grinding, inches per minute ft Table traverse feed rate or throughfeed of work in
f, = Plunge infeed rate, inches per minute .enterless grinding, millimeters per m;nute
G = Grinding ratio = Volume metal removed,3 in
3 ip = Plunge infeed rate, millimeters per minute
3
Volume wheel wear, in G = Grinding ratio - Volume metal removed, mm 3
L Length of workpiece ground, inches Volume wheel wear, mm
hpq = Horsepower required at motor. hp Lw Length of workpiece ground, millimeters
n, = Regulating wheel rpm kWg = Power required at motor, kilowatts
n, = Grinding wheel rpm n, Regulating wheel rpm
n, = Rotary table rpm (vertical spindle surface grind3r) n, Grinding whpe rpm
n,. =Work rpm nt = Rotary table rpm (vertical spindle surface grinder)
P, - Uitit horsepower, horsepower per cubic inch per minute n, = Work rpm
s = Feed per revolution of work, inche P = Unit powe,*, kilowa Its per cubic centimeter per minute
t =Axial wear from face of grinding wheel (vertical spindle s = Feed per revolution of work, millimeters
surface grinder) t = Axial we3r from fa:;e of grinding wheel, millimeters
v,= Peripheral speed of grinding wheel, feet per minute (vertical spindfe surface grinder)
v.= Peripheral speeu of work, feet per minute v, = Peripheral speed of grinding wheel, meters per second
w == Maximum contact width of grinding wheel on work v. = Peripheral spee of work, meters per minute
(vertical spinole surface grinder) w,. = Maximum contact width of grinding wheel on work,
Z Metal removal rate, cubic inches per minute millimeters (vertical spindle surface grinder)
(centerless Z = Metal removal cubic centimeters
rate,inclination per minute
grinder) wheel inclination angle, degrees
= Regulating = Regulating wheel angle, degrees (centrless
grinder)

20-22
 Grinding Formulas and Charts 20.4

IC
13,
~C

00

00

~Mq~jcm

.0 CM

0. Z- 0
'E

4, - 4 o

\ / .! c;
0~

- - 4, a

C))

:k0j 0
> 0)

0. V)
IM, 0

0 3. 0
0 i 0 - 0

4) 0 c
cc Tc
0.

an CL

X4!4 > Ii
II20-20
20.4 Grinding Formulas and Charts

>.3 x
Z 3 OD CM x
)c 3

WO
-0 cm c,.0
cm Iii II
CF N0 N
CC 3

x~

t ot C

l XW
0 IRx

Z xx
N U O
oU Ci cc.~
NN 0

a. 4 :d O xiV
0 N Aj
X VV0'"

a. Ii x
clIi c)ii x '
z N N. 0\

x NC
NN 0
C',I
-c
xa'
2m CR N Lq
E x .0
Ii C4C

- )
N 01
N '-
z0
x
1!-

(0>0 X B
TU
I
C C M

- CF-

MI N
C~~~ ;72
co C.)
d ~
-qII
*,
i
a0 x ' .. x

z C4
20-24c
 Grinding Formulas and Charts 20.4

jj c

Co x C
-I,: V ~ xl

Z ~ cl w

NO CDj No CDxC

ir CM~ .
IN
w-w 00S0
U Z 0 c cl)1.5

N D N C

x -C

IwR 1C
O
-, .- ,X

-j a:1 - -Dc

V, t

>NN N

z z ci
CC U*_ cI co axtu
LJa0 CJ1 c)

U C.) Je
> >t

0
c,1 N4 -

c)
a Nj O
x
.2.
a~ -j '0-

N uZ
b C
-r

-a
x

-f
- 0

0L 0 M
Illi
a a

> 10

ojo

-1_ E ~ -- --- j ~~-_

20.4 Grinding Formulas and Charts

C 0Ox
C

c n 0 U)

0cD

D U)) 0
0 S)
Z ::-, 2 2
o 2. - 0 S -
oc U))

CL -
E.a

-~

.0

o 0)

oC,
___v I ___

*0
C5
c)
U)

II

cm) C

-~~5 - -

00. I ( f r . ___
CC

q- t c Q Cd(
- - - - - - a
- - 0w/m
jamo ow d __

20_-26 _
Grinding Formulas and Charts 20.4

EI

0~

q o

C5

CD

0o
_00

66 C

20-2)

__0

-=~--O
-- S
20.4 Grinding Formulas and Charts
bc or bw
Crossfeed
in/pass a Z
It or Depth ot Metal Pg *hpg
Table Work width grind removal rate Unit hp hp at
feed rate in in/pass m&/mn hplnlmin motor
-100

-80
C- 0.5
- E 002 S
6.00-
g0.03 50
004 - 08
005 4.0
0.06 10
0.08 3.0
.1 =0-006
-2000
150 -0.005 1.5
1500 .- 0.2
1500-0004 0 2.0
1.0 2.0
100 - 03 1.5
- 0.4 -0.003
80--1000 - 0.5
- 0.6 -0.002 2.0 30
-800 - 0.8 1.0- 3.0
60- _ 10
6000.001 0.8 4.0 4.0
50- 6008 % , 50 5
. 60 5.0
40- 50 ,200006 -6 Z 8.0 6.
- 400
400 3.0
3o , - 0.0005
-00004 - 0.5 100
30-4, 304.0 0.0003 . . 8.0
S300 60 -0.0002 . -100

20- 80 0.3 30.0 N

10.0
200 0.0001 -- 40.0
15 -50.0 ' 15.0

150 02
-20.0
10 0.15
100
130.0

Example: Vertical spindle - Traverse grinding Traverse grinding* Z ftx bc x a (Horiz. spindle)
Gray Iron, 180 Bhn Z ft x bN x a (Vert. spindle)
Given: ft = 665 in/min (56 ft/min) bw 2 in Pg X Z
a = 0.0006in/pass Pg =15hp/in3/min hpg E
Then; Z - 0.8in3 /min hpg =15hp
*hpg = Horsepower at spindle motor

for 80%spindle drive efficiency

Figure 20.4-4 Alignment chad for determining metal removal rate and horsepower required at motor:
traverse grinding (reciprocating table) for horizontal and vertical spindle surface grinding.

20-28
 Grinding Formulas and Charts 20.4
b or bw
ft Width of cut a
Table or Z hpg
Depth of Metal Pg
feed rate Work width hpa
grind remora. rate
remova!~h Unit raeUtth
hp mtor
inch in/pass in,/min hp/in3!min

-10.0

80
. S 0.02
EE 60
0.- 0.03 0.5
-S
.S 0 350 -0.6 -
004
0 50
-. 05 - 4.000.8
- 0 06 -- 0Z
0.08 - o
0.1 3.0 1.0
-2000
150
1500 0.2 0.006 2.0 1.5
100 -0 005
0.3
"0.4 -0.004
- 0 041,5 .02.0 2.0
80 '1000 -0.5 0.003
_ - 0.6 0.002
800 2.0
0.8
60 -_ 1.0 3.0 3.0
50- 600 0 fnn - 0.8 4.0
- 0.0008 5.0 4.
40 500 __ 2.0 Q~t -6.0
*N . - 0.0006 0.6 8 -5.0
- 400 3.0 0.6
0
30- 4.0 --0.25 - -- 0.6
5.0 -0.0003
300 - 0.4
206.0 -0.0002 -20.0 0.8
20 - 8 .0 .-
200oooi40 210.0 -0.3 30.0 -10.0
15 -0.0001 B -40.0
15- 50.0
150 -0.2
10 15.0

0.15
-20.0
100
3
-. 0
Example: Vertical spindle - Plunge grinding
Plunge grnding Z = ft x b x a fHoriz. spindle)
1020 steel, 120 Bhn Z = ft x bw x a (Vert. spindle)
Given: ft = 40 ft/min bw = 2 in a = 0.0005 in/pass hpg A Z
Pg = 10.5 hplin'/min
Then: E
Z = 0.48 in'/min
iipg = 6.4 hp
*hpg =Horsepower at spnil
motor for 80% spindle
drive efficiency

Figure 20.4-5 Alignment chart for determining

metal removal rate and horsepower required
plunge grinding (reciprocating table) for horizontal at motor:
and vertical spindle surface grinding.

20-29
20.4 Grinding Formulas and Charts
dvi a
ft Oa.
Table feed of Depth Z
of Metal Pg
rate work hpg
grind removal rate Unit hp
in/min in hp at motor
in/pass in3/min hp/in 3/min
-5.0

-4.0
.

3.0
x
J1.0

2.0 0.5
- 0.6
-300 0.1 Z0.8
1.0
"0.010 2.0
:200 0.2 0.008 1.0 2.0
0.3 0.006
-0.005 -. C 3.0 3.0
0.4 -0.004
0.5 4.0
0.003 0.6 5.0
06 4.0
- 6.0
100 0.8 0.002 0.5 " 8.0, 5.0
80 " 0"0.0i
F "
.0
n :0.0008
-- 10.0
- 20.0 8.0
-#0 ~~ -.3.0
- 0.0006 0.
0005 -30.0
50 4.0 0.0
-00004 - 40.0
40 5.0 20.0
500.0003 5
6.0 - 50.0
8.0 -0.0002
30 =10.0

-0.0001 20.0
20 0.1

30.0

-40.0
10
9 50.0
-8
88 -6O.O
7 .
Example: Centertype cylincirical - Traverse
grinding Traverse grinding: Z = x a x ft x dwl
8620 steel, 170 Bhn
Given: ft = 50 in/min
Pg 15hp/;n3 /minEdwl 2 in a - 0.0006 in/pass h E
12 _-
Then: Z = 0.88in'/min hpg , 3.5hp "hpg Horsepower
for at spindle motor
80% spindle drive efficiency

Figure 20.4-6 Alignment chart for determining

metal removal rate and horsepower required
traverse grinding for centertype cylindrical, at motor
centerless and internal grinding.

20-30

_ _
4
 Grinding Formulas and Charts 20.4
nw
S Work Tp z
Feed or work rpm Inteed Metal Pgh tp
Work dia., Width cut.zj Mv-il rate th
in/rev in/min in Unit hpmor
in in 3/min hp/in3/minmto
-0-002 10 -002
0.2

F20 4 0.03
/~-
-100
80.
.1 ' 0.3
/
50o~ 00 0.4 %~5
-0.0008 -0.05 -0.2/ -0.5
4
10 .6 10.0 0.;3 0.6 -50.0

r 200:; 02000
-010
5.00
5.
4.0
0.5 -0.8 -30.0 3

.0003
'7403.0
0.0 4 00
50 .5
1.0
1. 120.0

20
20
50 0.1 10.
2.0 1.5
1
-0.0002 -1000 0.20 1.0 3. 0.25.
14.0 4.0\ 10
-2000 0.0 0.5, .
3.0 .
2.08
0.010.40
0 . o o i4
0.3 /10.06 =
.0 1.0
500 -. 0 0.2 -5.0
4

080 I 8.0

1.00
10.02
_

Example: Centertype cylindrical - Plunge grinding

Plfunge grinding: Z= ir x b x fpx dwl
4145 steel, 316 Bhn _

P9x
Given: S -O.00025 in/rev nw = 100 rpm hPgZ
dw, 3m
in~
b =1 in P8 11.6 hpfin 3 /min
Then: fp = 0.026 in/min *See figure 20.4-3 for unit power values
Z =0.25 in3 /min hpg 3.6 hp for centertype cylindrical grinding__

thp = Horsepower at spindle motor

for 85% spindle drive efficiency

Figure 20.4-7 Alignment chart for determining

metal removal rate and horsapower required at
plunge grinding for centertype cylindrical, centerless motor
and internal grinding.

20-31
 I "
Abrasive Machining 20.5
Grinding has traditionally been used to provide final work- This reduces floor space and capital investment require-
piece finish and din' 9sional accuracy. About 1962. the nients. Further economnies may result from the use of worn.
term -abrasive mach " appeared in the literature to coa-se-grain belts for finishing passe-s
cover those grinding perations used for stock removal as
well as for the production of the final finish and accuracy
The Abrasive Belt Machine
There are various tves of abrasive grind'-g operations: Machines used for belt grinding have two common fea-
the prominent ones are descr:bed below tures: all are very rigid and al! utilize high horsepower.
Rigidity is at least as important as horsepower in obtaining
good abrasive economies. The common types of machines
VERTICAL SPINDLE, ROTARY TABLE in belt machining are centerless bel: grinder, surface belt
SURFACE GRINDING grinder, cylindrical belt grinder, and roll belt grinder.

Vertical spindle surface grinding hzs been employed The Abrasive Belt
many years as a stock removal operat-fn on many coniTion
commercial alloys. It has been used in the automotive in- Grinding belts used for abrasive machining are resin bond
dustry for grinding cast iron and steel components in lieu of coated with either aluminum oxide, silicon carbide. or dia-
milling. The normal stock removal of 0.125 to 0.250 inch Mord grains. The grain is electrostatically coated to the
13.2 to 6.4 mini on cas, ags and forgings has been accom- belt in order to control orientation, dispersal and thickness.
plished on parts whicl have essentially flat. unencumbered There is up to three times more chip clearance in a coarse
surfaces. In recent years. there has been an extension of the grird-ng belt than in a comparable grinding wheel. This
application of vertical spindle surface grinding to many permits high metal removal rates at low pressures. Most
larger parts. including machine tool beds and tables. cylin- failures of belts are caused by loading, glazing and strip-
der heads, gear housings, motor cases. etc- Machines are ping (shedding) which are discussed as follows:
being built with table sizes up to 14-foot 14 ml diameter and
up to 300 horsepower 1225 kWI. It may be advantageous to 9 Loading is the filling of areas between abrasive grains.
redesign parts to take advantage of the benefits of this The use of lubricants and a weaker bond can retard
operation. loading

The recommended grinding conditions for this operation * Glazing is the dulling of the abrasive grains resulting
are contained in section 8.4. where it may be noted that from the usc of strong bonds. It can be eliminated by
wheel speeds in most common use vary between 3.400 and changing to a weaker bond and using a more -aggres-
5.000 feet per minute 117 and 25 mi/sl. sive- contact wheel.

* Stripping is the shedding or breaking away of the bond

and grains from the belt backing. It can be corrected by
RECIPROCATING TABLE SURFACE changing to a bond that has greater adhesion.
GRINDING
Abrasive grinding is being applied for heavy stock removal Contact Wheels and Platens
using reciprocating table machines with both vertical and When the correct contact wheel or platen is used behind
horizontal grinding wheel spindles. The application of the the belt. belt sharpness and cutting efficiency are main-
horizontal spindle. reciprocating table abrasive grinding is taied by breakdown of the dulled abrasive grains, thus
being augmented by the application of crush dressing to the producing and thereby presenting sharp grains to the work
grinding wheel, which minimizes idle time in the grinding during the useful life of the belt. Stock removal rates are
operation. Data for surface grinding with horizontal approximately in direct proportion to the pressure anplied.
spindle, reciprocating table machines are given in section within the capabiliti of the grain size and bond type used.
8.1. Horizontal spindle, reciprocating table surface grind-
ing competes with milling on certain metals such as high The ability of the contact wheel o platen to make the belt
temperature alloys which are extremely difficult to mUll. cut is termed -aggressiveness." For optimum stock re-
moval. a hard rubber (90 durometer) contact wheel with
45*serrations. 0.25-inch 16.4 mml land. and 0.50-inch 112.7
ABRASIVE BELT MACHINING mini wide grooves provides aggressive cutting action and
sheds dulled abrasive grains from the belt to eliminate glaz-
ing. Hard contact wheels are used both for heavy stock re-
The Process moval and for high accuracy. It is not uncommon to hold
Abrasive belt machining, once confined to polishing and accuracy between -0.0005 inch 1=0.013 mini. Good abra-
minor metal removal, has become a high-metal-removal- sive belt operations consume only 4.5 to 7 horse-ower per
rate process. The advent of stronger and sharper grains, cubic inch per minute 10.20 to 0.32 kWtcm3 /mninl when
better bonds, and stronger belts accounts in part for the in- grinding low carbon steel. compared to 6 to 10 horsepower
creasing popularity of abrasive belt machining. It can take per cubic inch per minute 10.27 to 0.46 kW/cm3imin! for
the place of conventional grinding, polishing and similar comparable bonded wheel operations. Centerless belt
operations. For high production. one machine can be grinding removal rates vary from 0.25 cubic inch per inch
equipped with several heads. each with a different belt so 10.16 cnti-3mml of belt width on small bars to 1 cubic inch
that roughing and finishing can be performed in one pass. per inch 10.65 cm:imml of belt width on larger bars. In

20-33
20.5 Abrasive Machining

comparison, the new wide-wheel centerless grinders re- Machine Design Considerations
move only 0.6 to 0.75 cubic inch per inch 10 39 to 0.48 Grinding machines designed for high-efficiency grinding re-
cm 3/mml width on large bars and require 8.3 horsepower quire special considerations which prohibit the conversion
per inch 16.2 kWl width of wheel compared to 7.5 horse- of existing grinders into high-efficiency grinders. The de-
power per inch 15.6 kWl width for a belt sign requirements for high-efficiency grinders include the
There are six types of belts as follows: following:

" Paper-backed with two glue coatings. * High spindle speeds to provide grinding wheel speeds of
12,000 to 18,000 feet per minute 160 to 90 m/sl.
" Paper-backed with a glue making-coat and a heat-resist- 0 Hig' work speeds, at least double that of normal
ant resin sizing-coat. grinders.
* Cloth-backed with a glue making-coat and a heat-resist- * High horsepower to accommodate the high rates of
ant resin sizing-coat. metal removal.
" Cloth-backed with two resin coats. * High rigidity and freedom from vibration.

" Cloth-backed, specially waterproofed with two resin a Automatic wheel balancing on the spindle to minimize
coats. grinding wheel vibration
" Belts containing dry lubricants. * Provision for the safety of the operator, the passerby and
the machine tool, including use of special guard systems
Abrasive Belt Machining Conditions to contain the wheel in case of wheel breakage.
Abrasive belt speeds range from 600 feet per minute * Special coolant application systems to ensure that the
13 m/sl on certain ceramics to 14,000 feet per minute 170
m/sl on nonferrous snag grinding. Most abrasive machin- grinding fluid reaches the grinding zone at the high
ing is done between 2,500 and 5,500 feet per minute 113 wheel speeds.
and 28 m/s, with the most commonly used speed being * Filtration systems to remove
em. the large quantities of swarf
4,500 feet per minute 123 m/si. Feee.- vary from one inch Fration syst
per minute 125.4 mm/min for heav slabbing cuts to 240 from the coolant system.
feet per minute 173 m/mini for precision centerless belt * Cooli .g systems to r.event overheating of the grinding
grinding applications. fluid.

HIGH-EFFICIENCY OR HIGH-SPEED The use of live centers rather than dead centers for cylin-
HGIY Odrical
GRINDING speed. grinders to accommodate the increased work

The name high-efficiency grinding is being used for abra-

sive machining employing very high grinding wheel speeds.
Wheel speeds of 12,000 to 18,000 feet per minute 160 to 90 Grinding Wheels
m/sl are being used today. By using high wheel speeds, it Special grinding wheels have to be designed to withstand
has been found that the rate of metal removal can be the high wheel speeds. Some of the design requirements in-
increased. dlude the following:
9 Providing a composite wheel with a hard, fine section to-
Types of High-Efficiency Grinding Machines ward the center, or a single-graded wheel impregnated
with resinoid in the center section for added strength.
Shoe-Type Centerless Grinders - These appear to be
the most numerous machines in production today and are 0 Wheel design involving clamping of wheel segments.
used primarily for abrasive grinding of bearing races.

Cylindrical Plunge Grinders - There are many of these cam Grinding Wheel Dressing
machines out in the field for grinding of pinion gears,
shafts, steering knuckles and other components as will be Diamond roll wheel dressing is being used to reduce the
described below, time for dressing the wheel.

Sernal Grinders - These machines are being used pri-

marily for the grinding of bearing races. Types of Materials and Components
Low carbon carburizing steel: stems of gears
Surface Grinders and Centers Grinders - Development Medium carbon alloy steel: steering knuckles, gear
work on the high spindle -,eed application of these grind- stems, Universal spiders
ers is under way, but few of these grinders are being used in Bearing steels-hardened: bearing raceb
production. Cast iron: crankshafts, slip yoke

20-34
 Abrasive Machining 20.5
Applications stock by plunge grinding both straight and formed parts.
Most of the high-efficiency cylindrical grinding applications The grinding wheels are crush dressed. The width of the
are plunge grinding operations. Cylindrical plunge grinding wheel or the length of the ground workpiece can be as
may economically replace turning under the following con- much as 12 inches 1305 min. A necessary requrement for
ditions where: this grinding system includes a high pressure coolant jet
spray which is traversed back and forth across the grinding _4
* The product of the diameter times the length of the grind wheel This jet spray blasts metal and ,warf loose from the
is greater than 4. grinding wheel and maintains a clean wheel. This method
of grinding is being used on steels and 1'-ih temperature al-
* The ground length does not usually exceed 7 inches 1178 loys. It is being applied to the grindi. jet engine com-
'Y
mml. ponents and mechanical test specimens instead of turning
and finish grinding.
* The stock removal is limited to about 0 25 inch 16.4 mml
on the diameter.
* The tolerance is less than 0.003 inch 1 0 075 mm). CREEP FEED GRINDING
Special problems (for example. interrupted cuts) which Creep feed grinding is a process whereby the grinding
might be more restrictive on turning than on grinding, wheel takes the full depth of cut in a single pass at an ex-
tremely slow feed rate. This process was developed in Eu-
* The surface roughness is 30 microinches Ra 10.76 pml or rope some twenty years ago but did not gain wide accept-
greater. ance until recently when specially designed grinding
machines with high stability, increased power and in'-
* The workpieces are mass produced, are manufactured in proved drive systems became available. With such ma-
large batches, or are similar parts produced in short chines it is possible to remove as much as 1 inch 125 mml of
runs. metal from flat or cylindrical surfaces in a single pass,
which rivals the capacity of milling machines.
Table 20.5-1 illustrates some workpieces which were suc-
cessfully high-efficiency machined and compares them with Metal removal rates as high as 1 cubic inch per second
the above list of economic guidelines. 116.4 cm 3/sl with wheel speeds of 20,000 feet per minute
1102 m/sl have been reported.
CYLINDRICAL CRUSH DRESS GRINDING With the present state of the art, it i,, imperative that the
process parameters be evaluated for each new application.
A recent addition to abrasive machining has been the de- This is especially true if the surface integrity of the part is a
sign of cylindrical grinders for removing large amounts of consideration.

TABLE 20.5-1 Mass Production Applications of High-Efficiency Grinding

1 1
CRITICAL PRODUCT DEPI HOF SURFACE
WORKPIECE MATERIAL TOLERANCE OF STOCK ROUGHNESS
dx L (on diameter)
inch pin R,

Stem pinion 8620 + 00025 7.5 varied none

or +.0015 1/8 to 1

Slip yoke Cast iron .0005 5.6 to 9.0 3/8 15 to 30

or 30 to 60

Steering knuckle Steel .0035 5.5 114 none

Sun gear Steel .001 7 3/8 none

Universal spider Steel .001 4.3 1/4 63 max.

Compressor cage Cast iron . 00075 j 25 1/4 40 max.

Crankshaft Cast iron s .0005 4.5 1/4 50 max.

SOURCE: C.B Matson, High effiency centertype grinding, Technical papei MR71-147. Society of Manufacturing Engineers, Dearborn, Mi, 1971.

20-35
 PiMCED114 PAZ BLANK-NOT W114LED

SECTION 21
ECONOMICS IN
MACHINING AND GRINDING

Introduction ...............................................................
........................................ . ..........
21-3
Effect of Engineering Design on Cost .............................................................21-3
Effect of Surface Roughness and Dimensional Tolerance on Cost ............... 21-3
.........
Machining Cost and Production Rata ................................................................... 21-3
Procedure for Calculating Cost and Production Rate ................................... 21-4
...............................
Determ ining Optim um Cutting Conditions ............................................................... 21-5
Shop Procedures for Optimization of Machining Conditions ........................................ 21-6
e ..................
21-6
iechnique for Calculating Cost and Production Rate .......................................................

21-1
 PiRECM.NG PAM B1,ANK-.I.OT FI PED

ECONOMICS IN MACHINING AND GRINDING 21

INTRODUCTION . ic cost of machining also is determined by the size,
and geometry of the component. A rigid part with
The annual labor and overhead cost for operating metal- aurfaces can obviously be machined quicker and at
cutting machine tools in the United States has been esti- I. r costs than a flimsy part with complex surfaces In ad-
mated to be approximately $115 billion, as shown in table 'ion. the engineering design specifications for accuracy
21-1. The total shipments of metalcutting machinery in the ,nd surface roughness play a major role in determining the
United States have exceeded $2 billion per year, and in machining cost.
1979 almost $2 billion was spent for small cutting tools.
From these data, it is obvious that metalcutting is an
enormous industry in the U.S.A. and that even a modest re-
duction in the cost of operating macine tools could very EFFECT OF SURFACE ROUGHNESS AND
well result in nationwide savings of billions of dollars per DIMENSIONAL TOLERANCE ON COST
year. It is apparent that similarly high proportionate
savings also can be achieved by individual companies in The relative cost of machining is closely associated with
industry, both dimensional tolerance and surface roughness. The
percentage machining cost in machining steel parts is
exemplified in figure 21-2. As the surface roughness
TABLE 21-1 Estimated Annual Labor and Overhead requirement becomes more stringent, the cost increases be-
TABL 21-1OpestatedAnualc LaborMachind Oerhed
Icause more than one cut on a given machine tool is re-
Cost for Operating Metalcuttng Machine Tcos In quired to achieve that level of roughness. For example, a
surface might have to be rough turned, then semi-finish
Tturned, then finally finish turned to achieve the required
machine tools c2,301,500* surface roughness. The surface roughness specification
may be even finer than that readily obtained by a chip re-
Average labor + overhead cost = $25 per hour moval process, and in this case, a second operation such as
Average working day = 8 hours grinding or even a third operation such as honing may be
Number of working days per year = 250 required to achieve the surface roughness as well as the di-
Average number of direct labor mensional accuracy. Figure 21-2 illustrates the great in-
personnel per machine 1 crease in cost that occurs in order to achieve the desired
Total cost of labor + overhead: finer surface roughnesses.
2,301,500 x $25 x 8 x 250 x 1 = $115,075,000,000
It appears reasonable to conclude that the cost of labor + over- The overall machining costs also are associated with di-
head for machining required for manufacturing inthe U.S.A. is of mensional tolerance. As a matte. of fact, close tolerance re-
the order of: quirements usually dictate finer surface roughnesses. The
$115,000,000,000 Annually interrelationship of dimensional tolerances, surface rough-
ness, and their effect on machining costs are illustrated in
Brsed on 12th American Machinist Inventory (1976-1978). (See summary the charts of figure 21-3.
in American Machinist. December 1978. p. 133-148.)

MACHINING COST AND PRODUCTION

There are two general approaches for studying the cost of RATE
machining in metalcutting plants. The first is to examine
the subject in a general or qualitative way, and the second It is possible to quantitatively determine the cost and pro-
is to make a quantitative analysis of cost and production duction rate for a given machining operation on a specific
rate. Both of these approaches are discussed in this section. work material. Equations have been developed to deter-
mine the cost per piece and the production rate in pieces
per hour for specific machining operations. The total cost
EFFECT OF ENGINEERING DESIGN ON for machining comprises costs associated with operating
COST the machine tool and costs associated with the cutter and
its reconditioning. The machine tool cost can be broken
When examining costs in a qualitative way, it should be down into idle cost, tool reconditioning cost, and feed or
pointed out that the basic cost in machining a component is cutting cost. The idle cost, which consists of rapid traverse,
determined by the design of the component. The basic cost load and unload, and tool change costs, remains constant
in machining is first determined by the material selected for with change in cutting speed, while the feed or cutting cost
the part, that is, by the material per se, its heat treatment, decreases with increasing cutting speed. The tool recondi-
and resultant metallurgical condition and hardness. Figure tioning cost generally increases with increasing cutting
21-1 indicates the relative cost of machining a given com- speed because greater cutter wear rate is associated with
ponent made from a wide variety of alloys. Based upon a the higher speeds. The total cost is the sum of all of the
part cost of $10 for turning 7075-T6 aluminum alloy, it can above cost elements. This total cost is seen to go through a
be seen that turning 1020 steel would cost $25, turning minimum at some intermediate cutting speed and then
4340 steel, quenched and tempered to 52 Re, would cost sharply increase. The production rate in pieces per hour in-
$100, apd turning Inconel 700 would cost over $300. A de- creases with increasing cutting speed, goes through a max-
tailed table of the relative time for machining the same imum and then decreases. Curves demonstrating these
group of alloys using various machining operations and tool relationships of machining cost and production rate to cut-
materials is given in table 21-2. ting speed are contained in figure 21-4.

21-3
21 ECONOMICS IN MACHINING AND GRINDING
Although the previous discussion has centered on the rela- Examples
tionship of cost to cutting speed, it should be pointed out
that cost also is a function of other machining parameters. 1. Example of a Cost and Production Rate
such as feed. depth of cut, width of cut, tool material, cut- Determination in Turning on a Conventional Engine
ting fluid. etc Lathe
Table 21-13 contains the time study and cost data for turn-
PROCEDURE FOR CALCULATING COST ing a shaft 3.5 inches in diameter by 19 inches long on a
AND PRODUCTION RATE conventional engine lathe. The material was 4340 steel,
quenched and tempered to 300 Bhn. Three types of tools
The following steps describe a method for calculating ma- (that is,brazed carbide, throwaway carbide, and high
chining cost and production rate. speed steel) were used for the cost investigation. The tool
life data are given in table 21-14. The tool life versus cut-
dMachining Parameters ting speed data sets are denoted by the circled numbers 1,
1. Machining Data and Ma2, 3, and 4 for th- C-7 carbide tool material, and 5,6. 7,
Data relating the tool lifc to machining parameters must be and 8 for the high speed steel tool material.
obtained for those work materials that ate to be machined.
Data can be obtained from handbooks and may also be ob-
tained from historical shop experiences. It is important to The lathe tool setup for turning using the brazed carbide.
have a well-defined format for recording and storing signifi- the throwaway carbide and the solid high speed steel tools
cant data. Typical data formats for turning, milling, drill- was the same as that illustrated in figure 21-5.
ing. reaming and tapping are shown in tables 21-3 through
21-5. Using the above data and the equations for turning from
tables 21-6 and 21-8, the machining cost and production
2. Cost and Production Rate Equations rate were determined. The calculations were performed on
2 C nost and p an IBM 1130 computer, and a I .intout of the results is
Equations
duction for for
rates determining costs, operating
various machining times,
operations are and pro-
listed in shown in figure 21-6. It should be noted that there are
trestsocaulinsonfobaedabdeolson
tables 21-6 and 21-8 for English units and tables 21-7 and three sets of calculations: one for brazed carbide tools, one
for
steelthrowaway carbide
tools. Using tools,
the tool and one
life data for C-7
for the solidcarbide
high speed
tool
21-9 for metric units. The first bracket of terms in the cost
equations determines the time and cost for the machine material and the time study data for brazed carbide tools
materal an ee s dy ata cho ofbfour caride tools.
tool. and the second bracket of terms determines the cost
for the cutter and its reconditioning. In tables 21-6 ad cost caklations were made at each of four cutting speeds.
21-7, the cost equations are given for turning, milling, drill-
ing or reaming. tapping. and center drilling or chamfering. Notice that the printout contains not only the total cost per
These equations apply to both conventional and numerical piece and the production rate in pieces per hour but also all
control machine tools. It should be noted that a separate the cost factors that make up the total cost. In the case of
equation is provided foi calculating the handling and setup the brazed carbide tool, there were ten cost factors; for the
costs. In the case of conventional machining, the two terms throwaway carbide tools, seven; and for the solid hig
inthis equation should be added into the appropriate oper- speed steel, eight. A quick glance at the cost factors in fig-
ation equation in order to calculate the handling and setup ure 21-6 indicates which are significant and which are in-
costs of a specific operation such as turning or milling, etc. significant. For example, with the brazed carbide tool.
In the case of NC machining, the individual equations are when cutting at 470 feet per minute. the total cost was
used for each machining operation in sequence, while the $5.33 per piece. Of this, the feeding cost was $1.50, the
handling and setup equation is used separately. as will be load and unload cost $0.92, the setup cost $0.42, the tool
illustrated in an example to follow. The equations for deter- change cost $0.49. and the tool sharpening cost $1.48. The
mining the operating time and the production rate for each less significant factors were as follows: rapid traverse cost
operation are given in tables 21-8 and 21-9. It is desirable $0.11, tool depreciation cost $0.13, rebrazing cost $0.16.
to program all of the cost and production rate equationc on tip cost $0.10, and the grinding wheel cost $0.02.
a computer for ease of calculations.
For the throwaway carbide tools. figure 21-6. it can be
3. Supporting Data Required to Complete seen that all the tool costs were virtually n:l. On the other
Calculations hand, when turning with solid high speed steel, the tool
In addition to tool life data, time study data and tool cost cost was an appreciable portion of the total cost. Thus,
data are required for a cost and production rate determina- when turning with high speed steel at 45 feet per minute
tion. Tables 21-10 and 21-11 list and define the variable the total cost was $21.29 per piece, the tool change cost
factors that appear in the cost and production rate equa- was $1.29, and the tool sharpening cost $2.58.
tions. Figure 21-5 illustrates the setup factors for various
n.achining operations. Note that "R" equals the total rapid The cost and production rates for turning 4340 steel at 300
traverse distance for a tool or cutter in one operation. Bhn were plotted against cutting speed. Figure 21-7 con-
whereas "e"equals the extra travel in feed. tains these plots for brazed carbide, throwaway carbide W
and high speed steel tools. The data show that the cost per
The derivation of the terms in the cost equations for turn- piece decreased as the cutting speed increased when using
ing and milling are given in table 21-12. throwaway carbide tools. The cost per piece was at a min-
imum at approximately 360 feet per minute for the brazed
The procedure described above has been applied in several carbide, and the cost per piece was at a minimum at ap-
situations to generate the examples that follow. proximately 60 feet per minute for the high speed steel.

21-4
 ECONOMICS IN MACHINING AND GRINDING 21
The minimum costs for turning within the range of expert- in number of holes drilled, by the hole length to get the drill
mental data were about $3.09 with the throwaway carbide. life in inches of travel required -, dull the drill. Using data
$4 44 with the brazed carbide and $18.62 with the high set 1. the drill life was 30 holes. The lengtt, of each hole
speed steel. The maximum production rate. also within the was 0 5 inch. Therefore. the drill life was T. = 15 inches
range of experimental data, was 8 picces per hour for the (30 x 0.5 inch).
throwaway carbide tools. 7 pieces per hour with the brazed
carbide tools. and 1.8 pieces per hour with the high speed Figure 21-10 is the computer printout of the results from
steel tools. using the drilling equation from table 21-6 to calculate the
cost per piece and the drilling equation from table 21-8 to
For those who would like to calculate the cost manually. determine the production rate.
the cost calculations for the example just described are
given in table 21-15 for turning with the brazed carbide Figure 21-11 shows the cost and production rate curves for
tool. this drilling operation. The data show that the 0.005 ipch
. Eper revolution feed can achieve higher production rates
2. Example of a Cost and Production Rate and lower costs than the 0.002 inch per revolution feed.
Determination in Face Milling on a Conventional provided that proper cutting speeds are used.
Milling Machine
Table 21-16 contains the time study and cost data for face 4. Example of Machining a Part on an NC Machining
milling a block 2 inches wide by 8 inches long. The work Center
material was 4340 steel, quenched and tempered to 341 An example of a 4340 steel forging machined on an NC ma-
Bhn. A two-inch wide cut was taken on the eight-inch long chining center is shown in figure 21-12. The operations
workpiece with 4-inch diameter milling cutters. A solid were to face mill the top surface, peripheral end mill the
high speed steel cutter and two types of carbide cutters (in- sides and ends, mill two slots and drill two holes. The time
serted tooth and throwaway insert) were used. The setup study and tool cost data are given in table 21-20. and the
used for this example was the same as that for milling illus- pertinent machining parameter and tool life data for the
trated in figure 21-5. various operations are given in table 21-21. The cost and
production rates for the individual operations were calcu-
The tool life data for the alloy are given in table 21-17. In lated on the computer and a printout is given in figure
this table, the sets of data relating tool life in inches per 21-13. Again. the computer prints not only the total cost
tooth to cutting speed in feet per minute for the alloy are but also the individual cost factors. It should be noted that
identified by the circled numbers 1 through 6. calculations were made for each of the individual oper-
ations, and for each operation a line of data shows the cost
The IBM 1130 computer was used to calculate the cost per corresponding to the feed. speed and tool life combination.
piece using the milling equation from table 21-6 and the The minimum cost for each of the opertions in the print-
production rate using the milling equation from table 21-8. out of figure 21-13 is circled, and a summary of the best
The compur printout of the results is shown in figure machining conditions is given in figure 21-14.
21-8.

Examination of the computer printout reveals the signifi-

cant cost factors and the comparative costs per piece and DETERMINING OPTIMUM CUTTING
production rates among the types of tools used. For in- CONDITIONS
tance. the printout shows that the use of a throwaway car-
bide cutter resulted in higher production and lower costs. As shown in the previous examples. there are cases where
This is more evident from examining figure 21-9. which in- the optimum cutting conditions lie beyond the available
dicates that the cost per piece in face milling the 4340 steel data. In order to optimize. it is necessary to determine the
did not vary as sharply for the throwaway carbide cutter as mathematical relationship between tool life and the per-
it did for the other cutters. The production rate curve for tinent cutting parameters such as speed, feed, and depth
the throwaway cutter lies above the other two types. Of and width of cut. Probably the most common approach is
specific interest is that for the data used in this example. to assume that Taylor's equation relating tool life to cutting
the mimimum cost and maximum productionatrate 550occurred
feet per speed applies:
cutters
for the case of throwaway carbide
minute. for turning
3. Example of a Cost and Production Rate vTn = S
Determination in Drilling Using a Conventional Drill
Table 21-18 contains the time study and cost data for drill- for milling. drilling, reaming and tapping
ing holes in 4340 steel, annealed to 212 Bhn. High speed
steel drills were used to drill five holes. one-half-inch deep v_,Il = S'
in each part. The drill diameter used was one-quarter inch.

The geometric setup used was the same as that illustrated where:
,for drilling in figure 21-5. v = cutting speed
T and Tt = tool life
The tool life data is listed in table 21-19. The sets of data S and St = reference cutting speed
giving the drill life in number of holes are identified by the n = tool life exponent
circled numbers I through 8. The cost and production
equations required that the drill life (TJ be expressed in (See table 21-10 or 21-11 for detailed definition of
inches. Therefore. it was necessary to multiply the drill lfe. variables.)

21-5
21 ECONOMICS IN MACHINING AND GRINDING

With these Taylor equations, the cost for the various ma- overall machining cost and production rate as a function of
chining operations can be minimized. This has been done the machining parameters using the iocedure outlined
by substituting the appropriate Taylor equation into the previously.
cost equation, differentiating the cost with respect to cut-
ting speed, and setting the derivative equal to zero. The
cutting speed calculations for minimum cost (v,,, cost) and TECHNIQUE FOR CALCULATING COST
for maximum production (vm5 . p!)for the conventional as
well as the NC machining operations are given in the equa- AND PRODUCTION RATE
tions in tables 21-22 and 21-23. The corresponding tool Although the equations used for the cost and production
life equations for minimum cost and maximum production rate calculations involve only simple mathematics, the de-
are given in table 21-24. The values of Vmincost and tailed analysis of a given machining setup will become very
vm. dj in the denominators must be calculated using the time consuming because many factors mLst be included.
appropriate equation(s) from table 21-22 or 21-23. With this in mind, techniques have been developed that al-
low the rapid analysis of a machining operation through the
The validity of the optimized determination depends, in use of computers and programmable calculators.
turn, on the validity of the constants n and S or St in the
Taylor equation. The most accurate values of these con- The cost and production rate equations given in tables
stants can be determined by actual experimentation (that 21-6 and 21-8 have been programmed in FORTRAN IV
is, by actual cutting tests). In so doing, it is also possible to for use on a computer with as little as 8K memory, such as
determine the range of cutting conditions over which the an IBM 1130. This program, called NCECO, is available
Taylor equation applies. The least reliable procedure is to through the Machinability Data Center and issupplied in
pick an average value for the Taylor constant from a hand- card-deck form and includes full documentation. With mi-
book. It is suggested that if one assumes the Taylor rela- nor n"ldifications for input-output, this program will oper-
tionship and proceeds to determine optimum cutting condi- ate on any digital computer supporting the FORTRAN IV
tions, these conditions should be verified by actual shop language. The program will accept any combination of ma-
tests. chining operations required for a part setup including: turn-
ing, face andend
milling, milling, drilling, reaming, tapping,
The relationship of cutting conditions to tool life as deter- center drilling chamfering. Capability exists to deter-
mined by actual cutting tests may be too complex to be rep- cented afe ringa pability eist toter
the sipl
th
resented byresnte b
simple Taloreqatin.Techniques
Taylor equation. Tspeed are mine the effects using allortypes
ofcarbide, of tools, that is, high
steel, brazed throwaway carbide. To run
now available to mathematically model the more complex this program. data such as that in table 21-13 is compiled
relationship of tool life to cutting speed, feed, and depth of
cut. The mathematical model can, in turn, be used to deter- or cardshchainputato
on which are input to The mter The
the computer. the computer
puter -
mine cost and production rate over the wide range of then prints out a detailed cost breakdown such as that
machining conditions with subsequent determination of shown in figure 21-13.
minimum cost. minimum cutting time and maximum pro-
duction rates. These techniques are too complex for in- With the advent of programmable calculators, it is now
clusion in this handbook, possible to perform these calculations quickly without uti-
lizing a large computer. A calculator generally uses semi-
SHOP PROCEDURES FOR OPTIMIZATION conductor electronics that allow the solving of a mathe-
OF MACHINING CONDITIONS matical problem using a series of keystrokes on the
machine. A programmable calculator has the ability to
When it is felt necessary to decrease cost or increase pro- store and automatically execute the series of keystrokes
ductivity of a machining operation, it is possible to experi- necessary to solve a particular problem. Using this feature.
meat on the shop floor by changing machining conditions. a programmable calculator can be instructed to perform all
It is necessary to keep careful records of the changes in cut- the calculations necessary for cost and production rate
ting conditions and the effect of these changes on tool life analysis with the user supplying only the data necessary for
as well as on production rates. the calculations. Two such programmable calculators are
the Hewlett-Packard HP-67 and the Texas Instrument
The first step is usually to increase the feed. The feed may TI-59.
be increased until either the specified surface roughness is
no longer obtained or the tool life starts to decrease. With The Hewlett-Packard HP-67 is a pocket-sized program-
the best feed, the next step is to increase and then decrease mable calculator powered by alternating current or re-
the cutting speed and observe the change in tool life. By chargeable batteries. All output is by digital display. The
this manner, the combination of feed and speed can be se- programs are stored on small magnetic strips and are read
lected to achieve maximum productivity. Additional fac- by the machine simply by inserting a strip in a slot on the
tors which may be investigated for their effect on tool life side of the machine. The small memory size of this machine
include cutting tool material, tool geometry, and cutting makes it necessary to use a separate memory strip for each
fluid. type of machining operation. The magnetic strips are
stored in a 3-by-5-inch card which gives all the necessary
Although the feed rate as a result of shop trials can be read- instructions for running a complete analysis. Since this cal-
ily observed, it is not possible to directly observe the effect culator is pocket-sized, it is well suited for doing these cal-
of these trials on the overall machining cost since the ma- culations right on the shop floor. An enlarged version of the
chining cost involves not only machine tool time but also instructions and sample inputs and outputs are shown in
the cutter cost. It is necessary, therefore, to calculate the figure 21-15.

21-6

_ --- .-- -_ -__.-- I -

 ECONOMICS IN MACHINING AND GRINDING
21
The T.xas Instruments TI-59 programmable
simiL- - -he Hewlett-Packard calculator. calculator is Also included is the capability to save
When attached the input data on
to a TI-FC100A printer, cost and time magnetic strips for later analysis without
analysis having to re-input
complished in an interactive mode. Instructions can be ac- all the data by hand. An example of the
cost and production
are printed time program run on the Texas Instruments
out to the user describing the necessary TI-59 calcu-
inputs. The results lator with printer is shown in figure 21-16.
of the calculations are also printed with
appropriate labels.

21.-i
21 ECONOMICS IN MACHINING AND GRINDING

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21-8
 ECONOMICS IN MACHINING AND GRINDING 21
TABLE 21-2 Relative Machining Time of Various Alloys Compared to 4340 Steel, 300 Bhn

JRELATIVE MACHINING TIME

Turning Face Milling EdMlig Dlin Tapg

MATERIAL GROUP
1CONDI- HARD 1 I El
MATERIAL TIOND NESS HSS arbide HSS Carbide HSS Carbide HSS HSS
_____
____ ____
____ ____ ____ I ___ ____ Wi
Bhn i __ _ _ _ _ _ _ _ _

Alloysteels 300 10 1.0 10 1.0 1.0 1.0

Q&T 400 2.5 1.7 5.0 25 2.0 25 1.7 25
430 &T 500 13.3 33 10.0 33 5.0 100 5.01 5.0
IQ&T 520 5.0 5.0 25.0 10.0 7.0 11.1 10.0 I 10.0
Ann 210 08 0.8 04 0.5 0.7 0.6 0.8 0.7

High strength D6ac

Norm

Ann
-1 320

220 0.8
i13 10

0.8
T 1.7

0.6
1.7

0.7
1.0
0.5
1.0
0.7
1.0
0.8
1.0
1.0
steels Q&T 5601 - 14.0 - 100 - 25.0 1.1" -
Ann 2001 0.8 09 0.5 0.5 0.9 1.0 0.8 1.3
H11 Q&T 3501 1 .7 2.0 1.7 20 3.3 5.0 1.4 1.7
Q&T 5201 -I 50 25.0 10.0 - 10.0 10.0 10.0
Maraging steels 200,250. Ann 320 1.7 0.8 1.0 1.4 0.9 0.9 0.9 1.3
.. 1 300 Grades Mar 500 33 2.5 2.5 5.0 5.0 5.0 3.0 50
Stainless steels, 302,304 Ann 180 0.8 0.9 1.1 1.0 1.0 1.1 0.8 1.0
austenitic 317.321 -

martensitic Q&T 300 1.7 1.3 2.0 2.0 1.7 1.3 0.8 1.3

420 Q&T 400 25 3.3 5.0 5.0 3.3 5.0 1.7 2.5
Stainless steels, 17-4 PH Ann 170 1.0 0.9 1.1 0.9 1.1 0.8 1.0 1.0
precipitation 17-7 PH
hardening
AM-350 Ann 300 1.4 1.4 1.4 1.4 1.4 1.0 1.4 1.3
17-4 PH
17-7 PH Q&T 400 25 20 3.3 3.3 2.5 5.0 2.5 2.5
AM-350

Titanium alloys Ti-100A - 175 0.7 0.7 0.8 1.4 0.4 0.8 0.5 0.8
Ti-5AI-2.5Sn Ann 300 1.4 1.4 1.4 25 0.5 1.3 0.7 1.0
Ti-6AI-4V Ann 310 1.7 20 2.0 33 1.0 2.0 1.2 1.3
STA 365 20 2.5 2.0 3.3 2.0 2.0 1.7 1.7
Ti-7AI-4Mo
Ti-6AI-6V-2Sn Ann 320 2.0 2.0 2.5 2.0 1.1 1.7 0.9 1.4
Ti-8AI-1Mo-1V
Ti-6AI-6V-2Sn STA 420 2.5 3.3 2.5 5.0 1.4 2.5 1.4 2.5
Ti-7AI-4Mo
Ti-13V-llCr-3AI ST 310 2.5 5.0 3.3 3.3 2.0 3.3 3.3 2.5
STA 400 2.5 5.0 3.3 10.0 3.3 4.0 10.0 3.3
High temperature Rete 41 ST 280 5.0 5.0 10.0 16.7 5.0 5.0 3.3 2.5
alloys Inconel700 STA 365 10.0 5.0 10.0 16.7 10.0 12.5 10.0 5.0
U-500 _
Nickel base Incone1718 ST 270 5.0 5.0 3.3 10.0 3.3 10.0 3.3 2.5
STA 370 5.0 5.0 5.0 10.0 12.5 12.5 5.0 5.0
Cobalt base HS25 ST 200 3.3 50 5.0 10.0 5.0 5.0 33 2.5
S-816 STA 300 5.0 10.0 10.0 12.5 10.0 10.0 5.0 3.3
Iron base A-286 ST 200 1.7 2.5 1.4 3.3 2.0 3.3 1.7 1.7
19-9DL STA 300 2.0 3.3 3.3 5.0 3.3 12.5 3.3 2.5
Aluminum 7075-T6 STA 75 0.12 0.3 0.06 0.1 0.1 0.3 0.1 0.5
alloys to
1 150'

Source R. L Vaughn and N.Zlatm. "Producibility Aspects of Aerospace Products with Regard to Machinability," ASTME PaperW
WE S7-29.1967.
*Condition: Ann-Annealed 0 &T-Quenched and Tempered *Brinell Hardness for 500 kg load
Norm-Normalized ST-Solution Treated 'Carbide Drill
Mar-Maraged STA-Solution Treated and Aged

21-9
21 ECONOMICS IN MACHINING AND GRINDING
400

Material: Steel

350

Approximate
______ _____ machining costs
300___

06 250

05

o 00

50

lowhes. 5D 250 125 63 3 2 T167

I Machining operations necessaryJI

-
Rough turn
Semi-j
finish jI
Rough turn turn I
r Semi- I
As cast, finish Finish I
Rough turn turn turnI
sawed. etc. . . *---

Semi-
finish FinishI
Rough turn turn turn Grind j
Semi-
finish Finish
Rough turn tunGrind Hone

Figure 21-2 Relative machining costs and surface roughness for steel parts. (Courtesy of Gel'eral
Electric Company)

21 -10
 ECONOMICS IN MACHINING AND GRINDING 21
Turning Face Milling Cylindrical Grinding
900 300
800 Tolerance
0002 and under

700 250
70-
25 rms Surface
600 0 200 - -%'.A roughness
- 60-
0e

Q
1500o
5
400 C 40'
Zi 30 100 - Tolerance
ToveOO 30 0 rms Surface
C 0 roughness
200 20
50
10 C

01 10
0
25 63 125 250 400 0*j
45 63 125 0.0001 0.00025 0.0005 0,001
Surface roughness value. rms Surface roughness value. rms
Dimensional tolerance. in

Surface Grinding Surface Grinding

(Reciprocating) Centerles Grinding
(Rotary)

40
160
3535
140__

0,

Infeed

Srface roughness 100 A~(plunge)

E 00 20 U
.9 80

U a
Througheed %
10 to -40

0
0.010v1 0.0005 0.001 0.002 01
0.0005 0.001 0.002 0.0001 0.0003 0.001
Dimensional tolerance, in Dimensional tolerance, in Dimensional tolerance. in
Figure 21-3 Effect of tolerance and surface
roughness on machining costs for several operations.
(L. J. Bayer, Analysis of manufacturing costs relative
to product design. Paper No. 56-A-9, American Society
- - of Mechanical Engineers, New York, NY. 1956)

21-11
21 ECONOMICS IN MACHINING AND GRINDING

Total production rate

'j))
0
C.)

C-L
CLC
W Toa0ahiigcs
0

*0

Too! reconditioning cost

Feed or
cutting cs

0 200 400 600 800 1000 1200 1400

Cutting speed, fpm

Figure 21-4 Machining cost and production rate versus cutting speed.

21-12
 ECONOMICS IN MACHINING AND GRINDING 21

- C) 0 toT o o N 0 ol 0T
m u QD1,' 11
Lii IC

c.5
cm vi1
" c"
q' acu
--
%D
01 o 00
o
ImcD
C
00(
.
c .I
010
0
0 WD 001
cDo lo

__ __jD ' i
cot

co C!
C, .

C> 0

Lo (D Doo 10
CD 6 6
0
6,
0 t t0
6 I 6
0 -
o

6I 6

.- -" co c ' ' -=--

co I c Ioco . +

ti 0 0 cm 0

___ ____ __ -i-- i---__ __ _

c3 c 2 a
to r D Id 0

p~
ELZ-- <100
_tn 0 in, P CL a C-i M

C0 0 c 0o t 0o
co co c
Z5, c oC co oV
 21 ECONOMICS IN MACHINING AND GRINDING

..........
0 0

0, 00

u, OLOo wt

0 0o
It m 0mf- 0-0
6o
0 Lo0
to

9T - n0)
00
s

te 13
_ _ _to
_ _ _
= L. 0

m~
* ~ -l
00
. Lo . o

0 W. c02 a c

0
==.2.

a. == i0 0m0
___9_ =. -6-.E2,

A 0

MU Lo tn W. c

C, _

-~ 'c

U) .)
(

-M -- ---
-6 _ _
 ECONOMICS IN MACHINING AND GRINDING 21

0UC 'I'0L
FE
Lo~C 00t

m0 ) 0
cv ) )

U) U,

0 0)
N o
0 0D
a. Ia

C.U

CV

-FU C.2
Um
- 5to,

c" tot)C

a--

to-
-~ .- 0 -U

cx (6 A

caz cm P.:_

c;0 a- PrE
0,

ca' CcoE3i

+_
__ co_ .
__
- R
-)

_ __ rC
-11
_ ~ C a) E.U
3-C.7
00

I=U) Ow 0 0V
~ ~ & N

~2 -1 B-
21 ECONOMICS IN MACHINING AND GRINDING

a,

+ + + + + O.

_o
0

+ + +o

*0
N C
cc

+ + +

0 C

I-,
0 +
+ + + ++ ca
f r

0 ++ + + +
+ + + + +

o ++ + +

LU cm N

. -

0 0
+ + +
. E ++
- 1-
CC

-1

.!7ccn 1---16
acc
C 2 E,
+ + + + E +
0 4) -1i> a
o L
+IN E +~ 0
.JiR C 0

* I c". ii & EfII I i

(I-~~ 0a 00 0 0 c

21-16
 " ECONOMICS IN MACHINING AND GRINDING 21

Q))
J++ -21 + 4)-

+ ++- + + +
+
0m

+ +

0 0CD 0

CC0
+ +

+ +>
0)~

to tO _ .)
C

+ +.4 4

00

Su-
.. 7E

cu: E

0) ++ + + +
0

C++
0L
-
+ +
) +
,) 0.j

21-17
21 ECONOMICS IN MACHINING AND GRINDING

TABLE 21-8 Equations for Calculating Operating Time TABLE 21-9 Equations for Calculating Operating Time
Per Piece and Production Rate When Using English Per Piece and Production Rate When Using Metric Units
Units
EQUATIONS FOR OPERATING TIME PER PIECE
EQUATIONS FOR OPERATING TIME PER PIECE
Turning
Turning D(L+ e) R ti DLtd
D(L+e) R t + DLt, t, - 318fr +- 318frvT
3.82fv r 3.82fvT Milling

Milling D(L + e) R t+ Ltd

D(L+e) R t, Lto, t- ,, 1Zf 4-- + +
t.,.-- + - + + 318Zftv r ZTt
3.82Zfv r ZT, Drilling and Reaming
Drilling and Reaming D(L ++e R t+ Ltd
D(L +e) R t, Lt,, t -318fV + + +
t -- - - + + r
3.82f,v r T, Tapping
Tapping D(L + e) R ti Ltd
mD(L+e) R t, Ltd r159pv
r +
t + - + -"59pv
1.91 v r T, Coner Drilling or Chamfering
Center Drilling or Chambering D(L+4) R 't Uctd
D(L+e) R I, + utd t- .. 1, ,, +
+ - + + - 3~rj-T
3.82frv r Th
EQUATION FOR PRODUCTION RATE
EQUATION FOR PRODUCTION RATE
60
60

-' + tL + )

21-18
 ECONOMICS IN MACHINING AND GRINDING 21
TABLE 21-10 Cost and Production Rate Equation Variables
(Definitions and applications for variables in English units)
APPLIES TO OPERATION

VARIABLE DEFINITION Turn Mill

- fDrill
and
-
Tap
Center
Drill
Ream
C Cost for machining one workpiece; $/workpiece V L. - V
C, Cost of each insert or inserted blade; S/blade ' V-
- No No No
CP Purchase cost of tool or cutter; S/cutter I V V v v
C,. Cost of gr.nding wheel for resharpening tool or cutter; S/cutter V V No No No
d Depth of cut, in , .- No No No
D Dia. of work in turning, of tool in milling, drilling, reaming, tapping; in o-
Ve V V
e Extra travel at feedrate (f, or fr) including approach, overtravel, and all
positioning moves; in V. 9. P,- ,, v
fr Feed per revolution; in v No V No V
ff Feed per tooth; in No z- No No No
G Labor + overhead in tool reconditioning department: $/min V - V V V
k, No. of times lathe tool, or milling cutter, or drill, or reamer or tap is
______ resharpened before being discarded - V V V v
k2 No. of times lathe tool or milling cutter is resharpened before inserts or
blades are rebrazed or reset .V- v No No No
k, No. of times blades (ar inserts) are resharpened (or indexed) before blades
(or inserts) are discarded V V No No No
L Length of workpiece in turning and milling or sum of length of all holes of
same diameter in drilling, reaming, tapping; in V- V- , V"
m No. of threads per inch No No No V No
M Labor + overhead cost on lathe, milling machine or drilling machine; $/min V V V V V

n Toot life exponent in Taylor's Equation V V V, V No

NL No. of workpieces in lot V V V V V-
N, No. of pieces between sharpenings V V V t-1
P Production rate per hour; workpieces/hour V V V V
r Rapid traverse rate; in/min V V V V ill
R Total rapid traverse distance for a tool or cutter on one part; in V V V V V
S Reference cutting speed for a tool life of T = 1 min; fpm V, No No No No
St Reference cutting speed for a tool life ofT, = 1 inch; fpm No V t.- No
tb Time to rebraze lathe tool or cutter teeth or reset blades; min V , No No No
td Time to replace dull cutter in tool changer storage unit; min V V V V V
ti Time to index from one type cutter to another between operations
(automatic or manual); min V V v V

tt Time to load and unload workpiece; min . i" i- v ,

t. Time (average) to complete one operation; min V V V V
t. Time to setup machine tool for operation; min V V V V V
tP Time to preset tools away from machine (in toolroom); min V PI V V V
t= Time to resharpen lathe tool, milling cutter, drill, reamer or tap; min/tool V V V V V
T Tool life measured in minutes to dull a lathe tool min V- No No No No
Th No. of holes per resharpening No No No No ,
T, Tool life measured in Inches travel of work or tool to dull a drill, reamer,
tap or one milling cutter tooth; in No V v V' No
uC No. of holes center drilled or chamfered in workpiace No No No No V,
v Cutting speed; fpm V V V V V
w Width of cut; In No v- No No No
Z No. of teeth :n milling cutter or no. of flutes in atap No V No V No

21-19
21 ECONOMICS IN MACHINING AND GRINDING

TABLE 21-1l Cost and Production Rate Equation Variables

(Definitions .0;(i
;pplicalt riorsforviri;bles imimetri( units)

APPLIES TO OPERATION
VARIABLE DEFINITION I Drl lnDrill-Center
T
I Ream'
C Cost for machining one workpiece; $/workpiece , V V V "
C Cost of each insert or inserted blade; S/blade V V No No No
C' Purchase cost of tool or cutter; S/cutter V V V V V
(;,. Cost of grinding wheel for resharpening tool or cutter; S/cutter V V" No No No
d Depth of cut; mm V V No No No
D Dia. of work in turning, of tool in milling, drillinyj, reaming, tapping; mm V V V V V
e Extra travel at feedrate (f,or f,) including approach, overtravel, and all
positioning moves; mm V . V V V
f, Feed per revolution; mm V No V No V

f, Feed per tooth; mm No V No No No

G Labor + overhead in tool reconditioning department; $/mn V V V V V
k, No. of times lathe tool, or milling cutter, or drill, or reamer or tap is
resharpened before being discarded V V V v V
K2 No. of times lathe tool or milling cutter is resharpened before inserts or blades
are rebrazed or reset V, V No No No
kj No. of times blades (or inserts) are resharpened (or indexed) before blades
(or Inserts) are discarded V V No No No
L Length of workpiece in turning and milling or sum of length of all holes of
same diameter In drilling, reaming, tapping: mm V, V V V V
M Labor + overhead cost on lathe, milling machine or drilling machine; $/mn V V V V V
n Tool life exponent In r,-por's Equation VP V V No

N, No. of workpieces In lot V . V V V

N, No. of pieces between sharpenings V V V V V
p Pitch of thread. mm No No No V No
P Production rate per hour; workpieces/hour V V V V V

r Rapid traverse rate; mm/mn V V V " V

R Total rapid traverse distance for a tool or cutter on one part; mm V V V V
S Reference cutting speed for a tool life of T - 1 min; m/min V No No No No
S, Reference cutting speed for a tool life of T, - 1 mm; m/min No V V V No
tb Time to rebraze lathe tool or cutter teeth or reset blades; min V V No No No
t' Time to replace dull cutter in tool changer storage unit; min V V V V
t, Time to Index from one type cutter to another between operations (automatic
or manual); mn V V V V V
tL Time to load and unload workplece min - V V V V
t0 Time (average) to ccmplete one operation; min V V " V
to Time to setup machine tool for opeation: mmn V V" V" V V
t' Time to preset tools away from machine (in toolroom); min V- V V Vo, v"
t, Time to resharpen lathe tool, milling cutter, drill, reamer or tap; min/tool V V V V V
T Tool life measured in minutes to dull a lathe tool; min V" No No No No
Tt No. of holes per resharpening No No No No V"
Tt Tool life measured in mm travel of work or tool to dull a drill, reamer, tap or
one milling cutter tooth; mm No V V V No
uc No. of holes center drilled or chamfered in workplace No No No No, V
v Cutting speed; m/min V V V V, V
w Width of cut: mm No v" No No No
Z No. of teeth in milling cutter or no. of flutes in a tap No v No V No

21-20
 ECONOMICS IN MACHINING AND GRINDING 21

Le R

Turning

R -. L e

t Workp~ece

Milling

. ,i i I

Fl
Drilling Reaming Tapping

Figure 21-5 Setups for various machining operations.

21-21
21 ECONOMICS IN MACHINING AND GRINDING
TABLE 21-12 Derivation of Terms in Cost Equations for Turning and Milling

TERMS TURNING MILLING

D x rpm 3.82 v 3.82 v

rpm to Cut speed v = 12 rom = -- D rpm = DD

in rev 3.82 v in rev 3.82 v

Feed rate, in/min -x- f x-
rev mm D tooth x no. teeth x---
mm = fxZx 0

N, = No. pieces between sharpenings Tool life. min 3.82 f,v T Tool life (Total length cut, in) ZT

Feed time. min DL Length each piece, in L

Distance in feed L+e . DL + e) (e + L)D

in/min 3.82 1,v 3.82 f, v 3.82 Z f,
v
D o

R R
R R
Rapid traverse time
r r
Set m Time to set up I.
No. pieces in lot N, NL

Tool Time to change tool DL td Ltd

change =
time N, = No. pieces 3.82 f, v T Z T,
between sharpenings

Tool 1 Purchased cost of cutter i C, 1 Cp

deprec. -x c x 1 x
cost N, No. times cutter N, (ki + 1) N, k, + 1)
is resharpened before
discarding

Tool
resharp. Time to 1 1xG
cost N resharpen cutter NxGto N'- t

Rebraze 1 Time to rebraze 1 5G 1 3

(or blade = - x -xG
reset) N, No. times tool is N, k2 N, k2
cost resharpened before
blades are rebrazed

Cost of each insert

Insert or 1 orblade 1 C, 1 zC,
blade .x o d1
cost N. No. times blades are N, k(3 N,xc 3
resharpened before
blades are discarded

Grinding 1 Cost of grinding wheel

wheel = xx for resharpening - xC, w
cost N, tool or cutter N,

21-22 FEW
 ECONOMICS IN MACHINING AND GRINDING 21
TABLE 21-13 Time Study and Cost Data for Turning 4340 Steel Shaft

BRAZED THROWAWAY SOLID

VARIABLE CARBIDE CARBIDE HSS
DEFINITION TOOL TOOL TOOL

R Total rapid traverse distance for a tool on one part, in 27.2 27.2 27.2
C, Cost of each carbide tip or insert, $ 5.00 3.15 -
Cp Purchase cost of tool, S 6.70 28.30 18 30
C. Cost of grinding wheel for resharpening tool, $ 0.07 - 0 02
d Depth of cut, in 0.1 0.1 0.1
D Diameter of work in turning, in 3.5 35 35
I, Feed per revolution, in a

G Labor and overhead cost on tool grinder, $/min 0.40 - 040

k, No of times lathe tool is resharpened before discarding (or no. times
insert is indexed before throwaway holder is discarded 12 2000 36
k2 No. of times lathe tool is resharpened before rebrazing or resetting 6 - -
k3 , No. of times insert is resharpened (or indexed) before insert is discarded 12 8 -
L ] Length of workpiece in turning, in 19 19 19
M Labor and overhead cost on lathe, $/min 0.15 0.15 0.15
N, No. of pieces in lot 20 20 20
r Rapid traverse rate, in/min 100 100 100
th Time to rebraze lathe tool, min 10 - -
td Time to change and reset tool u,.
time to index throwaway insert, min 5 4 5
t4 Time to load and unload workpiece, min 2.3 2.3 2.3
t Time to set up lathe for operation, min 21 21 21
t Time to resharpen too!, min 15 - 10
T Tool life, total time to dull tool, min
v Cutting speed, fpm_ _ _ _ _ __
e Extra travel of tool in feed (includes approach and overtravel in feed) 0.5 0.5 0.5

*These values are taken from Tool Lde Data. tpble 21-14.

2
21-23
21 ECONOMICS IN MACHINING AND GRINDING

-qr
C oI M
0 V L
F; -e IV

=0 0 l
C- co

B_ 0

-ED

U) c
ME-
cm

C -D

S z P 0
5 0 0

0-.

-6
0

0 (
CLo-
E- ID,

03 CD2 E a)
21-24
 ECONOMICS IN MACHINING AND GRINDING
21

COST AND PRODUCTION RATE FOR TURNING

BRAZED CARBIDE TOOLS

DATA. WORK *HARD.TOOL. *CUT- FEED 'TOOL* *F[ED.RAPD.LOAD* SET*TOOL*TOOL*TOOL*
SET* *NESS*RATL. *SPO* RE * TIP *GRIND*
NO.- MATEPIAL *LIFE* *COST.TRAVeUNLD* UP *CHNG*DEPR*SHPN*BRAZ. **TOTAL**PWOD
* *FIM* IN/REV. MIN- COST'VHEELS
I * 2 * # $* * * . I **COST *,RATE
$ & I * **I/PC "*PCiHR
I ASI 4340 300 C-7 470 0.0100 15 1.50 0.11 0.92 0.42 0.49 0.13
1.48 0.16 0.10 0.02 5.33
2' 7.0
AIST 4340 300 C-? 400 0.0100 30 1.76 0.11 0.92 0.42 0.29 0.07
0.87 0.10 0.06 0.01 4.61
3 AISI 4340 6.9
300 C-7 360 0.0100 45 1.95 0.11 0.92 0.42 0.21 0.06
0.64 0.07 0.04 0.01 4.44
4 AISI 4340 6.6
300 C-7 325 0.0100 60 2.17 0.11 0.92 0.42 0.18 0.05
0.54 0.06 0.04 0.01 4.48 6.3

COST AND PRODUCTION RATE FOR TURNING

THROUAWAY CARBIDE TOOLS
DATA. 10RK AHARD*TOOL. *CUT* FEED *TOOL* *FEEODRAPD.LOAD* SET*XNDX*HLDR-
SET* *NESSeMATL* *SPD* *INSERT*
*LIFE* *COST*TRAV*UNLD. UP *INSTeDEPR. *'TOTAL**PROD
NO.* MATERIAL * * FINe IN/REV* IN.* * COST *
I * S * S # S * *COST *cRAtE
S * * * *SI/PC **PC/HR
I AIST 4340 300 C-7 '70 0.0100 1s 1.50 0.11 0.92 0.42 0.04 0.00
0.10 3.09 8.0
2 AIST 4340 300 C-7 400 0.0100 30 1.76 0.11 0.92 0.42 0.02 0.00
0.06 3.29 7.4
3 AIST 4340 303 C-7 360 0.100 4S 1.95 0.11 0.92 0.42 0.02 0.00
0.04 3.46 7.0
4 AISI 4340 300 C-7 325 0.0100 60 2.17 0.11 0.92 0.42 0.01 0.00
0.04 3.66 6.6

COST AND PRODUCTION RATE FOR TURNING

SOLID HIGH SPEED STEEL TOOLS

DATA. WORK *HARDATOOL* *CUT* FEED *TOOL*
SET* 4NESS*RATL. OFEED*RAPD'LOAD* SETOTOOL*TOOL*TOOL.
*SPD* *LIFE* *COST*TRAV*UNLD UP *CHNG*DEPR*SHPN* *GRIND* *'TOTAL**PROD
NO.* MATERIAL . *
*F/R. *WHEEL*
IN/REV*NIN * S * S **COST **RATE
S * I * S * I
$ **SiPC **PC/HR
S AISI 4340 300 T-1 77 0.0100 15 9.14 0.11 0.92 0.42 3.01 0.75
6.03 0.03 20.41 1.8
6 AISI 4340 300 T-1 63 0.0100 30 11.17 0.1T 0.92 0.42 1.84 0.46 3.68
1 0.02 18.62 1.7
AISI 4340 300 T-t 54 0.0100 4S 13.03 0.11 0.92 0.42 1.43 0.35
2.87 0.01 19.15
8 1.5
AISZ 4340 300 T-I 4S 0.0100 60 15.64 0.11 0.92 0.42 1.29 0.32 2.58
0.01 21.29 1.3

Figure 21-6 Printout of cost and production rate

results for turning 4340 steel with three tool materials.

I
i
21-25
I
I
I
21 ECONOMICS IN MACHINING AND GRINDING

8 ~Throwaw~ay carbide11

_______ I _______
_______ _______ Brazed carbide

a. 2 _ _

0 L_____

100 200 300~ 400 500 600

__
20.00HS_____

15.00 ____ ____1-

CL

60 10.00

Brazed carbide
5.00

0 100 200 300 400 500 600 700

Cutting speed. fpm

Figure 21-7 Cutting speed versus cost and production rate for turning 4340 steel (quenched and tem-
pered, 300 Bhn) with three tool materials.

21-26 __
 ECONOMICS IN MACHINING AND GRINDING 21
TABLE 21-15 Manual Cost Calculations for Turning 4340 Steel Shaft With Brazed Carbide Tool

Operation Turn, shaft, 3.5-inch diameter by 19 inch~es long

Material: 4340 Steel. Q&T. 300 Bhn
References: Table 21-13. Brazed carbide tools
Table 21-14, Data set 1
Figure 21-6. Brazed carbide tools, data set 1

Feed cost M x -DL 0.40 x3.5 x19

3.82 tr v 3.82 x 0.010 x 470
2a + L 2 x4 + 1
Rapid traverse cost =Mx - = 0.40x- - $.11
r 100
Load & unload cost =M x t, = 0.40 x 2.3 = $0.92
t. 21
Setup cost Mx~-
M 0.40 x- SO043
N, 20
Too chngecos MxDL t, 0.40 x3.5 x19 x 5 $
Too chngecos M 582 -vT- 3.82 x0.010 x470 x15 O4
1 C, _ DL C'
Tool depreciation cost =- x - x
N, 1(,+ 1 3.82 f, vt k, + 1
3.5 x 19 x 6.70 -1 x6.70 01
3.82 x0.010 x470 x15 12 + 1 4.04 13

Tool resiiarpeningocost XO.40Oxt x 0x.40 X15 S1.48

21-27
21 ECONOMICS IN MACHINING AND GRINDING

TABLE 21-16 Time Study and Cost Data for Face Milling, 2 Inches Wide by 8 inches Long
(Material: 4340 steel, quenched and tempered, 341 Bhn)

!NSERTED
TOOTH SOLID
CARBIDE THROWAWAY He,
VARIABLE DEFINITION TIP INSERT CUTTER
a Approach of cutter to work, in 90 9.0 90
C, Cost of each nserted tooth, throwaway insert, or I
carbide tip, $ 250 2.35 -
C, Purchase cost of cutter, $ 137 00 248.00 310.00
C. Cost of grinding wheel for resharpaning cutter,
$/cutte, 0.30 -0 35
d Depth of cut, in *
D Diameter of milling cutter, in 4.0 4.0 4.0
e Overtravel of mil!ing cutter past workpiece, in. 5.0 5.0 5.0
f, Feed per tooth, in 0 0
G Labor and overhead cost on cutter grinder,
$/min 040 - 0.40
ki No of times cutter is resharpened before being
discarded 9000 9000 20
kz No of
(ortimes cutter
blades) areisreset
resharpened before inserts
(o; rebrazed) 4- ,
k3 No of times blades (or inserts) are resharpened (or
indexed) before blades (or inserts) are disco-rded 12 8 -
L Length of workpiece, in 8.0 80 8.0
M Labor and overhead cost on r ,Pmg machine. $/min 0.40 0 40 0 40
N No. of workpieces in lot 100 100 100
r Rapid traverse rate, in/aim 150 150 150
tb Time to reset blades or to rebraze cutter teeth,
min 30 --

Time to change cutter or index all inserts in

cutter, mn 10.0 6.0 10.0
tL Time to load and unload workpiece, min 3 3 3
t. Time to set up milling machine for operation, min 60 60 60
t' Time to resharpen cutter, min/cutter 80 - ;9
T, Tool life measured in inches travel of work to
dull one cutter tooth, in 0 *
v Cutting speed, fpm * *

w Width of cut, in 2.0 2.0 2.0

Z No. of teeth in milling cutter 6 6 14

*These values are taken from Tool Life Data, table 21-17

21-28
 ECONOMICS IN MACHINING AND GRINDING
21

EE E
= o (o c

oc
0l , t) L
6, 6'

-C2

0
0.
a =s

0 C

I-

0z Co

0z 0

Cf C

I-0

-I-
W
_o
zel

= C2
L3
0 -- ~E - I-
0, -

1-

21-29
21 ECONOMICS IN MACHINING AND GRINDING

COST AND PRODUCTION RATE FOR MILLING

INSERTED TOOTH - CARBIDE TIP

DATA'* WORK
:IARD'TOOL 'CUT *FEED/'TOOL * :FEEDORAPD:LOAD*SET-'CUTR:BODYTCUTR*BLAD*BLADGRND* "*TOTAL"*PROD:
SET' 'NESS'*ATL* 'SPD 'TOOTHLIFE * 'COST*TRAV*UNLO UP *CHNG*DEPR'SHPN*RSET'COST*'HL.* "COST "RATE'
NO.' MATERIAL * * *FIN * IN 'IN/TN' ' S ' S ' S * S ' S S ' S * S ' S ' S ' "S/PC."PC/HR

6 AISI 4340 341 C-6 680 0.005 20.0 0.2? 0.08 1.20 0.24 0.2? 0.00 2.13 0.20 0.08 0.02 4.41 11.7

S AISI 4340 341 C-6 550 0.005 50.0 0.33 0.08 1.20 0.24 0.11 0.00 0.85 0.08 0.03 0.01 2.93 12.2

6 AIS! 4340 341 C-6 340 0.005 80.0 0.53 0.08 1.20 0.24 0.07 0.00 0.53 0.05 0.02 0.00 2.73 11.3

COST AND PRODUCTION RATE FOR MILLING

THROWAWAY INSERT

DATA: WORK 'HARD'TOOL* *CUT *FEEDI'TOOL * *FEED'RAPD'LOAD'SET-*INDX'BODY*INSERT' **TOTAL**PROD'

SET' 'NESS*ATL' 'SPD *TOOTH'LIFE * 'COST'TRAVUNLD* UP 'INST'DEPR' COST * *COST "*RATE*
NO.* MATERIAL ' ' *'F/ ' IN 'IN/TN' ' S 2 'S 'S S * S ' "$S/PC.*"PC/HR

4 AISI 4340 341 C-6 680 0.005 20.0 0.27 0.08 1.20 0.24 0.16 0.00 0.12 2.07 12.3

5 AISI 4340 341 C-6 550 0.005 50.0 0.33 0.08 1.20 0.24 0.06 0.00 0.05 1.96 12.5

6 AISI 4340 341 C-6 340 0.005 80.0 0.53 0.08 1.20 0.24 0.04 0.00 0.03 2.13 11.4

COST AND PRODUCTION RATE FOR MILLING

SOLID HIGH SPEED STEEL CUTTER

DATA' WORK 'HARD'TOOL' 'CUT 'FEED/'TOoL * 'FEED'RAPD'LOAD*SET-'CUTR'CUTR'CUTR'GRND' "TOTAL ?PROD:

*
SET' NESS'HATL' 'SPD 'TOOTH'LIFE ' 'COST'TRAV'UNLD UP 'CHNG'DEPR'SHPN'WHL.' "COST *RATE
NO.' MATERIAL * ' ' *F/M * IN *INITH' ' S ' S * S ' S * S S* ' S S ' "*SIPC.*PCIHR

I AISI 4340 341 TIS 93 0.010 17.0 0.42 0.08 1.20 0.24 0.13 0.50 1.08 0.01 3.66 11.6

2 AISI 4340 341 TIS 76 0.010 22.0 0.51 0.08 1.20 0.24 0.10 0.38 0.83 0.01 3.36 11.2

3 AISI 4340 341 i1S 62 0.010 32.0 0.63 0.08 1.20 0.24 0.0? 0.26 0.57 0.01 3.06 10.P

Figure 21-8 Printout of cost and production rate results for face milling 4340 steel with three cutter materials.

21-30
 ECONOMICS IN MACHINING AND GRINDING 21

120

0 2 carbide

C,

10.

5.0

4.

CL Solid HSS
0

21.0

0 100 200 300 400 500 600 70

tempered,~~nsete
treto mtras carid tipwt

213
21 ECONOMICS IN MACHINING AND GRINDING
TABLE 21-18 Time Study and Cost Data for Drilling Five Holes, 0.25-Inch Diameter by 0.5-Inch Deep
(Material- 4340 steel, annealed, 212 Bhn)

VARIABLE DEFINITION DATA

a Approach of drill to work, in 30

C' Purchase cost of drill, S/drill 0.92
D Diameter of drill, in 0.25
f, Feed per revolution, in
G Labor and overhead cost on tool grinder, $/min 0.40
ki No. of times drill is resharpened before being discarded 12
L Sum of lengths of all holes of same diameter, in 2.5
M Labor and overhead cost on drilling machine, $/min 0.40
N_ No. of workpieces in lot 70
r Rapid traverse rate, in/min 100
t' Time to change drill, min 0.5
tt Time to load and unload workpiece, min 1.0
t' Time to set up drill for operation, min 25
I, Time to rasharpen drill, min/drill 5
T_ Tool life in inches travel of drill to dull drill, in +
u No of holes of same diameter in workpiece 5
v Cutting speed, fpm
e Extra travel in drilling, in 2.5
*These values are taken from Tool Life Data, table 21-19.
'Drill life data given intable 21-19 are innumber of holes to dull drill. and equation requires these data in inches. Therefore, to obtain T, the number of holes
ismultiplied by ie hole length (05 inch)

I
2

21-32
 ECONOMICS IN MACHINING AND GRINDING
21

~ z 0V Pn
W- 0
'A .cN 0
0;
Oga No N..4
fu f N N t.y N

00

r
a
(Vi Lfl
0 0
0 C

- a,

4.
.4 , '
_j0ILN 0 '
0
.. . . .... . . .. . . . . .

'coo 0~~_ a: 0j 0 - 0
4.xw 0 40

QQ.,,. . . . . . . . . .
.4 ' j - w, 0 0

00
.43
7 o 0

z- .4 04

5',0o
0)
lot~f
Sn.c. ;

o 2 ! 0) 00

0 K,
0 G0
05
N

0
0a 0 0 0 0
P S Wn
frE '~ o n 0 a
CV 0
0 ~~~~~0
,N
-l N 'A
N
-
N A
n
' 0
of50 0'

0
U 0 0 0 0 003
21 ECONOMICS IN MACHINING AND GRINDING
30_____
0

0 25

1.8

1.6

2 2

2.00

1.80

0.0052
ipr

~, 1.60

1.0

0.8

25 50 75 100 125 150 175 200

Cutting speed. fpm

Figure 21-11 Cutting speed versus cost and production rate for drilling holes in 4340 steel (annealed __

to 212 Bhn) using two feed rates.

21-341
 ECONOMICS IN MACHINING AND GRINDING
21

0to
00

CO~ C

CD
CL0 -

to

CD

ca,

0)

E
tr. Z _
JU-1~ t woCCUt
to a)

to UU

CD"

000
I N-

21-35
21 ECONOMICS IN MACHINING AND GRINDING

TABLE 21-20 Time Study and Cost Data for Machining 4340 Steel Forging on an NC Machining Center
OPER. I Part No.
NO. OPERATION 456987-003
N 010 Face mill top surface PartI Name 45698-Si3
Bracket-Slider
N 020 Peripheral end mill sides and ends Material AISI 4340 Steel Forg.

N 030 i End mill two slots in top surface j Condition Normalized

N 040 j Drill (2) 0.250-inch dia.
t holes [i Hardness Bhn
331Bh

VARI- OPERATION NO.

ABLE DEFINITION N 010 N 020 N 030 N 04C
C, Cost of each insert or inserted blade; S/blade I 340 - - -
C,
C, Purchase cost ofwheel
Cost of grinding tool orfor
cutter: S/cutter!tool or cutter; S/cuttert
resharpening 245.00
- 15.00
0.10 10.00
0.10 _-0.80

d 1 Depth of c..t, in 1 0.100 0.250 0.250 -

D i Dia. of tool in milling and drilling; in 4.000 1.000 0.750 0.250
e -xtra travel at feedrate (f, or f,) including approach, overtravel,
and all positioning moves; in 500 5.50 2.25 0.50
I, Feed per revolution; in - - - I
f, Feed per tooth; in I
G Labor + overhead in tool reconditioning department; $/min 040 0.40 0.40 0.40
k, No. of times milling cutter or drill is reused before being discarded 9000 7 7 12
k2 No. of ,imes milling cutter is resharpened before inserts (or blades) are I
rebrazed (or reset) . . . .
k3 No. of times blades (or inserts) are resharpened (or indexed) before blade 8 - --
S (or inserts) are discarded
L Length of workpiece in milling or sum of length of all holes of same diameter

in drilling; in 1 10.00 26.25 8.40 1.00

M Labor + overhead cost of machining center 0 83 0.83 0.83 0.83
NL No. of workpieces in lot 20 20 20 20
Rapid traverse rate; 150 150 150 150
R Total rapio traverse distance for a cutter on one part; in 43.00 27.25 46.35 41.00
tb Time to rebraze cutter teeth or reset blades; min - - - i

td Time to replace dull cutter in tool changer storage unit; min 3.0 3.0 3.0 3.0
t. Time to index from one type cutter to another between operations (automatic
o: manual); min 0.1 0.1 0.1 0.1
t; Time to load and unload workpiece; min 20 2.0 2.0 2.0
to Time to setup machine tool for operation; min 60 60 60 60
tp Time to preset tools away from machine (in toolroom); min 20 15 15 12
t, Time to resharpen lathe tool. milling cutter, drill, reamer or tap; min/tool - 15 15 5
T, Tool life measured in inches travel of work or tool to dull a drill, reamer, tap or
one milling cutter tooth; in I
v Cutting speed; fpm
w Width of cut; in 3.50 0.75 0.75 -
Z No. of teeth in milling cutter or no. of flutes in a tap 6 4 4 1
*These values taken from Tool Life Data, tab:e 21-21.

21-36
 ECONOMICS IN MACHINING AND GRINDING 21
TABL.E 21-21 Tool Life Data for Machining 4340 Steel ont an NC Machining Center

FACE MILLING*
I TOOL
MATL TOOL
GEOMETRY
____I I i
ON
utp ' CUT- TOOL TOOL
UFEITOOTH
cogriaIO kims- IDaWn ill.' TOIGOEP 1MOTHFEED richres
work travel

I
MATERIAL AN jHARD- Trig try ANL- j -J FUID OF OF P E NDOi
MIISTRUCTIE NESS bw. Grig. 06 AA~lt CAl TR* l ECEP . OD CUT CUT ITOOTHI POWtT CUUSPEWD.fpm
m

Aoy LNe Nomalized j 5 i 47 70 183 95

430320 370 C-6 Up 0 -7 45 -5 6i' 00167

PEIPHEIA EN MILING

COWTN
11111113- RO. WIDTHFEED LIFE
TUG DEPTH Inches
work travel

-MD-HR.Tattry CUTTER NO FUPOR Mx " -RVI OF TOFiM

D -VSCUT

Normalized -
1
M HSI 1
Aiua
331 SS
HS
uiie0750
Sen J01 4 2 Down 30 10 0.6
in8
1 1.2 200700001 5108
155010 70

MIATRI [-1
MIL
~TOOL
N - HAR- Trade try CUTTER KO FlITTE MEIIL-"six
1K
END MILL SLOTTING

TOOL
GEMETY
Chow- FLUID OF OF IS 11 i
MICICUE MWS rd
136 TYPE Olk ToUl118TH 06 Anb IA.- r
IEMA E CUT CUT TOOH OU CIITTUG6siEEO
lwn

Alloy steel Nomlze oid 3I-T @)i

5109
4340 -13311 M2 H 0750 4 2 I- 30 10 45 10.250 0.750 0 002 0012 ,1019
5
___ j
AZclai eH d.1 ~ j 1be 000D 1n 7 120 544

DRILLING
OW
OSIIA IMILLIMZ DRILEUBY {
____L ' OIILI
Bni I ir i _i

Noral40 3311 Twist 025 2. 1.7_9_1__1002 .1

10 50 100 150
4
Sigle tooth cutter except as noted74
*Cuffing Fluid Code
00 Dry
I i Soluble Oil

21-37
21 ECONOMICS IN MACHINING AND GRINDING

N/C MACHINING COSTS AND OPERATION TIMES

FOR
PART NO.-456987-003 * PART NAME-BRACKET-SLIDER * LOT SIZE- 2G
MATERIAL-AISI 4340 STEEL.NORMALIZEDACICULAR - HARDNESS- 331

DATA.OPER: MACHG *TOOL*SPEED'FEED -TOOL *FEED*RAPD.LOAD*SET-ATOOL*TOOL-*TOOL'TOOL.BLAO#INSTGRNDTOOL*

F 'TOTAL "OPER.

SET NO.'
0 OPER. :RATL' S :LIFE *COST'TRAV'UNLD' UP *IkDX'REPL":DEPRSHPNRSET:COSTNHL 'PRST: : COST ::TIME
NO. * *$ SN S* S ' S* S
S % S S S
$ * I *. HIl.

30001 N010 FR-TA C-6 670. 0.005 47. 0.65 0.24 0.08 0.09 0.00 0.09 0.28 e 1.27

30002 NO1 FM-TA C-6 540. 0.005 70. 0.80 0.24 0.08 0.06 0.00 0.06 0.19 1.44 1.43

30003 NO1O FM-TA C-6 445. 0.005 83. 0.98 0.24 0.08 0.05 0.00 0.05 0.16 1.56 1.62

30004 WO1O FM-TA C-6 345. 0.005 95. 1.26 0.24 0.08 0.04 0.00 0.04 0.14 1.81 1.96

30005 NO20 EM-HSS R2 155. 0.004 50. 2.78 0.15 0.08 0.33 0.25 0.79 0.01 0.79 4.03
413)

30006 N020 EM-HSS M2 100. 0.004 100. 4.31 0.15 0.08 0.16 0.12 0.39 0.01 0.39 5.63 5.67

3000? N020 EM-HSS NQ 80. 0.004 140. 5.39 0.15 0.08 0.12 0.09 0.28 0.00 0.28 6.40 6.92

30008 N020 EM-HSS M? 70. 0.004 220. 6.16 0.15 0.08 0.07 0.06 0.18 0.00 0.18 6.88 7.79

30009 N030 EN-HSS M2 65. 0.002 50. 3.34 0.26 0.08 0.10 0.OS 0.25 0.00 0.25 Q-3) 4.56

30010 N030 EM-HSS M2 54. 0.002 110. 4.02 0.26 0.08 0.05 0.02 0.11 0.00 0.11 4.66 5.31

30011 N030 EM-HSS M2 43. 0.002 190. 5.05 0.26 0.08 0.03 0.01 0.07 0.00 0.07 5.56 6.52

30012 N040 DRILL MI 90. 0.002 10. 0.45 0.23 0.08 0.25 0.01 0.20 0.48 1.70 1.22

30013 N040 DRILL Mi 74. 0.002 25. 0.35 0.23 0.08 0.10 0.00 0.08 0.19 1.23 1.16

30014 N040 DRILL R1 60. 0.002 50. 0.68 0.23 0.08 0.05 0.00 0.04 0.10 1.18 1.25

30015 N040 DRILL MI 50. 0.002 80. 0.81 0.23 0.08 0.03 0.00 0.02 0.06 1.24 1.39

30016 N040 DRILL "1 74. 0.005 5. 0.22 0.23 0.08 0.50 0.01 0.40 0.96 2.40 1.24

30017 N040 DRILL MI 45. 0.005 25. 0.36 0.23 0.08 0.10 0.00 0.08 0.19 1.05 0.93

30018 N040 DRILL R1 36. 0.005 50. 0.45 0.23 0.08 0.05 0.00 0.04 0.10 0.98 z

30019 N040 DRILL MI 30. 0.005 90. 0.54 0.23 0.08 0.03 0.00 0.02 0.05 0.96 1.06

LOAD. UNLOAD AND SETUP TIME AND COST 1.66 2.49 4.15 5.00

NOTE - FEED UNITS ARE IPR FOR TURNING, DRILLINGREAMING, AND CENTERDRILLING OR CHAPFE ING
FEED UNITS ARE IPT FOR MILLING
TOOL LIFE UNITS ARE IN, FOR MILLING, DRILLING, REANINGAND TAPPING
TOOL LIFE UNITS ARE MIN. FOR TURNING
TOOL LIFE UNITS ARE NO. OF HOLES FOR CENTERDRILLING OR CHAMFERING

Figure 21-13 Printout of cost and production rate results for machining 4340 steel forging on an NC machining center.

21-38
 ECONOMICS IN MACHINING AND GRINDING 21

NIC MACHINING COSTS AND OPERATION TIMES

FOR
PART NO.-456987-003 * PART NAME-BRACKET-SLIDER * LOT SIZE- 20
RATERlAL-AISJ 4340 STEELhORRALIZED.ACICULAR * HARDNESS- 331

OATA.OPER' MACHG :TOOL'SPEED'FEED :TOOL * FEED*RAPDeLOADeSET-'TOOL*TOOL'*TOOL.?OOL.BLADtINST.GRNDTOOL. *TOTAL **OPEN.

SET NO.' OPER. eMATL'
N * 'LIFE 'COST*TNAV:UNLD' UP 'INDX:REPLteOEPNSHPN*RSETeCOSTUHL *PAST* * COST **TIRE
NO. 'SFN' ' S S * SSS
S S # S* S e * S MIN.

30001 NO10 FM-TA C-6 670. 0.005 47. 0.65 0.24 0.08 0.09 0.00 0.09 0.28 1.43 1.27
30005 N0Z0 EN-HSS M? 155. 0.004 50. 2.78 0.15 0.08 0.33 0.25 0.79 0.01 0.79 5.18 4.03
30009 N030 EM-HSS M2 65. 0.002 50. 3.34 0.26 0.08 0.10 0.05 0.25 0.00 0.25 4.34 4.56
30018 N040 DRILL *I 36. 0.005 50. 0.45 0.23 0.08 0.05 0.00 0.04 0.10 0.95 0.98

LOAD, UNLOAD AND SETUP TINE AND COST 1.66 2.49 4.1s S.00
7.22 .88 1.66 2.49 .32 .57 .30 1.08 .09 .01 1.42 16.05 .84
NOTE - FEED UNITS ARE IPA FOR TURNING, DRILLING.REANING AND CENTERKILLINS OR CHARFERING
FEED UNITS ARE IPT FOR MILLING
TOOL LIFE UNITS ARE IN, FOR MILLING,. DRILLING, REARING.AND TAPPING
TOOL LIFE UNITS ARE NIN. FOR TuRNING
TOOL LIFE UNITS ARE NO. CF HOLES FOR CENTERDRILLING OR CHAMFERING

Figure 21-14 Best conditions for machining 4340 steel forging on an NC machining center.

21-39
21 ECONOMICS IN MACHINING AND GRINDING
TABLE 21-22 Optimized Cutting Speed Equations for Use with English Units

For Turning

+ +
+ t 1 k2 C + Gt,

S +ej n
n(L+e)

V FnLn)LtdJ
e)[o(-

For Milling
n
n ,+
n
+ 1 nMD(L+e)
v , (S,) L
LGtd++
3.2f t + b + - + C, + Gt-
82LMt + k, + 1 + Gtk

n
n + l
1 ( nD(L+e) I
o () n
[3.82f Lt J

For Drilling or Reaming

n
n +I
St = 1nMD(L+e)
v ...
[ C)I Gc + Gtd)]
3.82f, L td + k, + G4+1,

()n+1
-- nD(L+e)

For Tapping
1 r
=5 (
)fl 1 .91L (t, + knnD+) t G)

= f +i mnDI +ne) ne) 1

n
. 1.91Ltd j

W-71mnD(~e) +

V - P~_ (St

21-40
 " ECONOMICS IN MACHINING AND GRINDING 21
WA I.LL1-23 Oplhnlzoud C1ltliti Spood Eclunillos for Uso wilh Moiric,lilll

For Turnling

....
,

For Milling

v~ nn+I
101, L ML, +1 C( +] O
rr1 + + + +

+ e)
ji ; r k~~t Ii,
v~~~~~~
,,., .....
- ( 1, [p.D(L
~~~318,L,

For Drilling or Reaming

- (',)" 1 ' M
td + nn Gs, + a

n .. . . . . .. - ,,,, ,

For Topping
n
1 '
..... r1 L n) I-c
+ _ -- + )mj

n
( 8 )1 + 1 n +pLt
v......, -

N1 - 1
 w-U

21 ECONOMICS IN MACHINING AND GRINDING

TABLE 21-24 Optimized Tool Life Equations for Use
with English or Metric Units

For Turning
1

1
Tmm. p . [

For Milling, Drilling, Reaming or Tapping

1

Tt moxpro
[

II

WZ

I
N.
A

21-42 --
 ECONOMICS IN MACHINING AND GRINDING 21

00

Q)' - - a . V
0-C4N V
0Lc ,0ci4 ;6u uC - ) =

CC)

T. 0. 0)
co 0U C)

0 -j 0

10 o- 'o
0.~~F ~ 0 ' (]1
*61) V)0N to 2 O

o c' o ei ' C -- nC

C)
-WW CC U) W )LJWc, C)

- -- F- R, t- < 0 0 N--UU
cc f 0 0

LLu

k- F- JAM
o(, - E
C., - av " ..

az 4r(.
0)
2-E > C a
rcrc E ~I c -r Zc !; C]-
-

ZC)ca C CL
_ _ _, 4) ! 0 ' -

a)- CD 04
ii~~ 0
.0 r) u) - ) -
.0 --
- EI 4 )

0 0
11E -,J 0, Ll ( C 0

LU - C10 ) co r-o O0OO

*vD -~~
-21: 43

ZO '~o0 -~~ -c--

21 ECONOMICS IN MACHINING AND GRINDING

I LOT SIZE I 1. Lotsize

- -LEFP '
"-ES
" , 2 Setup time. minutes

:- LOADI,'IL I l1 H - - 3 Load and unload time. minutes

4 1NDEX; T i E . r![t' 4 Index time. minutes

1,
5 OVERH ,DOL..- N- 5 Labor and overhead, dollars per minute
F;, 4
6 REFL: TP-:LII 4 4- 6. Dull tool replacement time. minutes
j- '

7 i I ERT I C.T 7 insert cost. dollars

:3. 15
8 NO OF EDGE:-; 8.Number of cutting edges

9 PRESET COT
0: T 9. Preset cost. dollars
0.
10 R TRAVERS I 1 10. Rapid traverse distance inches

11 F T R TE ,F 11 Rapid traverse rate. inches per minute

12 E":T R TRA'k.) T,t I -12. Extra travel in feed, inches

:-; -,1RT:' _i ,!1 H - 13. Work diameter, inches

14 CU1T Li'iTH; I- - - 14. Cutting length, incl"s

T '5 L : 15. Tool life, minutes

I" "

i . :_PEE i 16. Cutting speed. feet per minute

325,
7 ....P T.% l -,17 Feed. inches per revolution
0.' 0:i
TItlE i.: ll

J4, i. E 4 -U Constant time. minutes

5 - ,,-X
62. Fi eedin;- ,:he. minutes I
0:3 5 70949 12 TL Tool time, minutes
9. 07 01 65 ? TOT Total time. minutes

C: OST
,-., Constant cost, dollars
15122
6 S F FD- - Feeding cost. dollars
,4, .9 .:.
0 TL Tool cost. dollars
6.3
6 3.,:, 16 Z- TOT -- Total cost, dollars

Figure 21-16 Example of the cost and production program as run on the .9 calculator.

21-44

- ,_ -,+ -- - --- _ , _ _._.--

 SECTION 22
MACHINE CHATTER
AND VIBRATION

Introduction .................... .............................................. ........... 22-3

Causes of Vibration ........................ ........................... .... 22-3
Dam ping ....................................................... ............ ........ .................................. 22-5
Responses of Structures to Periodic Forces ............................... . ............ 22-6
Self-Excited Chatter . .................................................................... ....................... . .. 22-12
Troubleshooting Chatter ........................ ........................... .22-17
Regenerative Chatter Checklist ................. ............................... ...... ...................... 22-22

NOTE: The material in this section was adapted in large part from a home-study course and reference marnal entitled "How to
Troubleshoot Machine Chatter and Vibration" with permission of Manufacturing Education Copyright 1978 by Manufacturing Educa-
tior, P 0. Box 36050. Cincinnati. Ohio 45236

22-1
 MACHINE CHATTER AND VIBRATION 22
INTRODUCTION structures. Cast iron is more resistant to deflection than
aluminum, steel is even better. and tungsten carbide is su-
Problems arising from machine tool-workpiece vibration perior Since cast iron is an easily obtainable material and
are among the major obstacles to greater productivity in less expensive to machine than steel, it is often used in ma-
metal cutting The vibratory motion between a cutting tool chine tool structures in spite of its lower modulus of elastic-
and a workpiece is recorded on the workpiece surface and. ity Tungsten carbide is very expensive and costly to ma-
depending upon the severity of the oscillatory motion and chine, hence. it is used where performance is more
the surface finish specifications. may result in parts with important than cost
unsatisfactory surface quality Excessive vibration or chat-
ter may also seriously decrease tool life. In addition, chat- For a given material, the deflection of a structure is a func-
ter affects the life of bearings and other machine com- tion of the applied load and the geometry Equation 22-1
ponents. although this is not well understood.' 4 can be used to predict the deflection of the cantilever beam
with a round cross section. illustrated in figure 22-1.
Higher production rates and more severe cutting condi-
tions encountered in modern shops reveal another vibra- 64PL 3
tion problem-excessive noise This problem usually stems d = - (Eq. 22-1)
known as
from the high frequency vibrational condition
chatter, and while it may have only a slight physical effect where:
on surface finish, recent government regulations have fo- d = beam deflection. inches
cused sharply upon the noise environment of the machine P = force on the end of the beam, pounds
tool operator. L = length of the beam. inches

It is necessary to solve a vibration problem if unsatisfactory D = beam diameter, inches

tool life. surface finish, or noise result Many experienced E = modulus of elasticity. pounds per square inch
shop people are aware of chatter and vibration, but few
have the training to identify the types of vibration problems
and the appropriate methods for their solution The dis- P
cussion that follows provides an understanding of the A
causes of machine tool-workpiece vibration problems and L
alternative approaches for their elimination.

CAUSES OF VIBRATION 7=-

Deflection of Machine Elements A d

In order to analyze vibration problems, it is important first D
to understand the deflection characteristics of materials d 64D
The most important material prcerty governing deflection 3nED'
is the modulus of elasticity. For most structures, the
amount of elastic. nonpermanent, deflection for a given Section A-A
load is inversely proportional to the modulus of elasticity.
Thus. a higher modulus will result in a lower deflection. Figure 22-1 Deflection of a cantilever beam.
Table 22-1 give, the modulus of elasticity of materials
commonly used in machine tools. tooling, and fixturing.
TABLE 22-1 Modulus of Elasticity of Some Common Equation 22-1 only applies "exact y'"to a slender beam sol-
Materials idly held on one end by a massiv.. base. However, it can be
used to approximate the deflection of a boring bar extend-
MATERIAL MODULUS OF ELASTICITY, E(psi) ing from a tool post or tool holder, a slender workpiece
sticking out of a vise, a spindle nose extending beyond its
Aluminum 9.000.000 front bearings, or any "slender" beam or "thin" plate that
Cas; iroq 14,000.000 (varies widely) projects for some unsupported distance. In this case, "slen-
Steel 29 000,000 der" and "thin" are relative terms and may refer to some
Tungsten carbide 86,000,000 very heavy cross sections that have an unsupported length
several times their thickness. In equaticn 22-1. the beam
diameter (D) is raised to the fourth power and ie beam
lenth (L) to the third power. implyipg that both are very
It is iruportant to note that all steels, regardiess of Piloy important quantities influencing beam deflection.
content. heat treatment or hardness, have approximately
the same modulus of elas, icity. The elastic modulus de- For a given beam, a given percentage increase in overhang
pends on the fundamental atomic structure of the material, length (L) prcduces a much greater percentage increase in
while strength and hardness are very dependent on small deflection. For example, a doubling of bear. length results
percentages of elements which do not affect the modulus. in an eight-foid increase in deflection. Thus in tooling and
Of the materials listed in table 27-1, aluminum is the poo- fixture design. an absolute minimum of ove hang should he
rest material for minimizing th de!lection of machine used. Boring bar design is an example whee a length-to-

22-3
22 MACHINE CHATTER AND VIBRATION

diameter ratio of greater than four or five to one is consid- Forcing of Structures
ered impractical A given percentage increase in diameter The important terminology of vibration a- -sis is tlus-
(D) has an even greater effect on reducing deflection than trated in figure 22-3 and is used extensivel: i the follow-
length had on increasing deflection: hence, it is important ing discussion Included are:
to have the diameter of overhanging members as large as
possible Amplitude. A. is the maximum displacement from the
equilibrium position It is one-half of the peak-to-valley
Structural Stiffness distance and is not the total displacement from the top-
The stiffness of a structure can be interpreted as the most peak to the lowest valley
amount of force required to produce an inch of deflection Period T. is the time required to complete one full
Equation 22-2 can be used to calculate the stiffness of a cycle of vibration.
structure in pounds per inch.
p Frequency. f. is the number of cycles which are com-
K = dd (Eq 22-2) pleted in a given amount of time. usually one second.

where:
K = stiffness. pounds per inch
P = force. pounds
d = deflection. inches o I-----
For example. if a machine deflects 0.001 inch under a load - '
of 800 pounds. the stiffness is: A

800>
K 800.000 lb/in
0.001 C
o
If the stiffness of a structure is known. its deflection under "
load can be calculated from a modified form of equation CL - Equilibrium position
22-2: f T-
P
K Figure 22-3 Periodic motion of a vibrating struc-
ture.
The term "directional stiffness- is used to describe the stiff-
ness of a structure when loaded in different directions. This
is an important concept because many machines. tools, and
workpieces have both stiff and weak directions. If a ma- Equation 22-3 is an important relationship between fre
chinig setup is made so that cutting forces are aimed to- quency and period:
ward the weak direction. excessive deflection and possible
chatter will occur. If the setup is changed so that the forces
are in the stiff direction. the problem will be minimized or f(cycles per second) (Eq. 22-3)
eliminated. As an example, consider figure 22-2: if this T (sec) (
beam is loaded in the Z or the X directions, it will be very
rigid. Loaoing the beam in the Y direction produces the Another name for -cycles per second- is Hertz. For ex-
greatest deformation and. therefore. the lowest directional ample. 20 cycles per second is the same as 20 Hertz. While
stiffness. the term Hertz is the officir! standard for frequency in the
p U. S. A.. many prefer to use the more descriptive term cy-
Y cles oer second, or cps. The term cps will be used in this
discussion.

Most people are familiar with things that start vibrating by

giving them a pus.. and letting go. If the "structure" vi-
Z brates, it does so at a frequency determined by the struc-
ture itself, not by the force or displacement given it. The
initiation of vibration in machine tools is often by forces
that fluctuate periodically, that is. by 'orces that vary with
time. The structure is said to be -excited" by the fluctuating
force. Motcr unbalance is a common method by which pe- J
riodic forces in machinery are introduced. Another ex-
ample of periodic forces in machining is the variation in
cutting forces introduced by cutting through a keyway con-
Figure 22-2 Illustration of the concept of direc- tained in a shaft. The cutting force will drop to zero each I
tional stiffness. For this beam the stiff directions are time the tool tip enters the keyway and return to its nomi-
X and Z; the weak direction is Y. nal value after the tool re-enters the workpiece. 1=

j
2

22--4
 MACHINE CHATTER AND VIBRATION 22
The occurrence of forced vibrations in a milling operation cast iron has much higher internal damping This figure
can be expected for three major reasons First. the number might lead to the conclusion that cast iron machine struc-
of teeth in contact with the workpiece is changing con- tures have a much better vibration resistance than those
stantly Second, the angular orientation of the force built from steel
changes as the tooth rotates. Third. the chip thickness
changes as the tooth moves through the arc of contact. Fig-
ure 22-4 is an illustration of an actual recording of milling
forces II Forced vibration is obviously present in all three
cutting force components. F. F. and F.

0 22(rev)

High Internal Damping

0
I '50 u_

I FZ -50

-- 0

I I I * I I "

0 002 0.04 0.06 0.08 0.1

Time, sec Low Internal Damping

Figure 22-5 Diagrams showing the difference in
Figure 22-4 Fluctuation of the cutting force com- internal damping of cast iron and steel.
ponents in a mlling operation. (Adapted from
HOSOii!)
Material damping. however, is not the whole siory because
joint damping, or "squeeze film" damping. is also very im-
portant in machinery. Oil becomes trapped between mating
DAMPING surfaces that move apart during vibration. Oil is sucked in
and fills the gap as surfaces move apart and is forced out
Damping is the behavior of a system that tends to resist when they close. This motion of the oil heats it, absorbing
rapid movements. If a beam is struck with a hammer and energy. While this is the most powerful source of damping
vibrates for a long time. it is said to be lightly damped. If in joints, some damping takes place in dry joints as a result
the beam stops vibrating almost immediately, it is said to of friction and the squeezing of air in and out. This damp-
be highly damped. Theoretically. a system that had no ing is generally much less significant. however.
damping would go on vibrating forever, at the same initial
amplitude. This can not occur in practice because all mate- Figure 22-6 iustrates that the damping of a machine in-
rials have sonic amount of internal damping Because of creases as components are added to it Most of the damp-
the basic way in which materials deform, all of the work ing in the completed machine results from the joints be-
that is done to deflect an elastic member can not be recov- tween the various components, rather than from the
ered when the member is released. Most of the energy is re- internal damping of the structura! -"omponents
covered, but a small amount remaining in the member is
converted ;nto heat. This small energy loss causes the vi- The third major category of damping is that intentionally
bration amplitude to decrease very slightly each cycle, added to a machine to improve its resistance to vibration.
A common. non-metalcutting example of this is the auto-
Different materials have different amounts of internal mobile shock absorber. Similarly. tuned damped vibration
damping. Figure 22-5 illustrates the different damping absorbers provide a convenient way to improve the vibra-
characteristics of cast iron and steel and shows clearly that tion resistance of many machine tools.

22-5
22 MACHINE CHATTER AND VIBRATION

B
Bed 0.045
Only .

C-

Bed + ,., I
Carriage 7 aA Z0.015.. .

Bed +
ed + ~e0 100 200 300
Headstock r-ULa-Pl Load -- P, ib

Figure 22-7 Deflection versus static load behavior

of a cantilever beam.
Bed +
Carriage,
Headstock
K 300 6670 lbin
0.045
Complete [L .04
C ejNote that n, load along the line in figure 22-7 divided by
the corresponding deflection gives this same value of static
stiffness.

Suppose a load that varies from 100 to 300 pounds is ap-

0 0.1 0.2 0.3 plied to the beam. (The peal--to-valley variation in load is
300 - 100 = 200 pounds. The force amplitude isthe halffre-
of
Amount of damping the peak-to-valley value, or 100 pounds.) Suppose
(log decrement) quency of load application is one cycle every two hours, or
0 00014 cycles per second. This is so 3low that vibration
Figure 22-6 Influence of material and of joints on analysis is not necessary to predict what will happen. The
damping. (Adapted from Peters s) force and deflection will creep slowly up and down the
static deflection curve between points A and B in figure
22-7 At any pcint in time. the value of the deflection for
the varying force acting at that instant will be the same as
the value of the deflection if the force were statiz.

RESPONSES OF STRUCTURES TO If the fk triation is increased to one cycle per minute,

the speeo . t11 so slow that the bar does not know that it
PERIODIC FORCES is being vibi ,ted. Ifthe force variation is increased to one
cycle per second. or even faster. it is not obvios that the
Static and Dynamic Stiffness results will be the same. In order to understand what hap-
The analysis of the behavior of structures under dynamic pens at higher frequencies of force variation, it is necessary
loads is far more complicated than that of structural behav- to introduce thr concept of dynamic stiffness. Dynamic -

ior under steady loads The basic principle is that at very stiffness. Kg,. is the ratio of the force amplitude. F. to the
low frequencies the structure responds to dynamic loads v. lion amplitude. A. at a certain vibration frequency.
the same as it does to static loads To emphasize this. con- Kd = K; that is. the dyiamic and static stiffnesses are the
sider figure 22-7 which shows the deflection versus static same.
load behavior of a cantilever beam. The concept of dynamic stiffness. K,. can be understood
from the curve of figure 22-7 showing load versus deflec-
This graph could be computed from the deflection equation tion. For the example illustrated in figure 22-7. where a
for a specific be-am at various loads. At 100 pounds, the de- peak-to-valley force of 200 pounds (F = 100 pounds) gave
flectio, is 0.015 inch, at 200 pounds. it is 0.030 inch. etc.
a peak-o-valley displacement of 0.045 - 0.015 0.030
The static stiffness. K. is the value of steady force acting on
the structure divided by the deflection it produces. The
static stiffness of the beam producing the data of figure
22-7 is 6.670 pounds per inch as shown by the following Kd = 6670 b/in
calculation: 0.015

22-6
 MACHINE CHATTER AND VIBRATION 22
where: Further suppose the hand is moved up and down. very
F forcc amplitude (the maximum increase in slowly at first. then at higher and higher frequencies. Let us
the oscillatory force from its average value, examine what happens to the heavy object. It would be ob-
that is one half of its peak-to-valley value) served first that the heavy object always moves at the same
frequency as the hand. This is elementary. but important. It
A = vibration amplitude, suggests that when there is a suspected forced vibration
problem the cause of the problem can be tracked down by
Note that this is exactly the same as the value of K. illus- knowing its frequency.
trating the fact that as long as the force and displacement
data fall on the same curve, their ratios remain the same At very low frequencies the heavy object moves exactly the
and the dynamic stiffness is the same as the static stiffness. same distance as the hand. Thus. the amplitude of the hand
and object are the same and there is no additional stretch
Figure 22-8 shows the force pattern acting on a structure in the spring. This behavior is typical of all structures. As
at a low frequency and the resulting motion of the struc- the frequency increases, the spring begins to stretch and
ture. This illustrates a very basic point of vibration trouble- the amplitude of the object becomes larger than that of the
shooting: namely. the structure almost always vibrates at hand. Eventually a frequency is reached where a given
the same frequency as the periodic force that is causing it to hand movement results in a very large object amplitude
vibrate.In figure 22-8 there is a "phase difference- between This condition is called resonance. The frequency where
the two waves: that is. the peaks of the displacement trace resonance occurs is called the natural frequency. f.,. which
occur slightly later than those of the force trace. In spite of is also the frequency at which the dynamic stiffness is the
this. the period. T. is the same for both waves and con- lowest. As the frequency is increased beyond the natural
sequently the frequency must be the same. frequency. the amplitude of the object continually de-
creases until finally the hand can shake very rapidly while
the object appears to remain motionless-

It may be concluded from these observations that a ma-

20- "\F\ chine structure will vibrate easi'y if it is forced at frequen-
cies near its natural frequency. It will hardly vibrate if
forced at a frequency well above the natural frequency. At
T(me, frequencies well below the natural frequency, the structure
01 0.2 0.3 0.4 sec will vibrate at some intermediate amplitude. The natural
LL -10 frequency of a simple structure, such as a heavy object sus-
-20-V pended cr a spring, can be calculated from equation 22-4.

Phase difference '1 W (Eq. 22-4)

where:
f,- = natural frequency, cycles per second
0.001- K = spring stiffness. pounds per inch
A 0.001"
o / '"
02 0.2i 0 .' \Time.
0p W = object weight. pounds
When troubleshooting vibration problems, equation 22-4 is
1 T 0.2 -seldom
--- used to estimate the natural frequency: however, it
o is useful for estimating the effects of changes in stiffness
and we;ght.
Figure 22-8 Representative force and dis-
placement patterns of a structure vibrating at a low
frequency. Behavior of Complex Structures
Figures 22-9 and 22-10 show respectively a motor on its
mounting bracket and its frequency response. The system
There are a few rare cases of unusual structures and un- has a static stiffness of 8.330 pounds per inch and a natural
usual forme wave shapes where the above relationship be- frequency of 20 cycles per second. In frequency analysis, it
tween displacement and force is not true. but these cases is common to plot the compliance, which is the reciprocal
require an expert to analyze. For purposes of investigating of the static stiffness. Figure 22-11 represents the fre-
common vibration problems, always proceed as though this quency response of a machine column having a stiffness of
rule (italicized above) werc true. because it will lead to the 50,000 pounds per inch and a natural frequency of 50. If
best approach to the problem: namely, measure the vibra- the bracket of figure 22-9 is attached to this column, the
tion frequency and look for possible sources of forcing at frequency response of the bracket mounted on the column
that same frequency. will contain the natural frequency of both the bracket and
the column. A composite frequency response can be con-
structed using simple logic. At low frequencies the motion
Behavior of Simple Structures of #he weak bracket is much greater than that of the stiff
Suppose a heavy object is suspended from a weak spring column. Therefore, up to the lowest natural frequency. only
and the upper end of the spring is held in someone's hand. bracket deflection occurs and the composite response

22-7
22 MACHINE CHATTER AND VIBRATION

a 0.0006

0 -

S0.00012

X
0 O - f I
0 10 20 30 40
Frequency - t, cps

Figure 22-10 Frequency response of the system

shown in figure 22-9.

Figure 22-9 Schematic diagram of a motor

mounted on a bracket.

_ 0.0006

6 0.0004,

o1
0
E
o 0.00002

0 10 20 30 40 50 60

Frequency - f, cps
Figure 22-11 Frequency response of a machine column.

curve will be identical to the bracket response curve. At there are two natural frequencies. namely, at 20 and at 50
the resonance of the bracket, both the motor and bracket cycles per second.
will be vibrating and forcing the column. However. since
the motion of the column is still very low at this frequency. Most real machine structures are much more complicated
the combined frequency response will still be the same as than the above example: for instance. figure 22-13. taken
the bracket response through its resonance The frequency from reference 15. shows the frequency response of a drill
response of the bracket-column will continue to be equal to press. Logarithmic scales are used as graph axes in figure
the frequency response of the bracket alone, until the forc- 22-13 to compress it to a reasonable size. The peaks in this
ing frequency is close to the column resonance- At this fre- figure represent resonances of the structure at 23. 33. 38.
quency. and at h;gher frequencies. the column response is 70. 100. 110. 170. 230. 300. 380 and 500 cycles per sec-
much greater than the bracket motion: therefore, the com- ond. Each peak is associated with a different vibration pat-
posite response is equal to the column response. tern of the various components that make up the drill
press. Although the frequency response of most machine
The composite frequency response for this system is illus- tools is more like figure 22-13 than the system response de-
trated in figure 22-12. This is the response curve that scribed by figure 22-12. vibraticn problems are generally
would be observed if the motor and brack( t were tested not this complex because they often involve only one fre-
while mounted on this column. Under these conditions quency. Consequently. the other resonances can be ignored

22-8
 MACHINE CHATTER AND VIBRATION 22
00008

*0.0006-
00

00.0004

0.0002 -

0
0 10 20 30 40 50 60 70

Frequency - f. cps

Figure 22-12 Composite frequency response of a mounted motor and column.

0.00001

._0
S

&0.000001

E
0
0.0000001

10 100 1000

Frequency - f,cps

Figure 22-13 Frequency response diagram of a drill press.

and the real machine considered as a complex system with bration amplitu,'- at r--scaance divided by the vibration
only one natural frequency. amplitude at low frequencies for equal force amplitudes.
The r, ,,onance amplifcation is also the ratio of the static
stiffness, K. to the dynamic stiffness. Kd. at resonance. In
Influence of Damping figure 22-15 the static compliance is 0.00001 inches per
It was noted that damping has a strong influence on the pound while the maximum compliance at resonance is
amplitude of free vibration when a system is started vibra- 0.00005 inches per pound. Therefore. the resonance ampli-
ting and allowed to die out. Damping also has a very strong fication is (0.00005 + 0.00001 =) 5.
influence on the amplitude of forced vibration, particularly
at resonance. The family of curves in figure 22-14 shows For a lightly damped system the resonance amplification
the frequency response of a simple vibrating system with might be ten to thirty. while for heavy damping it might be
varying amounts of damping. In this figure the amplitude of one-and-one-half to four. These ranges point out the impor-
the force is F. the vibration amplitude is A. and the fre- tance of damping in machinery. It is sometimes fairly easy
quency is!. to reduce the vibration amplitude by adding damping to a
lightly damped structure vibrating near resonance. Almost
The degree to which a vibrating system is damped can be any dampirg added to a lightly damped structure improves
measured by its -resonance amplification- which is the vi- dynamic stiffness by a factor of two or three which, in turn.

22-9
22 MACHINE CHATTER AND VIBRATION

-=o

C
LZ0. Response curve for
light damping
Increasing
o damping I
C I
C- 0.3,1 I
,,-Response curva for
0Eo heavy damping

1.0.
___-2.0,

Frequency - f. cps
Figure 22-14 Influence of damping on the frequency response of a vibrating system.

0.00006
0Dynamic compliance

0.00005
ZZ Resonance frequency
-: 0.00004 -

D 0.00003
C

E 0.00002
0

0.00001
Static compliance

Frequency - f. cps

Figure 22-15 Determination of resonance amplification.

reduces vibration amplitudes by one-half to one-third of Data From Machine Structures

their original value. The same reduction in vibration ampli- Figure 22-16 presents typical values of major natural fre-
tude can be obtained by increasing the static stiff;ess. K. quencies on 13 different machine tnls.' 0 The 40 natural
(that is. decreasing the static compliance) whicn may be frequencies from these machines were combined into M
both difficult and expensive, groups. Three natural frequencies were observed between

22-10
 MACHINE CHATTER AND VIBRATION 22
0 and 25 cycles per second. seven between 25 and 50 cycles Low natural frequencies are typical of the vibration of
per second, eight between 50 and 75 cycles per second: etc- heavy components. such as a whole machine rocking on its
The data of figure 22-16 show that natural frequencies of- mounts. The 100 to 300 cycles per second range corre-
ten occur in the range of 0 to 100 cycles per second. that a sponds to vibrations of good. stiff, lower weight corn-
fair number are widely spread over the ragge of 100 to 300 ponents. for example. a lathe bed. In practice. vibration
cycles per second. and that there were no important natu- problems occasionally occur at natural fvCqvCeiCs Wl"
ral frequencies over 300 cycles per second for this particu- above 300 cycles per second but. in most cates. these are
lar group of machine tools associated with tool. not machine, vibration. Equation
22-4 demonstrates the characteristics necessary to obtain
high natural frequency values. If a component has a stiff-
ness of 5 00.000 pounds per inch. then its effective weight
can be only about 19.5 pounds to give a natural frequency
as high as 500 cycles per second, since:

0-25 98 500.000
fN, . d 500 cps
19.5
25-50

Any weight greater than 19.5 pounds will result in a fre-

50475 quency lower than 500 cycles per second. Boring bars and
________--_---__-__slender end mills are typical components with natural fre-
quencies in the range of 500 cyck: per second and above.
75-100 -
-1 Another useful number is the resonance amplification, that
is. the ratio of static to dyniamic stiffness. Figure 22-17
C. 100-125 shows this quantity for seven different machine tools. '-- ,
U These values normally fall in the range of 5 to 30. Lower
I values ar obtained when the vibration involves sliding
o 125-150 ___ joints. F.ch as the rocking of a lathe saddle on its ways.
Higher values correspond to the vibration of solid com-
ponents such as the twisting of a mili zng machi colum n
150-175

z 175-200
8- A
200-225 _ _
D 7-

225-250 6
5-

250-275 4

275-300 "6 2

I i I I I I I 4 S

0 1 2 3 4 5 6 7 8 9 10 _

Number of resonant frequencies 0-5 5-10 10-15 15-20 20-25

falling in each range Resonance amplification - RA

Figure 22-16 Typical values of natural frequen-

cies on thirteen machine tools. (Compiled from Figure 22-17 Resonance amplification data from
Long.6 Koeniv.berger.7 Ganoissart, s Tobias,9 and seven machine tools. (Compiled from Long.6
Tlusty'O) Koenigsberger 7and Tobias9)

22-11
22 MACHINE CHATTER AND VIBRATION

The final value needed from the testing of real machines is chatter and can ahvays be solved by resharpening the tool.
the dynamic stiffness at resonance Listed in table 22-2 are It is described here only to keep it from being confused
values obtained from nime machine tools of all sizes and with other types of machine tool vibration.
shapes.

Regenerative Chatter
TABLE 22-2 Dynamic Stiffness as Resonance The important type of self-excited chat:er is regenerative
chatter. Regenerative chatter is di.,incut to troubleshoot
MACHINE DYNAMICIinFFNESS. since it is almost impossible to predict why the machine is
chattering. Nearly every machining variable affects it
sometimes. but only a fev affect it all the time This is the
A 15.40O source of much of the shop lore about chatter. some of
B 27.500 which is usually true and some of which is seldom true
C 33.300
D 33.500 In regenerative chatter. a small disturbance. as a result of
E 58.900 small forced vibrations. cutting force fluctuations. etc..
F 71.500 eauses the tool to vibrate relative to the workpiece. Small
G 122.000 bumps are left on the machined surface. Since most turning
H 410.000 cuts normalh overlap the previous cut to some degree.
I 478.000 these bumps make the cut a little deeper when they show
up on the next revolution and have the same effect as a vi-
Source Data corrp-led from Long,' Koer.sberger. Gan~issart.- Tob:as.* bratory force. This causes the tool to vibrate even though
, the or:ginal disturbance has disappeared. For a well-
behave, cut. the bumps left by the forced vibration on the
second revolution will be a little smaller than the original
A dynamic stiffmss of 15.000 pounds p-r inch represents a bumps. and after a number of revolutions, they will totally
light duty machine ool. nA. meant for heav" stock re- disappear.
moval. Stiffness values of 400.000 and up represent ma-
ch'nes that are capable of very heavy stvck removal. Pro- in a situation leading to chatter- the bumps will become
ductivity of heavier duty machine tools will often be limited greater each revolution and eventually become so great
by the rigidity of the tooling. workpiece. or fixtures put on that visible. audi-le chatter occurs. The mathematical
them. study of whether threse bumps will grow or die out is called
stabihty theor_ This study is described in several different
ways in some excellent technical publications. - The most
SELF-EXC 1TED CHATTER important practical vndmngs of stabilit% theory are as
follows:
The vibrations discussed to this oint were caused by
forces resultmng from factors including unbalance. eccen- 1. In some ranges -f machine speed. the tendency to chat-
trici-y. and misalignments. There is. however. a totally dii- ter increases or decreases as the speed is changed
ferent t-,vne of vibration known as self-excited chatter. s'ightly_ This is because severe chatter can only occur
When there is no external forcing. the structure itself deter- when the wave that is feeding back from the previous
mines whether there will be self-excited chatter. based on revolution is in a certain relationship to the present mo-
its rigidity and the cutting conditions. There are two types tion of the tool- For example. if the bump in the work-
of self-excited chatter. high freuency chatter and regener- piecc surface is increasing the force. and at ti-e same
at-e chatter time the tool -s moving out of the work decreasing the
force. the net result might be zero force variation, and
no tendency to chatter. This phenomenon relates to the
High Frequency Chatter cutting speed and the natural frequency of the machine.
High frequency chatter Is the result of high frequency viha- As speed is changed. the machine might go from heavy
tion that sometimes occurs when tools become very dull. chatter to no chatter and back again to heav.y chater.
The tool vibrates in the direction of the cutting speed and
results in high-pitchd noise and - workpiece surface that 2. The chatter frequency is very close to that machine nat-
is rot deeply scalloped. This type of chatter is caused by ural frequency having the highest resonance peak flow-
the desrease in the rubbing force on the tool flank as the est dynamic stiffness).
cutting sneed increases. During cutting. a hard spot in the
work. or a small vibration from a vre small unbalanced 3. Chatter never occurs until the severity of the cut
force. may result in a very slight increase in cutting force. reaches a certain level. dependent on the minimum
This. in turn. causes a very slight increase in the defection dynamic stiffness of the machine ciructure at resonance.
of the cutting tool in the direction of the cutting spe-d, Above a certain !evel of cut severity, chatter always oc-
While the tool is deflectina in this direction, the sped is de- curs. The threshold level depends on many different cut-
creased slightly, causing a slight increase in cutting force. ting and structural p,-rameters and is very difficult to
which causes more deflection. etc. This cycle continues un- predict accurately.
til the cuttiug force has buit up so high that the tool snaps
back to its original position. overshoots, and the cycle re- 1. The maximum severity of cut which can be taken with-
peats itself. This is not an important type of self-excited out chatter is clozicly related to the value of the min-

22-12
 MACHINE CHATTER AND VIBRATION 22
imum dynamic stiffness at the highest resonance peak. Chatter occurs when the cutting severity is equal to or
The frequency response that is most important is not greater than the structural vibration resistance. Mathe-
the response of the machine but the response to the forc- matically. chatter occurs if:
ing between the tool and the workpiece, which includes
the tool, tool holder, machine, fixturing, and workpiece. QL, L CKd,1 , (Eq. 22-5)
Doubling the least dynamic stiffness permits taking a
cut that is approximately twice as heavy, where:
Q = workpiece material tendency to chatter
5. The tendency to chatter increases in proportion to the L, = total length of cutting edge engaged
total length cutting edge engaged in the cut. The total C = factor depending on cutting speed and
cutting force and power are not important. How large a resonant frequency
chip is being produced is not important. Kil = minimum dynamic stiffness at the high-
est resonance peak of the machine tool-
6. The tendency of various workpiece materials to chatter workpiece system
is in proportion to the cutting forces they produce. Ma-
terials which produce high cutting forces are capable of Table 22-3 contains a compilation of Q values for a wide
only light chatter-free cuts. Materials producing low range of workpiece materials and hardness ranges.
machining f-rces are capable of heavy cuts without
chatter.

TABLE 22-3 Chatter Tendency for Common Work Materials

CHATTER
MATERIAL GROUP HARDNESS TENDENCY
Bhn or R. 0

Free machining carbon steels, wrought 100-150 09

150-200 1.0
200-275 1.2
275-325 1.4
325-375 1.6
375-425 1.8

Carbon steels, wrought and cast 85-125 0.8

125-175 1.0
175-225 1.2 S
225-275 1.4
275-325 1.6
325-375 1.8
375-425 2.0

Free machining alloy steels, wrought 150-200 1.1

200-275 1.4
275-325 1.6
325-375 1.8
375-425 2.0
45- 48 Rc 2.2
48- 52 R, 2.5

Alloy steels, wrought and cast; 125-175 1.1

High strength steels, wrought; and Maraging steels, wrought 175-225 1.3
225-275 1.5
275-325 1.7
325-375 1.9
375-425 2.1
45- 48 R, 2.4
48- 52 r. 2.9

Tool steels, wrought and cast 150-200 1.3

200',-27- 1.6
275-325 1.8
325-375 2.0
375-425 2.2
45- 48 R, 2.7
48- 52 R, 3.2

22-13
22 MACHINE CHATTER AND VIBRATION

TABLE 22-3-Continued
CHATTER
MATERIAL GROUP HARDNESS TENDENCY
Bhr --' Q

Nitriding steels, wrought 200-250 1.4

300-350 1.8

Armor plate 200-250 1.6

250-300 1.8
300-350 2.0
350-400 2.3
400-450 2.6
Structural steels, wrought 100-150 1.0
150-200 1.2
200-250 1.4
300-350 1.6
350-400 1.8
400-450 2.0

Free machining stainless

steels, wrought austenitic 135-185 1.5
185-225 1.7
225-275 1.9
275-325 2.1
325-375 2.3

ferritic & martensitic 135-185 1.5

185-225 1.7
225-275 1.9
275-325 2.3
375-425 2.7

Stainless steels, wrought

and cast austenitic 135-185 1.8
185-225 1.9
225-275 2.1
275-325 2.3
325-375 2.6

ferritic & martensitic 135-185 1.8

185-225 1.9
225-275 2.1
275-325 2.3
325-375 2.6
375-425 2.9
42- 45 R, 3.2
45- 48 R, 3.4
48- 52 R, 4.0

Precipitation hardening stainless steels, wrought and cast 150-200 2.4

275-325 2.7
325-375 3.0
375-440 3.4

Gray cast iron 120-150 0.6

150-200 0.8
200-220 1.0
220-260 1.2

Ductile cast iron 140-190 0.9

190-225 1.1
225-260 1.3
260-300 1.5

22-14 -- - -
 MACHINE CHATTER AND VIBRATION 22
TABLE 22-3-Continued

CHATTER
MATERIAL GROUP HARDNESS TENDENCY
Bhn or R, 0

Malleable cast iron 110-160 0.9

160-200 1.1
200-240 1.3
240-280 1.5
280-320 1.7

Aluminum alloys, wrought and cast 30- 80 0.5

80-125 0.6
(500 kg load)

Magnesium alloys, wrought and cast 50- 90 0.4

(500 kg load)

Titanium alloys, wrought and cast 150-200 1.2

200-250 1.4
250-300 1.6
300-350 1.8
350-400 2.0
400-450 2.2

Copper alloys, wrought 10- 60 Re 0.6-0.9

GO-1 00 Re 1.0-1.2

Copper alloys, cast 40-1 00 0.6-0.8

100-200 0.8-1.6
(500 kg load)M

Nickel alloys, wrought and cast 80-150 1.5

150-200 2.2
200-250 2.8
300-320 3.5

High temperature alloys 200-300 2.0-3.0

300-375 2.0-5.0
375-425 3.0-6.0

Refractory alloys, wrought, cast, and P/ M 175-250 2.0-6.0

250-300 3.0-7.0
300-350 4.0-7.0

Zinc alloys, cast 80-100 0.5

Lead alloys 5-30 0.3

Tin alloys (500 kg load)

22-i15 i
22 MACHINE CHATTER AND VIBRATION
Machining Tests * Chatter
A number of researchers have made cutting tests to study d 0.8F 0 Borderline chatter
self-excited chatter. Figure 22-18 shows what happens . o\ * No chatter
during the turning of a bar if the depth of cut is gradually o*
0\[ *Ae
increased. The vibration amplitude is measured and "5 o G .... /
plotted as a function of the depth of cut. The low vibration .0.4- 0 \0 *0o0 0 a A
level at light cuts represents the background vibration level " o00 &'k at10 00 * * (V' o\ *
of the machine resulting from unbalance and irregularities r 0 0 0 0 0 0 0 0 '-a.C -0 0 0 -.
in the drive train. The sharp increase in vibration at a cer- 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
tain -critical width of cut" is characteristic of regenerative 0
chatter. The actual amplitude during chatter is likely to 0 500 1000 1500
vary greatly. Not much is known about how the amplitude Workpiece speed, rom
is determined, but once chatter occurs, the amplitude is al- Figure 22-19 Experimental results of a study on
most always too great. The solution is to eliminate chatter regenerative chatter. Lobed line denotes borderline
rather than to determine why the machine vibrates at a cer- of chatter.
tain level.

- Region of chatter The reason for the "lobes" in the figure where certain
speeds enable increased chatter-free widths of cut is the in-
0 terrelationship between cutting speed and regenerative
chatter. The lack of chatter at very low cutting speeds is
a called "low-speed stability." This phenomenon is not com-
pletely understood, but it is likely the result of small areas
Iof tool-workpiece contact just behind the cutting edge.
Experiments have been performed to show that dull tools
c Critical width or depth of cut and low tool flank clearance angles increase low-speed
-_ stability.
so
8 r While chatter theory is very good at explaining experimen-
.- ,, -1- - Background vibration level - - tal results (other than the enhanced stability at low cutting
speeds), it is difficult to use in solving chatter problems.
Chatter theory is not good at predicting just when a ma-
, ,. , chine will start to chatter. More theory development is nec-
Depth or width of cut essary before this can be done.
Figure 22-18 Experimental procedure to de- Factors lntluencing Chatter
termine the critical width of cut for regenerative It seems logical that the more power consumed in a cut,
chatter.
and the higher the cutting forces, the greater the likelihood
of chatter. This is wrong. Chatter theory says that the se-
verity of the cut is the chatter tendency of the material mul-
tiplied by the length of tool edge in the cut. This relation-
Repeating this experiment at various cutting speeds dem- ship was given as equation 22-5. More power may or may
onstrates how this "critical width" is affected. Tests were not mean greater tendency to chatter. The chatter tend-
run at the speeds and widths of cut denoted by the circles in ency of a workpiece material is closely related to the cut-
figure 22-19. The solid circles represent chatter, the open ting forces and power that occur. The theoretical chatter
circles represent chatter-free cutting, and the half-solid cir- tendency of a variety of workpiece materials is listed in
cles represent borderline chatter (more than background table 22-3. The tendency to chatter is generally propor-
vibration but less than violent chatter). The dashed line is tional to the expected cutting power. Low values are asso-
an attempt to sketch the borderline of chatter. Useful con- ciated with aluminum, intermediate values with ordinary
cepts to be learned from this figure include the following: cast irons and steels. and high values with the difficult-to-
machine alloys often found in aerospace applications. The
1. Below a certain width of cut. there is no chatter at any chatter tendency numbers in the table show that. all other
speed. factors being equal, a cut three times as heavy can be taken
with a 175 Bhn free machining carbon steel as with a 350
2. At slightly greater widths of cut. it is possible to get into Bhn cast precipitation hardening stainless steel.
or out of chatter by changing workpiece speed.
Another major factor influencing cutting severity is the
3. Chatter occurs at large widths of cut except at very low length of the cutting edge. In rough turning, the length of
speeds. the cutting edge in the workpiece is approximately equal to
the radial depth of cut. Thus, if one-half inch is being taken
4. Very large chatter-free widths of cut can be taken only if off the diameter of a bar, the cut is twice as severe as if one-
the cutting speed is low enough. quarter inch were being removed. Note the lack of impor-

2 4

22-16

-.----.- -..- ~~---~------- --

 MACHINE CHATTER AND VIBRATION 22
tance of the feed rate. According to chatter theory and sup- Table feed
porting test data. light feeds are just as likely to cause direction
chatter as heavy feeds. This implies that a radial depth of
cut of 0.300 inch with a feed per revolution of 0.001 inch
chatters sooner than a 0.250-inch radial depth of cut with a
feed per revolution of 0.030 inch. While the heavier cut re-
quires much more power. chatter is less likely to occur. +

The important dimension affecting chatter in plunge cut- 2

ting with a cutoff or form tool is the width of the tool. When
cutting off a flimsy workpiece. a 1/8-inch wide cutoff tool is
twice as likely to chatter as is a 1/16-inch wide tool. Again. Workpiece
the feed rate is an unimportant variable from the viewpoint
of chatter. In drilling, the length of the cutting edges en-
gaged is approximately equal to the drill diameter. The
chisel edge has a strong stabilizing influence not predicted Number of teeth in contact, N = 2
by theory. When a hole is enlarged and the chisel edge is
not cutting. the tendency to chatter is proportional to the Figure 22-21 Schematic diagram illustrating the
difference between the diameters. method that can be used to determine the number
of teeth in contact with the workpiece during
Chatter in milling is a more complicated process to under- milling.
stand because its characteristics are three-dimensional.
However. it can be simplified by the following procedure.
The length of cut of a single tooth is first identified as illus-
trated in figure 22-20. The number of teeth in contact is TROUBLESHOOTING CHATTER
then determined using the method shown in figure 22-21.
The cutter should be "rotated" to produce the maximum Problem Identification
number of teeth in contact. namely, the situation when one There are two types of vibration in machine tools: forced
tooth (for example, tooth 1) is about to leave the cut. The and self-excited. Multi-tooth cutter impact. gear drive ir-
total length of cutting edge in contact is the length per regularities and unbalance, and motion of the machine
tooth times the number of teeth in contact. This number foundation contribute to forced vibration which results in
determines the cut severity. As in turning, feed rate is not surface irregularities in machined parts. In cutting oper-
considered since the chatter tendency in face milling is in- ations free from these factors, vibration enters as self-ex-
dependent of the table feed rate. Consequently. for the cited chatter, a basic instability of the cutting mechanism
same metal removal rate. a shallow cut at high feeds is itself. Figure 22-22 contains a flow chart that may be used
preferable to a deep cut at light feeds. to identify which type of vibration problem is present. The
following discussion amplifies the steps in this process and
provides guidelines relative to dealing with both types of
vibration.

The vast majority of chatter problems are caused by self-

excited vibration. A less frequent problem is chatter result-
ing from interrupted cuts forcing the structure at its reso-
Cutter tooth nant frequency. To solve these problems, the first step is to
be able to distinguish between the two. Alternative fixes
can then be logically accomplished.

The key to troubleshooting chatter problems is determin-

ing the chatter frequency. While special sensors and elec-
tronic instruments can be used, it is often possible to deter-
mine frequency without instruments by measuring the
Length of spacing between chatter marks on the workpiece surface.
cutting edge Figure 22-23 shows chatter marks on a typical turned sur-
face. In the enlargement, the marks are numbered for easy
reference. The correct measurement of chatter -wave
length" is between corresponding points of mark 1 and
Workpiece mark 2, or of mark 3 and mark 4, or of mark 5 and mark 6.
Note that the spiral. marks 1-3-5-7, has no significance.
since the tool path is to be followed in making measure-
ments. The tool makes mark 1, mark 2, etc., as it moves
Table feed direction along the feed lines. After a complete revolution of the
workpiece, it passes adjacent to mark I making mark 3,
Figure 22-20 Schematic diagram showing length followed by mark 4, and another revolution later with
of culting edge in milling, marks 5 and 6, etc.

i 22-17 i
~ _
22 MACHINE CHATTER AND VIBRATION
Feel vibration of structure
near spindle during cutting*

Stop machine

vibration Yes Forced vibration

stopped
>as from outside machine

SRun machine through dry

cycle and feel structure

Or,
cycle Yes Fo d vibration
vibrates samevirto
as cit'ing from inside machine
cycle

NN c
Increase t, n

re-calculate: then deasSelt-

decrease RPM. cut, and echatter i,n vibration excited

vibration Y Frequency
due to
cutting changes
f in Reduce feed to 1/2. 1/4. 1/8
proporion t and feel structure

I~o Forced
samcut Ys vibration
has due to
Sef- e c e
process

Trick" problem. Try cures

If unsafe, measure for forced. Then try cures
instead of feeling for self-excited. Probably
due~_ chne
need expert _to pinpoint. /
euefedtI/.14 _o -
Figure 22-2 Flow chart for identifying vibration problems.

22-18
 MACHINE CHATTER AND VIBRATION 22

,,
"1oilm
$11: m m

,'' "
S! S

, 1
3

5 WL

4
42
7

V7
WL4
6

3g
4F

IWL = Chatter wave length

Figure 22-23 Chatter marks on a turned surface. I_

WL = Chatter wave length

Figure 22-24 Chatter marks on a milled surface.

Figure 22-24 shows a similar situation for face milling. Once the chatter wave length or spacing is measured, the
Again. no importance should be given to the spiral pat- frequency of vibration may be calculated as follows:
terns, marks 1-2-3, or marks 4-5-6. By following the feed
lines, the marks were found to be made in the following se-
quedce: V
Tooth 1: Mark 4; off the workpiece f (Eq. 22-6)
Tooth 2: Mark 5: mark 1; off theworkpiece. 5 (WL)
Tooth 3: :,;idk 6; mark 2; off the workpiece. where:
f = vibration frequency in cycles per second
The chatter wave length is again measured by moving V cutting speed in feet per minute
along, not across, feed lines. WL = length (or chatter mark spacing) in inches
5 = constant introduced because of the units
In practice, the chatter wave length should be measured used
several times. Unequal measurements are usually caused
by continuing vibration during the disengagmeat of the tool For example, if the chatter wave length spacing in the pre-
from the work. These extra vibration marks overlay the vious milling example is 0.1 inch, and if the cutting speed is
true pattern and make the spacing of marks meaningless. 20ftp minute. n the c ucy s
This problem can be minimized or avoided by disengaging
the feed as quickly as possible or by rapid traversing away
from the workpiece in the direction perpendicular to the f= = 400 cps
chatter-marked surface. 5(0.1)

22-19
22 MACHINE CHATTER AND VIBRATION

BAD CONDITION BETTER CONDITION

Turning
slotted
workpiece

LZ7 + -+El

Change
top
rake

Face

_-_ Change
Lrake
_____ radial t

Slab

___ Change
helix
angle

Figure 22-25 Suggested methods for reducing the magnitude of forced vibrations.

Whether the vibration problem is the result of interrupted speed. The fundamental principle here is that self-excited
cutting can be determined quickly by increasing or decreas- chatter occurs at a frequency near the natural frequency,
ing the cutting speed by 50 percent. After each cut at a dif- regardless of the spindle speed, but forced vibrations al-
ferent speed. measure the chatter marks and recalculate ways occur at the forcing frequency. A 50-percent change
the frequency. The chatter is the result of interrupted cut- in cutting speed will make very liftle.change in the fre-
ting if the frequency changes in proportion to the cutting quency of self-excited chatter. The same change in speed
i

22-20--
 MACHINE CHATTER AND VIBRATION 22
should change the frequency of forced vibration by 50 per- ful method of reducing self-excited chatter. Self-excited
cent. chatter occurs less frequently for a heavier chip load of
0.010 inch or greater than for a light chip load of 0.005
Another sure way to identify self-excited chatter is to re- inch or less. The heavier feed rate increases the cutting
duce the severity of the cut. As the length of cutting edge force but not the length of cutting edge engaged in the
engaged is decreased, a point is reached where a small de- workpiece and. hence, slightly reduces the tendency of the
crease in cutting edge length causes a dramatic decrease in material to chatter.
vibration. The decrease may be associated with "width of
cut" or "depth of cut" depending on the particular cutting If the cutting speed is low (less than 200 feet per minute) or
operation: however, it is never associated with the feed if the chatter frequency is high (1.000 cycles per second or
rate. more). a reduction in the cutting speed tends to reduce
chatter. Almost any size cut can be takern without chatter if
the cutting speed is lowered sufficiently. This added stabil-
Elimination of Forced Vibration ity at low speeds is associated with springback of the
If the problem is identified as being forced vibration, try machined surface just behind the cutting edge. A small con-
either to reduce the magnitude of the forcing vibration or to tact force is created that tends to push the tool out of the
increase the stiffness of the machine tool system. One way work and resist chatter. The effect is much more pro-
to reduce the magnitude of the forced vibration is to change nounced for tools with low clearance angles. Tool wear
tool angles so that the cutting load is picked up gradually. stabilizes the cut since the worn edge acts like a low clear-
Figure 22-25 illustrates how bad situations can be changed ance angle generating a force which opposes tool pene-
into better ones. Another possible way to reduce the forced tration into the work. If the clearance angle and the speed
vibration is to reduce the feed rate. The vibration ampli- can be reduced. chances of solving the problem are
tude should change in proportion to the feed rate: there- improved.
fore. if only a slight reduction is needed, decreasing the
feed rate is an appropriate solution. One final technique which applies to both self-excited and
forced vibration is redirecting the cutting force toward a
A change in the cutting speed often has dramatic effects on stiffer direction of the structure. For example. the turning
reducing forced vibration. Either an increase or a decrease tool with a 45-degree lead angle on the top in figure 22-26
in cutting speed. depending on which side of the resonance will chatter much sooner than the one shown on the bottom
peak the machine is operating. may reduce the vibration with a zero lead angle. Because the cutting force is per-
enough to solve the problem. If the machine tool is being pendicular to the cutting edge. a major portion of the force
forced at a frequency just below the natural frequency. a is aimed in the weak bending direction of the bar in the
small increase in speed will increase vibration amplitude, first case (a). However. in the second case (b) the force is
and further increases in speed will reduce vibration ampli- aimed along the very rigid axis of the bar. There is no
tude. On the other hand. a reduction in speed will immedi- simple rule for aiming the force in a more rigid direction
ately reduce amplitude. The opposite response is true if the except in the simplest of cases. A combination of analysis
forced vibration started out above the natural frequency. and judgment is required.
Since there is no way to tell in advance which situation
applies, try either an increase or a decrease in cutting
speed of at least 20 percent. whichever is easiest. If the re-
sults are not positive, try changing the speed in the other
direction. 07
A technique that sometimes works in milling is to change
the direction of the cutting force away from a weak direc- 0.7F
tion of the structure toward a strong direction. This cannot (a)
a)
always be done scientifically because force direction or ma-
-

such
chine directional rigidity may not be known. Changes
as feeding a face mill in the Y-direction rather than in the a 45*
X-direction or changing the table feed direction in slab
milling have been known to work.

Eliminatlor. ,f Self-Excited Vibration

Decreasing the length of the cutting edge in the cut will
eventually eliminate self-excited chatter. In turning, this
means reducing the radial depth of cut. In face milling, the
axial depth can be reduced or every other tooth can be re- F f
moved from the cutter with a corresponding reduction in (b)
feed rate. In cutting with an end mill. either the radial
depth or the axial depth may be reduced, or a cutter with
fewer teeth may be use.,

Dulling or stoning the cutting edge is a method that often -

reduces regenerative self-excited chatter, particularly at Figure 22-26 Influence of lead angle, a,on direc-
low cutting speeds. Increasing the feed rate is another help- tion of cutting force, F.-.

22-21
-b
22 MACHINE CHATTER AND VIBRATION
REGENERATIVE CHATTER CHECKLIST e Try an axial stepped milling cutter design.
* Try changing from climb to up milling (or vice versa) to change
By applying the principles outlined above, many difficult vi- the force direction.
bration and chatter problems can be solved. Others require
experts who have powerful instruments to give them data GRINDING
not available from a simple approach. Often the measure- * Redu e the width of grind.
ments lead to the conclusion that the machine has a weak- * Reduce the stock removal rate.
ness that can be corrected. Further analysis leads to sug-
gestions for stiffening the machine, or adding a vibration a Dress the grinding wheel more frequently.
damper. Even if it is eventually necessary to go to an ex- Use a sharper dress (more lead, greater depth, sharper
pert for a solution to a particular vibration problem, the diamond) if possible.
suggestions contained in table 22-4 should always be tried * Use a softer grinding wheel.
first. There is a good chance that one of these simple tech- * Reduce excessively high work speeds.
niques will yield a solution. * Use a backrest on slender workpieces.

TABLE 22-4 Checklist of Methods To Eliminate

Vibration and Chaffer Problems

TURNING
" Lower the stock removal per pass.
" Try a heavier feed if presently feeding below 0.010 inch per rev.
* Reduce the width of cut of the form tool.
" Use a steadyrest on slender bars.
" Chuck slender bars at their center and turn end-for-end.
" Use a smaller nose radius on the tool to keep the cuiting forces
away from the radial direction.
* Modify the cutting edge angle to be more radial keeping the
forces away from the radal direction.
" Consider using the Kennametal Roller Devibratorl-(or
equivalent) on slender bars.
" Minimize the tool overhang.

BORING
" Use the largest possible boring bar diameter.
" Reduce the borino bar length to as short as possble.
" Make the tool nose radius as small as possible to minimize the
radial force.
" Use a side cutting edge angle as radial as possible to reauce
the radial force.
" Reduce the stock removal in roughing.
" Consider a damped boring bar for LID's greater than 6.
" Consider solid carbide boring bars for L/D's over 4.
" Consider reaming after semi-finish boring for finish borin
problems.
" Consider multi-tooth boring bars for roughing operat:s.

MILLING
" Reduce the stock removal per pass.
" Reduce the width of cut.
" Try heavier feeds if presently feeding below 0.01 ( inch per
tooth.
" Try reducing the RPM when using high speed steei cuttcrs.
" Try dulling the cutting angles of high speed steel culters.
" Avoid high wrap-around angles in end mill cutting.
" Generate an interior radius rather than plunging the cutter.
" Try using serrated edge end mills.
" Use a cutter with half as many teeth.
" Remove half of the inserts in a face milling cutter.
" Try a face miii with a random tooth space design.
" In face milling, use more of a comer angle to get cutting edge
mo.e toward the finished surface and reduce x z., y horizontal
force components.
* In face milling, try feeding at 90 to the present feed direction.

22-22
 MACHINE CHATTER AND VIBRATION 22
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1. Ostwald. P. F. and Shambli,. J. E. 1968. Effects of 8. Gandissart. Ph. and Van Herck. P. 1964. Influence des
dynamic chip breaking upon surface microgeometry vibrations sur le fini de surface et lerreur de forme
and free chip dimension. Transactionsof the ASMdE 90 dans les passes de finition. CRIF Report. University of
(Series B): 71-78. Louvain. Louvain. Belgium.

2. Kristoffy. I. et al. 1965. Influence of vibrational energy 9. Tobias. S. A. 1961. Schwingungen an Werkzeug-
on metalworking processes, U. S. Air Force Technical maschinen.Munich: Carl Hanser Verlag.
Report AFML-TR-65-2 11. Wright-Patterson Air
Force Base. OH. 10. Tlusty. J. et al. 1962. Selbsterregte Schwingungen an
Werkzeugmaschinen. Berlin: VEB Verlag Technik.
3. Langenecker. B. et al. 1964. Effect of ultrasound on
deformation characteristics of structural metals. U S. 11. Hahn. R. 1954. On the theory of regenerative chatter
Navy NAVWEPS Report 8482. NOTS TP 3447. in precision grinding operations. Transactionsof the
U. S. Naval Ordnance Test Station. China Lake. CA. ASME 76 (May): 593-597.

4. Andrew. C. 1965. Chatter in horizontal milling. Pro- 12. Merritt. H. 1965- Theory of seli-excited machine tool
ceedings of the Institutionof Mechanical Engineers 179 chatter. Transactions of the ASME 87 (Series B):
(Part 1. No. 28): 877-898. 447-454.

5. Peters. J. 1965. Survey of methods for increasing the 13. Kegg. R. L. and Sisson. T. R. 1968. Trouble shooting
damping of machine tools. Report tc the General As- chatter by improving cutting conditions. Technical Pa-
sembly of CIRP. per MR68-615. Society of Manufacturing Engineers.
Dearborn. MI.
6. Long. G. W. et al. 1968. The effect and control of chat-
ter vibrations in machine tool processes. U. S. Air 14. Hosoi. T. and Hoshi. T. 1977. Cutting action of ball
Force Technical Report AFML-TR-68-35. Wright- end mill with a spiral edge. Annals of the CIRP26(1):
Patterson Air Force Base. OH. 49-53.

7. Koenigsberger. F. and Tlusty. J. 1969. Machine tool 15. How to troubleshoot machine chatter and vibration.
structures.Volume 1. London: Pergamon Press. 1978. Manufacturing Education. P. 0. Box 36050.
Cincinnati, OH 45236.

1U J

22-23
 C FACG
Sd BLAW-W' FIhIQD

SECTION 23
NUMERICAL CONTROL
MACHINING

23.1 NC Machining Guidelines ......................................................................................................... 23-3

Introduction ...................................................................................................................... 23-3
Selection of Ports for NC Machining ................................................................................... 23-3
Selection of Machining Conditions for NC Machining ........................................................ 23-5
Tooling for NC Machining .................................................................................................. 23-6

23.2 NC Vocabulary ........................................................................................................................... 23-9

zI

23-1
 PIEG IMP PAM &LANK-NOr FIL-ED

NC Machining Guidelines 23.1

INTRODUCTION that can profile and sculpture workpieces. Other NC con-
tinuous path operations include: flame cutting. sawing,
Numerical control (NC) is a sophisticated and versatile grinding, welding, and even operations such as the appli-
form of automation that continues to significantly impact cation of adhesives. We should note that continuous path
the manufacturing industry. One of the more commonly ac- systems can be programmed to perform point-to-point oper-
cepted definitions of NC is that given by the Electronics In- ations, although the reverse (while technically possible) is
dustries Association (EIA): "Asystem in which motions are infrequently done. One important concept of continuous
controlled by the direct insertion of numerical data at some path operation is that the positional relationship between
point The system must automatically interpret at least the tool and the workpiece must be provided for at all
some portion of this data." times because the path the cutter follows in moving from
one position to another ultimately determines the work-
The numerical control system consists of the five basic, in- piece shape.
terrelated components as follows:
1. Data input devices
2. Director (or machine control unit)
3. Machine tool or other controlled equipment SELECTION OF PARTS FOR NC
4. Servo-drives for each axis of motion MACHINING
5. Feedback devices for each axis of motion
NC is not the answer to all manufacturing problems. Con-
These components operate together to provide an in- ventional machine tools or automatic transfer-line machin-
tegrated system that performs nearly all of the machine op- ery may provide better solutions to particular problems.
crator's functions. While there are many varieties of these Usually, the ,nswer is based on lot size. NC is often advan-
components available, they all can be categorized into one tageous for small or moderate lot sizes, for example, from 1
of the five groups listed above. The major components of a to 100. It is important to note that there is a predomin nce
typical NC machine tool system are shown in figure 23.1-1. of lot sizes of this magnitude in industry today.
Numerically controlled machine tools are commonly classi- As manufacturing costs continue to rise, the economic ne-
fled as being either point-to-po,, or continuous path. The cessity for cost-reduction programs and increased machine-
simplest form of numerical control is the point-to-point ma- tool utilization requires that careful consideration be given
chine tool used for operations such as drilling, tapping, bor- to the selection of numerical control applications. Since
ing, punching, spot welding, or other operations which can various philosophies exist among companies as to when
be completed at a fixed coordinate position with respect to NC should be used, there currently is no general rule that 31
the workpiece. T he tool does not contact the workpiece can be applied.
until the desirea coordinate position has been reached; con-
sequently, the exact path by which this position is reached Parts selection for NC should be based on an economic
is not important. The programming of these systems is ele. evaluation, including scheduling and machine availability.
mentary and can be done by anyone who has both the abil- Economic considerations affecting NC part selection in-
ity to read engineering drawings and a basic understanding clude alternative methods, tooling, machine loadings, man-
of machining principles and practices. ual versus computer-assisted part programming, and other
applicable factors.
With continuous path (that is, contouring) NC systems,
there is contact between the workpiece and the tool as the Thus, numerical control should be used only where it is
relative movements are made. Continuous path NC sys- more economical or does the work better or faster, or
tems are used primarily for milling and turning operations where it is more accurate than other methods. The selec-

Machine tool table Feedback

device Director device or other device or
controlled equipment transducer

oo.0
DoQ~~ .000 il
000 E ___

Feedback loop

Figure 23.1-1 Simplified numerical control system.

23-3
a
23.1 NC Machining Guidelines
tion of parts to be assigned to NC has a significant effect on In general. if a part surface can be defined mathemati-
its payoff. The following guidelines which may be used for cally, it can be machined by NC.
parts -election describe tho:e parts for which NC may be
applicable: 8. Parts which require REPEATABILITY from part
to part and lot to lot
TOOLING
1. Parts which require SUBSTANTIAL
COSTS in relation to the total manufacturing costs Data stored on tape or other input media will not per-
by conventional methods mit an operation to be forgotten or skipped.

For example, NC should be used where expensive drill 9. VERY EXPENSIVE parts where human error
jigs, templates. or models are otherwise required. Drill would be very costly and increasingly so as the
bushings are not needed for NC: consequently, the ii- woul er cotln
tial or replacement costs associated with drill jigs in
conventional drilling do not apply to NC. Even prior to machining, the cost of the forging or cas-
2. Parts which require LENGTHY SETUP TIMES ting required may be high or the material itself may be
compared to the machine run time in conventional expensive.
machining 10. HIGH PRIORITY parts where lead time and flow
time are serious considerations
Rapid setup of NC jobs is common because part fix-
turing is simple. This makes NC economical for jobs Usually, the flow time from blueprint to the finish-ma-
where the machine run time is short. chined part is considerably less With NC machining,
provided that the programming can be expedited
3. Parts which are machined in SMALL OR VARI- through any backlog. Special tooling, if required, is
ABLE LOTS usually simpler for NC than for conventional machin-

Usually, the savings in setup time and handling using ing and can be designed and built faster.
NC machine tools outweighs the higher operating 11. Parts with ANTICIPATED DESIGN CHANGES
costs of NC compared to conventional equipment.
4. A WIDE DIVERSITY OF PARTS requiring fre- Changes can be made on the tape or other data input
quent changes of the machine setup and a large media with relative ease compared to changes in hard
tooling inventory if conventionally machined tooling.

This is a common situation in the aerospace, the ma- 12. Parts which involve a LARGE NUMBER OF OP-
chine tool, and the job shop industries. The quantities ERATIONS or MACHINE SETUPS
are not large enough to justify transfer machines as
used in the automotive industry. The part dimensions Part operations may be complicated, tedious, and diffi-
and configurations may cover such a broad range that cult to follow. NC machining allows data on the tape
adequate inventory may be prohibitively large. NC to be utilized repeatedly once it is satisfactorily pro-
may be used to provide spare part capability without grammed. This is a considerable advantage over con-
storing the parts or bulky fixtures and tooling after the ventional machining where the complexity of following
product is no longer marketed the instructions continues for each part. NC can also
utilize a variety of successive, interchangeable tools

5. Parts which are PRODUCED AT INTER- without time losses for machine stoppage, setups, and
MITTENT TIMES because demand for them is transfers. For example, parts requiring straight-cut
cl "Iic milling combined with many drilling, reaming, and tap-
ping operations are excellent choices for the less so-
This occurs where part requirements are seasonal or phisticated machining centers.
subject to production scheduling for assembly.
Whereas conventional machining requires the costly 13. Parts where NONUNIFORM CUTTING CONDI-
storage of templates, tools and fixtures, NC requires TIONS are required
only tape Storage.
The cutting speed, feed, or depth
of cut may need to be
6. Parts which have COMPLEX CONFIGURATIONS varied because of the part configuration. Such varia-
requiring close tolerances and machined relation- tions may be incorporated into the NC program.
ships
14. Parts which require 100 percent INSPECTION or I
NC with ii.ultiaxis capability makes simultaneous ma- require measuring many checkpoints resulting in
chining motions possible, and parts can be produced high inspection costs
which previously were impossible to produce by con-
ventional methods. With the inherent dimensional repeatability of NC, it is
often necessary to inspect only the first and last pieces
7. Parts which have MATHEMATICALLY DE- completely and to spot check the critical dimensions
FINED COMPLEX CONTOURS on the other pieces.

23-4
 NC Machining Guidelines 23.1
15. FAMILY OF PARTS and analyzed to determine the most economic operating
conditions. Computer and calculator programs are avail-
These are parts that are in the same general class with able to carry out the simple, but long and tedious. calcu-
respect to configuration or manufacturing sequence lations. 1.2 Machining data relating tool life with cutting
but vary in dimensions. This situation is particularly speed and other parameters are required for these calcu-
common in the machine tool industry. Common setups lations. Such data are contained in this and in other MDC
may be used for these parts, and programming time publications. Section 21 of this handbook and reference 3
may be reduced by using the same basic format or at the end of this section outline and demonstrate this
macro's for all the parts in the family. approach.

16. MIRROR-IMAGE PARTS

SELECTION OF MACHINING
In the aerospace industry, it is quite common to have CONDITIONS FOR NC MACHINING
dimensionally identical parts which are mirror images
of each other. These are usually referred to as left- and The importance of selecting proper machining conditions is
right-hand parts. Many similar situations exist otitside an essential step in good machining practice. To be suc-
the aerospace industry. For example. a housing with cessful, every machining operation using NC equipment
internally and externally machined surfaces may be must be based on a sound foundation of planning, coordina-
impossible to fabricate in one piece. For manufac- tion and feedback. The most widely used criteria for ma-
turing purposes. it could be made in two symmetrical chinability include tool life, surface roughness. accuracy,
halves (that is, left- and right-hand parts). With NC, and power consumption. Of these, tool life is the most com-
both parts may be made utilizing one program tape by monly used and has been extensively related to the cutting
actuating the mirror-image switch on the control and conditions. Machinability data are needed to predict the
changing to opposite hand cutting tools if required. life of a cutting tool in relation to some known reference
The mirror-image capability is provided as an option value. It is important to be aware of all the variables that
on most NC systems. may affect the resulting tool life whenever data are ac-
cumulated for future use. Some of the more important vari-
17. NEW PARTS for which conventional tooling does ables, in broad groupings, include the following:
not already exist
e Cutting tool design including material
Production of a new product alone is seldom sufficient
justification for using NC. Significant cost savings do e Tool characteristics
not begin to accrue until new parts are planned for
NC. However, in the first stages of the NC installation, * Workpiece properties
a proper selection balance should be maintained be-
tween old and new parts. In this manner, during the * Characteristics of the machine tool
learning period the NC machine can be properly
loaded while allowing conventional machining of the * Dimensions of the cut
old parts should any problem arise. This dual planning
eliminates needless part delays and possible stock 9 Presence or absence of a cutting fluid and its properties
outs.
With a knowledge of these variables and the degree of vari-
18. Parts which are suitable for MAXIMUM MACHIN- ability within each grouping, it is possible to achieve pre-
ING on NC machine tools dictable tool life.

Although it is best if parts can be machined completely Machinability data in various degrees of sophistication are
on NC machine tools, allied conventional machining available for use by industry for NC machining. These data
operations often are required. An exception is the man- include (1) recommended starting conditions and (2) wide
ufacturing cell or work center concept common to range machining data.
group technology. In this situation, the operator of an
NC machine may also do part deburring, drilling or This Machining Data Handbook contains recommended
tapping of holes on peripheral equipment manually starting conditions for most of the significant work mate-
while waiting for the NC machine to finish its cycle. By rials and machining operations. It supplies the recom-
balancing operations timewise between the NC ma- mended feed, speed, tool material, tool geometry, and
chine and manual equipment, a reduction in the over- cutting fluid, as well as data for determining the horse-
all processing time can be achieved. Usually, however, power requirements for various machining operations.
if only the most time-consuming, conventional oper- These recommended starting conditions are currently the
ations are replaced by NC, many of the benefits of NC most practical and readily accessible data'for genera! shop
will be minimized or eliminated, application.

Cost studies should be performed for parts that are selected Detailed machining data covering the tool life obtained un-
when one or more of the above guidelines apply. Some- der a wide range of machining parameters, such as speed,
times even simple configuration parts will show savings by feed, tool material, tool geometry, and cutting fluids, are
NC production, so cost studies are advised for these parts very useful in selecting a set of conditions for machining at
as well. Various cutting conditions should be investigated lower costs or higher production rates. Detailed machining

23-5

~ -
23.1 NC Machining Guidelines
parameters can be obtained from laboratory studies or percent of their total available time actually cutting, while
from shop studies by varying the pertinent parameters and for NC machines, cutting time may be on the order of 70
observing their effect on tool life. percent. A major contributing factor in this reduction of
nonproductive time has been the development of quick-
Machinability data that are accurate, reliable and appro- change and preset tooling. Because there is high initial in-
priate are essential to the success of NC machining. The vestment in the capital equipment used, it is essential that
philosophy of NC manufacturing, involving its high level of every avenue be followed that increases the percentage of
automation, demands the use of the best available data. machining time. The primary objective of tooling for NC is
The high cost and productive capacity of NC are frequently to assure that there is complete compatibility between it
such ritical factors that every effort must be made to find and all the engineering and economic criteria by which nu-
the best set of operating conditions. merically controlled machines are justified.

Since data for conventional machining are often conserva- Tooling systems for NC must incorporate the principles of
tive, they are not particularly suitable for NC machining eliminating operator error and maximizing productivity.
operations. Further, such data are often too simple or These goals can be achieved using the strategies that
based on information that is too generalized. NC machining follow:
conditions selected from these data may result in signifi-
cant machine underutilization and reduced profits. 1. Automatic tool chauging for sequential operations

For NC machining, the feeds and speeds are most often 2. Off-machine presetting of tools
computed quantities rather than being dependent solely on
operator judgment. The effect of this is m.oi e consistent re- 3. Speeding up the manual replacement and changeover of
suits because the operator-indvccU variables are minimized tools
or eliminated. Another approach sometimes employed with
NC feed and spetd selection is to program the cutting con- 4. Reducing machine adjustments caused by tool deflec-
ditions or the high side and then use override controls to tion and wear
suit actual conditions.
5. Using the NC program to facilitate tool selection and
Specialized machinability data systems are being devel- changing
oped for NC because simple data systems are inadequate.
Reasons for this inadequacy are as follows: For NC applications, it is typical that less hard tooling is
required than for comparable operations on conventional
* The higher cost of NC machine tools and machining time machines. Numerical control, with its relatively in-
expensive tooling, eliminates the need for expensive jigs,
" Programming costs fixtures, cams, master parts, form tools, etc. Lower tooling
costs enhance the justifiability of parts for production with
* Variations in NC machine tools and NC production NC equipment. The inherent accuracy and repeatability of
req