STEP 1 Workpiece Materials Web

1
Duplex SS
COPYRIGHT 2008, Seco Tools AB
42CrMo4
Ca-treated 316L
Workpiece materials
1/82
Workpiece material
Carbon steel Free cutting steel
Carbon steel
Machinability
Alloy
steel
Austenitic
SS
Titanium
Alloys Nickel based
alloys
Cobalt based
Special
alloys
high temp
alloys
General construction steel

Chemical, petrochemical, medical, gas
and paper industry
Energy production, aviation and space travel
2/82
Workpiece material
Chemical
composition
Thermal
conductivity
Mechanical
properties
Non-alloy steel and cast steel

Low-alloy steel and cast steel
High-alloy steeland cast steel
SS and cast steel (fer/mar)
Stainless steel (austenitic)
Grey cast iron

Ductile cast iron
Nodular cast iron (ferritic/perlitic)
Non-ferrous metals
Aluminium and aluminium alloys
Super alloys
Titanium and titanium based alloys
Hard cast iron

Hardened steel
Inclusions
Self-hardening
Workpiece
origination
Material
structure
3/82
Machinability
Environment
Cutting forces
Surface integrity
800
800
600
600
400
400
200
200
-200
-200
-400
-400
-600
-600
-800
3120
3100
3080
3060
3040
3020
3000
2980
-800
0
50
100
150
200
250
Fy
Fx
Fz
0
10
Tool wear
Chip formation
f
vc
4/82
Machinability
Machining method
Cutting material
Cutting geometry
Cutting conditions
vc
Workpiece material
Chemical
composition
Thermal
conductivity
Toolholders
Mechanical
properties
Inclusions
Machinability
Work
hardening
Workpiece
raw material
Material
structure
Human factor
Machine
Clamping
Cooling
5/82
Machinability
Material to be machined
The process
steel SS GCI etc.
roughing - 1/2 rough - finishing
Cutting speed
Vc
Carbide grade
Cutting depth
ap
Feed
f
Geometry
The correct insert

6/82
The cutting process
7/82
The cutting process
Cutting forces
The cutting force can be divided
into:
Axial force component
Radial force component
Tangential force component
The tangential force determines

the cutting force.
The combination of tangential and
radial force is the main cause of
any vibration and workpiece
deformation.
Radial force
Axial force
Tangential force
8/82
The cutting process
Hard materials
Fc = Kc11 * b * h 1-mc
Superalloys
Kc11 = specific cutting force

b = chip width
h = chip thickness
Non-ferrous materials
Cast iron
Stainless steel
Steel
0
1 000
2 000
3 000
4 000
5 000
6 000
7 000
(Typical example )
kc11 (N/mm)
9/82
Workpiece materials
10
Materials with high ductility

DO
Low carbon steel and aluminium,

Group 16.
Soft
LO
D1
L1
Continuous chips, difficult to

machine.
Decrease ductility to increase
machinability.
Materials with low ductility

DO
LO
Gray cast iron, Gr.12.

Hard
Discontinuous chips.
Increase ductility to increase
machinability.
10/82
Workpiece materials
11
High hardness materials

Tool steel, Group 6
Hardened Steel, Group 7
Superalloys, Group 21
Cast iron, Group 15
Low hardness materials

Aluminum, Group 16
Low carbon steel, Group 1
Materials that work harden
diameter
(proportional to penetration)
Stainless steel, Groups 8, 9, 10 & 11

Superalloys, Groups 20, 21
11/82
Difficult
to machine
ed
en
rd
Ha
Ni a
lloy
sup
era
lloy
Ti a
H
lloy
igh
al l
oy
ste
el
Sta
inle
ss s
Duc
tee
tile
l
iron
l
ee
st
n
ir o
st
Ca
Large cutting forces (Tensile strength)
Workpiece materials
Cast
alu al
loy
Una
lloy
ed s
teel
Alumin
ium
Easy
to machine
Long chips (Ductility (%))
12/82
The cutting process
13
Temperature
Heat conductivity of tool material

and workpiece material.
Cutting speed.
Geometry of cutting edge.

This temperature (gradient)
Largely determines the wear
factor and tool life.
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Thermal conductivity
14
Materials with high thermal conductivity
Copper, Group 18
Aluminium, Group 16
Low carbon steel, Group 1
Materials with low thermal conductivity
Titanium, Group 22
Superalloys, Groups 20, 21
14/82
Surface integrity
15
Residual tension MPa
Surface integrity is the general term used to describe the properties and
the condition of a machined workpiece with regard to the surface and subsurface.
800
800
600
600
Tension
400
400
200
200
-200
-200
Compression
-400
-400
-600
-600
-800
-800
0
(Typical example )
50
100
150
Depth under the surface (m)
- Surface finish:
- Residual tension:
- Self-hardening:
- Heat affected zone (HAZ):
200
250
Rt,Ra
Pressure or tensile forces
Retention of austenite/hard martensite
Lower hardness
15/82
Surface integrity
16
Workpiece material
Tool
Selfhardening
Workpiece
material
Tool
Selfhardening
16/82
Surface integrity
17
17/82
Surface stresses
Tension
18
Compression
Crack
Crack
Influencing factors are the cutting speed, cutting edge wear, cutting
edge angle and cutting method (radial turning or classical), the cutting
depth, the feed and the nose radius.
Great influence on fatigue properties
18/82
Surface stresses
(Typical example )
19
Depth from surface

19/82
Machinability rating
Material
20
Machinability Rating
9S20 cold rolled steel
100
Ductile cast iron
35
Stainless steel 440
50
Aluminium 2024-T
150
9S20 is assigned a rating of 100

and other materials are compared to this standard.
20/82
21
Non-alloy steeland cast steel.

Low-alloy steel and cast steel
High-alloy steeland cast steel
Stainless steel and cast steel (fer/mar)
< 600 N/mm2

< 900 N/mm2
> 900 N/mm2
< 750 N/mm2
Stainless steel (austenitic)
> 750 N/mm2
Grey cast iron

Ductile cast iron
Nodular cast iron (ferritic/perlitic)
Non-Ferrous metals
Aluminium and aluminium based alloys
Superalloys
Titanium and titanium based alloys
Hard cast iron

Hardened steel
> 60 Shore
> 45 HRC
21/82
22
Aluminium & alloys
Grey cast iron
Steel
Stainless steel
Machinability
Super alloys
and titanium
22/82
23
Workpiece materials
applications cutting materials
Change in
properties
Steel, steel castings
Turning, copying, threading and milling, high cutting

speeds, small or medium chip sections.
P20

Malleable cast iron with long
chips
Turning, copying, milling, medium cutting

speeds and chip sections
P30

Malleable cast iron with long
chips
P10
Steel
P40
P50
Turning, milling, planing, medium or low cutting speeds, medium

or large chip sections, and machining in unfavorable conditions.
Steel, steel castings with sand

inclusion and cavities
Turning, planing, slotting, low cutting speeds, large chip section

with the possibility of large cutting angles for machining in
unfavorable conditions.
Steel, steel castings of medium

or low tensile strength, with
sand inclusion and cavities
For operations demanding very tough carbide; turning, planing,

slotting, low cutting speeds, large chip sections with the possibility
of large cutting angles for machining in unfavorable conditions.
Cutting
material
Toughness
Finish turning and boring; high cutting speeds, small chip section,
accuracy of dimensions and fine finish vibration-free operation.
Cuttting
conditions
Resistance to wear
Application
P01
Material to be machined
Increasing feed
Subgroups
Increasing cutting speed
Class
colour
Areas of application for the various cutting materials

1.
Influence on cutting conditions.
2.
Influence on properties of cutting materials.
23/82
24
(Typical example )
MN 2006 Turning page 31
24/82
Group Number
Family Name
1 to 6
Mild and alloy steels
Hardened Steel
8 to 11
Stainless steels
11 to 15
Cast irons
16 to 19
Non-ferrous alloys
20 to 21
Superalloys /High temperature alloys
22
Titanium alloys
25
Rule of thumb: Within a family of workpiece material groups, machining difficulty increases as the group
number increases.
25/82
26
Mild and Alloy Steels

Groups 1 through 7
0.028 to 2.0% carbon
Small amounts of other
metals
Nickel
Chromium
Manganese
26/82
27
Group 1: Mild and Alloy Steels

Properties
Machining
Uses
Carbon content < 0.28%
Tough, cheap, and impact resistant
Easily worked
Soft and gummy
50 to 100% machinability rating
Stringy, continuous chips
Watch for BUE
Easy to machine at high cutting speeds
High speed: MTCVD (AL2O3)
Med. speed: CVD (TiC, TiN)
Low speed: PVD (TiCN)
Hub caps, stampings, wheels
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28
Group 3: Ordinary Carbon Steels

Properties
Carbon content: 0.28 to 0.50%
Harder and stronger
Tough, cheap, and impact resistant
Easily worked, soft and gummy
Machining
Uses
45 to 65% machinability rating
Stringy, continuous chips
Watch for BUE
Moderately difficult to machine
Med. speed: CVD (TiC, TiN)
I-beams, auto frames, axle housings
28/82
29
Group 6: Tool Steels

Properties
Machining
Uses
Carbon content: 0.50 to 2.0%
Small amounts of nickel, molybdenum, chromium, and/or

vanadium.
Very high hardness.
Tougher and stronger.
35 to 65% machinability rating.
Difficult to machine.
Watch insert flank wear.
Reduce cutting speed.
Medium speed: CVD (TiC, TiN)
If RC > 45, use CBN
Tool steel, springs, bearings, dies, punches
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30
Stainless Steels
Groups 8 through 11.
At least 10.5% chromium.
Less than 1.2% carbon.
Properties which increase from
Group 8 to 9 to 10 to 11.
Corrosion resistance.
Hardness.
Temperature resistance.
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31
Stainless Steels
Alloyed steel with maximum 1.2% carbon

and at least 10.5% chromium.
Cr2O3
Chromium
Oxygen
31/82
Stainless Steels
32
Stainless steel structures

Ferritic
Martensitic
Austenitic
Duplex
The microstructure and alloy elements are the determining factors.

They determine properties such as heat resistance,
corrosion resistance, oxidation resistance.
And also the machinability!!
Ferritic stainess steel (400 series, e.g. 405, 430, 442)
(low carbon steel + Cr).
Martensitic stainless steel (400 series, e.g. 403, 416, 422)
(ferritic stainless steel + C).
Precipitation hardened stainless steel (PH-steel, e.g. 15-5PH, 17-4PH, PH13-8Mo))
(martensitic stainless steel + Cu, Al, Nb).
Austenitic stainless steel (300 series, e.g. 301, 304, 316)
(ferritic stainless steel + Ni).
Duplex stainless steel (200 series)
(austenitic stainless steel - Ni + Mn, N).
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Stainless Steels
33
Influence of material structure

120
Machinability (%)
100
80
60
40
20
0
Ferritic SS
Martensitic SS
Austensitic SS
Duplex SS
PH SS
(Typical example )
33/82
Stainless Steels
34
Ti Mn
Manganese
Titanium
Carbon
Nickel
Nitrogen
Chromium
Molybdenum
Ca Pb
Machinability
Lead
Ni
Calcium
Sulphur/phosphor
Mo Cr
Build up edge problems.

Hard, very homogenous surfaces (scales).
Poor surface finish.
Burring.
Poor chip formation and difficult chip removal.
34/82
35
Stainless Steels
The PRE factor is a criterion for the corrosion resistance
The resistance of the stainless steel to pitting is indicated by the PRE factor
(Pitting Resistance Equivalent).
PRE factor = % Cr + 3.3 x % Mo + 30 x % N
PRE factor = % Cr + % Ni (when no Mo or N)
The PRE factor determines heavily the machinability

35/82
Cutting speed V30 (m/min)
Stainless Steels
36
Martensitic
Martensitic - austenitic
Duplex
Austenitic
Reference cutting speed

- 30 minutes tool life
- b/h = 10
- flat insert
- untreated cutting edge
- uncoated P20
(Typical example )
PRE value
36/82
Stainless Steels
37
Low thermal conductivity

The heat which needs to be
removed in the chip and the
workpiece is concentrated in
the insert in stainless steel.
(plastic deformation)
37/82
Stainless Steels
38
Self-hardening (surface hardening)
Hardness
If the tension in the stainless

steel exceeds the elongation
limit, stainless steel will
show self-hardening.
This is the case

in the shearing zone.
(Typical example )
This is made worse through

formation of Cr2O3 (quickly
and always).
Distance from the surface
38/82
Cutting speed zones

Total
Friction
Wear
Technically optimum
39
Diffusion
Oxidation
Cutting Build up edge
Temperature / cutting speed

39/82
Cutting speed zones
40
Cutting build up edge

3
Tendance for build up edge
60 m/min
100 m/min
Cutting speed
40/82
Cutting speed zones
41
Cutting speed zone 1

Low productivity zone 40 - 60 (m/min)
Use TiN or TiCN coated (PVD) tough inserts or uncoated tough
inserts (P25-P40, K20).
Use cooling to keep the temperature down.
Use small chip sections (sharp inserts).
High tool life is possible.
Long finishing times Low productivity and high costs.
Reliability questionable.
41/82
Cutting speed zones
42

Build up edge wear zone 60 - 100 (m/min)
Chip
Burs on chip
Burs on workpiece
Build up edge
Great build up edge in this area.

Avoid cutting speed zone 2.
42/82
Cutting speed zones
43

Roughing High productivity zone 100 - 300 (m/min)
Use tough coated inserts (P25C) or wear resistant uncoated inserts

(P15) or cermet.
Use inserts with big positive rake (approx. 200).
Aim for large chip sections (f > 0.15 (mm/t), ap > 1 (mm)).
Do not use cooling except if there could be problems with chip removal.
43/82
Cutting speed zones
44

Finishing High productivity zone 120 - 350 [m/min]
Cutting speeds approx. 25% higher than in roughing.
Use cermet, P15 (uncoated), PVD coated micrograin grades.
Feed f = 0.05 - 0.15 (mm/t) and ap > 0.5 (mm).
If f < 0.05 (mm/t) en ap < 0.5 (mm) use uncoated K20.
Use abundant coolant to keep the temperature low.
In contour milling with small radial cutting depths, apply a cutting depth
factor and do not use coolant.
44/82
Stainless Steels
45
Machining in stainless steel requires five times as many cutting

edges as the same process in classical steel.
Be careful with other problems such as interrupted cuts and casting
scales.
Austenitic structure
Duplex structure
Nitrogen reinforced structure
Precipitation hardened SS
Pre-processing
Threading (following)
number of workpieces
Also pay attention to:
Avoid false economies

Turning (previous)
Insert wear
45/82
Stainless steel turning
46
Chip formation
Burring
Sticky chipping
Build up edge (wear)
46/82
47
Chip formation
AISI 304
Ck 45
AISI 304 Ca
47/82
48
Machine
Select maximum stability and capacity.
Avoid worn machines for accurate work.
48/82
49
Toolholder
Select the largest possible shank

section.
Select a strong insert clamping system.
Minimize the projection length.

Select sound seating.
49/82
50
Working method
Select varying cutting depths for

heavy and lengthy roughing
processes.
Roughing with entering angle of

75 or 45.
Then finish with 90.
50/82
51
Working method
For heavy roughing, use variable cutting depths.
51/82
52
Rough workpiece
First chamfer if possible. In

burnished pieces, always
begin by removing
burnished residue.
52/82
53
Inserts
Select strong inserts with sharp
geometries (entering angle).
Select large nose radius.
Select internal positive single sided

inserts and external double sided
negative inserts.
53/82
54
Cutting conditions
Use large cutting depths.
Use large feeds.
Change inserts regularly (not too much

wear).
54/82
Stainless steel milling
55
Some advice
1.
Smooth cutting process is important (smooth cutting geometry, large rake angle, sharp yet
reinforced cutting edges (small T phase/honing)).
2.
Good chip removal.
3.
Cutting under the hard surface layer.
4.
Use down-milling.
5.
Limit heat development
6.
1.
cooling (at the right place).
2.
thick chip (0.08 mm min hm) to gain sufficient mass for maximum heat removal.
Average chip thickness (very important)

1.
cutter positioning (10% D on exit side of workpiece).
2.
feed = > T - phase/honing.
7.
Cutting depth at least 1 mm and no finishing passes (unless absolutely essential) (friction).
8.
Maximum carbide mass (to remove heat).
55/82
56
Some advice feed and cutting depth
average chip thickness (hm) is very important and critical for tool life (verify with cutting edge
geometry - M/ME).
Inco / SS (+ feed / + tool life) (titanium, if short tool life, reduce feed).
if inserts with T-phase are used, the feed must be greater than this phase.
avoid feed = 0 (helical interpolation milling instead of drilling).
small cutting depths shorten the tool life.
minimum cutting depth 1 mm.
the smaller the cutting depth, the higher the cutting speed required (correct cutting temperature)
(cutting speed factor in contour milling).
56/82
57
Some advice cutting speed

High cutting speed method
15 to 20 minutes tool life.
Low cutting speed method

45 to 60 minutes tool life.
High pressure cooling >50 bar

Higher cutting speed.
Low tool life - 45 to 100 minutes.
Use high cutting speed if possible.
High cutting speed method
Low cutting speed method
Most stainless steels are easily machined, except PH-SS and cooling is not necessary
most of the time.
Good chip evacuation (removal of chips from the workpiece).
1.
2.
3.
Low cutting speed (low temperature) Vc= 30 - 60 m/min.

Build-up in cutting edge zone.
High cutting speed (high temperature) Vc= 100 - 300 m/min.
57/82
58
Group 8: Stainless Steels

Properties
Machining
Uses
Little or no alloying elements other than carbon and

chromium.
Good corrosion and temperature resistance.
Easy to machine.
Soft, continuous chips.
Watch for BUE (built-up edge).
Use positive rake tools.
Cobalt enriched zone.
MTCVD coatings.
Cookware, surgical tools, pump components.
58/82
59
Group 9: Stainless Steels

Properties
Machining
Uses
May contain nickel, molybdenum, sulphur, and

vanadium.
Increased hardness.
Increased corrosion and temperature resistance.
More difficult to machine.
Stringy, brittle chips.
Watch for notching at DOC line.
Use positive rake tools
MTCVD coating.
Piping pumps, process equipment.
59/82
60
Group 10 and 11: Stainless Steels

Properties
Machining
Uses
May contain nitrogen and titanium.
Excellent corrosion and temperature resistance.
Very high hardness.
Very difficult to machine.
Watch for surface work hardening.
Flank wear and edge chipping are typical failure

modes.
Use positive rake tools.
MTCVD coatings.
CBN and ceramics.
Piping, pumps, process equipment in demanding

conditions.
60/82
61
Cast Irons
Groups 12 through 15
Greater than 2.0% carbon
Tend to be abrasive to
machine
May also contain:
Magnesium
Silicon
Sulphur
Phosphorus
Brake drums
61/82
62
Group 12: Cast Irons

Properties
Machining
Uses
Carbon in form of flakes.
Abrasive
Low to medium hardness.
Strong and cheap to produce.
Moderately difficult to machine.
Machine at high cutting speeds.
High speeds: AL2O3.
Medium speeds: CVD (TiC, TiCN, AL2O3).
Low speeds: PVD (TiAIN) and CVD (TiC).
Engine blocks, inexpensive castings.
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63
Groups 13 & 14: Cast Irons

Properties
Machining
Uses
Cerium and magnesium cause carbon to form spheroids.
Harder and more abrasive.
More ductile, less brittle.
High speed: AL2O3; CBN; ceramic (SiN).
Medium speed: CVD (TiC, TiCN, AL2O3).
Low speed: PVD (TiAIN) and CVD (TiC).
Crankshafts, structural parts, pulleys, brakes.
63/82
64
Group 15: Cast Irons

Properties
Machining
Uses
Silicon causes carbon to form spheroids.
Called ductile cast iron.
Excellent tensile strength.
Good wear resistance.
Cheaper and lighter than steel.
High cutting forces.
Analogous to interrupted-cut.
Negative rake for strength.
High speed: AL2O3; CBN; ceramic (SiN).
Medium speed: CVD (TiC, TiCN, AL2O3).
Low speed: PVD (TiAIN) and CVD (TiC).
Gears, truck springs, turbo-compressor housings,

crankshafts.
64/82
65
Non-Ferrous Alloys
Less than 50% iron.
Most metals are soft
(except for tungsten
carbide).
Machinability varies over a
wide range.
Aluminium piston
65/82
66
Aluminium
Low density.
High strength.
Good thermal conductivity.
Good corrosion resistance.
1xxx
99% Al
2xxx
+ Cu
3xxx
+ Mn
4xxx
+ Si
5xxx
+ Mg
6xxx
+ Mg, Si
7xxx
+ Zn
8xxx
+ Other elements
66/82
67
Aluminium
Some advice
General
Carbide grade or PCD.

Polished rake surface.
Positive rake angle.
Coarse pitch cutter.
Large chip evacuation grooves.
Cutting speed
600 to 2000 (max) m/min with carbide inserts.
1500 - 6000 m/min with PCD inserts.
Feed
0.15 to 0.50 mm/rev.
67/82
68
Aluminium
Some advice
Build-up of cutting edge
Adjust cutting speed / use coolant / very positive geometry.
Chip control and evacuation

Open pitch cutter when milling.
Wash chips away with coolant.
Burring
Use micro-sharp cutting edges.
Abrasive wear
Carbide grade or PCD.
Finishing
With coolant, not for roughing.
Close pitch cutters

For large table feed, but needs power.
68/82
69
Group 16: Aluminum (<16% Si)

Properties
Machining
Uses
Properties enhanced by alloying with silicon, copper,

and magnesium.
High strength to weight ratio and corrosion

resistance.
Excellent tensile strength.
Cheaper and lighter than steel.
Group 16 includes silver, brass, and gold.
Stringy, continuous chips.
Watch for BUE.
Free machining; run at high cutting speeds.
Use positive rake tooling.
Auto body panels, wheels, aerospace applications.

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70
Group 17: Aluminum (>16% Si)

Properties
Machining
Uses
Alloyed to enhance strength.
Increased hardness.
Very abrasive.
Group 17 includes aluminum-bronze, cupro-nickel,

and magnesium-bronze.
Non-free machining.
Machine at slower cutting speeds.
Engine blocks.
70/82
71
Group 18: Difficult Non-Ferrous

Properties
Machining
Uses
Group 18 includes difficult to machine alloys of

copper, babbit, and bronze.
Good strength.
High ductility and toughness.
Very abrasive.
Watch for BUE.
Tends to tear.
Bushings, bearings, valve seats.
71/82
72
Group 19: Super Hard Alloys

Properties
Machining
Uses
Group 19 includes tungsten carbide.
Very high hardness.
Very high strength.
Abrasive
Machine at very slow cutting speeds.
Dies, punches, and wear parts.
72/82
73
Superalloys/High Temperature Alloys

High strength.
Maintain properties at
elevated temperatures.
Very difficult to machine.
73/82
74

Nickel, iron and cobalt alloys, the most important properties
being:
Exceptional strength.
Corrosion resistance at high temperatures.
74/82
75

.
Superalloys
Nickel based
Inconel 600
Waspoloy
Ren N4
MAR-M-247
Nickel-iron based
Inconel 718
Inconel 706
Hastelloy X
Cobalt based
Iron based
MAR-M 509
X40
Haynes 188
FSX-414
A-286
Discaloy
Haynes 556
75/82
76
Titanium Alloys
Titanium
Alpha alloy
HCP
Alpha-Beta alloy
Mix
Beta alloy
BCC
High strength/weight ratio.

High strength/creep resistance up to 500C.
Excellent corrosion resistance.
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77
Superalloys and Titanium Alloys

Machinability of superalloys
More heat generation upon machining (structure) and low thermal conductivity.
This means higher cutting temperatures.
Increasing strength at higher temperatures (basic property) (cutting temperature).
This means higher cutting forces.
Difficult chip control (greater toughness).
Carbide precipitates (due to heat treatment).
Work-hardening (hard layer).
Machinability of titanium alloys

Low thermal conductivity. This means higher cutting temperatures.
Small Youngs modulus (workpiece deformation, tolerances, vibrations).
Chemically very reactive (oxidation) (ignition and combustion during machining).
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78
Superalloys and Titanium Alloys

General recommendations
Machine in softest possible state.
Positive rakes.
Sharp cutting edges.
Strong basic geometry (nose radius).
Stable working conditions.
Avoid workpiece deformation.
Use small entering angles.
Single-pass cutting or varying cutting depth.
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79
Group 20: Superalloys

Properties
Machining
Uses
Hardness < 35RC.
Group 20 includes nickel, cobalt, and iron alloys.
Very high hardness.
Very abrasive.
Machine at very slow cutting speeds.
Work hardens rapidly.
Notching at DOC line.
High cutting forces and temperatures.
Watch for BUE.
Prosthetics, heat exchangers, aviation, maritime,

plumbing.
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80
Group 21: Superalloys

Properties
Machining
Uses
Hardness > 35RC.
Group 21 includes nickel, cobalt, iron alloys,

Inconel600, HastelloyX, Monel400.
Extremely high hardness.
Very abrasive.
Similar issues as Group 20 but to a greater degree.
Machine at extremely slow cutting speeds.
Work hardens rapidly.
Notching at DOC line.
High cutting forces and temperatures.
Watch for BUE.
Jet engines.
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Group 22: Refractory Metals

Properties
Machining
Uses
Group 22 includes titanium, niobium, tantalum,

molybdenum, and tungsten.
High temperature resistance.
Poor oxidation resistance in air.
High thermal conductivity.
Flex readily.
Sometimes flammable.
May react with tool materials.
Low coefficient of thermal expansion.
Machine at very low cutting speeds.
Watch for BUE.
Aircraft frames, nuclear plants.
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Questions?
82/82

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Carbon steel Free cutting steel

General construction steel

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Non-alloy steel and cast steel

Stainless steel (austenitic)

Grey cast iron

Hard cast iron

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steel SS GCI etc.

roughing - 1/2 rough - finishing

The correct insert

The cutting process

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The cutting process

The tangential force determines

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The cutting process

Kc11 = specific cutting force

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Materials with high ductility

Low carbon steel and aluminium,

Continuous chips, difficult to

Materials with low ductility

Gray cast iron, Gr.12.

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High hardness materials

Low hardness materials

Materials that work harden

Stainless steel, Groups 8, 9, 10 & 11

Large cutting forces (Tensile strength)

Long chips (Ductility (%))

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The cutting process

Heat conductivity of tool material

Geometry of cutting edge.

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Materials with high thermal conductivity

Low carbon steel, Group 1

Materials with low thermal conductivity

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Superalloys, Groups 20, 21

Residual tension MPa

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COPYRIGHT 2008, Seco Tools AB

Great influence on fatigue properties

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Depth from surface

9S20 cold rolled steel

Ductile cast iron

Stainless steel 440

9S20 is assigned a rating of 100

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Non-alloy steeland cast steel.

< 600 N/mm2

Stainless steel (austenitic)

> 750 N/mm2

Grey cast iron

Hard cast iron

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