1. TECHNICAL DATA
TROUBLE SHOOTING FOR TURNING ...........................................................Q002
CHIP CONTROL FOR TURNING .....................................................................Q004
EFFECTS OF CUTTING CONDITIONS FOR TURNING..................................Q005
FUNCTION OF TOOL FEATURES FOR TURNING .........................................Q007
FORMULAE FOR CUTTING POWER .............................................................. Q011
TROUBLE SHOOTING FOR FACE MILLING ..................................................Q012
FUNCTION OF TOOL FEATURES FOR FACE MILLING ................................Q013
FORMULAE FOR FACE MILLING ...................................................................Q016
TROUBLE SHOOTING FOR END MILLING ....................................................Q018
END MILL TERMINOLOGY ..............................................................................Q019
TYPES AND SHAPES OF END MILLS ............................................................Q020
PITCH SELECTION OF PICK FEED ................................................................Q021
TROUBLE SHOOTING FOR DRILLING ..........................................................Q022
DRILL WEAR AND CUTTING EDGE DAMAGE ..............................................Q023
DRILL TERMINOLOGY AND CUTTING CHARACTERISTICS .......................Q024
FORMULAE FOR DRILLING............................................................................Q027
METALLIC MATERIALS CROSS REFERENCE LIST .....................................Q028
DIE STEELS......................................................................................................Q032
SURFACE ROUGHNESS .................................................................................Q034
HARDNESS COMPARISON TABLE ................................................................Q035
JIS FIT TOLERANCE HOLE ............................................................................Q036
JIS FIT TOLERANCE SHAFT ..........................................................................Q038
DRILL DIAMETERS FOR PREPARED HOLES ...............................................Q040
HEXAGON SOCKET HEAD BOLT HOLE SIZE...............................................Q041
TAPER STANDARD ..........................................................................................Q042
INTERNATIONAL SYSTEM OF UNITS ............................................................Q043
TOOL WEAR AND DAMAGE ...........................................................................Q044
CUTTING TOOL MATERIALS ..........................................................................Q045
GRADE CHAIN .................................................................................................Q046
GRADES COMPARISON TABLE .....................................................................Q047
INSERT CHIP BREAKER COMPARISON TABLE ...........................................Q053
Q001

2. TECHNICAL DATA
TROUBLE SHOOTING FOR TURNING
Insert Grade Cutting Style and Design Machine,
Selection Conditions of the Tool Installation of Tool
Solution
Honing strengthens
Decrease power and machine
Increase clamping rigidity of
Improve tool holder rigidity
the cutting edge
Coolant
Cutting speed
Decrease holder overhang
Corner radius
Select a grade with better
Select a grade with better
thermal shock resistance
Depth of cut
Lead angle
the tool and workpiece
Select a tougher grade
Select a harder grade
adhesion resistance
soluble cutting fluid
Select chip breaker
Do not use water-
Rake
Feed
Determine dry or
Class of insert
wet cutting
Up Up
backlash
Trouble Factors
Down Down
Improper
a
tool grade
Insert wear
quickly Improper cutting
a a a a a
generated edge geometry
Improper
a a a
cutting speed
Deterioration of Tool Life
Wet
Improper
a
tool grade
Improper
a a
cutting conditions
Lack of cutting
a a a
Chipping or edge strength.
fracturing of
cutting edge Thermal crack
a a a a a a
occurs Dry
Build-up edge
a a a a a
occurs Wet
Lack of rigidity a a a a
Poor insert
a
Dimensions accuracy
Out of Tolerance
are not
constant Large cutting resistance
a a a a a a a a a
and cutting edge flank
Improper
Necessary to a
tool grade
adjust often
because of
over-size Improper
a a
cutting conditions
TECHNICAL DATA
Deterioration of
Welding occurs a a a
Surface Finish
Wet
Poor finished Improper cutting
a a
surface edge geometry
Chattering a a a a a a a
Improper
Generation
Workpiece over a a a
cutting conditions
of Heat
heating can
cause poor
accuracy and Improper cutting
short life of insert a a a
edge geometry
Q002

3. Insert Grade Cutting Style and Design Machine,
Selection Conditions of the Tool Installation of Tool
Solution
Honing strengthens
Decrease power and machine
Increase clamping rigidity of
Improve tool holder rigidity
the cutting edge
Coolant
Cutting speed
Decrease holder overhang
Corner radius
Select a grade with better
Select a grade with better
thermal shock resistance
Depth of cut
Lead angle
the tool and workpiece
Select a tougher grade
Select a harder grade
adhesion resistance
soluble cutting fluid
Select chip breaker
Do not use water-
Rake
Feed
Determine dry or
Class of insert
wet cutting
Up Up
backlash
Trouble Factors
Down Down
Notch wear a
Burrs improper a a a
(steel, aluminium) cutting conditions Wet
Improper cutting a a a a a
edge geometry
improper
Burrs, Chipping etc.
a a
cutting conditions
Workpiece chipping Improper cutting a a a a a
(cast iron) edge geometry
Vibration occurs a a a a
Improper
a
tool grade
Improper
a a a
cutting conditions Wet
Burrs
(mild steel)
Improper cutting a a a
edge geometry
Vibration occurs a a a a
improper
a a a a
cutting conditions Wet
Large chip
long chips a
control range
Poor Chip Dispersal
Improper cutting a a
edge geometry
improper
TECHNICAL DATA
a a a
cutting conditions Dry
Chips are short Small chip a
and scattered control range
Improper cutting a a
edge geometry
Q003

4. TECHNICAL DATA
CHIP CONTROL FOR TURNING
y CHIP BREAKING CONDITIONS IN STEEL TURNING
Type A Type B Type C Type D Type E Type
Small Depth of Cut
d<7mm
Small Depth of Cut
d=7 ─ 15mm
l < 50mm Less Than 1
Curl Length l Curless l > 50mm
1 ─ 5 Curl
i 1 Curl Curl Half a Curl
aIrregular con- aRegular con- aChip scattering
tinuous shape tinuous shape aChattering
Note aTangles around aLong chips Good Good aPoor finished
tool and work- surface
piece aMaximum
a Cutting speed and chip control range of chip breaker
In general, when cutting speed increases, the chip control range tends to become narrower.
0.6 0.6 0.6
vc=50m/min vc=100m/min vc=150m/min
0.5 E 0.5 E 0.5 E
Feed (mm/rev)
Feed (mm/rev)
Feed (mm/rev)
0.4 0.4 0.4
B B D B D
0.3 D 0.3 0.3
C
0.2 0.2 C 0.2
C
0.1 0.1 0.1 A
A
A
1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
Depth of Cut (mm) Depth of Cut (mm) Depth of Cut (mm)
Workpiece : S45C(180HB) Tool : MTJNR2525M16N
Insert : TNMG160408 Dry Cutting
Grade : P10Cemented Carbide
a Effects of coolant on the chip control range of a chip breaker
If the cutting speed is the same, the range of chip control differs according to whether coolant is used or not.
0.6 Coolant : Dry 0.6 Coolant : Wet
(Emulsion)
0.5 E 0.5
E
Feed (mm/rev)
Feed (mm/rev)
0.4 0.4
TECHNICAL DATA
B D B
0.3 0.3 D
C
C
0.2 0.2
A
0.1 0.1 A
1 2 3 4 5 6 1 2 3 4 5 6
Depth of Cut (mm) Depth of Cut (mm)
Workpiece : S45C
Cutting Conditions : vc=100m/min
Q004

5. EFFECTS OF CUTTING
CONDITIONS FOR TURNING
y EFFECTS OF CUTTING CONDITIONS
Ideal conditions for cutting are short cutting time, long tool life, and high cutting accuracy. In order to obtain these conditions, selection of
efficient cutting conditions and tool, based on work material, hardness, shape and machine capability is necessary.
y CUTTING SPEED
Cutting speed effects tool life greatly. Increasing cutting speed increases cutting temperature and results in shortening tool life. Cutting speed
varies depending on the type and hardness of the work material. Selecting a tool grade suitable for the cutting speed is necessary.
500 Workpiece : JIS S45C 180HB
400 UE6110 Tool Life Standard : VB = 0.3mm
UE6105 Depth of Cut : 1.5mm
AP25N Feed : 0.3mm/rev
Cutting Speed (m/min)
300
UE6020 Holder : PCLNR2525M12
NX2525 Insert : CNMG120408
200 UE6035
Dry Cutting
150 NX3035
US735
UTi20T
100
80
60
10 20 30 40 60 100
Tool Life (min)
P Class Grade Tool Life
500 Workpiece : JIS SUS304 200HB
400 Tool Life Standard : VB = 0.3mm
Depth of Cut : 1.5mm
Feed : 0.3mm/rev
Cutting Speed (m/min)
300
Holder : PCLNR2525M12
US7020
Insert : CNMG120408-MA
200 Dry Cutting
150
US735
100 UTi20T
80
60
10 20 30 40 60 100
Tool Life (min)
M Class Grade Tool Life
UC5105 Workpiece : JIS FC300 180HB
Tool Life Standard : VB = 0.3mm
400
Depth of Cut : 1.5mm
UC5115
Feed : 0.3mm/rev
Cutting Speed (m/min)
300
Holder : PCLNR2525M12
UE6110 Insert : CNMG120408
AP25N Dry Cutting
200
NX2525 HTi10
150
TECHNICAL DATA
100 UTi20T
80
60
10 20 30 40 60 100
Tool Life (min)
K Class Grade Tool Life
a Effects of Cutting Conditions
1. Increasing cutting speed by 20% decreases tool life by 1/2. Increasing cutting speed by 50% decreases tool life by 1/5.
2. Cutting at low cutting speed (20─ 40 m/min) tends to cause chattering. Thus, tool life is shortened.
Q005

6. TECHNICAL DATA
EFFECTS OF CUTTING
CONDITIONS FOR TURNING
y FEED
When cutting with a general type holder, feed is the distance a holder moves per workpiece revolution. When milling, feed is the
distance a machine table moves per cutter revolution divided by the number of inserts. Thus, it is indicated as feed per tooth. Feed
rate relates to finished surface roughness.
a Effects of Feed 0.4
1. Decreasing feed rate results in flank wear and shortens tool
Flank Wear (mm)
0.3
life.
2. Increasing feed rate increases cutting temperature and 0.2
flank wear. However, effects on the tool life is minimal
compared to cutting speed. 0.1
3. Increasing feed rate improves machining efficiency.
0 0.03 0.06 0.08 0.1 0.2 0.3 0.6
Feed (mm/rev)
Cutting Conditions Workpiece : JIS SNCM431 Grade : STi10T
Tool Shape : 0-0-5-5-35-35-0.3mm
Depth of Cut ap=1.0mm Cutting Speed vc=200m/min
Cutting Time Tc=10min
Feed and Flank Wear Relationship in Steel Turning
y DEPTH OF CUT
Depth of cut is determined according to the required stock removal, shape of workpiece, power and rigidity of the machine and tool rigidity.
a Effects of Depth of Cut 0.4
Flank Wear (mm)
1. Changing depth of cut doesn't effect tool life greatly. 0.3
2. Small depths of cut result in friction when cutting the 0.2
hardened layer of a workpiece. Thus tool life is shortened.
0.1
3. When cutting uncut surfaces or cast iron surfaces, the
depth of cut needs to be increased as much as the machine 0 0.03 0.05 0.1 0.2 0.5 1.0 2.0 3.0
power allows in order to avoid cutting impure hard layers Depth of Cut (mm)
with the tip of cutting edge to prevent chipping and Cutting Conditions Workpiece : JIS SNCM431 Grade : STi10T
Tool Shape : 0-0-5-5-35-35-0.3mm
abnormal wear. Feed f=0.20mm/rev Cutting Speed vc=200m/min
Cutting Time Tc=10min
Depth of Cut and Flank Wear Relationship in Steel Turning
Depth of
Cut
Uncut Surface
TECHNICAL DATA
Roughing of the Surface Layer that Includes Uncut Surface
Q006

7. FUNCTION OF TOOL FEATURES
FOR TURNING
y RAKE ANGLE
Rake angle is a cutting edge angle that has a large effect on cutting resistance, chip disposal, cutting temperature and tool life.
200
Tool Life Standard Tool Life Standard : VB=0.4mm
Cutting Speed
VB=0.4mm Depth of Cut : 1mm Feed= 0.32mm/rev
140
(m/min)
Positive Rake 100 120
Rak
Angle 80
e An
100
Rak
(+)
e An
gle 1
Cutting Resistance
Tool Life (min)
1400
Vertical Force
Positive Insert 50
Vertical Force
gle 6
Rak
5°
1200 Depth of Cut : 2mm
(N)
e An
Feed : 0.2mm/rev
°
30 Cutting Speed : 100m/min
1000
gle -
20 Rake Face Mean
10°
600
Temperature
Depth of Cut : 2mm
Temperature
500 Feed : 0.2mm/rev
Cutting
Cutting Speed : 100m/min
(°C)
10
-15 -10 -5 0 5 10 15 20 25
Negative Rake Rake Angle (°)
Angle 6
50 100 200 Cutting Conditions
(─)
Cutting Speed (m/min) Workpiece : JIS SK5 Grade : STi10T
Negative Tool Shape : 0-Var-5-5-20-20-0.5mm
Insert Cutting Conditions Dry Cutting
Grade : STi10
Depth of Cut : 1mm Feed : 0.32mm/rev Effects of Rake Angle on
Workpiece : JIS SK5
Cutting Speed, Vertical Force,
Chip Disposal and Rake Angle Rake Angle and Tool Life and Cutting Temperature
a Effects of Rake Angle When to Increase Rake Angle When to Increase Rake Angle
1. Increasing rake angle in the positive (+) direction in the Negative ( ─ ) Direction in the Positive (+) Direction
improves sharpness. uHard workpieces. uSoft workpieces.
2. Increasing rake angle by 1° in the positive (+) uWhen the cutting edge strength is uWorkpiece is easily machined.
direction decreases cutting power by about 1%. required such as for uncut uWhen the workpiece or the
3. Increasing rake angle in the positive (+) direction surfaces and interrupted cutting. machine have poor rigidity.
lowers cutting edge strength and in the negative
(─ ) direction increases cutting resistance.
y FLANK ANGLE
Flank angle prevents friction between flank face and workpiece resulting in smooth feed.
Rake Angle 6°
0.3
vc e
0.2 =2 tur
Flank Wear (mm)
00 ac
Wear Depth Wear Depth Fr $
vc=1
00 Flank Angle $
0.1
Large Flank Wear
Small Flank Wear
vc=
50
0.05
3° 6° 8° 10° 12° 15° 20°
TECHNICAL DATA
(Same)
(Same)
Flank Angle ($)
D.O.C
D.O.C
%° %° Cutting Conditions
Small Flank Angle Large Flank Angle Workpiece : JIS SNCM431 (200HB)
Grade : STi20 Tool Shape : 0 • 6 • $ • $ • 20 • 20 • 0.5
Flank angle creates a space between tool and workpiece. Depth of Cut : 1mm Feed : 0.32mm/rev Cutting Time : 20min
Flank angle relates to flank wear. Flank Angle and Flank Wear Relationship
a Effects of Rake Angle When to Decrease Flank Angle When to Increase Flank Angle
1.Increasing flank angle decreases flank wear
uHard workpieces. uSoft workpieces.
occurrence.
uWhen cutting edge strength is uWorkpieces suffer from work
2.Increasing flank angle lowers cutting edge
required. hardening easily.
strength.
Q007

8. TECHNICAL DATA
FUNCTION OF TOOL FEATURES
FOR TURNING
y SIDE CUTTING EDGE ANGLE (LEAD ANGLE)
The side cutting edge angle reduces impact load and affects the amount of feed force, back force and chip thickness.
Workpiece : JIS SCM440
80 Grade : STi120
f= Same f= Same f= Same Depth of Cut : 3mm
60
5B
Feed : 0.2mm/rev
B
1.1
1.04
Dry Cutting
40
B
0.97 0.8 30
h h 7h B : Chip Width
Tool Life (min)
f : Feed
20
kr =0° kr=15° kr=30° h : Chip Thickness
kr : Side Cutting
Side
Side
Edge Angle
Side Cutting Edge Angle and Chip Thickness
Cutt
Cuttin
10
ing E
8
g Ed
a Effects of Side Cutting Edge Angle (Lead Angle)
dge
ge A
6
Ang
1. At the same feed rate, increasing the side cutting edge angle increases the chip contact 5
ngle
le 15
length and decreases chip thickness. As a result, the cutting force is dispersed on a longer 4
0°
cutting edge and tool life is prolonged. (Refer to the chart.)
°
3
2. Increasing the side cutting edge angle increases force a'. Thus, thin, long workpieces
100 150 200 300
suffer from bending in some cases.
Cutting Speed (m/min)
3. Increasing the side cutting edge angle decreases chip control.
4. Increasing the side cutting edge angle decreases the chip thickness and increases chip Side Cutting Edge and Tool Life
width. Thus, breaking chips is difficult.
When to Decrease Lead Angle When to Increase Lead Angle A a'
A
uFinishing with small depth of cut. uHard workpieces which produce a
uThin, long workpieces. high cutting temperature.
uWhen the machine has poor uWhen roughing a workpiece with
rigidity. large diameter.
uWhen the machine has high Force A is divided
Receive force A.
rigidity. into a and a'.
y END CUTTING EDGE ANGLE
The end cutting edge angle avoids interference between the machined surface
and the tool (end cutting edge). Usually 5° ─15°.
a Effects of End Cutting Edge Angle End Cutting
Edge Angle
1. Decreasing the end cutting edge angle increases cutting edge strength, but
it also increases cutting edge temperature.
2. Decreasing the end cutting edge angle increases the back force and can
result in chattering and vibration while machining.
3. Small end cutting edge angle for roughing and large angle for finishing are
Back Relief Angle Side Flank Angle
recommended.
y CUTTING EDGE INCLINATION
TECHNICAL DATA
Cutting edge inclination indicates inclination of the rake face. During heavy cutting,
the cutting edge receives an extremely large shock at the beginning of each cut. True Rake
Angle
Cutting edge inclination keeps the cutting edge from receiving this shock and (─)
Cutting Edge
prevents fracturing. 3° ─ 5° in turning and 10° ─ 15° in milling are recommended. End Cutting Edge
Inclination
Angle
Main Cutting Edge
a Effects of Cutting Edge Inclination Corner Radius
Side Cutting
1. Negative ( ─ ) cutting edge inclination disposes chips in the workpiece
Edge Angle
direction, and positive (+) disposes chips in the opposite direction.
2. Negative ( ─ ) cutting edge inclination increases cutting edge strength, but it
also increases the back force of cutting resistance.
Thus, chattering can easily occur.
Q008

9. y HONING AND LAND
Honing Width Honing Width Land Width
Honing Angle
Honing and land are cutting edge shapes that
maintain cutting edge strength.
R
Honing can be round or chamfer type. The
optimal honing width is approximately 1/2 of the
feed. Land is the narrow flat area on the rake or
flank face. Round Honing Chamfer Honing Flat Land
Principal Force (N)
5000 100 1700
VB KT
Tool Life (Number of Impacts)
R Honing R Honing
1600
C Honing C Honing
50
1500
Tool Life (min)
1000
1400
500 1400
20
Feed Force (N)
900
10 800
100
0 0.02 0.05 0.1 0.2 0.5 700
5
Honing Size (mm) 0 0.02 0.05 0.1 0.2 0.5 600
Workpiece : JIS SNCM439 (280HB) Honing Size (mm) 800
Grade : P10 Workpiece : JIS SNCM439 (220HB) R Honing
Back Force (N)
Cutting Conditions : vc=200m/min ap=1.5mm Grade : P10 700
C Honing
f =0.335mm/rev Cutting Conditions : vc=160m/min ap=1.5mm
f=0.45mm/rev 600
Honing Size and Tool Life Honing Size and Tool Life 500
Due to Fracturing Due to Wear 400
0 0.02 0.05 0.1 0.2 0.5
Honing Size (mm)
Workpiece : JIS SNCM439 (220HB)
Grade : P10
Cutting Conditions : vc=100m/min ap=1.5mm
f=0.425mm/rev
Honing Size and Cutting Resistance
a Effects of Honing
1. Enlarging the honing increases cutting edge strength, tool life and reduces fracturing.
2. Enlarging the honing increases flank wear occurrence and shortens tool life. Honing size doesn't affect rake wear.
3. Enlarging the honing increases cutting resistance and chattering.
TECHNICAL DATA
When to Decrease Honing Size When to Increase Honing Size
uWhen finishing with small depth uHard workpieces.
of cut and small feed. uWhen the cutting edge strength is
uSoft workpieces. required such as for uncut
uWhen the workpiece or the surfaces and interrupted cutting.
machine have poor rigidity. uWhen the machine has high
rigidity.
* Cemented carbide, coated diamond, and indexable cermet inserts have round honing as standard.
Q009