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engineer-mechanical:machining [2019/02/12 16:16]
jjensen [CSI MANT 140]
engineer-mechanical:machining [2019/02/20 22:48] (current)
jjensen [Turning - Step 2 - Tool bit and insert geometry selection]
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         * {{engineer-mechanical:​machining:​carbidetippedstylecande.png|Figure 1-0 American National Standard Style C and E Carbide Tipped Tool, Machinery'​s Handbook, 27th Edition, p. 769-770}}         * {{engineer-mechanical:​machining:​carbidetippedstylecande.png|Figure 1-0 American National Standard Style C and E Carbide Tipped Tool, Machinery'​s Handbook, 27th Edition, p. 769-770}}
     * C6 Carbide Inserts with chipbreaker TCMT 32.52 - \$33 [[https://​www.ebay.com/​itm/​TCMT-32-52-Carbide-Insert-C6-Grade-1-2-5-8-3-4-Turning-Tools-Pk-10-/​131572093049?​hash=item1ea24ed079|ebay - All Industrial ALL-20206]]     * C6 Carbide Inserts with chipbreaker TCMT 32.52 - \$33 [[https://​www.ebay.com/​itm/​TCMT-32-52-Carbide-Insert-C6-Grade-1-2-5-8-3-4-Turning-Tools-Pk-10-/​131572093049?​hash=item1ea24ed079|ebay - All Industrial ALL-20206]]
 +    * [[http://​catalogs.kennametal.com/​BookshelfView/​|Kennametal Master Catalog - Turning Tools]]
  
 === CSI Toolholders and Inserts === === CSI Toolholders and Inserts ===
   * Insert Geometry for Cold Rolled/Mild Steel   * Insert Geometry for Cold Rolled/Mild Steel
     * {{engineer-mechanical:​machining:​kennametal-insert-geometry-steel.png|Kennametal Insert Geometry and Grade for Cold Rolled Steel}}     * {{engineer-mechanical:​machining:​kennametal-insert-geometry-steel.png|Kennametal Insert Geometry and Grade for Cold Rolled Steel}}
 +  * Grade KCP10B produces excellent surface finishes on most steels and cast irons - problem have to high SFM and RPM
 +    * [[http://​www.carbidedepot.com/​TCMT3252LF-KCP10B-P418037.aspx|TCMT3252LF KCP10B]]
 +  * Grade KCP10 produces excellent surface finishes on most steels and cast irons - problem have to have high SFM and RPM
 +    * [[http://​www.carbidedepot.com/​TCMT3252LF-KCP10-P231192.aspx|TCMT3252LF KCP10]]
 +  * Grade KC5010 (KC730 and KC5010 use same carbide but KC730 can run 50 SFM slower which is needed on a manual lathe) works well on 1018 Cold Rolled Steel, only problem is the insert tip breaks easily - Jim at CSI.edu purchases these
 +    * KCU10 is a newer version of KC5010, so basically the same
   * Grade KC730 is best for low RPM, other inserts want to run at 1600 RPM min. Has a PVD thin gold coating.   * Grade KC730 is best for low RPM, other inserts want to run at 1600 RPM min. Has a PVD thin gold coating.
 +    * **TCMT3252LF KC730 order# 1162011 - Randy at Kennametal likes this best for manual machining**
 +      * [[http://​www.carbidedepot.com/​TCMT3252LF-KC730-P17586.aspx|Carbide Depot - TCMT3252LF KC730]] 2LF = 2 is 1/32 = 0.030 min depth of cut, LF=Light Finish
 +      * 1/32 nose radius gives a better finish than the 1/64
 +      * TCMT3252LF KCP25B 5698121 (works at low RPM, works with hot-rolled)
 +      * TCGT3252LF KC5010 order# 1522949 - very good ground insert, gives good finish (good for Aluminum)
     * RPM = 3.82 SFM / Diam  (revolutions per minute)     * RPM = 3.82 SFM / Diam  (revolutions per minute)
     * SFM = 0.262 X Diam X RPM (surface feet per minute)     * SFM = 0.262 X Diam X RPM (surface feet per minute)
     * {{engineer-mechanical:​machining:​kennametal-cuttingspeed.png|Kennametal Cutting Speed for Cold Rolled Steel}}     * {{engineer-mechanical:​machining:​kennametal-cuttingspeed.png|Kennametal Cutting Speed for Cold Rolled Steel}}
   * Carbide Turning Insert   * Carbide Turning Insert
-    * #1162011 TCMT32.52 LF Grade KC730 - can run at slower RPM like 400+    * #1162011 TCMT32.52 LF Grade KC730 - can run at slower RPM like 400 [[http://​www.carbidedepot.com/​TCMT3252LF-KC730-P17586.aspx|TCMT3252LF KC730]] 
 +    * TCMT325211 has nose radius 1/32, is it available in grade KC730 or KC5010? [[http://​www.carbidedepot.com/​TCMT3252LF-KC5010-P57487.aspx|TCMT3252LF KC5010]]
   * Carbide Threading Inserts   * Carbide Threading Inserts
     * #1112958 for aluminum and can be used with mild steel     * #1112958 for aluminum and can be used with mild steel
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   * Kennametal Catalog#   * Kennametal Catalog#
     * NTP3R     * NTP3R
-    * NT3RK (recommended by Randy Kopka, Senior Analyst, Customer Application Support, na.techsupport@kennametal.com 1-800-835-3668)+    * NT3RK (recommended by Randy Kopka, Senior Analyst, Customer Application Support, na.techsupport@kennametal.com 1-800-835-3668, subject line - attention Randy) 
 +  * Sandpaper with Cloth Backing to add a fine finish to 1018 steel 
 +    * [[https://​www.wttool.com/​index/​page/​category/​category_id/​19573/​|Superior Abrasives Shur-Kut Premium Shop Rolls]]
  
  
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     * Layout is the initial step in any machining process. Understanding the concepts and proper utilization of semi-precision and precision layout techniques is important for every machinist. The machinist should know the function of a scriber and the types of layout instruments used with surface plates.     * Layout is the initial step in any machining process. Understanding the concepts and proper utilization of semi-precision and precision layout techniques is important for every machinist. The machinist should know the function of a scriber and the types of layout instruments used with surface plates.
  
-==== Cutting Speed Formulas ==== + 
-  * Machinery'​s Handbook, 27th Edition, p. 1016 +
-  * {{engineer-mechanical:​machining:​cutting-speed-formulas-machinery27th-p1016.png|Figure 1-0 Cutting Speed Formulas, Machinery'​s Handbook, 27th p. 1016}}+
  
 === Turning Speeds and Feeds and Depth of Cut === === Turning Speeds and Feeds and Depth of Cut ===
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     *      * 
   * Step 2 - calculate the feed rate (IPR, inches per revolution)   * Step 2 - calculate the feed rate (IPR, inches per revolution)
-  * Step 2 - desired cut diameter in inches of workpiece+
   * Definition of cutting speed   * Definition of cutting speed
     * feet per minute (fpm)     * feet per minute (fpm)
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   * What about Material Removal Rate (MRR)? Seems like a balance, more material you remove the more wear and tear on equipment.   * What about Material Removal Rate (MRR)? Seems like a balance, more material you remove the more wear and tear on equipment.
  
-==== Turning - Tool bit selection ====+==== Turning ​- Step 1 - Select Workpiece Material Group ==== 
 +  * K - Cast Iron 
 +  * Tool Steel 
 +  * Stainless Steel 
 +  * P - Steel 
 +    * P0 
 +      * ASTM A36 - hot rolled steel 
 +      * AISI 1018 - cold rolled steel 
 +    * P1 
 +      * AISI 12L14 - cold rolled steel 
 +  * Aluminum 
 +  * Delrin 
 +  * {{engineer-mechanical:​machining:​kennametal-material-groups.png|Kennametal Material Groups}} 
 + 
 +==== Turning - Step 2 - Tool bit and insert geometry ​selection ==== 
 +  * Triangle Shape - TCMT32.52 LF Grade KC730 
 +    * Kennametal# 1162011 [[http://​www.carbidedepot.com/​TCMT3252LF-KC730-P17586.aspx|Carbide Depot - TCMT3252LF KC730]] at \$16 each 
 +    * more economical, get 3 tips instead of 2, downside larger insert so difficult to get into tight spaces 
 +  * Diamond Shape - DPGT3251HP KC5010 
 +    * Kennametal# 1310719 [[http://​www.carbidedepot.com/​DPGT3251HP-KC5010-P56802.aspx|Carbide Depot - DPGT3251HP KC5010]] at \$14.50 each 
 +      * Note HP is High Positive and typically used on Aluminum 
 +    * use when need to get into tight areas on the lathe 
 +  * Square Shape 
 +    * SNMG432FW KCP10 order# 3749368 - has 8 cutting edges (4 corners and top & bottom) 
 +      * SN = Square Negative 
 +      * FW = Finish Wiper, the wiper feature does a second level cut to provide a smoother finish 
 +      * KCP10 grade can cut without oil (KC730 needs oil) 
 +    * Holder - MSRNR124B order# 1096149 - has a 15deg lead angle 
 +    * If experience chatter, try the following 
 +      * increase or decrease RPM 
 +      * tighten workpiece tailstock
   * Kennametal Catalog Numbers - [[https://​www.kennametal.com/​en/​resources/​metalworking-literature.html|Interactive Catalog]]   * Kennametal Catalog Numbers - [[https://​www.kennametal.com/​en/​resources/​metalworking-literature.html|Interactive Catalog]]
     * CNMG432FP     * CNMG432FP
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       * 4 = 4/64" or 1/16"       * 4 = 4/64" or 1/16"
  
 +==== Turning - Step 3 - Insert Grade ====
 +  * Manual Lathe - machining cold rolled steel
 +  * KC730 is best grade for this, even with 1600 RPM and 0.0012 in/rev (#1 IATX gear setting on Sharp lathe) feed the finish is smooth but looks blemished
 +    * {{engineer-mechanical:​machining:​kennametal-kc730-finish.jpg?​600|Figure 1-0 KC730 Finish}}
 +    * {{engineer-mechanical:​machining:​kennametal-kc730-finish2.jpg?​600|Figure 1-0 KC730 Finish - Close up}}
 +  * KCU10 is a newer version of KC5010 (owned by csi.edu), both are a good choice
 +  * {{engineer-mechanical:​machining:​kennametal-select-grade.png|Figure 1-0 Insert Grade - KCU10}}
 +
 +==== Turning - Step 4 - Feed Rate and Depth of Cut ====
 +  * Lookup manufacture recommended feed rate and depth of cut 
 +    * {{engineer-mechanical:​machining:​kennametal-depth-of-cut.png|Figure 1-0 Depth of Cut}}
 +
 +==== Turning - Step 5 - Cutting Speed (SFM or FPM) ====
 +  * Lookup cutting speed of insert grade
 +    * KC730 has 400 SFM (Surface Feet per Minute or FPM=Feet Per Minute)
 +    * KCU10 and KC5010 has 450 SFM
 +    * {{engineer-mechanical:​machining:​kennametal-cutting-speed.png|Figure 1-0 Cutting Speed Chart - Kennametal}}
 +  * Machinery'​s Handbook, 27th Edition, p. 1016
 +  * {{engineer-mechanical:​machining:​cutting-speed-formulas-machinery27th-p1016.png|Figure 1-0 Cutting Speed Formulas, Machinery'​s Handbook, 27th p. 1016}}
 +
 +
 +
 +==== Turning - Step 6 - Spindle Speed (RPM) ====
 +  * Lookup Spindle Speed (RPM = Revolutions Per Minute)
 +  * Machinery'​s Handbook, 27th Edition, p. 1016
 +  * {{engineer-mechanical:​machining:​cutting-speed-machinery-handbook28th-p988.png|Figure 1-0 RPM for Various Speeds, Machinery'​s Handbook, 28th p. 988}}
 ===== How to make these parts ===== ===== How to make these parts =====
   * How would I make a flange? [[http://​www.allied-grp.com/​warrenalloy/​products/​flanges|Allied Group Flanges]] has several flanges that can be purchased. When I made a flange, the hole pattern only fit in one setting, that is if I rotate the flange, then the holes didn't line up. This is due to the difficulty of laying out the pattern and the drill bit on the drill press wandering a little bit.   * How would I make a flange? [[http://​www.allied-grp.com/​warrenalloy/​products/​flanges|Allied Group Flanges]] has several flanges that can be purchased. When I made a flange, the hole pattern only fit in one setting, that is if I rotate the flange, then the holes didn't line up. This is due to the difficulty of laying out the pattern and the drill bit on the drill press wandering a little bit.
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   * [[http://​www.bullberry.com/​|Bullberry Barrel Works]] in Hurricane Utah   * [[http://​www.bullberry.com/​|Bullberry Barrel Works]] in Hurricane Utah
  
 +===== NIMS Certification =====
 +
 +==== Turning I ( Between Centers) ====
 +  * [[https://​www.nims-skills.org/​credentials/​turning-i-between-centers|Turning I (Between Centers)]]
 +  * [[https://​www.nims-skills.org/​resources/​study-material/​357|Turning I Sample Test]]
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