face grooving & turning -user guide

8/12/2019 Face Grooving & Turning -User Guide

1/17


2/17ISCAR202

Machining Data for Facing

Hardness Material

ISO Material Condition HB No.

< 0.25 %C Annealed 420 125 1

>= 0.25 %C Annealed 650 190 2

< 0.55 %C Quenched and tempered 850 250 3

>= 0.55 %C Annealed 750 220 4

P

Quenched and tempered 1000 300 5

Annealed 600 200 6

930 275 7


1200 350 9

Annealed 680 200 10


Non-alloy steeland cast steel, freecutting steel

Low alloy steel andcast steel(less than 5%all elements)

High alloyed steel, cast steel,and tool steel

Ferritic/pearlitic 180 15

Pearlitic 260 16

K Ferritic 160 17

Pearlitic 250 18

Ferritic 130 19

Pearlitic 230 20

Cast iron nodular (GGG)

Grey cast iron (GG)

Malleable cast iron

Ferritic/martensitic 680 200 12M Martensitic 820 240 13Austenitic 600 180 14

Stainless steel andcast steel

Not cureable 60 21

Cured 100 22

12% Si High temperature 130 25

>1% Pb Free cutting 110 26

Brass 90 27

Electrolitic copper 100 28

Duroplastics, fiber plastics 29

Hard rubber 30

Aluminum-wrought alloy

Aluminum-cast,alloyed

Copper alloys

Non-metallic

Fe based Annealed 200 31

Cured 280 32

Annealed 250 33

S Ni or Co based Cured 350 34 Cast 320 35 RM 400 36

Alpha+beta alloys cured RM 1050 37

High temp. alloys

Titanium and Ti alloys

Hardened 55 HRc 38

H

Hardened 60 HRc 39

Cast 400 40

Hardened 55 HRc 41

Hardened steel

Chilled cast iron

Cast iron

TensileStrength[N/mm2]

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3/17B203

IC9015 IC908/508 IC635 IC9054 IC354 IC428 IC20

120-200 20-40

100-180 20-40

150-220 40-60

130-200 40-60

130-200 40-60

120-200 30-50

110-145 95-125 85-115 100-130 90-120 85-110 75-95 65-85 75-100 70-90

60-85 50-75 45-65 55-75 50-70

280-500

180-250

250-400 200-300

60-100

130-220

120-200

80-150

20-40 20-30

15-30 15-20

15-20 15-20

15-20 15-20 15-20 15-20

90-120 80-100

20-50 20-40

Coated Uncoated

120-155 105-135 95-125 110-145 100-130

110-145 95-125 85-115 100-130 90-120

95-120 85-105 75-95 90-110 80-100

95-155 85-135 75-125 90-145 80-130

85-145 75-125 65-115 75-130 70-120

85-110 75-95 65-85 75-100 70-90

70-90 65-80 55-70 65-80 60-75

70-90 65-80 55-70 65-80 60-75

60-70 50-65 45-55 55-65 50-60

Cutting Speed (m/min)

USER GUIDE


4/17ISCAR204

Machining Data for Facing

Hardness Material

ISO Material Condition HB No.

< 0.25 %C Annealed 420 125 1

>= 0.25 %C Annealed 650 190 2

< 0.55 %C Quenched and tempered 850 250 3

>= 0.55 %C Annealed 750 220 4

P


Annealed 600 200 6

930 275 7


1200 350 9

Annealed 680 200 10


Non-alloy steeland cast steel, freecutting steel

Low alloy steel andcast steel(less than 5%all elements)

High alloy steel, cast steel,and tool steel

Ferritic/pearlitic 180 15

Pearlitic 260 16

K Ferritic 160 17

Pearlitic 250 18

Ferritic 130 19

Pearlitic 230 20

Cast iron nodular (GGG)

Grey cast iron (GG)

Malleable cast iron

Ferritic/martensitic 680 200 12M Martensitic 820 240 13Austenitic 600 180 14

Stainless steel andcast steel

Not cureable 60 21

Cured 100 22

12% Si High temperature 130 25

>1% Pb Free cutting 110 26

Brass 90 27

Electrolitic copper 100 28

Duroplastics, fiber plastics 29

Hard rubber 30

Aluminum-wrought alloy

Aluminum-cast,alloyed

Copper alloys

Non-metallic

Fe based

Annealed 200 31

Cured 280 32

Annealed 250 33

S Ni or Co based Cured 350 34 Cast 320 35 RM 400 36

Alpha+beta alloys cured RM 1050 37

High temp. alloys

Titanium and Ti alloys

Hardened 55 HRc 38

H

Hardened 60 HRc 39

Cast 400 40

Hardened 55 HRc 41

Hardened steel

Chilled cast iron

Cast iron

TensileStrength[N/mm2]

USER GUIDE


5/17B205

40-140 0.02-0.08 0.015-0.05

40-120 0.02-0.07 0.015-0.04

40-140 0.02-0.08 0.015-0.04

40-120 0.02-0.07 0.015-0.04

40-140 0.02-0.06 0.015-0.04

40-120 0.02-0.07 0.015-0.04

40-120 0.02-0.08 0.015-0.04 40-120 0.02-0.07 0.015-0.04

40-100 0.02-0.06 0.015-0.03

150-320 0.02-0.08 0.015-0.05

100-250 0.02-0.08 0.015-0.05

150-300 0.02-0.08 0.015-0.05 150-300 0.02-0.08 0.015-0.05

100-150 0.02-0.08 0.015-0.05

80-230 0.02-0.08 0.015-0.05

70-200 0.02-0.08 0.015-0.05

50-180 0.02-0.08 0.015-0.05

20-40 0.02-0.06 0.015-0.04

15-30 0.02-0.06 0.015-0.04

15-20 0.02-0.06 0.015-0.04

15-20 0.02-0.06 0.015-0.04 15-20 0.02-0.06 0.015-0.04

40-120 0.02-0.06 0.015-0.04

20-50 0.02-0.06 0.015-0.04

CuttingSpeed(m/min)

40-180 0.02-0.08 0.015-0.05

40-130 0.02-0.06 0.015-0.04

40-120 0.02-0.06 0.015-0.04

40-140 0.02-0.08 0.015-0.04

40-140 0.02-0.08 0.015-0.04

40-120 0.02-0.06 0.015-0.03

40-120 0.02-0.05 0.015-0.03

40-140 0.02-0.08 0.015-0.04

40-120 0.02-0.08 0.015-0.03

GFQRIC528

Feed (mm/rev)

PICCOIC228

Feed (mm/rev)

USER GUIDE


6/17ISCAR206

Face Machining Guide Tool SelectionFollow three recommendations to choose the right tool for high peformance.

W

Choose the widest possible

insert and tool, according

to the cutting width andgeometry to be machined.

T max

Choose the shortest tool blade

overhang, according to the

maximum depth required.

D min

MinorDiameter

MajorDiameter

Choose the tool range with the

largest diameter depending on

the initial grooving diameter

required in the application.

Remark:On integral shank tools the given range refers to the holder capacity.

USER GUIDE

Face Machining Guide Tool AdjustmentPrior to machining, check and adjust the following tool positions.

Check the cutting edge

height at center line, machine

in light turning down to

center, and check for burr.

// 0.015 4mm

Check parallelism of cutting

edge and the machined

surface. Correct position

can guarantee good surface

quality when face turning in

both directions.


7/17B207

Optimizing the Machining Sequence

Recommended machining sequence in roughingoperation using multifunction HELIFACEtools.

Groove at the initial

diameter up to the depth

of cut selected for next

step in face turning.

Continue with face

turning away from

center.

1

2

After rapid positioning

back into initial groove,

continue with face

turning to center.

Note: When face grooving, reduce the speed by 40% in relation to that used in face turning.

3

USER GUIDE


8/17ISCAR208

Optimizing Machining Sequence

Groove at the initial diameter tothe final depth of groove and

continue face turning away from

center to the tangential point on

the radius.

Recommended machining sequence in finishingthe part, using multifunction HELIFACEtools.

Finish major diameter

toward the bottom and

generate the radius.

Position the tool in rapidmovement in the initial groove,

continue face turning to center,

without touching the machined

roughing steps on the wall.

1

2

3

Finish boring the minor

diameter to the bottom, up

to final depth.4

Note: When face grooving, reduce the speed by 40% in relation to that used in face turning.

USER GUIDE


9/17B209

The Multifunction Advantage

The HELIFACEinternal boring bar

HFIR/L MCtype with internal coolantcan replace the three different ISO tools

and shorten machining time by 20%.

A single HELIFACEmultifunction

tool HFHLmachines the whole

part: grooving, face turning andchamfering, replacing three ISO

tools and reducing machining

time by 40%.

A single integral HELIFACEtool

HFHPL-Mreplaces three ISOtools and reduces machining time

by 50%.

USER GUIDE

1

2

3


10/17ISCAR210

Insert Replacement

EDG 33B

Simple to operate; controlled rotation requires low force; guarantees limitedupper jaw movement and secures maximum load on blade.Two extractor pins are placed in the two holes in the holder blades.

The New Eccentric Extractor

Indexing

Place the EDG Extractor in theholes as shown in Fig 1.Step 1-Press the extractor to thelower jaw of the tool.Step 2-Slightly press the upperpin to the maximum possible.

Step 3-Rotate the eccentrichandle to lift the upper jaw.

Fig 1. Fig 2.

1 2

3

USER GUIDE

MaterialGroups

ISO P ISO H ISO M ISO S ISO K ISO N

1 - 11 38 - 41 12 - 14 31 - 37 15 - 20 21 - 28

Steel Hard SteelStainless

SteelHigh Temp Cast Iron Nonferrous

Tougher Tougher Tougher Tougher Tougher Tougher

FACING

Harder Harder Harder Harder Harder Harder

IC908 IC508

IC9015 IC508

IC9015 IC08

IC9054

IC354 IC418

Tougher Tougher Tougher Tougher Tougher Tougher

Grades Selection for Facing Applications

IC9025

IC9054

IC908

IC908 IC20

IC428IC20

First choice


11/17B211


The workpiece shown was machined using three different conventional tools.

An indexable drill for bottom drilling.1

A standard internal boring bar

with trigon insert for roughing

and finishing.2

A standard internal boring bar with

trigon insert for bottom machining.

This operation requires a small diametershank and long overhang.

3

The HELIFACE internal

boring barHFIR/L MC

type with internal coolant

can replace the three

different ISO tools andshorten machining time by

20%.

USER GUIDE

The HELIFACE Solution


12/17ISCAR212

This part was machined using three different conventional tools.



A single HELIFACE multifunction

tool HFHLmachines the whole

part: grooving, face turning and

chamfering, replacing three ISO

tools and reducing machining

time by 40%.

A modified external ISO tool

for face roughing to center.1

A boring bar for finishing

the major diameter.2

A face grooving tool for

grooving and chamfering.3


A single integral HELIFACE tool

HFHPL-Mreplaces three ISO

tools and reduces machining

time by 50%.

A standard ISO tool for

external turning.1

A boring bar for face

turning and chamfering.2

A face grooving tool for

grooving, recessing and

chamfering.

3

USER GUIDE


13/17B213

Machining Conditions in Face Grooving

Recommended feed range for grooving, with HFPR/Linserts in various widths,using HFHR/Ltoolholders.

mm/rev

0.15

0.03

0.05

0.07

0.09

0.11

0.13

3 4 5 6 mm

0.1

0.12

0.15 0.15

0.04 0.04

0.05 0.05

Width of Inserts (W)

Feed

Chip shapes for grooving, according to width of insert and feed,using HFHR/Ltoolholders.

W

=3,

4mm

W=5,

6mm

f=0.05mm/rev f=0.08mm/rev f=0.10mm/rev f=0.15mm/rev

Note:In face grooving. Curled and long chips mayflow out more easily from deep grooves.

USER GUIDE


14/17ISCAR214

Machining Conditions in Face Turning

mm4.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

0.1 0.2 0.3 mm/rev0.05 0.15 0.25

HFPR/L 3003

HFPR/L 4004

HFPR/L 5004

HFPR/L 6004

Recommended depth of cut and feed range for face turning withHFPR/Linserts in various widths, using HFHR/Ltoolholders.

DepthofCut

Feed

Chip shapes in face turning with inserts HFPR/L-5004& HFPR/L 6004and HFHR/L toolholders

ap=1mm

ap=2m

m

ap=3mm

ap=4mm

f=0.10mm/rev f=0.20mm/rev f=0.25mm/rev f=0.30mm/rev

Note:In roughing, increase feed at small depth of cut, and reduce feed at large depth of cut

USER GUIDE


15/17B215

Face Grooving and Turning Recommendations

Using Adapters for 3 mm inserts

Recommended feed range for grooving with GRIP 3... andHGPL 3...inserts.Feed range changes according to adapter type.

Recommended depth of cut and feed range for turning with GRIP 3... andHGPL 3... inserts.Feed range changes according to adapter type.

mm/rev0.08

0.02

0.03

0.04

0.05

0.06

0.07

4060 4060 4080 4080 4080 m/min

0.08

0.02

0.08

0.020.020.020.02

0.05

0.07

0.04

mm1.2

0.4

0.6

0.05

1.0

0.06 0.07 0.090.08 0.1 0.11 0.12 mm/rev

0.8

0.2

0.04

HGAIR/L 12-3T6HGAER/L 12-3T6



HGAIR/L 25-3T9


HGAIR/L 14-3T7HGAER/L 14-3T7HGAIR/L 17-3T8HGAER/L 17-3T8

HGAIR/L 21-3T9HGAER/L 21-3T9HGAIR/L 25-3T9


Cutting Speed Vc

Feed

Feed

DepthofCutap

Note:In roughing, increase feed at small depthof cut, and reduce feed at large depth of cut.

USER GUIDE


16/17ISCAR216

Recommended feed range in grooving with 4-6 inserts and HFAIR/L & HFAER/L adapters.

Recommended depth of cut and feed range in turning with HFPR/Linserts and HFAIR/L & HFAER/L adapters. Feed range changes according to adapter type.

mm/rev0.12

0.04

0.06

0.08

0.09

0.10

4 5 6

0.05

0.07

mm

0.12

0.10

0.07

0.050.05

0.04

0.11

mm2.5

0.5

1.0

1.5

2.0

0.1 0.20.05 0.15 0.25 mm/rev

HFAIR/L- ...5HFAER/L- ...5



Width of Inserts (W)

Feed

Feedf

DepthofCutap

Note:in roughing, reduce feed when depth of cut isincreased, and increase feed at small depth of cut.

Face Grooving and Turning Recommendations

Using Adapters for 4-6 mm inserts

USER GUIDE


17/17

Semi-Standard Face Groovingand Undercutting Tools

W

TB

W

TB

L

F

W

T

HSKKMCAPTO

D

T

D

d

The following drawings show typicalsemi-standard face grooving toolswhich can be ordered. Please specifyall relevant dimensions and attachworkpiece material geometric details.

1

3

5

B

L

T

W

F

W

T

F

L

HSKKMCAPTO

a

F

W

B

2

4

6

Specially Tailored

USER GUIDE

face grooving & turning -user guide

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