N9
N
N
Technical Guidance
References
Technical Guidance
Turning Edition N10
Milling Edition N15
Endmilling Edition N19
Drilling Edition N22
SUMIBORON Edition N27
References
SI Unit Conversion List N31
Steel and Non-Ferrous Metal Symbols Chart (1)
N32
Steel and Non-Ferrous Metal Symbols Chart (2)
N33
Hardness Scale Comparison Chart N34
Standard of Tapers N35
Dimensional Tolerances for Regularly Used Fits
N36
Dimensional Tolerances and Fits N38
Finished Surface Roughness N39
Technical Guidance /
References
N9 to N39
N
N
N10
N
Technical Guidance /
References
Relation Between Cutting Speed and Cutting Force
1,600
800
0
240160800
Cutting Speed (m/min)
Rake angle: -10°
Rake angle:
Principal Force (N)
Relation Between Rake Angle and Cutting Force
1,600
2,000
2,400
2,800
20 10 0 10 20
Rake Angle (Degree)
Principal Force (N)
2,000
4,000
6,000
8,000
0 0.1
0.04
0.2 0.4
Feed Rate (mm/rev)
Traverse Rupture Strength
When feed rate decreases, specific cutting force increases.
Specific Cutting Force (MPa)
800MPa
600MPa
400MPa
Relation Between Feed Rate and Specific Cutting Force (For Carbon Steel)
500
1000
1500
3500
4000
0.4 0.8 1.2 1.6
Nose Radius (mm)
Principal
force
Feed force
Back force
Large nose radius
increases back force.
Cutting Force (N)
Relation Between Nose Radius and Cutting Force
Cutting Force
P =
k
c
× q
1,000
=
k
c
×
a
p
×
f
1,000
P
: Cutting force (kN)
k
c
: Specific cutting force (MPa)
q
: Chip area (mm
2
)
a
p
: Depth of Cut (mm)
f
: Feed Rate (mm/rev)
Calculating Cutting Force
F
c
: Principal force
F
f
: Feed force
F
p
: Back force
Ff
Fp
Fc
Theoretical Surface Finish
Machined Surface Roughness
Ways to Improve Machined Surface Roughness
(1) Use an insert with a larger nose radius.
(2) Optimise the cutting speed and feed rate
so that built-up edge does not occur.
(3) Select an appropriate insert grade.
(4) Use wiper insert
Actual Surface Roughness
Steel:
Theoretical surface finish x 1.5 to 3
Cast iron:
Theoretical surface finish x 3 to 5
h =
f
2
× 10
3
8 × r
ε
h :
Theoretical surface roughness (μm)
f : Feed rate (mm/rev)
r
ε
: Nose radius (mm)
f
h
P
c
: Net power requirement (KW)
v
c
: Cutting speed (m/min)
f
: Feed rate (mm/rev)
a
p
: Depth of cut (mm)
k
c
: Specific cutting force (MPa)
H
: Required horsepower (HP)
η
: Machine efficiency
(0.70 to 0.85)
Calculating Power Requirement
RoughValue of Kc
Aluminium: 800MPa
General Steel: 2,500 to 3,000MPa
Cast Iron: 1,500MPa
P
c
=
v
c
×
f
×
a
p
×
k
c
60 × 10
3
×
η
H =
P
c
0.75
Calculating Cutting Speed
· n : Spindle speed (min
-1
)
· v
c
: Cutting speed (m/min)
· f : Feed rate (mm/rev)
· a
p
: Depth of cut (mm)
· D
m
: Diameter of work piece (mm)
n : Spindle speed (min
-1
)
v
c
: Cutting speed (m/min)
D
m
: Diameter of work piece (mm)
π
: 3.14
(1) Calculating rotation speed from cutting speed
Refer to the above table
(2) Calculating cutting speed from rotational speed
(Ex.)
v
c
=150m/min,
D
m
=100mm
n =
1,000 × 150
=
478 (min
-1
)
3.14 × 100
øD
m
n
a
p
f
n =
1,000 × v
c
π
× D
m
v
c
=
π
× D
m
× n
1,000
Technical Guidance
Basics of Turning
Turning Edition
Feed Direction
Work : SCM440(38HS)
Inserts : TNGA2204 SS
Holder : PTGNR2525-43
Cutting Conditions
:
v
c
=100m/min
a
p
=4mm
f =0.45mm/rev
N11
N
Technical Guidance /
References
Forms of Tool Failures
Cat. No.
Name of Failure
Cause of Failure
Resulting from
Mechanical Causes
(1) to (5)
(6)
(7)
Flank Wear
Chipping
Fracture
Due to the scratching effect of hard grains contained in the work
material.
Fine breakages caused by high cutting loads or chattering.
Large breakage caused by the impact of excessive mechanical forces
acting on the cutting edge.
Resulting from
Chemical Reactions
(8)
(9)
(10)
(11)
Crater Wear
Plastic Deformation
Thermal Crack
Built-up Edge
Swaft chips removing tool material as it flow over the top face at high
temperatures.
Cutting edge is depressed due to softening at high temperatures.
Fatigue from rapid, repeated heating and cooling cycles during machining.
Adhesion or accumulation of extremely-hard work material on the cutting edge.
Tool Wear
This double logarithm graph shows the relative tool life of the specified wear over a range
of cutting speeds on the X-axis, and the cutting speed along the Y-axis.
Tool Life (V-T)
Flank Wear Crater Wear
Cutting Time T (min)
Initial wear
Steady wear
Sudden
increase
in wear
Flank Wear Width V
B
(mm)
Cutting Time T (min)
Flank Wear Width K
T
(mm)
Wear increases rapidly right after cutting
starts, it then progresses at a moderate and
proportionate pace up to a certain point
where it suddenly increases rapidly again.
Wear increases in proportion to the
cutting time.
Flank Wear Crater Wear
Tool Wear
Cutting Time (min)
Flank Wear Width
(mm)
v
B
v
c
1
1 2 3 4
v
c
2
v
c
3
v
c
4
Cutting Time (min)
Crater Wear Depth
(mm)
v
c1
v
c3
v
c4
v
c2
KT
T'1 T'2 T'3 T'4
Tool Life
Tool Life (min)
Cutting Speed
(m/min)
v
c1
v
c2
v
c3
v
c4
InT1 InT2 InT3 InT4
Tool Life (min)
Cutting Speed
(m/min)
v
c1
v
c2
v
c3
v
c4
InT'1 InT'2 InT'3 InT'4
Forms of Tool Wear
Burrs occur
Higher cutting force
Poor surface finish
Edge wear VC
Bad chip control
cutting edge fracture
Poor machining accuracy,
Burrs occur
Side flank wear
VN1
Flank Wear
Crater Wear
Flank average wear VB
Face flank wear
VN2
Crater wear KT
Technical Guidance
Tool Failures and Tool Life
Turning Edition
N12
N
Technical Guidance /
References
Insert Failure and Countermeasures
Type of Insert Failure Cause Countermeasures
Flank Wear
· Grade lacks wear resistance.
· Cutting speed is too fast.
· Feed rate is far too slow.
· Select a more wear-resistant grade.
P30 P20 P10
K20 K10 K01
· Use an insert with a larger rake angle.
· Decrease the cutting speed
· Increase feed rates.
Crater Wear
· Grade lacks crater wear resistance.
· Rake angle is too small.
· Cutting speed is too fast.
· Feed rate and depth of cut are too
large.
· Select a more crater-wear-resistant grade.
· Use an insert with a larger rake angle.
· Change the chipbreaker.
· Decrease the cutting speed
· Reduce feed rates and depth of cut.
Chipping
· Grade lacks toughness.
·
Cutting edge breaks off due to chip build-up.
· Cutting edge lacks toughness.
· Feed rate and depth of cut are too
large.
· Select a tougher grade.
P10 P20 P30
K01 K10 K20
· Increase amount of honing on cutting
edge.
· Reduce rake angle.
· Reduce feed rates and depth of cut.
Fracture
· Grade lacks toughness.
· Cutting edge lacks toughness.
· Holder lacks toughness.
· Feed rate is too fast.
· Depth of cut is too large.
· Select a tougher grade.
P10 P20 P30
K01 K10 K20
·
Select a chipbreaker with a strong cutting edge.
·
Select a holder with a larger approach angle.
· Select a holder with a larger shank size.
· Reduce feed rates and depth of cut.
Welding or Built-up Edge
· Inappropriate grade selection.
· Dull cutting edge.
· Cutting speed is too slow.
· Feed rate is too slow.
·
Select a grade with less affinity to the work
material like coated carbide or cermet
grades.
· Select a grade with a smooth coating.
· Use an insert with a larger rake angle.
· Reduce amount of honing.
· Increase cutting speeds.
· Increase feed rates.
Plastic Deformation
· Grade lacks thermal resistance.
· Cutting speed is too fast.
· Feed rate is too fast.
· Depth of cut is too large.
· Not enough cutting fluid.
· Select a more crater-wear-resistant grade.
· Use an insert with a larger rake angle.
· Decrease the cutting speed
· Reduce feed rates and depth of cut.
· Supply sufficient amount of coolant.
Notch Wear
· Grade lacks wear resistance.
· Rake angle is too small.
· Cutting speed is too fast.
· Select a wear-resistant grade.
P30 P20 P10
K20 K10 K01
· Use an insert with a larger rake angle.
·
Alter depth of cut to shift the notch location.
Technical Guidance
Tool Failure and Remedies
Turning Edition
N13
N
Technical Guidance /
References
Type of Chip Generation
Spiralling Shearing Tearing Cracking
Shape
Work material Work material
Work material
Work material
Condition
Continuous
chips with good
surface finish.
Chip is sheared
and separated by
the shear angle.
Chips appear to
be torn from the
surface.
Chips crack
before reaching
the cutting point.
Application
Steel, Stainless
steel
Steel, Stainless
steel (Low speed)
Steel, Cast iron (very low
speed, very small feed rate)
Cast iron,
Carbon
Influence Factor
Factor of Improvement Chip Control
(1) Increase Feed Rate (f)
f
1
1
t
1
f
2
2
t
2
f f
2
f
1
then t
2
t
1
When feed rate increases, chips
become thick and chip control improves.
(2) Decrease Side Cutting Edge (
θ
)
ff
t
1
t
2
1
1
2
2
2 1
then t
2
t
1
Even if feed rate is the same, smaller
side cutting edge angle makes chips
thick and chip control improves.
(3) Decrease Nose Radius (rε)
f f
1
2
2
1
t
1
t
2
2 1
then
t
2
t
1
Small
nose
radius
Large
nose
radius
Even if feed rate is the same, a smaller
nose radius makes chip thick and chip
control improves.
* Cutting force increases in proportion with
the length of the contact surface. Therefore,
a larger nose radius increases back force
which induces chattering. With the same
feed rate, a smaller nose radius produces a
rougher surface finish.
Type of Chip Control
Chip Types
Depth
ABCDE
Large
Small
Evaluation
NC Lathe
(For Automation)
General Lathe
(For Safety)
Good: C type, D type
A type:
Twines around the tool or workpiece, damages the machined
surface and affects safety.
Poor
B type:
Causes problems in the automatic chip conveyor and chipping occurs easily.
E type:
Causes spraying of chips, poor machined surface due to
chattering, chipping, large cutting force and high temperatures.
Depth of Cut (mm)
4.0
2.0
0.1 0.2 0.3 0.4 0.5
Feed Rate (mm/rev)
Side Cutting Edge Angle
45°
15°
0.2 0.25 0.3 0.35
Feed Rate (mm/rev)
Nose Radius (mm)
1.6
0.8
0.4
0.5 1.0 1.5 2.0
Depth of Cut (mm)
Easy
Large
Small
Fast
Work deformation
Rake angle
D.O.C.
Cutting speed
Difficult
Small
Large
Slow
Technical Guidance
Chip Control
Turning Edition
N14
N
Technical Guidance /
References
Thread Cutting Methods
Cutting Method Characteristics
Radial Infeed
· Most common threading technique, used mainly for small pitch threads.
· Easy to change cutting conditions such as depth of cut, etc.
· Longer contact points lead to more chatter.
· Difficult to control chip evacuation.
· Damage on the trailing edge gets larger faster.
Flank Infeed
· Effective for large pitch threads and blemish-prone work material surfaces.
· Chips evacuate from one side for good chip control.
· The trailing edge side is worn, and therefore the flank is easily worn.
Corrected Flank Infeed
· Effective for large pitch threads and blemish-prone work material surfaces.
· Chips evacuate from one side for good chip control.
· Inhibits flank wear on trailing edge side.
Alternating Flank Infeed
· Effective for large pitch threads and blemish-prone work material surfaces.
· Wears evenly on right and left cut edges.
· Since both edges are used alternatively, chip control is sometimes difficult.
Direction of CutFeed Dir.
Leading
Edge
Trailing
Edge
Troubleshooting for Threading
Failure Cause Countermeasures
Cutting Edge Failure
Excessive Cutting Edge Wear
· Tool material · Select a more wear-resistant grade
· Cutting condition
· Decrease the cutting speed
· Optimise coolant flow and density
· Change the number of passes.
Uneven Wear on Right and Left
Sides
· Insert attachment
· Check whether the cutting edge inclination angle is
appropriate for the screw lead angle.
· Check whether the tool is mounted properly.
· Cutting condition
· Change to corrected flank infeed or alternating flank
infeed
Chipping · Cutting condition · If caused by a built-up edge, increase cutting speed
Breakage
· Packing of chips
· Supply enough amount of coolant to the cutting
edge.
· Cutting condition
·
Increase the number of passes while decreasing the depth of cut per pass.
·
Use different tools for roughing and finishing applications.
Shape and Accuracy
Poor Surface Roughness
· Cutting condition
·
If blemished due to low-speed machining, increase the cutting speed.
· If chattering occurs, decrease the cutting speed.
·
If the depth of cut of the final pass is small, make it larger.
· Tool material · Select a more wear-resistant grade
· Inappropriate cutting
edge inclination angle
· Select a correct shim to secure relief on the side of
the insert.
Inappropriate Thread Shape · Insert attachment · Check whether the tool is mounted properly.
Shallow Thread Depth
· Small depth of cut · Check cutting depth
· Tool wear · Check damage to the cutting edge.
Technical Guidance
Basics of Threading
Turning Edition
N15
N
Technical Guidance /
References
Parts of a Milling Cutter
Milling Calculation Formulas
Body diameter
Body
Ring
Boss diameter
Hole diameter
Keyway width
Keyway depth
Axial rake angle
Chip pocket
Clamp bolt
Face angle
relief
Indexable insert
Cutter diameter (nominal diameter)
Locator
Clamp
Radial rake angle
Reference ring
Face cutting
edge angle
Face cutting
edge
(Wiper cutting
edge)
Chamfer
Reference ring
True rake
angle
Peripheral
relief angle
A
A
Cutting edge inclination
angle
Corner angle
Approach Angle
Cutter height
External
cutting edge
(Principal
cutting edge)
Power Requirement
Relation Between Feed Rate, Work Material, Specific Cutting Force
10.000
8.000
6.000
4.000
2.000
0
0.1
0.04
0.2
0.4 0.6 0.8 1.0
Feed Rate (mm/t)
Specific Cutting Force
(MPa)
Horsepower Requirement
Chip Removal Amount
No
Symbol
Work Material
Alloy Steel
Carbon Steel
Cast Iron
Aluminium Alloy
(1)
1.8 0.8 200
(2)
1.4 0.6 160
(3)
1.0 0.4 120
Figures in table indicate these characteristics.
·
Alloy steel and carbon steel: Traverse rupture strength
σ
B(GPa)
· Cast iron: Hardness HB
P
c
=
a
e
× a
p
× v
f
× k
c
Q × k
c
60 × 10
6
×
η
60 × 10
3
×
η
H =
P
c
0.75
Q =
a
e
× a
p
× v
f
1,000
P
c
: Power requirement (kw)
H : Required horsepower (HP)
Q : Chip removal amount (cm
3
/min)
a
e
: Cutting width (mm)
v
f
: Feed rate (mm/min)
a
p
: Depth of cut (mm)
k
c
: Specific cutting force (MPa)
Rough value
Steel: 2,500 to 3,000MPa
Cast iron: 1,500MPa
Aluminium: 800MPa
η
: Machine efficiency (about 0.75)
Technical Guidance
Basics of Milling
Milling Edition
Calculating Cutting Speed
Cutter
Work
material
ø
D
c
n
v
f
n
v
f
f
z
a
p
Calculating Feed Rate
v
c
=
π
× D
c
× n
1,000
v
f
=f
z
× z × n
f
z
=
v
f
z × n
v
c
: Cutting speed (m/min)
π
: 3.14
D
c
: Cutter diameter (mm)
n : Rotational speed (min
-1
)
v
f
: Feed rate per minute (mm/min)
f
z
: Feed rate per tooth (mm/t)
z : Number of teeth
n =
1,000 × v
c
π
× D
c
N16
N
Technical Guidance /
References
Rake Angle Combination
Negative - Positive Type Double Positive Type Double Negative Type
Edge Combination and
Chip Removal
A.R: Axial rake angle
R.R: Radial rake angle
A.A: Approach angle
:
Chip and removal direction
: Rotation
A.A (30° to 45°)
Positive
Negative
A.A
(15° to 30°)
Positive
Positive
Negative
Negative
A.A (15° to 30°)
Advantages
Excellent chip removal and cutting
action
Good cutting action
Double-sided inserts can be used
and higher cutting edge strength
Disadvantages
Only single-sided inserts can be
used
Lower cutting edge strength and only
single-sided inserts can be used
Dull cutting action
Application
For Steel, Cast iron, Stainless steel,
Alloy steel
For general milling of steel and low
rigidity work piece
For light milling of cast iron and
steel
Series WGC Type, UFO Type DPG Type DNX Type, DGC Type, DNF Type
Chips (Ex.)
·
Work material: SCM435
· v
c
=130m/min
f
z
=0.23mm/t
a
p
=3mm
Functions of the Various Cutting Angles
Description
Symbol
Function
(1)
(2)
Axial rake angle
Radial rake angle
A.R.
R.R.
Determines chip removal direction, built-
up edge, cutting force
Available in positive to negative (large to small) rake angles; Typical combinations:
Positive and Negative, Positive and Positive, Negative and Negative
(3) Approach angle A.A. Determines chip thickness, chip
removal direction
Large: Thin chips and small cutting
force
(4) True rake angle T.A. Effective rake angle
Positive (Large): Excellent machinability
Low cutting edge strength.
Negative (Small)
: Strong cutting edge and
easy chip adhesion.
(5) Cutting edge inclination angle I .A. Determines chip control direction
Positive (Large): Excellent chip control and small cutting
force. Low cutting edge strength.
(6) Face cutting edge angle F.A. Determines surface roughness Small: Improved surface roughness.
(7) Relief angle
Determines edge strength, tool life, chattering
True Rake Angle Chart (T.A)
+30°
1 1 20° 25° 30° 35°
+25°
+20°
+15°
+1
+ 5°
- 5°
-1
-15°
-20°
-25°
-30°
+30°
+25°
+20°
+15°
+1
+ 5°
- 5°
-1
-15°
-20°
-25°
-30°
+30°
+25°
+20°
+15°
+1
+ 5°
- 5°
-20°
-25°
-1
-15°
45°50°55° 60° 65° 70° 75° 80° 85° 90°40°
Approach Angle A.A
True Rake Angle T.A
-30°
Axial Rake Angle A.R
Radial Rake Angle R.R
(2)
(1)
(3)
(4)
<Formula> tan T.A=tan R.R · cos A.A + tan A.R · sin A.A
(Ex.) (1) A.R
(2) R.R
(3) A.A
(Axial rake angle)
(Radial rake angle)
(Approach angle)
= +1
= –30°
= 60°
-> T.A. (True rake angle) = –8° (4)
Inclination Angle (I.A) Chart
-30°
1 1 20° 25° 30° 35°
-25°
-20°
-15°
-1
- 5°
+ 5°
+1
+15°
+20°
+25°
+30°
+30°
+25°
+20°
+15°
+1
+ 5°
- 5°
-1
-15°
-20°
-25°
-30°
-30°
-25°
-1
- 5°
+ 5°
+20°
+25°
+1
+15°
45°50°55° 60° 65° 70° 75° 80° 85° 90°40°
+30°
-20°
-15°
Approach Angle A.A
Inclination Angle I.A
Axial Rake Angle A.R
Radial Rake Angle R.R
(1)
(3)
(2)
(4)
<Formula> tan
I
.R=tan A.R · cos A.A – tan R.R · sin A.A
(Ex.) (1) A.R
(2) R.R
(3) A.A
(Axial rake angle)
(Radial rake angle)
(Approach angle)
=–1
=+1
= 25°
->
I
(Inclination angle) =–15° (4)
Technical Guidance
Basics of Milling
Milling Edition
N17
N
Technical Guidance /
References
Relation Between Engagement Angle and Tool Life
Work material feed direction V
f
Cutting Width W
øD
c
Rotation
Insert
Engagement angle E
The Engagement angle denotes the angle
at which the full length of the cutting edge
comes in contact with the work material,
with reference to the feed direction.
· The larger E is, the shorter the
tool life.
· To change the value of E:
1) Increase the cutter size.
2)
Shift the position of the cutter.
Relation to Cutter Diameter
Large Diameter
f
Small
øD
c
n
Small Diameter
f
Large
øD
c
n
Relation to Cutter Position
f
n
Small
f
n
Large
Relation to Tool Life
0.4
-30° 30° 60°
0.3
0.2
0.1
S50C
Engagement Angle
Tool Life (Milling Area) (m
2
)
-20° 40° 60° 80°20°
0.6
0.4
0.2
FC250
Engagement Angle
Tool Life (Milling Area) (m
2
)
Surface roughness without wiper flat
Influence of different face angles on surface finish
HC
· Work : SCM435
· Cutter: DPG5160R
(Single tooth)
· v
c
= 154m/min
f
z = 0.234mm/t
a
p
= 2mm
· Face Cutting Edge Angle
(A): 28'
(B): 6'
Surface roughness with straight wiper flat
HF
h: Projection value of wiper insert
Fc: 0.05mm
Al: 0.03mm
HW
Wiper insert
Norm
a
teeth
h
Effects of having wiper insert (example)
· Work : FC250
· Cutter: DPG4100R
· Insert : SPCH42R
· Face run-out : 0.015mm
· Radial run-out: 0.04mm
· v
c
= 105m/min
f
z
= 0.29mm/t
(1.45 mm/rev)
(C) : Only normal teeth
(D) : With 1 wiper insert
f : Feed rate per revolution (mm/rev)
HC
HW
Hc: Surface roughness with only normal teeth
Hw: Surface roughness with wiper insert
To Improve Surface Roughness
(1) Inserts with wiper flat
When all the cutting edges
have wiper flats, a few teeth are
intentionally elevated to play the
role of a wiper insert.
·
Insert equipped with straight wiper flat
(Face angle: 15' - 1°)
·
Insert equipped with curved wiper flat
(Curvature R500 (example))
(2) Wiper insert assembling system
A system to protrude one or
two inserts (wiper inserts) with
a smooth curved edge just a
little beyond the other teeth
to wipe the milled surface.
(Applies to WGC, RF types, etc.)
Relation between the number of simultaneously engaged cutting edges and cutting force:
· 0 or 1 edge in
contact at same
time.
· Only 1 edge in
contact at any time.
· 1 or 2 edges in
contact.
· 2 edge in
contact at any
time.
· 2 to 3 edges in
contact.
a) b) c) d) e)
Time Time Time Time Time
Cutter
Cutting
force
Cutting
force
Cutting
force
Cutting
force
Cutting
force
Work
material
Normally, cutting width is considered to be appropriate with 70 to 80% of the cutter diameter engaged as shown in example
d). However, this may not apply due to the actual rigidity of the machine or work piece, and machine horsepower.
(C)
×1,000
Feed rate per rev.
20
20
15
10
5
(Only
normal
teeth)
Roughness
(µm)
(D)
×1,000
20
20
15
10
5
Roughness
(µm)
(With 1
wiper
insert)
(A)
Feed rate
per tooth
Feed rate
per tooth
(B)
×2,000
×100
Feed rate
per tooth
Feed rate
per tooth
Technical Guidance
Basics of Milling
Milling Edition
N18
N
Technical Guidance /
References
Failure Basic Remedies Remedy Examples
Cutting Edge Failure
Excessive Flank Wear
Tool Material
Cutting
Conditions
· Select a more wear resistant grade.
Carbide
P30 P20
Coated
K20 K10 Cermet
· Reduce cutting speeds. Increase
feed rate.
· Recommended insert grades
Excessive Crater Wear
Tool Material
Cutting
Conditions
· Select a crater-resistant grade.
· Reduce cutting speeds. Reduce
depth-of-cut and feed rate.
· Recommended insert grades
Chipping
Tool Material
Tool Design
Cutting Conditions
· Change to tougher grades.
P10 P20 P30
K01 K10 K20
·
Select a negative-positive cutter configuration with a large
peripheral cutting edge angle (small approach angle).
· Reinforce the cutting edge (Honing).
· Select a strong edge insert (G H).
· Reduce feed rates.
· Recommended insert grades
· Recommended cutter: SEC-WaveMill WGX Type
· Cutting conditions: Refer to H22
Breakage
Tool Material
Tool Design
Cutting
Conditions
·
If it is due to excessive low speeds or very low
feed rates, select an adhesion resistant grade.
· If it is due to thermal cracking, select
a thermal impact resistant grade.
·
Select a negative-positive (or negative) cutter
configuration with a large peripheral cutting
edge angle (small approach angle).
· Reinforce the cutting edge (Honing).
·
Select a stronger chipbreaker (G H)
·
Increase insert size (Thickness in particular).
· Select appropriate conditions with
regards to the particular application.
· Recommended insert grades
· Recommended cutter: SEC-WaveMill WGX Type
· Insert thickness: 3.18
4.76mm
· Insert type: Standard
Strong edge type
· Cutting conditions: Refer to H22
Others
Unsatisfactory
Machined Surface
Finish
Tool Material
Tool Design
Cutting
Conditions
· Select an adhesion resistant grade.
Carbide
Cermet
·
Improve axial runout of cutting edges.
Use a cutter with less runout
Attach correct inserts.
· Use wiper inserts.
·
Use special purpose cutters designed for finishing.
· Increase cutting speeds
· Recommended insert grades
* marked cutters can be fitted with wiper inserts.
Chattering
Tool Design
Cutting Conditions
Others
·
Select a cutter with sharp cutting edges.
· Use an irregular pitched cutter.
· Reduce feed rates.
·
Improve workpiece and cutter clamp rigidity.
· Recommended cutter
For Steel: SEC-WaveMill WGX Type
For Cast Iron: SEC-Sumi Dual Mill DGC Type
For Non-Ferrous Alloy: High Speed cutter for Aluminium RF type
Unsatisfactory Chip
Control
Tool Design
·
Select cutter with good chip removal features.
· Reduce number of teeth.
· Enlarge chip pocket.
· Recommended cutter: SEC-WaveMill WGX Type
Edge Chipping On
Workpiece
Tool Design
Cutting Conditions
·
Increase the peripheral cutting edge angle
(decrease the approach angle).
·
Select a stronger chipbreaker (G
L).
· Reduce feed rates.
· Recommended cutter: SEC-WaveMill WGX Type
Burr On Workpiece
Tool Design
Cutting Conditions
·
Select a cutter with sharp cutting edges.
· Increase feed rates.
·
Select an insert designed for low burr.
·
Recommended cutter: SEC-WaveMill WGX Type + FG Breaker
DGC
Type + FG Breaker
Steel Cast Iron
Non-Ferrous Alloy
Finishing
T250A (Cermet)
ACK200 (Coated Carbide)
BN700 (SUMIBORON)
DA1000 (SUMIDIA)
Roughing
ACP100 (Coated Carbide) ACK200 (Coated Carbide) DL1000 (Coated Carbide)
Steel Cast Iron
Roughing
ACP300 (Coated Carbide)
ACK300 (Coated Carbide)
Steel Cast Iron
Finishing
ACP200 (Coated Carbide)
ACK200 (Coated Carbide)
Roughing
ACP300 (Coated Carbide) ACK300 (Coated Carbide)
Steel Cast Iron
Non-Ferrous Alloy
General Purpose
Cutter
Insert
WGX type*
ACP200
(Coated Carbide)
DGC type
ACK200
(Coated Carbide)
RF type*
H1 (Carbide)
DL1000 (Coated Carbide)
Finishing
Cutter
Insert
WGX type
T250A (Cermet)
FMU type
BN7000 (SUMIBORON)
RF type
DA1000 (SUMIDIA)
Steel Cast Iron
Non-Ferrous Alloy
Finishing
T250A (Cermet)
ACK200 (Coated Carbide)
DA1000 (SUMIDIA)
Roughing
ACP100 (Coated Carbide) ACK200 (Coated Carbide) DL1000 (Coated Carbide)
Tool Failure and Remedies
Technical Guidance
Troubleshooting for Milling
Milling Edition
N19
N
Technical Guidance /
References
Parts of an Endmill
Calculating Cutting Conditions
(Square Endmill)
(Ball Endmill)
Center Cut
With Center Hole
Diameter
Body
Cutter sweep
Neck
Neck
diameter
Shank
Shank
diameter
Shank length
Neck length
Length of cut
Overall length
Centre hole
Land width
Relief width
Radial relief
Radial primary
relief angle
Radial secondary
clearance angle
Margin width
Margin
Land
Land width
Rake face
Rake angle
Flute
Flute depth
Chip pocket
Rounded
flute bottom
Centre hole
Heel
Web
thickness
Axial primary relief angle
Ball radius
Axial secondary
clearance angle
Concavity angle of
end cutting edge (*)
Helix angle
Radial
cutting edge
End cutting edge
Corner
End gash
* Centre area is lower than the periphery
Calculating Cutting Speed
v
c
: Cutting speed (m/min)
π
: 3.14
D
c
: Endmill diameter (mm)
n : Spindle speed (min
-1
)
v
f
: Feed rate (mm/min)
f :
Feed rate per revolution (mm/rev)
f
z
: Feed rate per tooth (mm/t)
z : Number of teeth
a
p
:
Axial Depth of Cut (mm)
a
e
:
Radial Depth of Cut (mm)
R : Ballnose Radius
Calculating Feed Rate Per Revolution and Per Tooth
Calculating Notch Width (D
1
)
Cutting speed and feed rate (per revolution
and per tooth) are calculated using the
same formula as square endmill.
a
p
a
D
c
a
p
D
c
p
f
Pick feed
a
p
Depth of cut
a
p
D
c
p
f
Side milling
Slotting
Technical Guidance
Basics of Endmilling
Endmilling Edition
v
c
=
π
x D
c
x n
1,000
n =
1,000 x v
c
π
x D
c
v
f
= n x f f =
v
f
n
f
z
=
f
=
v
f
zn x z
v
f
= n x f
z
x z
D
1
= 2 x 2 x R x a
p
a
p
2
N20
N
Technical Guidance /
References
Up-cut and Down-cut
Relation Between Cutting
Condition and Deflection
Endmill
Specifications
Side Milling Slotting
Work: Pre-hardened steel
(40HRC)
Cutting Conditions
: v
c
=25m/min
a
p
=12mm
a
e
=0.8mm
Work: Pre-hardened steel
(40HRC)
Cutting Conditions
: v
c
=25m/min
a
p
=8mm
a
e
=8mm
Cat.
No.
Number
of Teeth
Helix
Angle
Feed rate Feed rate Feed rate Feed rate
0.16mm/rev 0.11mm/rev 0.05mm/rev 0.03mm/rev
Style Style Style Style
Up-cut Down-cut Up-cut Down-cut Up-cut Down-cut Up-cut Down-cut
230
°
430
°
Results
·
The tool tip tends to back off with the down-cut.
·
4 teeth offers more rigidity and less backing off.
·
The side of the slot tends to cut into the up-cut side toward the bottom of the slot.
·
4 teeth offers higher rigidity and less deflection.
Side Milling Slotting
Wear Amount Surface Roughness Condition
Work: S50C
Endmill: GSX21000C-2D
(ø10mm, 2 teeth)
Cutting Conditions
: v
c
=88m/min
(N=
2800min
-1
)
v
f
=
560mm/min
(f
z
=
0.1mm/t
)
a
p
=15mm
a
e
=0.5mm
Side Milling
Dry,Air
f
z
f
z
Work Feed Direction
Work material
(a) Up-cut
Work Feed Direction
Work material
(b) Down-cut
f
z
Work Feed Direction
Work
material
Up-cut
Down-cut
(a) Up-cut (b) Down-cut
Work Feed Direction
Work Feed Direction
Work material Work material
50 100 150 200 2500
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
Cutting Length (m)
Flank Wear Width (mm)
Up-cut
Down-cut
5
4
3
2
1
0
Up-cut
Down-cut
Up-cut
Down-cut
Feed Dir. Vertical Dir.
Rmax (µm)
Cutting surface
Reference surface
Down-cutUp-cut
GSX
20800
S
-
2
DGSX40800S-2D
Technical Guidance
Basics of Endmilling
Endmilling Edition
N21
N
Technical Guidance /
References
Troubleshooting for Endmilling
Failure Cause Remedies
Cutting Edge Failure
Excessive Wear
Cutting Conditions
Tool Shape
Tool Material
· Cutting speed is too fast
· Feed rate is too fast
· The flank relief angle is too small
· Insufficient wear resistance
· Decrease cutting speed and feed rate.
· Change to an appropriate flank relief angle
· Select a substrate with more wear
resistance
· Use a coated tool
Chipping
Cutting Conditions
Machine Area
· Feed rate is too fast
· Cutting depth is too deep
· Tool overhang is too long
· Work clamps are weak
· Tool is not firmly attached
· Decrease cutting speed.
· Reduce depth of cut
· Adjust tool overhang for correct length
· Clamp the work piece firmly
· Make sure the tool is seated in the chuck
properly
Tool Fracture
Cutting Conditions
Tool Shape
· Feed rate is too fast
· Cutting depth is too deep
· Tool overhang is too long
· Cutting edge is too long
· Web thickness is too small
· Decrease cutting speed.
· Reduce depth of cut
· Reduce tool overhang as much as possible
· Select a tool with a shorter cutting edge
· Change to more appropriate web thickness
Others
Shoulder Deflection
Cutting Conditions
Tool Shape
· Feed rate is too fast
· Cutting depth is too deep
· Tool overhang is too long
· Cutting on the down-cut
· Helix angle is large
· Web thickness is too thin
· Decrease cutting speed.
· Reduce depth of cut
· Adjust tool overhang for correct length
· Change directions to up-cut
· Use a tool with a smaller helix angle
· Use a tool with the appropriate web
thickness
Unsatisfactory
Machined Surface
Finish
Cutting Conditions
· Feed rate is too fast
· Packing of chips
· Decrease cutting speed.
· Use air blow
· Use an insert with a larger relief pocket.
Chattering
Cutting Conditions
Tool Shape
Machine Area
· Cutting speed is too fast
· Cutting on the up-cut
· Tool overhang is too long
· Rake angle is large
· Work clamps are weak
· Tool is not firmly attached
· Decrease the cutting speed
· Change directions to down-cut
· Adjust tool overhang for correct length
· Use a tool with an appropriate rake angle
· Clamp the work piece firmly
· Make sure the tool is seated in the chuck
properly
Packing of Chips
Cutting Conditions
Tool Shape
· Feed rate is too fast
· Cutting depth is too deep
· Too many teeth
· Packing of chips
· Decrease cutting speed.
· Reduce depth of cut
· Reduce number of teeth
· Use air blow
Technical Guidance
Troubleshooting for Endmilling
Endmilling Edition
N22
N
Technical Guidance /
References
Margin width
Margin
Body
clearance
Flute
Flute
width
Land width
Chisel edge angle
Cutting
edge
Chisel edge corner
Chisel edge
Depth of
body clearance
Diameter of
body clearance
Chisel edge length
Web thickness
Web thinning
Web
Cutter sweep
Relief angle
Rake
angle
A:B or A/B = Flute width ratio
Straight shank
Tang length
Tang
thickness
A
B
Flank
Height of point
Drill
diameter
Cutting
edge
Outer
corner
Heel
Body clearance
Rake face
Point angle
Leading edge
Back taper
Lead
Helix angle
Flute length
Overall length
Shank length
Taper shank
Neck
length
Neck
Tang
Tang
thickness
Parts of a Drill
Point Angle and Force
Minimum Requirement Relief Angle
Relation Between Edge Treatment and Cutting Force
Point Angle and Burr
Web Thickness and Thrust
Decrease Chisel Width by Thinning
Point angle (small) Point angle (large)
ø
ø
f
f: Feed rate (mm/rev)
0.2 0.3 0.4
0
2,000
4,000
6,000
8,000
0.2 0.3 0.4
0
20
40
60
Feed Rate (mm/rev)
Feed Rate (mm/rev)
Torque (N·m) Thrust (N)
Thrust
Thrust
Removed
S type N type X type
When point angle is large, thrust becomes
large but torque becomes small.
When point angle is large, burr height becomes low.
Work: SS
41
Cutting Speed v
c
=
50
m/min
0.05 0.10 0.15
118
140
150
0.20 0.25
0
0.2
0.4
0.6
0.8
Burr Height (mm)
Feed Rate (mm/rev)
Web thinning decreases the thrust concentrated
at the chisel edge, makes the drill edge sharp,
and improves chip control.
f
* Large relief angle is needed at the centre of the drill.
Typical types of thinning
S type: Standard type used generally.
N type: Suitable for thin web drills.
X type: For hard-to-cut material or deep
hole drilling. Drill starts easier.
Drill
: Multi-drill KDS215MAK
Width : 0.15mm 0.23mm
Work
: S50C (230HB)
Cutting Conditions : v
c
=50m/min, Wet
Technical Guidance
Basics of Drilling
Drilling Edition
N23
N
Technical Guidance /
References
Reference of Power Requirement and Thrust
Cutting Condition Selection
Control Cutting Force for
Low Rigid Machine
High Speed Machining Recommendation
f: Feed rate (mm/rev)
Work material: S48C (220HB)
The following table shows the relation between edge treatment width and cutting force. If a problem caused by
cutting force occurs, reduce either the feed rate or the edge treatment width.
Cutting Conditions
Edge Treatment Width
0.15mm
0.05mm
v
c
(m/min) f(mm/rev)
Torque (N·m) Thrust (N) Torque (N·m) Thrust (N)
40 0
.
38 12
.
82
,
820 12
.
02
,
520
50 0
.
30 10
.
82
,
520 9
.
41
,
920
60 0
.
25 9
.
22
,
320 7
.
61
,
640
60 0
.
15 6
.
41
,
640 5
.
21
,
100
If there is surplus capacity with enough machine power and sufficient rigidity, adopting higher efficiency
conditions would improve the tool life; however, sufficient amount of coolant must be supplied.
Drill : ø10mm
Work : S50C 230HB
Work
: S50C (230HB)
Cond.: f = 0.3mm/rev
H = 50mm
Life
: 600holes (Cutting length: 30m)
Margin
Flank face Rake face
10 20 30 40
0
2
4
6
8
f =0.3
f =0.2
f =0.1
10 20 30 40
0
12,000
10,000
8,000
6,000
4,000
2,000
f =0.3
f =0.2
f =0.1
Diameter øD
c
(mm) Diameter øD
c
(mm)
Power (kw)
Thrust (N)
Wear Example
v
c
=
60
m/min v
c
=
120
m/min
Technical Guidance
Basics of Drilling
Drilling Edition
Explanation of Margins (Difference between single and double margins)
Single Margin (2 guides: circled parts)
Double Margin (4 guides: circled parts)
Shape used on most drills
4-point guiding reduces hole bending and undulation for
improved stability and accuracy during deep hole drilling.
N24
N
Technical Guidance /
References
Chuck
Run-out Accuracy
Peripheral Run-out Accuracy
when Tool Rotates
Influence of Work
Material Surface
How to Use a Long Drill
For the run-out accuracy of web-thinned drills, not
only the difference in lip height (B) but also the run-
out after thinning (A) is important.
When the tool rotates
The peripheral run-out accuracy
of the drill mounted on the spindle
should be controlled within
0.03mm. If the run-out exceeds
the limit, the drilled hole will also
become large causing an increase
in the horizontal cutting force,
which may result in drill breakage.
When the work material rotates
Not only the peripheral run-out at the drill edge (A)
but also the concentricity at (B) should be controlled
within 0.03mm.
Work material with slanted or uneven surface
If the surface of the hole entrance or exit is
slanted or uneven, decrease the feed rate to 1/3
to 1/2 of the recommended cutting condition.
Problem
When using a long drill (e.g. XHGS type and XHT
type), DAK type drill, or SMDH-D type drill at high
rotation speeds, the run-out of the drill tip may cause
a deviation of the entry point as shown on the right,
bending the drill hole and resulting in drill breakage.
Remedies
(A): The run-out accuracy of thinning point
(B): The difference of the lip height
0
0 05
0 10
0 15
0 20
0 25
0 005 0 02 0.05
0.050.005 0.02 0.020.1 0.1
0.1
MDS140MK
S50C
v
c
50m/min
f 0 3mm/rev
mm
mm
mm
Centre
run-out
(A)
Peripheral
run-out
(B)
Hole Expansion
(Units: mm)
0 0.05 mm 010kg
0.005
0.09
Peripheral
Run-out
* Horizontal cutting force.
Drill: MDS120MK Work material: S50C (230HB)
Cutting Conditions
c
=50m/min, =0.3mm/rev, =38mm
Water soluble coolant
Hole Expansion Cutting Force*
Run-out: within 0.03mm
Run-out: within 0.03mm
(Exit) (Entrance)
Hole bend
Position shift
Method 1
Step 1
Step 2
Drilling under
recommended
condition
Method 2 * Low rotational speed minimises centrifugal forces and prevents drill bending.
Step 1 Step 2 Step 3
Drilling under
recommended
condition
1xD pilot hole
(same dia.)
Short drill
Technical Guidance
Basics of Drilling
Drilling Edition
N25
N
Technical Guidance /
References
Drill Regrinding
When to regrind
When one or two feed marks (lines) appear on the margin,
when corner wear reaches the margin width, or when small
chipping occurs, it indicates that the drill needs to be sent
for regrinding.
How and where to regrind
We recommend applying regrinding and recoating.
Recoating is recommended to prevent shortening of
tool life. Note, ask us or an approved vendor to recoat
with our proprietary coating.
Regrinding on your own
Customers regrinding their own drills can obtain
MultiDrill Regrinding Instructions from us directly or
your vendor.
Tool life determinant
1 to 2
feed marks
Appropriate
tool life
Excessive
marks
Over-used
Power Consumption
(
kW
)
=
HB
×
D
c
0.68
×
v
c
1.27
×
f
0.59
/36,000
Thrust(N)=0.24
×
HB
×
D
c
0.95
×
f
0.61
×
9.8
Drill Maintenance Using Cutting Oil
Calculation of Power Consumption and Thrust
Work Clamping
High thrust forces occur during
high-efficiency drilling. Therefore,
the workpiece must be supported to
prevent fracture caused by bending.
Also, large torques and horizontal
cutting forces occur. Therefore, the
workpiece must be clamped firmly
enough to withstand them.
(1) Collet Selection
and Maintenance
Ensure proper chucking of
drills to prevent vibration.
Collet chucks (thrust bearing
type) provide strong and
secure grip force.
When replacing drills,
regularly remove cutting
debris inside the collet by
cleaning the collet and the
spindle with oil. Repair marks
with an oilstone.
(2) Drill Installation
The peripheral run-out of the
drill mounted on the spindle
should be controlled within
0.03mm.
Do not chuck on the drill flute.
Drill chucks and keyless chucks
are not suitable for MultiDrills as
they have a weaker grip force.
If drill flute inside the holder, chip
removal will be obstructed thus
causing damage to the drills.
Collet Chuck
Collet
If there are marks, repair with an
oilstone or change to a new one.
Edge run-out to be
within 0.03mm.
Do not grip on the
drill flute.
Collet
Drill Chuck
(1) Choosing of
Cutting Oil
If cutting speed is more than
40m/min, cutting oil JISW1 type 2
is recommended for its good
cooling effect & chip removal
ability as it is highly soluble.
If cutting speed is below 40m/min
and longer tool life is a priority,
non-water cutting oil JISA1 type 2,
an activated sulphuric chloride oil,
is recommended for its lubricity.
* Non-water soluble oil may be
flammable. To prevent fire, a
substantial amount of oil should
be used to cool the component
so that smoke or heat will not be
generated.
(2) Supply of Coolant
If using an external supply of
coolant, fill a substantial amount
from the inlet. Oil pressure range:
0.3 to 0.5 MPa, oil level range:
3 to 10 /min.
If using an internal supply of
coolant (Ex: HK Type) for holes
For holes ø4 or smaller, the oil
pressure must be at least 1.5MPa
to ensure a sufficient supply of
coolant.
holes ø6 or larger: 0.5 to 1.0 MPa
for hole depths below 3 times the
drill diameter, and 1 to 2 MPa or
more for hole depths more than 3
times the diameter.
Use high pressure
at entrance
Easy usage
Use high pressure at entrance
Vertical drilling
Horizontal
drilling
External supply of coolant
Internal supply of coolant
Coolant supply
holder
Machine
internal supply
Bending Fracture
Especially
large drills
* When designing the machine, an allowance of 1.6 x Power Consumption
and 1.4 x Thrust should be given.
Technical Guidance
MultiDrill Usage Guidance
Drilling Edition
Calculating Cutting Speed
Calculating Feed Rate Per Revolution and Per Tooth
T =
H
v
f
Calculation of Cutting Time
Calculation of Power Consumption and Thrust
c
Hole Depth
v
c
=
π
x D
c
x n
1,000
n =
1,000 x v
c
π
x D
c
v
f
= n x f f =
v
f
n
v
c
: Cutting Speed (m/min)
π
: Circular Constant 3.14
D
c
: Drill Diameter (mm)
n : Spindle Speeds (min
-1
)
v
f
: Feed Rate (mm/min)
f :
Feed Rate per Revolution (mm/rev)
H : Drilling Depth (mm)
T : Cutting Time (min)
HB
: Brinell Hardness
N26
N
Technical Guidance /
References
Troubleshooting for Drilling
Failure Cause Basic Remedies Remedy Examples
Drill Failure
Excessive Wear on
Cutting Edge
· Inappropriate cutting
conditions.
· Use higher cutting speeds. ·
Refer to the upper limit of the recommended conditions listed the Igetalloy Cutting Tools Catalogue.
· Increase feed rates. ·
Refer to the upper limit of the recommended conditions listed the Igetalloy Cutting Tools Catalogue.
·
Unsuitable cutting fluid.
·
Reduce pressure if using internal coolant.
·
1.5 MPa or below (external coolant if hole depth is L/D = 2 or less).
· Use cutting fluid with more lubricity. · Use JIS A1 grade No. 1 or its equivalent.
Chisel Point
Chipping
· Off-centre starts.
· Reduce feed rate at entry point.
· f=0.08 to 0.12mm/rev
·
Pre-processing to ensure flat contact surface.
· Use endmill to produce flat surface.
·
Equipment and/or work
material lacks rigidity.
·
Change cutting conditions to reduce resistance.
· Increase v
c
and decrease f (reduce thrust).
· Improve work material clamp rigidity.
· Cutting edge is too
weak.
· Increase size of chisel width. · Set chisel width from 0.1 to 0.2 mm.
·
Increase amount of honing on cutting edge.
·
Make thinning section of central area 1.5x current width.
Chipping On
Peripheral Cutting
Edge
· Inappropriate drilling
conditions.
· Decrease the cutting speed. ·
Refer to the lower limit of recommended conditions listed in the Igetalloy Cutting Tools Catalogue.
· Reduce feed rate. ·
Refer to the lower limit of recommended conditions listed in the Igetalloy Cutting Tools Catalogue.
·
Unsuitable cutting fluid.
· Use cutting fluid with more lubricity. · Use JIS A1 grade No. 1 or its equivalent.
·
Equipment and/or work material lacks rigidity.
· Improve work material clamp rigidity.
· Cutting edge is too
weak.
·
Increase amount of honing on cutting edge.
·
Make peripheral cutting edge 1.5x current width.
·
Reduce the amount of front flank angle.
·
Reduce the amount of front flank angle by 2° to 3°.
·
Peripheral cutting edge starts cutting first
· Increase margin width (W margin). · Increase margin width by 2 to 3x current width.
· Cutting interrupted
when drilling through
workpiece.
· Reduce feed rate. ·
Refer to the lower limit of recommended conditions listed in the Igetalloy Cutting Tools Catalogue.
·
Increase amount of honing on cutting edge.
·
Make peripheral cutting edge 1.5x current width.
·
Reduce the amount of front flank angle.
·
Reduce the amount of front flank angle by 2° to 3°.
Margin Wear
·
Inappropriate drilling conditions.
· Decrease the cutting speed. ·
Refer to the lower limit of recommended conditions listed in the Igetalloy Cutting Tools Catalogue.
· Unsuitable cutting
fluid.
· Use cutting fluid with more lubricity. · Use JIS A1 grade No. 1 or its equivalent.
· Increase coolant supply. ·
If using external coolant, change to internal coolant supply.
· Latent margin wear.
·
Early regrind to ensure adequate back taper.
· Regrind margin damage to 1 mm or less.
·
Unsuitable tool design.
· Increase amount of back taper. · Make back taper 0.5/100.
· Reduce margin width. ·
Decrease margin width to two-thirds of current width.
Drill Breakage
· Chip build-up.
·
Use optimal cutting conditions and tools.
·
Refer to the table of recommended conditions in the Igetalloy Cutting Tools Catalogue.
· Increase coolant supply. ·
If using external coolant, change to internal coolant supply.
·
Collet clamp lacks strength.
· Use collet with strong grip force.
· Replace collet chuck if damaged.
· Use collet holder one size bigger.
·
Equipment and/or work material lacks rigidity.
· Improve work material clamp rigidity.
Unsatisfactory Hole Accuracy
Oversized Holes
· Off-centre starts.
· Reduce feed rate at entry point.
· f=0.08 to 0.12mm/rev
· Decrease the cutting speed. ·
Refer to the lower limit of recommended conditions listed in the Igetalloy Cutting Tools Catalogue.
·
Pre-processing to ensure flat contact surface.
· Use endmill to produce flat surface.
· Drill bit lacks rigidity.
· Use optimal drill type for hole depth. · Refer to the Igetalloy Cutting Tools Catalogue.
· Improve overall rigidity of drill. · Large web with comparatively small flute.
· Drill bit has run-out
· Improve drill clamp precision. · Replace collet chuck if damaged.
· Improve drill clamp rigidity. · Use collet holder one size bigger.
·
Equipment and/or work material lacks rigidity.
· Improve work material clamp rigidity.
Poor Surface Finish
· Inappropriate cutting
conditions.
· Increase cutting speeds. ·
Refer to the upper limit of the recommended conditions listed the Igetalloy Cutting Tools Catalogue.
· Reduce feed rate. ·
Refer to the lower limit of recommended conditions listed in the Igetalloy Cutting Tools Catalogue.
·
Unsuitable cutting fluid.
· Use cutting fluid with more lubricity. · Use JIS A1 grade No. 1 or its equivalent.
Holes Are Not
Straight
· Off-centre starts. · Increase feed rates. ·
Refer to the upper limit of the recommended conditions listed the Igetalloy Cutting Tools Catalogue.
· Drill is not mounted
properly.
· Improve drill clamp precision. · Replace collet chuck if damaged.
· Improve drill clamp rigidity. · Use collet holder one size bigger.
·
Equipment and/or work
material lacks rigidity.
· Improve work material clamp rigidity.
· Select a double margin tool. · Refer to the Igetalloy Cutting Tools Catalogue.
Unsatisfactory Chip Control
Packing Of Chips
· Inappropriate drilling
conditions.
· Increase cutting speeds. ·
Refer to the upper limit of the recommended conditions listed the Igetalloy Cutting Tools Catalogue.
· Increase feed rates. ·
Refer to the upper limit of the recommended conditions listed the Igetalloy Cutting Tools Catalogue.
·
Poor chip evacuation.
·
Increase the amount or pressure of coolant applied if using internal coolant.
Long Stringy Chips
· Inappropriate drilling
conditions.
· Increase feed rates. ·
Refer to the upper limit of the recommended conditions listed the Igetalloy Cutting Tools Catalogue.
· Increase cutting speeds. ·
Refer to the upper limit of the recommended conditions listed the Igetalloy Cutting Tools Catalogue.
·
Cooling effect is too strong.
·
Reduce pressure if using internal coolant.
·
Keep pressure 1.5 MPa or lower if using internal coolant.
· Dull cutting edge. · Reduce amount of edge honing. · Reduce to around two-thirds of current width.
Technical Guidance
Tool Failure and Remedies
Drilling Edition
N27
N
Technical Guidance /
References
Application Map of the Various Tool Materials
Work Materials and their Cutting Speed Recommendations
300
100
200
Carburised or Induction Hardened Material
Bearing Steel Die Steel
Prone to notch wear
Wear fairly large Wear large
Cutting Speed (m/min)
Influence of Coolant on Tool Life
20
0.3
0.25
0.2
0.15
0.1
0.05
0
40 60 80 100 120 140
Cuttin
g
Time (min)
DRY
Oil-base coolant
Water soluble emulsion
Water soluble
In continuous cutting of bearing steel,
there is not much difference in dry or wet cut.
Flank Wear Width VB (mm)
DRY
Interrupted
Cutting
Heavy
Wet
To o l L i f e
Relation Between Work Material Hardness and Cutting Force
Relation Between Flank Wear and Cutting Force
0.05
300
200
100
0
100
0
100
0
0.10
Back Force (N)Principal Force (N)Feed Force (N)
Flank Wear Width VB (mm)
SCM430
65HRC
S55C
24HRC
Influence of Work Material Hardness on Cutting Force and Accuracy
45(HS)
106N
90
70
50
30
400
300
200
13μm
0
-10
-20
Hard
zone
Hard
zone
Soft
zone
Work: S38C
Shore Hardness
(HS)
Back Force
(N)
Dimension
( m)
Improvement of Surface Roughness by Altering the Feed Rate
Constant Feed Rate Variable Feed Rate
Stationary Notch Location
Previous edge position
Shifting Notch Location
Varying the feed rate spreads the notch location over a larger area.
Surface finish improves and notch wear decreases.
Relation Between Cutting Speed and Surface Roughness
400 80 120 160
0
0.1
0.2
0.3
Surface Roughness Ra ( m)
Machining Output (pcs.)
BN250 V=120
BN250 V=150
BN250 V=180
Work: SCM
420
H
58
to
62
HRC
Holder: MTXNR
2525
Insert: NU–TNMA
160408
Conditions:
v
c
=
120
,
150
,
180
m/min
f =
0
.
045
mm/rev
a
p
=
0
.
15
mm
Wet
At high cutting speeds, surface roughness is more stable.
Feed force
Principal force
Back
force
10
150
100
50
0
30 50 70
Principal force
Feed force
Back force
Hardness of Work Material (HRC)
Cutting Force (N)
Condition: C/speed v
c
=
80
m/min
D.O.C a
p
=
0
.
15
mm
Feed rate f
=
0
.
1
mm/rev
For hardened steel machining,
back force increases substantially
due to the expansion of flank wear.
External dimension at the
soft zone is smaller due to
lower cutting forces.
Work: SUJ
2
(
58
to
62
HRC)
Condition: TPGN
160304
v
c
=
100
m/min a
p
=
0
.
15
mm f =
0
.
1
mm/rev Continuous cutting
For continuous cutting, the influence of
coolant on tool life is minimal. However,
for interrupted cutting, coolant will shorten
the tool life because of thermal cracking.
Back force increases substantially for harder work materials.
Work :
Conditions
:
40 45 50 55 60 65
Hardness of Work Material (HRC)
Heavy
Light
Coated
carbide cermet
SUMIBORON
Ceramic
Interrupted
Cutting
Continuous
Cutting
SKD
11
4
U Slotting
Cutting speed v
c
=
100
m/min.
D.O.C a
p
=
0
.
2
mm
Feed rate f
=
0
.
1
mm/rev
Interrupted Cutting
SK
3
C/speed v
c
=
120
m/min.
D.O.C a
p
=
0
.
2
mm.
Feed rate f =
0
.
1
mm/rev
Cutting Speed
:
Depth of Cut
:
Feed rate :
v
c
=
120
m/min
a
p
=
0
.
5
mm
f =
0
.
3
mm/rev Dry
Technical Guidance
Hardened Steel Machining with SUMIBORON
SUMIBORON Edition
N28
N
Technical Guidance /
References
Advantages of Using SUMIBORON for Cast Iron Machining
Milling
Higher Accuracy
Longer Tool Life at Higher Cutting Speeds
High speed machining v
c
=2,000m/min
Surface Roughness 3.2Rz (1.0Ra)
Running cost is reduced because of economical insert.
Easy insert setting with the aid of a setting gauge.
Employs safe, anti-centrifugal force construction for high-speed conditions.
SUMIBORON BN Finish Mill EASY
Turning
Cast Iron Structure and Wear Shape Examples
Structure
FC FCD
Matrix
Pearlite Pearlite + Ferrite
Tool Wear Shape
Wet
Dry
(v
c
= 200 to 500m/min)
Dry
10
8
6
4
2
0
200 400
Surface Roughness
Rmax ( m)
Cutting Speed v
C
(m/min)
2.5 5 7.5 10 12.5
0
0.1
0.2
0.3
0.4
Dry
Wet (Water soluble)
Cutting Length (km)
Flank Wear Width VB (mm)
Crater wear
0 20 40 60 80 100 120 140 160 180 200
0.25
0.20
0.15
0.10
0.05
0.0
v
c
=600m/min
v
c
=600m/min
v
c
=1,000m/min
v
c
=1,500m/min
Ceramic
Ceramic
v
c
=400m/min
Number of Passes (Pass)
Flank Wear width (mm)
300
0
50
100
150
200
250
450 600 750 900 1,050 1,200 1,350 1,500
Dry
Wet
Cutting Conditions
p
=0.5mm
z
=0.15mm/
Number of Passes (Pass)
Cutting Speed (m/min)
Technical Guidance
High Speed Machining of Cast Iron withs SUMIBORON
SUMIBORON Edition
0.4 0.8 1. 6 3.2
BNS800
BN70 0 0
BNC500
Ceramic
Coated Carbide
Cermet
Good
Size Accuracy
Good Surface Roughness Ra ( m)
1,000
500
200
11020
BNS800
BN70 0 0
BNC500
Tool Life Ratio
Grey Cast Iron
Ceramic
Coated Carbide
Cermet
Cutting Speed (m/min)
500
200
1 10
BNX10
BNC500
BN7000
Ductile Cast Iron
Ceramic
Coated Carbide
Cermet
Cutting Speed (m/min)
Tool Life Ratio
Work : F
C250 Continuous cutting
Tool material : BN500
Tool Shape : SNGN120408
Conditions : v
c
=450m/min
a
p
=0.25mm
f
=0.15mm/rev
Dry&Wet
(water soluble)
Machine : N/C lathe
Work : FC250 200HB
Holder : MTJNP2525
Tool material : BN500
Tool Shape : TNMA160408
Conditions : v
c
=110 to 280m/min
f
=0.1mm/rev
a
p
=0.1mm
Wet
For machining cast iron with SUMIBORON, cutting speeds (v
c
) should be
200m/min and above. WET cutting is recommended.
Wet
(Water
soluble)
Dry cutting is recommended for high speed milling of cast iron with SUMIBORON.
(Conditions)
Work: FC250 Condition: a
p
=0.5mm f
z
=0.1mm/t Dry
Tool material: BN7000
Thermal cracks occur.
N29
N
Technical Guidance /
References
Powder Metal
Heat Resistive Alloy
Ni Based Alloy
Hard Facing Alloys
BNS800
(v
c
=300m/min, After 2km of cutting)
Whisker Reinforced Ceramic
(v
c
=50m/min, After 10m of cutting)
BNS800
After 2km of cutting
Influences of cutting speed (Grade BNX20, f =0.06mm/rev, L=0.72km)
v
c
=
300
m/min v
c
=
500
m/min
Influences of feed rate (Grade BNX20, v
c
=300m/min, L=0.18km)
f
=
0
.
12
mm/rev
f =
0
.
06
mm/rev
Influence of tool grade (v
c
=500m/min, f =0.12 mm/rev. L=0.36km)
BNX
20
BN
7000
Typical tool damage of CBN tool when cutting Inconel 718
12
050100
10
8
6
4
2
150 200
0.1
050100
0.2
0.3
0.4
0.5
150 200 050100
0.7
0.6
0.5
0.4
0.3
0.2
0.1
150 200
Flank Wear Width (mm)
Cutting Speed (m/min)
Cutting Speed (m/min)
Surface Roughness Rz ( m)
Max Height of Burr (mm)
Cutting Speed (m/min)
Flank Wear
Notch wear
Flank Wear
Notch wear
Flank Wear
Notch wear
Flank Wear
0 500 1000 1500 2000
600
500
400
300
200
100
0
BN7000
BNX20
Whisker Reinforced Ceramic
Cutting Speed (m/min)
Cutting Length (m)
0 1000 2000 3000
600
500
400
300
200
100
0
BN7000
BNX20
Whisker Reinforced Ceramic
Coated carbide (K series)
Cutting Speed (m/min)
Cutting Length (m)
Ti Based Alloy
Work: Ti–6A–4V
Insert: NF–DNMX120404
Cutting Conditions: v
c
=100m/min a
p
=0.1mm f =0.05mm/rev Wet
SUMIDIA positive type inserts are extremely good for Ti Alloy,
due to high cutting edge strength and high wear resistance.
Work: Ti–6A–4V
Insert: NF–DNMX120404
Cutting Conditions: v
c
=100m/min a
p
=0.1mm f =0.05mm/rev Wet
SUMIDIA positive type inserts are extremely good for Ti alloy,
due to high cutting edge strength and high wear resistance.
Work: Ti–6AI–4V
Tool: DNMA150412
Cutting Conditions: v
c
=120m/min a
p
=0.3mm f =0.25mm/rev Wet
Negative type insert in high fracture resistant BN7000, is suitable for
high-efficiency machining with large depth-of-cut and high feed rates.
200
0.20
0.15
0.10
0.05
0
40 60
BN7000
DA150 Breakage
Flank Wear Width V (mm)
Cutting Time (min.)
50
0.12
0.10
0.08
0.06
0.04
0.02
0
10 15
BN700 Breakage
Flank Wear Width V (mm)
Cutting Time (min.)
DA150
K10
50
0.12
0.10
0.08
0.06
0.04
0.02
0
10 15
DA150
BN700 Breakage
Flank Wear Width V (mm)
Cutting Time (min.)
K10
0.20 0.4 0.6 0.8 1. 0 1. 2
0
0.1
0.2
0.3
0.4
0.5
BNS800 (
c
=300m/min)
Whisker reinforced ceramic (
c
=50m/min)
Cutting is difficult
because of large wear at
c
=50m/min
Small wear at
c
=300m/min
Flank Wear Width (mm)
Cutting Length (km)
Comp.'s solid CBN
After
2
km of cutting
Chipping
0.50 1. 0 2.01. 5 2.5
0
0.02
0.04
0.06
0.08
0.10
BNS800
Comp.’s solid CBN
Chipping
No chipping
Flank Wear Width (mm)
Cutting Length (km)
0.5mm
Technical Guidance
Machining Hard-to-cut Materials with SUMIBORON
SUMIBORON Edition
SUMIBORON
Carbide Cermet
1. Flank Wear 2. Surface Roughness 3. Height of Burr
Work: SMF4040 equivalent, Process details: ø80-ø100mm heavy
interrupted facing with grooves and drilled holes. (After 40 passes)
Cutting Conditions: f=0.1mm/rev, a
p
=0.1mm, Wet
Insert: TNGA160404
For general powder metal components, carbide and cermet grades can perform up to v
c
=100m/min. However, around v
c
=120m/min
SUMIBORON, on the other hand, exhibits stability and superior wear resistance, burr prevention and surface roughness especially
at high speeds.
Conditions: f=0.06mm/rev, a
p
=0.3mm, Wet Conditions: f=0.12mm/rev, a
p
=0.3mm, Wet
Tool life criteria
Notch wear = 0.25mm ( )
Or flank wear = 0.25mm
BNX20 is recommended for high speed and low feed rates
BN7000 is recommended for cutting speeds below v
c
=240m/min.
Tool life criteria
Notch wear = 0.25mm ( )
Or flank wear = 0.25mm
BN7000 is recommended for cutting at high feed rates.
(Over f =0.1mm/rev)
Work: Colmonoy No.6
(NiCr-based self-fluxing alloy)
Insert : SNGN0 90308
Cutting Conditions
: v
c
= 50,300m/min
f = 0.1mm/rev
a
p
= 0.2mm
Dry
Work: Stellite SF-20
(Co-based self-fluxing alloy)
Insert : SNGN090308
Cutting Conditions
: v
c
= 50m/min
f = 0.1mm/rev
a
p
= 0.2mm
Dry
Conditions: a
p
= 0.3mm, Wet
N30
N
Technical Guidance /
References
Type of Insert Failure Cause Countermeasures
Flank Wear
· Grade lacks wear resistance.
· Cutting speed is too fast.
· Select a more wear resistant grade.
BNC2010,BN1000,BN2000
· Decrease the cutting speed.
Reduce the cutting speed to less than v
c
=200m/min.
(Higher feed rate reduces the overall tool-to-work contact time.)
· Use an insert with a larger relief angle.
Crater wear
· Grade lacks wear resistance.
· Cutting speed is too fast.
· Change to a high efficiency grade.
BNC2010,BNX25,BNX20
· Reduce cutting speed and increase feed rate (low-speed,
high-feed cutting).
Reduce the cutting speed to less than v
c
=200m/min.
(Higher feed rate reduces the overall tool-to-work contact
time.)
Breakage At Bottom of Crater
Flaking
· Grade lacks toughness.
· Back force is too high.
· Select a tougher grade (e.g. BNC2020 and BN2000).
· Select an insert with a stronger cutting edge
(Increase negative land angle and edge honing)
· If the grade has enough toughness, improve the cutting
edge sharpness.
Notch Wear
· High boundary stress.
· Change to a grade with a higher boundary wear resistance
(e.g. BNC2010 and BN2000).
· Increase the cutting speed (150m/min or more).
· Change to "Variable Feed Rate" method, which alters the
feed rate at every fixed number of outputs.
· Increase negative land angle and edge honing.
Chipping at Forward Notch Position
· Impact to front cutting edge is
too large or there is constant
occurrence.
· Change to a fine-grained grade with a higher fracture
resistance (e.g. BNC300 and BN350).
· Increase feed rates
(Higher feed rates are recommended to reduce chipping.)
· Select an insert with a stronger cutting edge
(Increase negative land angle and edge honing)
Chipping at Side Notch Position
· Impact to side cutting edge is
too large or there is constant
occurrence.
· Select a tougher grade. BN350,BNC300
· Reduce feed rate.
Increase the side cutting angle
· Increase insert nose radius
· Select an insert with a stronger cutting edge
(Increase negative land angle and edge honing)
Thermal Crack
· Thermal shock is too severe.
· Completely dry condition is recommended.
· Select a grade with better thermal conductivity.
· Decrease cutting speed, depth of cut, feed rate.
Technical Guidance
Tool Failure and Remedies
SUMIBORON Edition
N31
N
Technical Guidance /
References
SI Basic Unit
Quantity as a Reference of SI Unit
Quantity
Quantity
Name
Name
Symbol
Symbol
Length Meter m
Mass Kilogram kg
Time Second s
Current Ampere A
Temperature Kelvin K
Quantity of Substance
Mol mol
Luminous Intensity Candela cd
Basic Unit Provided with Unique Name and Symbol (Extracted)
Quantity
Quantity
Name
Name
Symbol
Symbol
Frequency Hertz Hz
Force Newton N
Pressure and Stress Pascal Pa
Energy, Work, and Calorie Joule J
Power and Efficiency Watt W
Voltage Volt V
Resistance Ohm Ω
SI Prefix
Prefix Showing Integral Power of 10 Combined with SI Unit
Coefficient
Name Symbol
Coefficient
Name Symbol
Coefficient
Name Symbol
10
24
Yo t a Y 10
3
Kilo k 10
-
9
Nano n
10
21
Zeta Z 10
2
Hecto h 10
-
12
Pico p
10
18
Exa E 10
1
Deca da 10
-
15
Femto f
10
15
Peta P 10
-
1
Deci d 10
-
18
Atto a
10
12
Te r a T 10
-
2
Centi c 10
-
21
Zepto z
10
9
Giga G 10
-
3
Milli m
10
-
24
Yocto y
10
6
Mega M 10
-
6
Micro μ
Specific Heat
J/(kg K)
1kcal (kg °C)cal/
(g °C)
12
.
38889
×
10
-
4
4
.
18605
×
10
3
1
Thermal Conductivity
W/(m K) kcal/(h m °C)
18
.
60000
×
10
-
1
1
.
16279 1
Rotating Speed
min
-
1
rpm
11
1
min
-
1
=
1
rpm
Power (Efficiency and Motive Energy) / Thermal Flow
W kgf m/s PS kcal/h
11
.
01972
×
10
-
1
1
.
35962
×
10
-
3
8
.
60000
×
10
-
1
1
×
10
3
1
.
01972
×
10
2
1
.
35962 8
.
60000
×
10
2
9
.
80665 1 1
.
33333
×
10
-
2
8
.
43371
7
.
355
×
10
2
7
.
5
×
10 1 6
.
32529
×
10
2
1
.
16279 1
.
18572
×
10
-
1
1
.
58095
×
10
-
3
1
1
W =
1
J/s, PS
Horsepower
Work / Energy / Calorie
J kW hkgfm kcal
12
.
77778
×
10
-
7
1
.
01972
×
10
-
1
2
.
38889
×
10
-
4
3
.
60000
×
10
6
13
.
67098
×
10
5
8
.
60000
×
10
2
9
.
80665 2
.
72407
×
10
-
6
12
.
34270
×
10
-
3
4
.
18605
×
10
3
1
.
16279
×
10
-
3
4
.
26858
×
10
2
1
1
J =
1
W s,
1
J =
1
N m
Pressure
Pa (N/m
2
) kPa MPa GPa bar kgf/cm
2
mmHg Torr
11
×
10
-
3
1
×
10
-
6
1
×
10
-
9
1
×
10
-
5
1
.
01972
×
10
-
5
7
.
50062
×
10
-
3
1
×
10
3
1
1
×
10
-
3
1
×
10
-
6
1
×
10
-
2
1
.
01972
×
10
-
2
7
.
50062
1
×
10
6
1
×
10
3
11
×
10
-
3
1
×
10 1
.
01972
×
10 7
.
50062
×
10
3
1
×
10
9
1
×
10
6
1
×
10
3
11
×
10
4
1
.
01972
×
10
4
7
.
50062
×
10
6
1
×
10
5
1
×
10
2
1
×
10
-
1
1
×
10
-
4
11
.
01972 7
.
50062
×
10
2
9
.
80665
×
10
4
9
.
80665
×
10
9
.
80665
×
10
-
2
9
.
80665
×
10
-
5
9
.
80665
×
10
-
1
17
.
35559
×
10
2
1
.
33322
×
10
2
1
.
33322
×
10
-
1
1
.
33322
×
10
-
4
1
.
33322
×
10
-
7
1
.
33322
×
10
-
3
1
.
35951
×
10
3
1
1
Pa =
1
N/m
2
Stress
Pa (N/m
2
) MPa (N/mm
2
) kgf/mm
2
kgf/cm
2
kgf/m
2
11
×
10
-
6
1
.
01972
×
10
-
7
1
.
01972
×
10
-
5
1
.
01972
×
10
-
1
1
×
10
6
1
1
.
01972
×
10
-
1
1
.
01972
×
10 1
.
01972
×
10
5
9
.
80665
×
10
6
9
.
80665 1 1
×
10
2
1
×
10
6
9
.
80665
×
10
4
9
.
80665
×
10
-
2
1
×
10
-
2
11
×
10
4
9
.
80665 9
.
80665
×
10
-
6
1
×
10
-
6
1
×
10
-
4
1
1
Pa =
1
N/m
2
, 1MPa =
1
N/mm
2
Principal SI Unit Conversion List coloured portions are SI units
Force
N kgf
11
.
01972
×
10
-
1
9
.
80665 1
Technical Guidance
General Information
SI Unit Conversion Table
N32
N
Technical Guidance /
References
Steel and Non-Ferrous Metal Symbols Chart
Carbon Steels
JIS AISI DIN
S10C 1010 C10
S15C 1015 C15
S20C 1020 C22
S25C 1025 C25
S30C 1030 C30
S35C 1035 C35
S40C 1040 C40
S45C 1045 C45
S50C 1049 C50
S55C 1055 C55
High Seed Steels
JIS AISI DIN
SKH2 T1
SKH3 T4 S18-1-2-5
SKH10 T15 S12-1-4-5
SKH51 M2 S6-5-2
SKH52 M3–1
SKH53 M3–2 S6-5-3
SKH54 M4
SKH56 M36
Austenitic Stainless Steels
JIS AISI DIN
SUS201 201
SUS202 202
SUS301 301 X12CrNi17 7
SUS302 302
SUS302B 302B
SUS303 303
X10CrNiS18 9
SUS303Se 303Se
SUS304 304
X5CrNiS18 10
SUS304L 304L X2CrNi19 11
SUS304NI 304N
SUS305 305 X5CrNi18 12
SUS308 308
SUS309S 309S
SUS310S 310S
SUS316 316
X5CrMo17 12 2
SUS316L 316L
X2CrNiMo17 13 2
SUS316N 316N
SUS317 317
SUS317L 317L
X2CrNiMo18 16 4
SUS321 321
X6CrNiTi18 10
SUS347 347
X6CrNiNb18 10
SUS384 384
Ni-Cr-Mo Steels
SNCM220 8620 21NiCrMo2
SNCM240 8640
SNCM415
SNCM420 4320
SNCM439 4340
SNCM447
Cr Steels
SCr415
SCr420 5120
SCr430 5130 34Cr4
SCr435 5132 37Cr4
SCr440 5140 41Cr4
SCr445 5147
Cr-Mo Steels
SCM415
SCM420
SCM430 4131
SCM435 4137 34CrMo4
SCM440 4140 42CrMo4
SCM445 4145
Mn Steels and Mn-Cr Steels for
Structurer Use
SMn420 1522
SMn433 1534
SMn438 1541
SMn443 1541
SMnC420
SMnC443
Carbon Tool Steels
SK1
SK2
W1-11
1
/
2
SK3 W1-10 C105W1
SK4 W1-9
SK5 W1-8 C80W1
SK6 C80W1
SK7 C70W2
Alloy Tool Steels
SKS11 F2
SKS51 L6
SKS43
W2-9
1
/
2
SKS44 W2-8
SKD1 D3 X210Cr12
SKD11 D2
Grey Cast Iron
FC100 No 20B GG-10
FC150 No 25B GG-15
FC200 No 30B GG-20
FC250 No 35B GG-25
FC300 No 45B GG-30
FC350 No 50B GG-35
Nodular Cast Iron
FCD400 60-40-18 GGG-40
FCD450 GGG-40.3
FCD500 80-55-06 GGG-50
FCD600 GGG-60
FCD700 100-70-03 GGG-70
Ferritic Stainless Steels
SUS405 405 X10CrAl13
SUS429 429
SUS430 430 X6Cr17
SUS430F 430F X7CrMo18
SUS434 434 X6CrMo17 1
Martensitic Stainless Steels
SUS403 403
SUS410 410 X10Cr13
SUS416 416
SUS420JI 420 X20Cr13
SUS420F 420F
SUS431 431
X20CrNi17 2
SUS440A 440A
SUS440B 440B
SUS440C 440C
Heat Resisting Steels
SUH31
SUH35
SUH36
X53CrMnNi21 9
SUH37
SUH38
SUH309 309
SUH310 310 CrNi2520
SUH330 N08330
Ferritic Heat Resisting Steels
SUH21 CrAl1205
SUH409 409 X6CrTi12
SUH446 446
Martensitic Heat Resisting Steels
SUH1 X45CrSi9 3
SUH3
SUH4
SUH11
SUH600
References
N33
N
Technical Guidance /
References
Steel and Non-Ferrous Metal Symbols Chart
Classifications and Symbols of Steels
Class
Material Symbol Code Description
Structural Steels
Rolled Steels for welded structures
SM
"M" for "Marine"-Usually used in welded marine structures
Re-rolled Steels
SRB
"R" for "Re-rolled" and "B" for "Bar"
Rolled Steels for general structures
SS
S for "Steel" and for "Structure"
Light gauge sections for general structures
SSC
C for "Cold"
Steel Sheets
Hot rolled mild steel sheets / plates in coil form
SPH
P for "Plate" and "H" for "Hot"
Steel Tubes
Carbon steel tubes for piping
SGP
"GP" for "Gas Pipe"
Carbon steel tubes for boiler and heat exchangers
STB
"T" for "Tube" and "B" for "Boiler"
Seamless steel tubes for high pressure gas cylinders
STH
"H" for "High Pressure"
Carbon steel tubes for general structures
STK
"K" for "Kozo"-Japanese word meaning "structure"
Carbon steel tubes for machine structural uses
STKM
"M" for "Machine"
Alloy steel tubes for structures
STKS
"S" for "Special"
Alloy steel tubes for piping
STPA
"P" for "Piping" and "A" for "Alloy"
Carbon steel tubes for pressure piping
STPG
"G" for "General"
Carbon steel tubes for high temperature piping
STPT
"T" for "Temperatures"
Carbon steel tubes for high pressure piping
STS
"S" after "SP" is abbreviation for "Special"
Stainless steel tubes for piping
SUS-TP
"T" for "Tube" and "P" for "Piping"
Steel for Machine Structures
Carbon steels for machine structural uses
SxxC
"C" for "Carbon"
Aluminium Chromium Molybdenum steels
SACM
"A" for "Al", "C" for "Cr" and "M" for "Mo"
Chromium Molybdenum steels
SCM
"C" for "Cr" and "M" for "Mo"
Chromium steels
SCr
"Cr" for "Chromium"
Nickel Chromium steels
SNC
"N" for "Nickel" and "C"for "Chromium"
Nickel Chromium Molybdenum steels
SNCM
"M" for "Molybdenum"
Manganese steels for structural use Manganese
Chromium steels
SMn
SMnC
"Mn" for "Manganese"
"C" for "Chromium"
Special Steels
Tool Steels
Carbon tool steels
SK
"K" for "Kogu"-Japanese word meaning "tool"
Hollow drill steels
SKC
"C" for "Chisel"
Alloy tool steel
SKS
SKD
SKT
S for "Special"
D for "Die"
T for "Tanzo"-Japanese word for "forging"
High speed tool steels
SKH
"H" for "High speed"
Stainless Steels
Free cutting sulphuric steels
SUM
"M" for "Machinability"
High Carbon Chromium bearing steels
SUJ
"J" for "Jikuuke"-Japanese word meaning "bearing"
Spring steels
SUP
"P" for "Spring"
Stainless Steels
SUS
"S" after "SU" is abbreviation for "Stainless"
Heat-resistant Steels
Heat-resistant steels
SUH
"U" for "Special Usage" and "H" for "Heat"
Heat-resistant steel bars
SUH-B
"B" for "Bar"
Heat-resistant steels sheets
SUHP
"P" for "Plate"
Forged Steels
Carbon steel forgings for general use
SF
"F" for "Forging"
Carbon steel booms and billets for forgings
SFB
"B" for "Billet"
Chromium Molybdenum steel forgings
SFCM
"C" for "Chromium" and "M" for "Molybdenum"
Nickel Chromium Molybdenum steel forgings
SFNCM
"N" for "Nickel"
Cast Irons
Grey cast irons
FC
"F" for "Ferrous" and "C" for "Casting"
Spherical graphite / Ductile cast irons
FCD
"D" for "Ductile"
Blackheart malleable cast irons
FCMB
"M" for "Malleable" and "B" for "Black"
Whiteheart malleable cast irons
FCMW
"W" for "White"
Pearlite malleable cast irons
FCMP
"P" for "Pearlite"
Cast Steels
Carbon cast steels
SC
"C" for "Casting"
Stainless cast steels
SCS
"S" for "Stainless"
Heat-resistant cast steels
SCH
"H" for "Heat"
High Manganese cast steels
SCMnH
"Mn" for "Manganese" and "H" for "High"
Non-Ferrous Metals
Class
Material Symbol
Copper and Copper Alloys
Copper and Copper alloys - Sheets,
plates and strips
CxxxxP
CxxxxPP
CxxxxR
Copper and Copper alloys - Welded
pipes and tubes
CxxxxBD
CxxxxBDS
CxxxxBE
CxxxxBF
Aluminium and Aluminium Alloys
Aluminium and Al alloys - Sheets,
plates and strips
AxxxxP
AxxxxPC
Aluminium and Al alloys
-Rods, bars, and wires
AxxxxBE
AxxxxBD
AxxxxW
Aluminium and Al alloys-Extruded shapes
AxxxxS
Aluminium and Al alloys forgings
AxxxxFD
AxxxxFH
Magnesium
Alloys
Magnesium alloy sheets and plates
MP
Nickel
Alloys
Nickel-copper alloy sheets and plates
NCuP
Nickel-copper alloy rods and bars
NCuB
Wrought
Titanium
Titanium rods and bars
TB
Castings
Brass castings
YBsCx
High strength Brass castings
HBsCx
Bronze castings
BCx
Phosphorus Bronze castings
PBCx
Aluminium Bronze castings
AlBCx
Aluminium alloy castings
AC
Magnesium alloy castings
MC
Zinc alloy die castings
ZDCx
Aluminium alloy die castings
ADC
Magnesium alloy die castings
MDC
White metals
WJ
Aluminium alloy castings for bearings
AJ
Copper-Lead alloy castings for bearings
KJ
References
N34
N
Technical Guidance /
References
Hardness Scale Comparison Chart
Approximate Corresponding Values for Steel Hardness on the Brinell Scale
Brinell
Hardness
3,000
kgf
HB
Rockwell Hardness
Vickers
Hardness
50kgf
HV
Shore
Hardness
HS
Traverse
Rupture
Strength
GPa
A
Scale
60kgf
brale
HRA
B
Scale
100kgf
1/10in
Ball
HRB
C
Scale
150kgf
brale
HRC
D
Scale
100kgf
brale
HRD
85.6 68.0 76.9 940 97
85.3 67.5 76.5 920 96
85.0 67.0 76.1 900 95
767 84.7 66.4 75.7 880 93
757 84.4 65.9 75.3 860 92
745 84.1 65.3 74.8 840 91
733 83.8 64.7 74.3 820 90
722 83.4 64.0 73.8 800 88
712
710 83.0 63.3 73.3 780 87
698 82.6 62.5 72.6 760 86
684 82.2 61.8 72.1 740
682 82.2 61.7 72.0 737 84
670 81.8 61.0 71.5 720 83
656 81.3 60.1 70.8 700 — —
653 81.2 60.0 70.7 697 81
647 81.1 59.7 70.5 690
638 80.8 59.2 70.1 680 80
630 80.6 58.8 69.8 670
627 80.5 58.7 69.7 667 79
601 79.8 57.3 68.7 640 77
578 79.1 56.0 67.7 615 75
555 78.4 54.7 66.7 591 73 2.06
534 77.8 53.5 65.8 569 71 1.98
514 76.9 52.1 64.7 547 70 1.89
495 76.3 51.0 63.8 528 68 1.82
477 75.6 49.6 62.7 508 66 1.73
461 74.9 48.5 61.7 491 65 1.67
444 74.2 47.1 60.8 472 63 1.59
429 73.4 45.7 59.7 455 61 1.51
415 72.8 44.5 58.8 440 59 1.46
401 72.0 43.1 57.8 425 58 1.39
388 71.4 41.8 56.8 410 56 1.33
375 70.6 40.4 55.7 396 54 1.26
363 70.0 39.1 54.6 383 52 1.22
352 69.3 (110.0) 37.9 53.8 372 51 1.18
341 68.7 (109.0) 36.6 52.8 360 50 1.13
331 68.1 (108.5) 35.5 51.9 350 48 1.10
Brinell
Hardness
3,000
kgf
HB
Rockwell Hardness
Vickers
Hardness
50kgf
HV
Shore
Hardness
HS
Traverse
Rupture
Strength
GPa
A
Scale
60kgf
brale
HRA
B
Scale
100kgf
1/10in
Ball
HRB
C
Scale
150kgf
brale
HRC
D
Scale
100kgf
brale
HRD
321 67.5 (108.0) 34.3 50.1 339 47 1.06
311 66.9 (107.5) 33.1 50.0 328 46 1.03
302 66.3 (107.0) 32.1 49.3 319 45 1.01
293 65.7 (106.0) 30.9 48.3 309 43 0.97
285 65.3 (105.5) 29.9 47.6 301 0.95
277 64.6 (104.5) 28.8 46.7 292 41 0.92
269 64.1 (104.0) 27.6 45.9 284 40 0.89
262 63.6 (103.0) 26.6 45.0 276 39 0.87
255 63.0 (102.0) 25.4 44.2 269 38 0.84
248 62.5 (101.0) 24.2 43.2 261 37 0.82
241 61.8 100.0 22.8 42.0 253 36 0.80
235 61.4 99.0 21.7 41.4 247 35 0.78
229 60.8 98.2 20.5 40.5 241 34 0.76
223 97.3 (18.8) 234
217 96.4 (17.5) 228 33 0.73
212 95.5 (16.0) 222 0.71
207 94.6 (15.2) 218 32 0.69
201 93.8 (13.8) 212 31 0.68
197 92.8 (12.7) 207 30 0.66
192 91.9 (11.5) 202 29 0.64
187 90.7 (10.0) 196 0.62
183 90.0 (9.0) 192 28 0.62
179 89.0 (8.0) 188 27 0.60
174 87.8 (6.4) 182 — 0.59
170 86.8 (5.4) 178 26 0.57
167 86.0 (4.4) 175 0.56
163 85.0 (3.3) 171 25 0.55
156 82.9 (0.9) 163 0.52
149 80.8 156 23 0.50
143 78.7 150 22 0.49
137 76.4 143 21 0.46
131 74.0 137 0.45
126 72.0 132 20 0.43
121 69.8 127 19 0.41
116 67.6 122 18 0.40
111 65.7 117 15 0.38
1) Figures within the ( ) are not commonly used
2) Rockwell A, C and D scales utilise a diamond brale
3) This chart was taken from the JIS Iron and Steel Handbook (1980)
References
N35
N
Technical Guidance /
References
Standard of Tapers
Morse Taper
Bottle Grip Taper
Bottle Grip Taper
(Units: mm)
Taper No.
D
(Standard)
D1 D2 t1 t2 t3 t4 t5 d2 d3 L
3 4
gb1 t7
Fig
BT30
31.75 46 38 20 8 13.6 2 2 14 12.5 48.4 24 7 17 M12 16.1 16.3
3
BT35
38.10 53 43 22 10 14.6 2 2 14 12.5 56.4 24 7 20 M12 16.1 19.6
BT40
44.45 63 53 25 10 16.6 2 2 19 17 65.4 30 8 21 M16 16.1 22.6
BT45
57.15 85 73 30 12 21.2 3 3 23 21 82.8 36 9 26 M20 19.3 29.1
BT50
69.85 100 85 35 15 23.2 3 3 27 25 101.8 45 11 31 M24 25.7 35.4
BT60
107.95 155 135 45 20 28.2 3 3 33 31 161.8 56 12 34 M30 25.7 60.1
(Units: mm)
Morse
Taper
Number
Taper
(1)
Taper
Angle
Taper Tang
Fig
Da
D1
(2)
Estimated
d1
(2)
Estimated
(Max) (Max)
d2
(Max)
b
C
(Max)
e
(Max)
Rr
0 0.05205 1°29'27" 9.045 3 9.2 6.1 56.5 59.5 6.0 3.9 6.5 10.5 4 1
1
1 0.04988 1°25'43" 12.065 3.5 12.2 9.0 62.0 65.5 8.7 5.2 8.5 13.5 5 1.2
2 0.04995 1°25'50" 17.780 5 18.0 14.0 75.0 80.0 13.5 6.3 10 16 6 1.6
3 0.05020 1°26'16" 23.825 5 24.1 19.1 94.0 99.0 18.5 7.9 13 20 7 2
4 0.05194 1°29'15" 31.267 6.5 31.6 25.2 117.5 124.0 24.5 11.9 16 24 8 2.5
5 0.05263 1°30'26" 44.399 6.5 44.7 36.5 149.5 156.0 35.7 15.9 19 29 10 3
6 0.05214 1°29'36" 63.348 8 63.8 52.4 210.0 218.0 51.0 19.0 27 40 13 4
7 0.05200 1°29'22" 83.058 10 83.6 68.2 286.0 296.0 66.8 28.6 35 54 19 5
American Standard Taper (National Taper)
1
19.212
1
20.047
1
20.020
1
19.922
1
19.245
1
19.002
1
19.180
1
19.231
Morse
Taper
Number
Taper
(1)
Taper
Angle
Taper Tang
Fig
Da
D1
(2)
Estimated
d1
(2)
Estimated
(Max) (Max)
d2
(Max)
d3
K
(Min)
t
(Max)
r
0 0.05205 1°29'27" 9.045 3 9.2 6.4 50 53 6 4 0.2
2
1 0.04988 1°25'43" 12.065 3.5 12.2 9.4 53.5 57 9 M 6 16 5 0.2
2 0.04995 1°25'50" 17.780 5 18.0 14.6 64 69 14 M10 24 5 0.2
3 0.05020 1°26'16" 23.825 5 24.1 19.8 81 86 19 M12 28 7 0.6
4 0.05194 1°29'15" 31.267 6.5 31.6 25.9 102.5 109 25 M16 32 9 1
5 0.05263 1°30'26" 44.399 6.5 44.7 37.6 129.5 136 35.7 M20 40 9 2.5
6 0.05214 1°29'36" 63.348 8 63.8 53.9 182 190 51 M24 50 12 4
7 0.05200 1°29'22" 83.058 10 83.6 70.0 250 260 65 M33 80 18.5 5
(1) The fractional values are the taper standards.
(2)
Diameters (D1) and (d1) are calculated from the values of (D) and other values of the taper. (values are rounded up to one decimal place).
Remarks 1. Tapers are measured using JIS B 3301 ring gauges. At least 75% must be correct.
2.
Screws must have metric coarse screw thread as per JIS B 0205, and 3rd grade precision as per JIS B 0209.
3
L
g
t1
t5
t2
t3
t4
4
t7
D1
D2
60°
d
2
d3
øD
b1
b1
7/24 Taper
K
r
t
S
a
ød 3
ød 2
ød 1
øD1
øD
60°
r
R
8°18'
a
C
b
ød
1
ød 2
øD1
øD
3
60°
ød1
øg
t
L
a
b
7/24 Taper
øD
American Standard Taper (National Taper)
(Units: mm)
Taper No.
Nominal Diameter
Dd1 L
(Min)
(Min)
3
(Min)
ga t b
Fig
30
1
1
/
4"
31.750 17.4 68.4 48.4 24 34
1
/
2"
1.6 15.9 16
4
40
1
3
/
4"
44.450 25.3 93.4 65.4 32 43
5
/
8"
1.6 15.9 22.5
50
2
3
/
4"
69.850 39.6 126.8 101.8 47 62 1" 3.2 25.4 35
60
4
1
/
4"
107.950 60.2 206.8 161.8 59 76
1
1
/
4"
3.2 25.4 60
–0.29
–0.36
–0.30
–0.384
–0.31
–0.41
–0.34
–0.46
Fig 3 Fig 4
1
19.212
1
20.047
1
20.020
1
19.922
1
19.254
1
19.002
1
19.180
1
19.231
References
Fig. 2 Drawing Thread TypeFig. 1 With Tang Type
N36
N
Technical Guidance /
References
References
Dimensional Tolerances for Regularly Used Fits [Taken from JIS B 0401 (1999)]
Dimensional Tolerances for Regularly Used Shaft Fits
Base
Dimension
(mm)
Tolerance Zone Class of Shaft Units μm
More
than
Max.
b9 c9 d8 d9 e7 e8 e9 f6 f7 f8 g5 g6 h5 h6 h7 h8 h9 js5 js6 js7 k5 k6 m5 m6 n6 p6 r6 s6 t6 u6 x6
3
-140
-165
-60
-85
-20
-34
-20
-45
-14
-24
-14
-28
-14
-39
-6
-12
-6
-16
-8
-20
-2
-6
-2
-8
0
-4
0
-6
0
-10
0
-14
0
-25
2 3
5
+4
0
+6
0
+6
+2
+8
+2
+10
+4
+12
+6
+16
+10
+20
+14
+24
+18
+26
+20
36
-140
-170
-70
-100
-30
-48
-30
-60
-20
-32
-20
-38
-20
-50
-10
-18
-10
-22
-10
-28
-4
-9
-4
-12
0
-5
0
-8
0
-12
0
-18
0
-30
2.5 4
6
+6
+1
+9
+1
+9
+4
+12
+4
+16
+8
+20
+12
+23
+15
+27
+19
+31
+23
+36
+28
610
-150
-186
-80
-116
-40
-62
-40
-76
-25
-40
-25
-47
-25
-61
-13
-22
-13
-28
-13
-35
-5
-11
-5
-14
0
-6
0
-9
0
-15
0
-22
0
-36
3 4.5
7.5
+7
+1
+10
+1
+12
+6
+15
+6
+19
+10
+24
+15
+28
+19
+32
+23
+37
+28
+43
+34
10 14
-150
-193
-95
-138
-50
-77
-50
-93
-32
-50
-32
-59
-32
-75
-16
-27
-16
-34
-16
-43
-6
-14
-6
-17
0
-8
0
-11
0
-18
0
-27
0
-43
4 5.5
9
+9
+1
+12
+1
+15
+7
+18
+7
+23
+12
+29
+18
+34
+23
+39
+28
+44
+33
+51
+40
14 18
+56
+45
18 24
-160
-212
-110
-162
-65
-98
-65
-117
-40
-61
-40
-73
-40
-92
-20
-33
-20
-41
-20
-53
-7
-16
-7
-20
0
-9
0
-13
0
-21
0
-33
0
-52
4.5 6.5
10.5
+11
+2
+15
+2
+17
+8
+21
+8
+28
+15
+35
+22
+41
+28
+48
+35
+54
+41
+67
+54
24 30
+54
+41
+61
+48
+77
+64
30 40
-170
-232
-120
-182
-80
-119
-80
-142
-50
-75
-50
-89
-50
-112
-25
-41
-25
-50
-25
-64
-9
-20
-9
-25
0
-11
0
-16
0
-25
0
-39
0
-62
5.5 8
12.5
+13
+2
+18
+2
+20
+9
+25
+9
+33
+17
+42
+26
+50
+34
+59
+43
+64
+48
+76
+60
40 50
-180
-242
-130
-192
+70
+54
+86
+70
50 65
-190
-264
-140
-214
-100
-146
-100
-174
-60
-90
-60
-106
-60
-134
-30
-49
-30
-60
-30
-76
-10
-23
-10
-29
0
-13
0
-19
0
-30
0
-46
0
-74
6.5 9.5
15
+15
+2
+21
+2
+24
+11
+30
+11
+39
+20
+51
+32
+60
+41
+72
+53
+85
+66
+106
+87
65 80
-200
-274
-150
-224
+62
+43
+78
+59
+94
+75
+121
+102
80 100
-220
-307
-170
-257
-120
-174
-120
-207
-72
-107
-72
-126
-72
-159
-36
-58
-36
-71
-36
-90
-12
-27
-12
-34
0
-15
0
-22
0
-35
0
-54
0
-87
7.5 11
17.5
+18
+3
+25
+3
+28
+13
+35
+13
+45
+23
+59
+37
+73
+51
+93
+71
+113
+91
+146
+124
100 120
-240
-327
-180
-267
+76
+54
+101
+79
+126
+104
+166
+144
120 140
-260
-360
-200
-300
-145
-208
-145
-245
-85
-125
-85
-148
-85
-185
-43
-68
-43
-83
-43
-106
-14
-32
-14
-39
0
-18
0
-25
0
-40
0
-63
0
-100
9 12.5
20
+21
+3
+28
+3
+33
+15
+40
+15
+52
+27
+68
+43
+88
+63
+117
+92
+147
+122
140 160
-280
-380
-210
-310
+90
+65
+125
+100
+159
+134
160 180
-310
-410
-230
-330
+93
+68
+133
+108
+171
+146
180 200
-340
-455
-240
-355
-170
-242
-170
-285
-100
-146
-100
-172
-100
-215
-50
-79
-50
-96
-50
-122
-15
-35
-15
-44
0
-20
0
-29
0
-46
0
-72
0
-115
10 14.5
23
+24
+4
+33
+4
+37
+17
+46
+17
+60
+31
+79
+50
+106
+77
+151
+122
200 225
-380
-495
-260
-375
+109
+80
+159
+130
225 250
-420
-535
-280
-395
+113
+84
+169
+140
250 280
-480
-610
-300
-430
-190
-271
-190
-320
-110
-162
-110
-191
-110
-240
-56
-88
-56
-108
-56
-137
-17
-40
-17
-49
0
-23
0
-32
0
-52
0
-81
0
-130
11.5 16
26
+27
+4
+36
+4
+43
+20
+52
+20
+66
+34
+88
+56
+126
+94
280 315
-540
-670
-330
-460
+130
+98
315 355
-600
-740
-360
-500
-210
-299
-210
-350
-125
-182
-125
-214
-125
-265
-62
-98
-62
-119
-62
-151
-18
-43
-18
-54
0
-25
0
-36
0
-57
0
-89
0
-140
12.5 18
28.5
+29
+4
+40
+4
+46
+21
+57
+21
+73
+37
+98
+62
+144
+108
355 400
-680
-820
-400
-540
+150
+114
400 450
-760
-915
-440
-595
-230
-327
-230
-385
-135
-198
-135
-232
-135
-290
-68
-108
-68
-131
-68
-165
-20
-47
-20
-60
0
-27
0
-40
0
-63
0
-97
0
-155
13.5 20
31.5
+32
+5
+45
+5
+50
+23
+63
+23
+80
+40
+108
+68
+166
+126
450 500
-840
-995
-480
-635
+172
+132
N37
N
Technical Guidance /
References
References
Dimensional Tolerances for Regularly Used Fits [Taken from JIS B 0401 (1999)]
Dimensional Tolerances for Regularly Used Fits
Base
Dimension
(mm)
Tolerance Zone Class of Hole Units μm
More
than
Max.
B10
C9
C10
D8 D9
D10
E7 E8 E9 F6 F7 F8 G6 G7 H6 H7 H8 H9
H10JS6 JS7
K6 K7 M6 M7 N6 N7 P6 P7 R7 S7 T7 U7 X7
3
+180
+140
+85
+60
+100
+60
+34
+20
+45
+20
+60
+20
+24
+14
+28
+14
+39
+14
+12
+6
+16
+6
+20
+6
+8
+2
+12
+2
+6
0
+10
0
+14
0
+25
0
+40
0
3 5
0
-6
0
-10
-2
-8
-2
-12
-4
-10
-4
-14
-6
-12
-
6
-
16
-
10
-
20
-
14
-
24
-18
-28
-20
-30
36
+188
+140
+100
+70
+118
+70
+48
+30
+60
+30
+78
+30
+32
+20
+38
+20
+50
+20
+18
+10
+22
+10
+28
+10
+12
+4
+16
+4
+8
0
+12
0
+18
0
+30
0
+48
0
4 6
+2
-6
+3
-9
-1
-9
0
-12
-5
-13
-4
-16
-9
-17
-
8
-
20
-
11
-
23
-
15
-
27
-19
-31
-24
-36
610
+208
+150
+116
+80
+138
+80
+62
+40
+76
+40
+98
+40
+40
+25
+47
+25
+61
+25
+22
+13
+28
+13
+35
+13
+14
+5
+20
+5
+9
0
+15
0
+22
0
+36
0
+58
0
4.5 7.5
+2
-7
+5
-10
-3
-12
0
-15
-7
-16
-4
-19
-12
-21
-
9
-
24
-
13
-
28
-
17
-
32
-22
-37
-28
-43
10 14
+220
+150
+138
+95
+165
+95
+77
+50
+93
+50
+120
+50
+50
+32
+59
+32
+75
+32
+27
+16
+34
+16
+43
+16
+17
+6
+24
+6
+11
0
+18
0
+27
0
+43
0
+70
0
5.5 9
+2
-9
+6
-12
-4
-15
0
-18
-9
-20
-5
-23
-15
-26
-
11
-
29
-
16
-
34
-
21
-
39
-26
-44
-33
-51
14 18
-38
-56
18 24
+244
+160
+162
+110
+194
+110
+98
+65
+117
+65
+149
+65
+61
+40
+73
+40
+92
+40
+33
+20
+41
+20
+53
+20
+20
+7
+28
+7
+13
0
+21
0
+33
0
+52
0
+84
0
6.5 10.5
+2
-11
+6
-15
-4
-17
0
-21
-11
-24
-7
-28
-18
-31
-
14
-
35
-
20
-
41
-
27
-
48
-33
-54
-46
-67
24 30
-33
-54
-40
-61
-56
-77
30 40
+270
+170
+182
+120
+220
+120
+119
+80
+142
+80
+180
+80
+75
+50
+89
+50
+112
+50
+41
+25
+50
+25
+64
+25
+25
+9
+34
+9
+16
0
+25
0
+39
0
+62
0
+100
0
8 12.5
+3
-13
+7
-18
-4
-20
0
-25
-12
-28
-8
-33
-21
-37
-
17
-
42
-
25
-
50
-
34
-
59
-39
-64
-51
-76
40 50
+280
+180
+192
+130
+230
+130
-45
-70
-61
-86
50 65
+310
+190
+214
+140
+260
+140
+146
+100
+174
+100
+220
+100
+90
+60
+106
+60
+134
+60
+49
+30
+60
+30
+76
+30
+29
+10
+40
+10
+19
0
+30
0
+46
0
+74
0
+120
0
9.5 15
+4
-15
+9
-21
-5
-24
0
-30
-14
-33
-9
-39
-26
-45
-
21
-
51
-
30
-
60
-
42
-
72
-55
-85
-76
-106
65 80
+320
+200
+224
+150
+270
+150
-
32
-
62
-
48
-
78
-64
-94
-91
-121
80 100
+360
+220
+257
+170
+310
+170
+174
+120
+207
+120
+260
+120
+107
+72
+126
+72
+159
+72
+58
+36
+71
+36
+90
+36
+34
+12
+47
+12
+22
0
+35
0
+54
0
+87
0
+140
0
11 17.5
+4
-18
+10
-25
-6
-28
0
-35
-16
-38
-10
-45
-30
-52
-
24
-
59
-
38
-
73
-
58
-
93
-78
-113
-111
-146
100 120
+380
+240
+267
+180
+320
+180
-
41
-
76
-
66
-
101
-91
-126
-131
-166
120 140
+420
+260
+300
+200
+360
+200
+208
+145
+245
+145
+305
+145
+125
+85
+148
+85
+185
+85
+68
+43
+83
+43
+106
+43
+39
+14
+54
+14
+25
0
+40
0
+63
0
+100
0
+160
0
12.5 20
+4
-21
+12
-28
-8
-33
0
-40
-20
-45
-12
-52
-36
-61
-
28
-
68
-
48
-
88
-
77
-
117
-107
-147
140 160
+440
+280
+310
+210
+370
+210
-
50
-
90
-
85
-
125
-119
-159
160 180
+470
+310
+330
+230
+390
+230
-
53
-
93
-
93
-
133
-131
-171
180 200
+525
+340
+355
+240
+425
+240
+242
+170
+285
+170
+355
+170
+146
+100
+172
+100
+215
+100
+79
+50
+96
+50
+122
+50
+44
+15
+61
+15
+29
0
+46
0
+72
0
+115
0
+185
0
14.5 23
+5
-24
+13
-33
-8
-37
0
-46
-22
-51
-14
-60
-41
-70
-
33
-
79
-
60
-
106
-
105
-
151
200 225
+565
+380
+375
+260
+445
+260
-
63
-
109
-
113
-
159
225 250
+605
+420
+395
+280
+465
+280
-
67
-
113
-
123
-
169
250 280
+690
+480
+430
+300
+510
+300
+271
+190
+320
+190
+400
+190
+162
+110
+191
+110
+240
+110
+88
+56
+108
+56
+137
+56
+49
+17
+69
+17
+32
0
+52
0
+81
0
+130
0
+210
0
16 26
+5
-27
+16
-36
-9
-41
0
-52
-25
-57
-14
-66
-47
-79
-
36
-
88
-
74
-
126
280 315
+750
+540
+460
+330
+540
+330
-
78
-
130
315 355
+830
+600
+500
+360
+590
+360
+299
+210
+350
+210
+440
+210
+182
+125
+214
+125
+265
+125
+98
+62
+119
+62
+151
+62
+54
+18
+75
+18
+36
0
+57
0
+89
0
+140
0
+230
0
18 28.5
+7
-29
+17
-40
-10
-46
0
-57
-26
-62
-16
-73
-51
-87
-
41
-
98
-
87
-
144
355 400
+910
+680
+540
+400
+630
+400
-
93
-
150
400 450
+1010
+760
+595
+440
+690
+440
+327
+230
+385
+230
+480
+230
+198
+135
+232
+135
+290
+135
+108
+68
+131
+68
+165
+68
+60
+20
+83
+20
+40
0
+63
0
+97
0
+155
0
+250
0
20 31.5
+8
-32
+18
-45
-10
-50
0
-63
-27
-67
-17
-80
-55
-95
-
45
-
108
-
103
-
166
450 500
+1090
+840
+635
+480
+730
+480
-
109
-
172
N38
N
Technical Guidance /
References
Dimensional Tolerances and Fits [Taken from JIS B 0401 (1999]
Standard Hole Fit for Regular Use
Standard
Hole
Tolerance Zone Class of Shaft
Clearance Fit
Transition Fit
Interference Fit
H6
g5 h5 js5 k5 m5
f6 g6 h6 js6 k6 m6
n6
p6
H7
f6 g6 h6 js6 k6 m6
n6
p6 r6 s6 t6 u6 x6
e7 f7 h7 js7
H8
f7 h7
e8 f8 h8
d9 e9
H9
d8 e8 h8
c9 d9 e9 h9
H10 b9 c9 d9
Note: These fittings produce exceptions depending on dimension category.
Standard Shaft Fit for Regular Use
Standard
Shaft
Tolerance Zone Class of Hole
Clearance Fit
Transition Fit
Interference Fit
h5 H6
JS6
K6 M6
N6
P6
h6
F6 G6 H6
JS6
K6 M6
N6
P6
F7 G7 H7
JS7
K7 M7 N7 P7 R7 S7 T7 U7 X7
h7
E7 F7 H7
F8 H8
h8
D8 E8 F8 H8
D9 E9 H9
h9
D8 E8 H8
C9 D9 E9 H9
B10 C10 D10
Note: These fittings produce exceptions depending on dimension category.
Interrelationship of Tolerance Zones for Regularly Used Standard Hole Fits
Note: The above table is for standard dimensions of more than 18 mm and less than or equal to 30 mm.
Interrelationship of Tolerance Zones for Regularly Used Standard Shaft Fits
Note: The above table is for standard dimensions of more than 18 mm and less than or equal to 30 mm.
Fit
Tolerance Zone Class of Hole
H6 H7 H8 H9 h5 h6 h7 h8 h9
H10
50
200
150
100
50
0
0
50
100
150
200
50
f6 g5 g6 h5 h6
js5 js6
k5 k6
m5 m6
n6 p6 e7 f6 f7 g6 h6 h7
js6 js7
k6
m6
n6 p6 r6 s6 t6 u6 x6 d9 e8 e9 f7 f8 h7 h8 c9 d8 d9 g8 e9 h8 h9 b9 c9 d9
M6
JS6
K5 M6 N6 P6 F6 F7 G6 G7 H6 H7
JS6 JS7
K6 K7 M6 M7 N6 N7 P6 P7 R7 S7 T7 U7 X7 E7 F7 F8 H7 H8 D8 D9 E8 E9 F8 H8 H9
B10
C9
C10
D8 D9
D10
E8 E9 H8 H9
H10
H9
H8
H7
H6
h5
h6
h6
h7
h8
h9
Dimensional Difference (µ
m)
Dimensional Difference (µm)
Standard
Hole
Fit
Tolerance Zone Class of Shaft
Clearance Fit
Transition Fit
Interference Fit
Clearance Fit
Transition Fit
Interference Fit
Sliding
Driving
Press
Strong Press
Shrinkage
Loose
Light Roll
Roll
Clearance Fit
Clearance Fit
Standard
Shaft
Interference Fit
Transition Fit
Clearance Fit
Clearance Fit
Transition Fit
Interference Fit
Clearance Fit
Clearance Fit
Clearance Fit
Clearance Fit
References
N39
N
Technical Guidance /
References
References
Finished Surface Roughness
Types and Definitions of Typical Surface Roughness
Types
Symbol
Method of Determination Descriptive Figure
Maximum Height
*1)
Rz
This is the value expressed in micrometers
(μm), obtained by extracting from the roughness
curve a segment of the reference length in the
direction of the mean line and measuring the
distance from the d eepest valley to the highest
peak of the extracted segment in the direction of
the longitudinal magnification of that roughness
curve.
Remarks: When obtaining Rz, care must be taken
to extract a segment of the reference
length from a portion having no
unusually high peaks and deep valleys
as they are considered as flaws.
Rp
Rz
Rv
m
Rz
=
Rp
+
Rv
Calculated Roughness
Ra
This is the value expressed in
micrometers (μm), obtained by
extracting from the roughness
curve a segment of the
reference length in the direction
of the mean line, plotting a
roughness curve of y = f(x) with
the X-axis set in the direction
and the Y-axis set in the direction
of the extracted segment, and
using the following formula.
Ra
m
Ra=ࠈ 㹰I[㹲G[
1
0
Ten-point Mean Roughness
*2)
RzJIS
This is the value expressed in
micrometers (μm), obtained by
extracting from the roughness curve
a segment of the reference length
in the direction of the mean line,
measuring the heights of the highest to
5th highest peaks (Yp) as well as the
heights of the deepest to 5th deepest
valleys (Yv) in the direction of the
longitudinal magnification of that mean
line of the that roughness curve, and
calculating the sum of the mean of the
absolute values of Yp and that of Yv.
Yp1
Yp2
Yp3
Yp4
Yp5
Yv1
Yv2
Yv3
Yv4
Yv5
m
(Yp1+Yp2+Yp3+Yp4+Yp5)+(Yv1+Yv2+Yv3+Yv4+Yv5)
5
RzJIS=
Designated values of the above types of surface roughness, standard reference length
values and the triangular symbol classifi cations are shown on the table on the right.
Relationship with Triangular Symbols
Designated
Values for
*1)
Rz
Designated
Values for
Ra
Designated
Values for
*2)
RzJIS
Standard
Reference
Length Values,
(mm)
*
Triangular
Symbols
(0.05)
0.1
0.2
0.4
(0.012)
0.025
0.05
0.10
(0.05)
0.1
0.2
0.4
0.25
0.8 0.20 0.8
1.6
3.2
6.3
0.40
0.80
1.6
1.6
3.2
6.3
0.8
12.5
(18)
25
3.2
6.3
12.5
(18)
25
2.5
(35)
50
(70)
100
12.5
25
(35)
50
(70)
100
8
(140)
200
(280)
400
(560)
(50)
(100)
(140)
200
(280)
400
(560)
——
Remarks: The designated values in the brackets do not apply
unless
otherwise stated.
* Due to the revision of JIS in 1994, the finishing symbols, triangular ( )
and wavy (~) symbols, were abolished.