Technical Information

Special Hybrid Grades

Features of Grades
Swiss special hybrid grades, extremely efficient in covering materials including steel, stainless steels, cast iron & high temp alloys.
S300
Unique Substrate / PVD coating for MILLING and DRILLING Application
  • PVD coating with optimal thermal resistance & added strength
  • Tough carbide substrate designed for demanding application
S100
Unique Substrate / PVD coating for TURNING Application
  • Substrate and PVD coating designed to balance edge strength & wear resistance
  • Excellent cutting performance under harsh machining condition
S500
Unique Substrate / SVC coating for MILLING and DRILLING Application
  • Thick coating optimized for cast iron applications
  • CVD coating with optimal thermal & wear resistance for turning applications
  • Exceptional cutting performance attributed to combination of carbide substrate and coating

Damage of Insert & Counter Measure

Description Solution

Rapid Flank Wear

 1. Inappropriate feed(f) rate

2. Cutting speed(s) too high

 1. Adjust feed(f) rate according to depth(ap), width(ae)

2. Reduce cutting speed(s)

Chipping

1. Feed(f) rate too high

2. Cutting speed(s) too low

3. Vibration of holder & machine

1. Reduce feed(f) rate

2. Increase cutting speed(s)

3. Reduce the tool overhang & improve the rigidity of machine and workpiece

Thermal Crack

 1. Insufficient coolant

2. Cutting speed(s) too high

 1. Check cooling system, supply enough coolant or use dry milling

2. Reduce cutting speed(s)

Build Up Edge

1. Cutting speed(s) too low

2. Insufficient coolant

3. Not enough rake angle

1. Increase cutting speed(s)

2. Supply enough coolant

3. Increase rake angle of change inserts

Notching

 1. Scaling or work hardening in workpiece surface area

2. Burrs in workpiece

1. Change/Vary cutting condition (feed & depth)

2. Change path or direction

Fracture

 1. Wrong insert shape or corner radius

2. Corner radius too small

3. Cutting force fluctuation too high

 1. Choose the insert with bigger corner or radius

Cratering

 1. Insufficient coolant supply

2. Cutting speed(s) and feed(f) rate too high

1. Increase coolant supply or concentration

2. Reduce cutting speed(s) and feed(f) rate

Plastic Deformation

 1. Cutting speed(s) too high

2. Too much stress applied on the cutting edge

1. Reduce cutting speed(s)

2. Supply enough coolant

3. Choose insert with bigger corner radius

Technical Formula

Cutting speed (Vc) [m/min.]

$$Vc={D . π . n }/{1000}$$ [m/min.]
Revolutions per minute (n) [rev./min.]

$$n={Vc . 1000 }/{D . π}$$ [rev./min.]
Feed rate (Vf) [rev./min.]

$$Vf={fn . n}$$ [rev./min.]
Feed per tooth [mm/tooth]

$$fz={Vf}/{n . z}$$ [mm/tooth]
Metal removal amount [cm3/min.]

$$Q={ae . ap . Vf}/{1000}$$ [cm3/min.]
Power consumption [kW]

$$Pc={Q . kc}/{60 . 102. n}$$ [rev./min.]
Material designations & dimensions
ae Width of cut [mm]
ap Depth of cut [mm]
D Cutter diameter [mm]
Dw Work piece diameter [mm]
fz Feed per tooth [mm/tooth]
π Circular constant
kc Specific cutting resistance [kgf/mm3]
n Revolutions of spindle [min. -1]
Pc Power consumption [kW]
Q Metal removal amount [cm3/min.]
Vc Cutting speed [m/min.]
Vf Feed rate [mm/min.]
fn Feed per revolution [mm/rev.]
z Effective number of edges [pcs.]
 n Mechanical efficiency [%]

 

Trouble Shooting

Trouble Cause Counter measure
Cutting conditions
Cutting speed Feed rate Depth of cut Coolant
Heat Inappropriate
cutting condition		 ↓ ↓ ↓
Poor surface
quality of
machined
surface		 Premature insert
wear		 ↓ ●
Chipping of cutting
edge		 ↓ ↓
Built up edge ↑ ↑ ●
Inappropriate
cutting condition		 ↑ ↓ ↓ ●
Chatter ↓ ↓ ↓ ●
Change of
cutting edge line		 Inappropriate
cutting condition		 ↓ ↑
Burr, Chipping
(Steel, Aluminum)		 Inappropriate
cutting condition		 ↓ ↑ ●
Chipping of
workpiece
(Cast Iron)		 Inappropriate
cutting condition		 ↓ ↓
Burr
(Mild steel)		 Inappropriate
cutting condition		 ↑ ●

- ↓ : decrease ↑ : increase : depends on status ● : use coolant

Universal Grades Comparison Chart : PVD MILLING and DRILLING

Universal Grades Comparison Chart : TURNING