Professional Documents
Culture Documents
FOR
MACHINING GUIDELINES
Foreword
This handbook is intended to establish a platform of practicable knowledge (or
methodology) for machining of P/M materials. In particular, the chapters on specic
machining techniques provide cutting parameters for materials, tools and methods. Also
shown is the inuence of alternative approaches such as with additives, oil impregnation,
and selection of tool, which aim to improve cutting operations. Thus this handbook
should serve as a practical guide and handy reference for those working with machining
of P/M materials.
Chapter three was written in cooperation with Sandvik Coromant and the Swedish
Institute of Metal Research. Chapters four and ve were written in cooperation with
Dormer Tools and IVF. All tests were sintered in a production furnace at GKN Sinter
Metals AB, Sweden.
Hgans AB
2004
3
Table of contents
1. Machinability . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1. Application of powder metallurgy . . . . . . . . . . . . . . . . . 6
1.2. History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3. Metal Powder Production . . . . . . . . . . . . . . . . . . . . . . . 7
2. Metal alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1. Alloying methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2. The powder metallurgy process . . . . . . . . . . . . . . . . . 17
2.3. Materials development . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4. Sintered Iron-based materials . . . . . . . . . . . . . . . . . . . 20
2.5. Alloying system: Microstructures and
mechanical properties . . . . . . . . . . . . . . . . . . . . . . . . 23
3. Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.1. Analysis of the Machining Process . . . . . . . . . . . . . . . . 39
3.2. Tool Wear and Tool Life . . . . . . . . . . . . . . . . . . . . . . . 44
3.3. Classification of P/M Materials for Turning . . . . . . . . . . 51
3.4. Influence of material, properties and
machining processes. . . . . . . . . . . . . . . . . . . . . . . . . 55
3.5. Surface Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.6. Cutting Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.7. Summary: Machining of P/M Materials . . . . . . . . . . . . . 82
3.8. Turning tool recommendations and cutting data . . . . . . 84
4. Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.1. Quality and Performance in Machining . . . . . . . . . . . . . 87
4.2. Increasing machinability . . . . . . . . . . . . . . . . . . . . . . . 88
4.3. Classification of P/M Materials for Drilling . . . . . . . . . . 88
4.4. Influence of Properties of P/M Materials . . . . . . . . . . . 91
4.5. Tool Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.6. Tool Treatments . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.7. Selection of Drill Type . . . . . . . . . . . . . . . . . . . . . . . 102
4.8. Drill Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.9. Use of Cutting Fluids . . . . . . . . . . . . . . . . . . . . . . . . 107
4.10. Hints for Optimal Drilling . . . . . . . . . . . . . . . . . . . . . 109
4.11. Economy and Productivity in Drilling . . . . . . . . . . . . 111
4.12. Setting Machine Limits . . . . . . . . . . . . . . . . . . . . . . 112
4
4.13. Formulae for Cutting Forces . . . . . . . . . . . . . . . . . . 113
4.14. Drill Recommendations and Cutting Data . . . . . . . . . 115
5. Tapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5.1. Classification of P/M Materials for Tapping . . . . . . . . 119
5.2. Influence of Additives . . . . . . . . . . . . . . . . . . . . . . . . 121
5.3. Selection of taps . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.4. Hints on Optimal Tapping . . . . . . . . . . . . . . . . . . . . . 127
5.5. Tapping Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.6. Tap and Cutting Data Recommendations . . . . . . . . . . 129
6. References . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5
1 Machinability
Powder metallurgy (P/M) is known for producing complex parts to very close tolerances
without the necessity of machining operations, yet machinability is still important for
some applications. Many components require surface-nish machining to reach nal
shape due to particular geometries (such as holes perpendicular to the pressing direction,
bevels, slots and threads), and also due to demands for even ner tolerances.
What then is machinability? One useful denition is: The material with the best
machinability is the one permitting the fastest metal removal rate with reliable and
satisfactory tool life and surface nish. Thus machinability focuses on efciency with
nishing processes for metal products.
Investigation of the P/M market reveals that about 60% of all components need
some kind of machining operation. Turning is by far the most frequently occurring
operation, but tapping, drilling, and discontinuous turning, are considered the most
difcult. Machining operations can account for up to 20% of the total production cost
of a component.
The machinability of a P/M component is dependent on the work-piece and tool
material properties, cutting conditions, and machine and cutting tool parameters.
Chemical composition, porosity, free machining additives, and production process
parameters such as compaction and sintering methods, also collectively inuence
machinability.
Optimization of machinability is limited by the mechanical properties of a given
component. The selection of a material grade for a component is mainly based on its
required mechanical properties. Consequently, there are limitations on chemical
composition adjustment for machinability. The addition of free machining additives,
and oil impregnation, remain as alternatives. New technologies, such as warm
compaction, can increase machinability due to an increase in density.
Since developments with more highly alloyed materials have increased the
mechanical strength of components, P/M technology requires guidelines for the
selection of tool material and cutting conditions. If certain guidelines are followed,
production costs are reduced and P/M is able to compete strongly with other
manufacturing processes.
Machinability
6
1.1 Application of powder metallurgy
As a metal-working technology, powder metallurgy (P/M) has the advantage compared
to other processes, that it can produce complex parts of high quality with close
tolerances, in an economical way. This is due to low energy consumption, high material
utilization and low capital cost for the technology. Additional advantages are its high
exibility and particular mechanical properties, related to microstructure, and the
possibility for development of new materials. Accordingly, the market share for P/M has
been increasing rather rapidly.
1.2 History
Industrial production of iron powder began in 1937 on the incentive of the General
Motors Corporation in the USA. In Europe, Hgans was active from 1922 in
producing high-quality sponge iron for the Swedish steel industry. This product was
used as high-purity melting stock for the production of special steels, such as tool steels
and stainless steel. Sponge iron, owing to its high porosity, could easily be comminuted
(reduced) to iron powder. However, due to its high content of reducible oxygen (2%)
and carbon (0.15%), the compressibility for this material was poor. After 1940, Hgans
introduced an annealing procedure, with which the residual oxygen and carbon content
were considerably lowered.
During World War II, iron metallurgy was dramatically developed in Germany.
Mainly due to a shortage of copper, artillery driving bands were produced from iron
powder, and 30,000 metric tons were produced in 1944. The iron material for this
purpose was mainly made by grinding wire cuttings and sheet clippings in hammer mills
of the type Hametag. Wartime innovations meant important iron powder processes
were developed. For example: gas atomization of a desulphurized cast iron melt, later
converted to the now commonly used water atomization process, and the electrolytic
process for production of iron, became practicable. Today water atomization is the
dominating process because it produces high compressibility in conjunction with high
density.
Metal Powder Production
7
1.3 Production - Introduction
Iron and steel powders for the manufacturing of sintered structural components
(including sintered porous bushings) are produced in many parts of the world. The
worldwide consumption of such powders has been growing increasingly fast over the last
three decades and reached 770 000 metric tons by the end of 2002.
Over the last thirty years, the quality of iron and steel powders has been continuously
improved and the spectrum of available grades has been widened. During the same
period, compacting- and sintering-techniques have become more and more
sophisticated. This development has lead to a substantially widened range of applications
for sintered iron and steel parts.
From Table 1, it can be seen that in 1965 iron powders were used almost exclusively for
low- and medium-density applications, i.e. for parts having pressed densities from 5.5 to
7.0g/cm
3
. First after about 1970, increasing quantities of iron powders were used for
high-density applications, i.e. for parts having pressed densities higher than 7.0g/cm
3
.
Between 1975 and 1985, low-alloyed iron powders appeared on the market and have
since been used in growing quantities for medium- and high-density applications, i.e. for
parts having densities higher than 6.7g/cm
3
.
This development of high density products has continued after 1995. It must be
mentioned that, at present (2004), the worldwide production capacity of iron and steel
powders is considerably larger than the consumption. Thus, there is no risk of shortage
for many years to come.
Machinability
8
At present there are two basically different production methods which together
account for more than 90% of the world production of iron and steel powders, viz. the
Hgans sponge-iron process and the water-atomizing process. The former process is based
on reduction of iron ore, yielding a highly porous sponge-iron which subsequently is
comminuted to powder. The latter process is based on atomization of a stream of liquid
iron (or steel) by means of a jet of pressurized water. Both processes will be described in
detail further below.
In the manufacturing of sintered parts, iron powders are always used admixed with a
small amount of lubricant in powder form in order to minimize the friction in the
compacting tool. In many cases, they are also blended with alloying elements in powder
form, like graphite, copper, nickel, molybdenum and others (in order to achieve
increased strength properties).
Since powder blends tend to segregate when transported and handled, Hgans AB
has developed special blending processes in which the alloying additives are safely bound
to the iron powder particles. Powdermixes produced according to these processes are
known as the trade names Distaloy
m
)
R
o
u
n
d
e
d
n
e
s
s
(
m
)
73.
72.
Machinability: Drilling
96
Figure 75. The effect of drill cutting speed on variations in surface nish and roundedness with
Distaloy SA (with and without additive MnS).
MnX added at 0.3% has a smaller effect on mechanical properties compared to MnS
[Ref. 7]. Improved results were achieved compared to 0.5% MnS addition, upon testing
with Distaloy AE+0.5% C. For high strength materials, the effect of MnX is greater.
With the mix ASC100.29+2% Cu+0.5% C, the effect is in the same range as 0.5%
MnS. (See gure 75; compare with gure 70.)
The effect of MnX is in the same range or better compared to MnS, in regard to feed
force (thrust) and torque (see gure 71 and gure 72, respectively).
Cutting speed (m/min)
S
u
r
f
a
c
e
f
i
n
i
s
h
(
m
)
R
o
u
n
d
e
d
n
e
s
s
(
m
)
74.
Influence of Properties of P/M Materials
97
Figure 76. Effect of MnX additive on relative tool life for two P/M materials. A = ASC100.29+2% Cu+
0.5% C+0.3% MnX. B = Distaloy AE+0.8% C+0.3% MnX.
The additive MnX prevents the decreases in machinability which otherwise occur when
machining feed rates are increased (see gure 76). In this case machinability is measured
by relative tool life.
To fully utilize the benets of MnX, the machine feed rate has to be increased. The
shorter tool life at higher feed rates does not balance the apparent increase in
productivity. Another conclusion is that MnX has an improved effect for high
performance grades of P/M mixes. It must be stated that drilling Distaloy AE +0.8% C
(or 0.5% as per gure 76) with an uncoated HSS drill is, from a productivity point of
view, not to be recommended without addition of MnX.
75.
Machinability: Drilling
98
Figure 77. Inuence on relative tool life of MnX added to two P/M materials, at various feed rates.
A=ASC100.29 +2% Cu+0.5% C. B=ASC100.29+2% Cu+0.5% C+0.3% MnX. C=Distaloy AE+0.5% C.
D=Distaloy AE+0.5% C+0.3% MnX.
Density
The main investigated mix (ASC100.29+2% Cu+0.5% C) revealed an increase of 5% in
tool life for the density range of 6.7 to 7.3 g/cm
3
. It is reported that a better machining
response, in terms of reduced drill torque and thrust levels, is obtained with increased
densities [Ref. 6].
Oil impregnation
The option of oil impregnation is one advantage that P/M technology can offer
compared with conventional steel. Internal lubrication on the cutting edge is possible
when material has been impregnated with oil. As a consequence, the cutting force
required and the variation of cutting forces are decreased. Performance for oil
impregnation compared with cutting uid and dry cutting of Distaloy HP+0.5% C is
shown in gure 77.
In recent years an alternative with minimal lubrication has been introduced. This
involves applied oil suspension on the tool every time it leaves the work material. Initial
tests reveal improvements in the same range as cutting uid and oil impregnation.
Feed rate (mm/r)
R
e
l
a
t
i
v
e
t
o
o
l
l
i
f
e
(
%
)
76.
Tool Materials
99
Figure 78. Cutting performance in terms of relative tool life for three conditions with Distaloy
HP + 0.5% C: dry cutting, uid-aided cutting, material oil-impregnated.
4.5 Tool Materials
Several grades of high speed steel and cemented carbide materials have been vital in the
development of machining tools for P/M components. Some of these materials have
themselves been produced with P/M technology. In a later Section 4.7 on drill selection
the application of these materials in the manufacture of drills will be apparent. The
general properties of these materials are covered in this section, along with a comparison
of two important tool materials. Treatment processes used with alloyed steels to achieve
high quality tools are discussed in the next section.
HSS - High speed steel
Since its introduction at the end of the 19th century high speed steel has become one of
the most important materials in the manufacture of cutting tools. High speed steels
exhibit hardness, toughness and wear resistance, characteristics which make them useful
in a wide range of applications.
HSCo - Cobalt high speed steel
Over the years new types of high speed steels have been developed. The principal
improvement in the eld of alloying has been use of cobalt. This development has led to
grades that feature excellent high temperature strength properties without compromise
to wear resistance and toughness. Drills, milling cutters, reamers and taps manufactured
from these grades meet the exacting demands of high productive machining.
Dry f=0.2 mm/r Liquid coolant
f=0.12 mm/r
Oil impregnation
f=0.12 mm/r
77.
Machinability: Drilling
100
HSCo XP - Sintered cobalt high speed steel
HSCo XP is a cobalt high speed steel produced using powder metallurgy technology.
High speed steel produced by this method exhibits superior toughness and grindability.
The use of XP steels is particularly advantageous when machining materials that are
difcult to cut or when the material is extremely hard. Taps and milling cutters have
particular advantage when made from XP grade steel.
Cemented carbide
The carbide grades P40 and K10 are most often used in the manufacture of solid carbide
drills. Micrograin K10 grades are today most common thanks to their good combination
of hardness and toughness. In the hardest and most abrasive P/M materials carbide drills
are essential to attain acceptable productivity and tool life. K10 micrograin grade
cemented carbide typically consists of 10% cobalt and 90% tungsten carbide (WC).
Comparison of two tool materials
In gure 78 comparison is shown between two materials used to manufacture high
performance tools. K10 grade cemented carbide rated higher than HSCo on three of the
four physical properties tested. The maximum value for each property was set at 100%
for purposes of the comparison.
Figure 79. Relative ratings of two high performance tool materials on four physical properties.
Alloy content
Alloys have, of course, frequently been used in the production of high performance
steels. The alloy contents of those grades of steel most often used in drills and taps are
shown in Table 9.
Relationship between HSCO and K10 regarding properties.
78.
Tool Treatments
101
4.6 Tool Treatments
Tools materials may be treated with a variety of surface treatments and coatings. These
allow tools to better meet the demands of more economical machining and improved
quality of machined surfaces. The following surface treatments and coatings have been
used to good effect, particularly with P/M materials.
Heat treatment
The highly alloyed high speed steels used today in the manufacture of cutting tools
require precision heat treatment. Extensive experience in heat treatment utilising the
most modern equipment, such as vacuum furnaces, ensures that the optimum
combination of properties essential to the efcient performance of a tool can be achieved
consistently. Meticulous attention to detail in all aspects of heat treatment is the only
guarantee of high and consistent quality in tool production.
Steam tempering
Steam tempering gives a strongly adhering blue oxide surface that acts to retain cutting
uid and prevent chip-to-tool welding, and thereby counteracts the formation of built
up edge. This is an advantage particularly in softer, less abrasive P/M materials
(ASC100.29, ASC100.29+2% Cu and Distaloy AE). Steam tempering can be applied to
any bright tool but its most useful applications are with drills and taps.
Nitriding
Nitriding is a process that is used to increase the hardness and wear resistance of the
surface of a tool. It is particularly suitable for taps used on abrasive P/M materials. Used
on twist drills when it is desirable to increase the strength and wear resistance of the
cylindrical lands.
TiN Titanium Nitride is a gold colored ceramic coating applied by physical vapor
deposition (PVD). High hardness combined with low friction properties ensure
Table 8. Alloying proportions in four high speed steels.
Grade C% W % Mo% Cr% V% Co%
M2 0.83 6.0 5.0 4.0 2.0
M35 0.80 6.0 5.0 4.0 2.0 5.0
M42 1.10 1.5 9.5 3.75 1.15 8.0
HSCo - XP 1.27 6.4 5.0 4.0 3.1 8.5
9.
Machinability: Drilling
102
considerably longer service life or alternatively, better cutting performance, with tools
that have been TiN coated. TiN is used mainly for coating of drills and taps. It gives in
most P/M materials longer tool life and allows tools to be used at higher cutting speeds.
AlTiN Aluminum Titanium Nitride is a multi layer ceramic coating applied by PVD
technology, which exhibits high toughness and oxidation stability. These properties make
it ideal for higher speeds and feed rates whilst at the same time improving tool life. It is
recommended to use AlTiN when machining abrasive P/M materials and for dry
machining.
4.7 Selection of Drill Type
Dormer Tools, as used in the tests reported here, are available in an extensive range of
standard and special drills. Materials and geometries are optimised to take account of the
cutting behaviour of particular work-pieces. When drilling a particular material at a
given speed and feed rate, drill performance is governed by the drill quality and a range
of other related factors. These are summarised below.
Factors inuencing drilling performance:
P/M-Material Drilled
Choice of Tool Holding
Depth of Hole
Stability of Work-piece Hold
Through or Blind Hole
Horizontal or Vertical Drilling
Dry or Cutting Fluid
Stationary or Revolving Drill
Condition of the Machine
Swarf Control
Machine Power Capacity
Most drills could be used to produce a hole in any material, but at what cost?
Commercial production requires skilful matching of tools, drills, materials and
machining processes. For maximum productivity in terms of greater tool life, hole
accuracy and other indicators of optimum performance, careful selection of drills, drill
Selection of Drill Type
103
speeds and feed rates is essential. The tables given in the nal section of this chapter
provide recommendations of drill types for different materials and applications (see
Section 4.14, gure 88 and Table 14).
The selection of drill type should be related to both the hardness of the material
being machined and productivity. This is shown schematically in gure 79.
Figure 80. Three drill types as a function of productivity and hardness of material to be drilled.
A range of High Speed Steel (HSS), High Speed Cobalt (HSCo) and solid carbide drill
types has been tested with P/M materials. Those drills listed in the recommendations
given later in this chapter (see gure 88 on page 117 ), are presented in the following
sections. For details of drills with other than cylindrical shanks see Dormer catalogues.
HSS standard drills
Standard HSS jobber drills for general applications and hole depths down to 4xD are the
A100, and for depths to 2.5xD, the A120. The shorter A120 has a special split point that
ensures easy starting and accurate drill location. Both drills have a standard cylindrical
shank (see images A and B in gure 80).
Standard HSS drills are useful with a large variety of P/M materials. They show best
performance in soft materials where an open point geometry ensures the cut material
will cleanly leave the utes.
79.
Machinability: Drilling
104
Figure 81. Standard HSS drill, (a) A100 and (b) A120.
HSS/HSCo high performance drills
The high performance family of ADX drills, which includes A510 and A520, has a
patented design. The design features include a quick helix, a 130 degree point with
special thinning, optimised ute space, and a bowed convex lip shape. The benets
include excellent swarf removal and accurate holes normally to H9. The major
advantage, however, is high attainable productivity. The special design combined with
the wear resistance of the TiN-coating substantially performs better than the uncoated
drills in most P/M materials. The A510 (Image C in gure 81) can be used down to 4xD
and the A520 (Image D in gure 81) down to 2.5xD. Both have cylindrical shanks.
Figure 82. High performance drill, (c) A510 and (d) A520.
(a) (b)
(c) (d)
80.
81.
Selection of Drill Type
105
High performance solid carbide drills
Coated high performance solid carbide drills are known as the CDX family of drills.
They include R510 (Image E in gure 82) and R520 (Image F in gure 82). Their rigid
design with its special convex lip shape ensures excellent swarf removal. Hole size
generally within H8 limits is produced, with good hole surface nishes and excellent
positional accuracy.
Solid carbide drills are the only acceptable choice for machining of high carbon
content Distaloy AE and Distaloy HP materials.
Figure 83. High performance coated solid carbide drill, (e) R510 and (f) R520.
(e) (f)
82.
Machinability: Drilling
106
4.8 Drill Dimensions
Various dimensions of a drill and drilling task must be considered to determine optimal
match of tool and operation. The effects of changes in drill length, hole diameter, and
feed and speed rates, are addressed in this section.
Drill length
One of the demands for an approved operation is good stability. The presence of pores in
the microstructure of a material leads to vibrations during drilling. Vibrations may be
minimized if a short drill length is used. This has been demonstrated with a cemented
carbide tool of different sizes (R510/R520). The effect increases with hardness, and was
signicant for Distaloy AE 0.5% C in gure 83. With Distaloy HP+0.5 % C the effect is
also large.
Figure 84. Difference in relative tool life with use of short (R520) and long (R510) drill for drilling of
Distaloy AE+0.5% C. Drilled dry at 0.12 mm/r.
Hole diameter
Nominal hole diameters vary somewhat between different types of drills. CDX and ADX
drills can, under the right cutting conditions and with a stable set up, produce holes with
a tolerance of H8 and H9, respectively. Standard drills reach a tolerance of H12. Actual
nominal hole diameters (in mm) for a range of drills are shown in Table 10.
83.
Use of Cutting Fluids
107
Hole depth and speed and feed rate
The depth of holes to be drilled has an inuence on the setting of optimal speed and feed
rates. As the ratio of hole depth to diameter increases, speed and feed rates should be
proportionally decreased. The recommendations given in Table 11 can be used as a
guideline for calculating reductions in machine rates when drilling holes deeper than
twice their diameter.
4.9 Use of Cutting Fluids
The application of cutting uids or liquid coolants generally improves machining
performance (see gure 84). If the additional operation to prevent oxidation can be
performed, taking the increased cost into account, the use of cutting uids has a
benecial effect. However, all recommendations given at the conclusion of this chapter
are for dry cutting conditions. This is due to the fact that oxidation of the component in
most cases cannot be tolerated.
Table 9. Selection of four drills showing nominal hole diameters: Deviations in
(mm).
Diameter
( mm)
CDX = H8 ADX = H9 PFX = H9 A100 = H12
3 0 / +0.014 0 / +0.025 0 / +0.040 0 / +0.100
> 3 < 6 0 / +0.018 0 / +0.030 0 / +0.048 0 / +0.120
> 6 < 10 0 / +0.022 0 / +0.036 0 / +0.058 0 / +0.150
> 10 < 18 0 / +0.027 0 / +0.043 0 / +0.070 0 / +0.180
Table 10. Recommended cutting speeds and feed rates at four hole depths.
Hole depth Percentage of
recommended speed, Vc
Percentage of
recommended feed, f
2 x D 100 % 100 %
3 x D 90 % 90 %
4 x D 80 % 80 %
5 x D 70 % 70 %
10.
11.
Machinability: Drilling
108
Figure 85. Inuence of cutting uid on relative tool life with three P/M mixes. A=Distaloy AE+0.5% C,
A510 f=0.2 mm/r. B=ASC100.29+2% Cu+0.5% C, A510 f=0.2 mm/r. C=ASC100.29+2% Cu +
0.5% C, A100 f=0.06 mm/r.
The effect of cutting uids is strongly dependent on the cutting speed. The -value for
cutting speed (vT-curve) is lower if a uid is used (see gure 85). For Distaloy AE the
same behaviour has been found [Ref. 8].
Figure 86. Effect of cutting speed on tool life (vT-curve) for drilling with and without cutting uid.
Using cutting uid when drilling with HSS-drills in P/M materials increases tool life at
factors approximately between 1.1 and 1.5 (see Table 12). These factors are valued for a
tool life of 300 hole. When the -value is taken into account, large differences can be
expected if an evaluation is made at a different tool life.
84.
85.
Hints for Optimal Drilling
109
An additional conclusion for machining of plain iron (>70% ferrite; see gure 68) with a
PVD-TiN coated HSS drill (A510), is that there is much to gain by use of cutting uid
and an increased cutting speed. With these materials, cutting uid will have more of a
lubricating than cooling effect. Taking into account the additional operation required to
protect the component from oxidation, the benet of cutting uid should be considered.
The total cost of the use of uids, work piece cleaning and the required changes to
the work environment should be compared with the cost of modern drilling tools,
especially those made of coated HSS and solid carbide. Coated carbide tools may be used
so that they have an impressively long tool life, even with low-speed machines, if special
attention is given to the control of vibrations. (See below for more on cutting data with
specic drills.)
4.10 Hints for Optimal Drilling
1. Select the best type of drill for your application. The tables at the end of this chapter
indicate the best drill to suit the P/M-material being drilled and give recommended
speeds and feed rates.
2. The work piece must be held rigid and the machine spindle should have no runout.
Rigidity can also be helped by using as short drill as possible.
3. The holder in which a straight shank drill is held must be of good quality. If the drill
slips in the holder and the feed is automatic, breakage of the drill can be the result.
With drills up to 6 mm a runout in the holder of up to 0.015 mm can be accepted.
4. If possible use recommended lubricants for cutting uid to enhance the life of the
tool. Ensure lubricants reach the drill point.
5. Do not allow the utes of a drill to become choked with swarf, especially on holes
deeper than 4X diameter. Withdrawal to clear the swarf may be required. Use special
parabolic ute drills for deeper holes.
6. Do not use 2-uted drills to open out existing drilled or cored holes as they are not
designed for this application.
Table 11. Correction factors for drill life increase with use of cutting uid.
Drill Factor
A100 1.25
A510 1.1 - 1.5
12.
Machinability: Drilling
110
7. When the drill is reground ensure that all wear is removed and check that the correct
point geometry is produced. Keep drills sharp.
Hints for carbide drilling
1. Use shortest possible drill.
2. Use machines with adequate stability.
3. Avoid unstable or weak tool-holders and work-pieces.
4. When vibrations are present, carbide tools are more prone to chipping than
HSS-tools.
5. Use shortest possible overhang for the application. It is better to use modular
adapters than to have a long overhang on the tool.
6. The tool-holder is very important so use holders of good quality and with small
runout (up to 0.01 mm).
Economy and Productivity in Drilling
111
4.11 Economy and Productivity in Drilling
Machining cost and productivity are probably the two most important parameters to
consider when deciding which tool that should be used and how to set up a drilling
process. The information in this section gives an indication of what can be expected
from different tools with four P/M materials.
Cost per hole
Economy in drilling has been determined according to cost per hole for a standard
machining procedure. Calculations of cost per hole were made on cutting data giving a
tool life of 15 minutes, no regrinding and a drill depth of 2xD. Tests were conducted to
allow comparisons with a standard iron powder and three P/M alloy materials when
machined with appropriate drill. (See gure 86 and refer to Section 4.7 above regarding
drill types.)
Figure 87. Comparative cost per hole with recommended drills (from a selection of three drills) in four
sintered iron materials. A=ASC100.29. B=Distaloy AE+0.5% C. C=Distaloy AE+0.8% C.
D=Distaloy HP+0.5% C.
The results shown in gure 86 indicate the economic limits of different tools. Material
classied as group 1 (i.e. ASC100.29 alloys) can be machined economically by a HSS
tool (A100). There is a clear difference for Distaloy AE+0.5% C: a coated HSS drill
(e.g. A510) should be selected. For Distaloy HP+0.5% C, the cemented carbide tool
(R520) replaces the coated HSS (A510) as the best choice.
The limits shown in gure 86 are only indications of drilling-material combinations
with different tools, and are likely to be the best choice from an economic point of view.
Time per hole
Productivity in drilling was determined according to time per hole for a standard
machining procedure. Calculations of seconds per hole were made on recommended
86.
Machinability: Drilling
112
cutting data and a drill depth of 2xD. See gure 87 for productivity results relevant to
the tool and material combinations as used in the above test for economy.
Figure 88. Comparative time for drilling single holes with recommended drills (from a selection of
three drills) in four sintered iron materials. A=ASC100.29. B=Distaloy AE+0.5% C.
C=Distaloy AE+0.8% C. D=Distaloy HP+0.5% C.
4.12 Setting Machine Limits
The drilling machine and the set up for a work piece are required to conform to
particular limits in order to maintain a certain quality of output and tool life. The limits
set should provide for the cutting forces and power input required, according to the
choice of tool and cutting data. The traditional choice of shortest possible drill is
important when machining P/M materials, as is a well-centering holder and a good
xture of the work piece.
It is difcult to set a stiffness value for a drilling machine in the same way as for
turning and milling operations. One procedure to reach a good reference for drilling
machines, is a follows:
1. Choose a P/M material similar to one listed in Table 8.
2. Use a drill for which specic feed force and cutting force values are indicated.
3. Determine the data from the cutting data chart (see gure 88).
4. Use the formulae shown below to calculate actual feed and cutting forces.
5. Test the drilling operation with the machine in question.
87.
Formulae for Cutting Forces
113
6. Evaluate as follows:
i. If the operation is running well: Repeat the test with higher cutting data until
there are vibrations or unacceptable work quality.
ii. If the operation fails: Repeat the test with reduced cutting data until the opera-
tion proceeds smoothly.
The cutting force levels thus determined, should be considered as the limit for the
machine. These limits, in cutting and feed forces, can then be used in planning new
operations and other diameters. (It is important to note that drilling with some tool wear
will increase the cutting force by up to 25%.).
4.13 Formulae for Cutting Forces
The following formulae are useful for calculating cutting data.
The maximum rotational speed (rpm) and the machine stability affect tool choice and
the choice of cutting data. Specic feed force and torque for some signicant P/M
materials.
Factor Symbol Formula Measurement
Cutting speed V
c
V
c
= (D
c
n) / 1000 m/min
Rotational speed n n = (V
c
1000) / (D
c
) rev/min
Feed rate f f = f
n
n mm/min
Machinability: Drilling
114
The formulae below can be used for approximate calculations of feed force and net
power consumption. (NB: Wear on tool and machine efciency is not considered in
these calculations.)
Table 12. Specic feed force and cutting force for A100 and R520 drills and a
range of P/M materials.
Specic feed force, k
f
Specic cutting force, k
c
Material groups A100
Fn=0.16-0.06
mm/rev
R520
Fn=0.12-0.20
mm/rev
Fn=0.16-0.06 mm/rev
Iron base
ASC100.29 2800-4600 4600-5800
ASC100.29+0.5% C 1900-3100 2800-3500
ASC100.29+0.45% P 2000-3300 3800-3500
ASC100.29+0.45%
P+0.5% C
3100-5000 2800-3500
ASC100.29+2% Cu 2600-3800 4600-5800
ASC100.29+2% Cu+
0.25% C
2400-3500 4100-5200
ASC100.29+2% Cu+
0.5% C
2400-3500 2900-3700
ASC100.29+2% Cu+
0.8% C
2900-4200 2800-3500
Diffusion bonded
Distaloy AE (4% Ni+1.5%
Cu+0.5% Mo)
2200-3500 3700-4600
Distaloy AE (4% Ni+1.5% Cu
+ 0.5% Mo)+0.5% C
3600-5000 3200-4000
Distaloy AE (4% Ni+1.5% Cu
+ 0.5% Mo)+0.8% C
3500-4400 2700-4600
Pre-alloyed with 1,5% Mo
Astaloy Mo+0.5% C 2700-4400 3500-4400
Distaloy HP (4% Ni+2% Cu)
+ 0.5% C
3700-4700
13.
Drill Recommendations and Cutting Data
115
4.14 Drill Recommendations and Cutting Data
In the following tables recommendations are given for drills to match materials in three
P/M alloy groups. In the drill table (gure 88), each recommended drill application is
rated as either excellent or acceptable. The speed and feed rates given are start values for
dry cutting of P/M material with a density of approximately 7.0 g/cm
3
. For each drill
application, numerical data represent recommended cutting speeds for a tool life of 15
minutes. With each cutting speed is a letter (T - Y) indicating recommended feed rate
for the cutting operation. The key to the letter notation is given in Table 14 on page 118,
where the code is transformed to numerical data (i.e. feed rate recommended for various
diameter drills).
Factor Symbol Formula Measurement
Drill diameter D
c
mm
Feed per revolution f
n
mm/rev
Specic feed force k
f
from Table 12
N/mm
2
Specic cutting force k
c
from Table 12
N/mm
2
Feed force F F = (D
c
f
n
k
f
) / 2 N
Power P
P = (D
2
fk
c
n) / 24010
6
kW
Machinability: Drilling
116
Selection of Drills Standard drills Applica
Recommendations and cutting data
A120 A100 A520
A001 A521
A524
Excellent for application.
Acceptable for applications
Example:
50 = Peripheral speed m/min. mid range +/- 10%.
V = Feed per rev See seperate Feed chart drills.
All recommendations dry, when machining with emulsion
speed by 10 - 50 %.
Material groups
HSS
2.5 x D
Blue
HSS
4 x D
Blue
HSS/HSCo
2.5 x D
TiN
ASC 100.29 50 V 50 V
ASC 100.29 + 0.5% C
Iron base
64 U 64 U
ASC 100.29 + 0.45% P 38 V 38 V
ASC 100.29 + 0.45% P + 0.5% C 24 U 24 U 41 Y
ASC 100.29 + 2% Cu 24 V 24 V
ASC 100.29 + 2% Cu + 0.25% C 50 U 50 U 87 Y
ASC 100.29 + 2% Cu + 0.5% C 45 T 45 T 78 Y
ASC 100.29 + 2% Cu + 0.8% C 25 T 25 T 44 Y
Distaloy AE (4% Ni, 1.5% Cu, 0.5% Mo) 31 U 31 U 45 X
Distaloy AE (4% Ni, 1.5% Cu, 0.5% Mo) + 0.25% C
Diffusion bonded
31 U 31 U 48 Y
Distaloy AE (4% Ni, 1.5% Cu, 0.5% Mo) + 0.5% C 20 T 20 T 31 Y
Distaloy AE (4% Ni, 1.5% Cu, 0.5% Mo) + 0.8% C 20 X
Astaloy Mo + 0.5% C 30 U 30 U 47 Y
Distaloy HP (4% Ni, 2% Cu) + 0.5% C
Pre-alloyed with 1,5% Mo
8 X
All recommendations dry, when machining with
cutting fluid increase speed by 10-50%.
Drill Recommendations and Cutting Data
117
Figure 89. Recommended drill selection from eight drill types for a range of P/M materials. Cutting data
is given for each recommended application (i.e. peripheral speed in meters/minute and feed rate code as
per Table 14).
pplication drills, HSCo Application drills solid carbide
A510 A577 R520 R522 R510
A511 R550 R552
A504
o HSS/HSCo
4 x D
TiN
HSCo
6 x D
AlTiN
K10
2.5 x D
TiN
K10
2.5 x D
AlTiN
K10
4 x D
TiN
41 X 41 V
87 X 87 V
78 X 78 V
44 X 44 V
45 W 45 U
48 X 48 V
31 X 31 V 80 W 80 W 60 V
20 W 20 V 80 W 80 W 60 V
47 X 47 V
8 W 8 U 83 W 83 W 50 V
88.
Machinability: Drilling
118
Table 14 indicates recommended feed rates for six drill sizes. The feed rates given (mm/r)
apply to drill applications as recommended in the drill table shown in gure 88.
Table 13. Drill feed chart.
Feed code
Diameter
3 mm 5 mm 8 mm 10 mm 12 mm 16 mm
T 0.04 0.06 0.09 0.11 0.13 0.17
U 0.07 0.09 0.14 0.17 0.20 0.23
V 0.10 0.13 0.20 0.25 0.28 0.32
W 0.13 0.17 0.26 0.33 0.38 0.43
X 0.15 0.21 0.33 0.42 0.48 0.55
Y 0.18 0.26 0.43 0.55 0.70 0.70
14.
Classification of P/M Materials for Tapping
119
5 Tapping
This chapter was written in cooperation with Dormer Tools and IVF.
Tapping is one of the most difcult machining operations, according to a study among
Hgans customers. This would explain the reported use of oil impregnation to assist the
operation. Straight ute taps of coated or uncoated high speed steel (HSS) are most
often used.
Tapping is closely related to drilling. There is an obvious need for a hole to perform a
tapping operation. The diameter of the hole is very important factor in determining
both thread quality and the useful life of a tap. A correct thread can only be made if the
hole is round and straight.
The recommendations given regarding drilling also apply to obtain a good thread.
(See previous chapter 4.)
5.1 Classication of P/M Materials for Tapping
Materials investigated for performance with tapping were the same as those evaluated for
drilling (see Chapter 4, Table 8). The tap used for the main evaluation was a straight
ute tap (E500).
With tapping in the dry condition, chip clamping severely inuenced performance
and therefore it was decided to perform the main comparison of materials with use of
applied emulsion.
To classify P/M material regarding tapping, evaluation of tool life of the tap is
necessary. The only investigation made was of torque. For this reason the classication
stated in the drilling and turning evaluations was used. Torque evaluated at a speed of
6.3 m/min (straight ute tap, applied uid) showed a correlation to hardness
(see gure 89).
Machining of P/M materials regarding Tapping
120
Figure 90. Correlation of torque in tapping and hardness of a range of P/M materials (as per Table 8).
Tapping with E500 straight uted tap, applied emulsion.
High strength material such as Distaloy AE + 0.8% C was only possible to tap if 0.3%
MnX was added. Materials with superior properties were impossible to tap. A further
conclusion from this evaluation is that density has a strong inuence on torque during
tapping. Additives as MnS and MnX and minimal lubrication decrease the torque.
Wet versus dry tapping
The turning and drilling evaluations (see previous chapters) demonstrated the
fundamental inuence in machining of the amount of ferrite present in the
microstructure of materials. However, tapping with emulsion revealed no such
relationship (see gure 89). With dry tapping, the effect of ferrite was apparent (see
Table 15).
There is a clear difference between the two machinability groups identied (viz.
alloys of ASC100.29 and Distaloy AE). With Distaloy AE+0.5% C, chip length was
much smaller compared to ASC100.29+2% Cu+0.5% C. This would explain the
performance shown in Table 15, torque values for tapping under dry and wet conditions,
with comparison of P/M materials according to proportion of ferrite present in
microstructures. For dry tapping the amount of ferrite must be taken into account.
89.
Influence of Additives
121
5.2 Inuence of Additives
Different types of additives used with P/M materials are described in Chapter 4 (see
Section 4.3). Investigated in relation to tapping was the effect of 0.5% MnS and 0.3%
MnX (see Table 16). It is clear that these two additives affect the tapping operation
differently. They also have different effects on each machinability group.
Table 14. Torque values for tapping under dry and wet conditions, with
comparison of P/M materials.
Material groups Ferrite
(%)
Torque Liquid uid
(Nm)
Torque dry
(Nm)
Iron base
ASC100.29+2% Cu 100
ASC100.29+2% Cu+0.25% C 80 0.75 1.57
ASC100.29+2% Cu+0.5% C 30 0.85 1.26
ASC100.29+2% Cu+0.8% C 1 0.98 1.47
Diffusion bonded
Distaloy AE (4% Ni, 1,5% Cu, 0,5% Mo) 90 0.7 1.81
Distaloy AE (4% Ni, 1,5% Cu, 0,5% Mo)+0,25% C 35 1 1.19
Distaloy AE (4% Ni, 1,5% Cu, 0,5% Mo)+0,5% C 8 1.17 1.36
Distaloy AE (4% Ni, 1,5% Cu, 0,5% Mo)+0,8% C 2
Table 15. Torque values for tapping of two P/M alloy groups with addition of
additives MnS and MnX, under dry and wet conditions.
Material groups Torque Liquid uid
(Nm)
Torque dry
(Nm)
Iron base
ASC100.29+2% Cu+0.5% C 0.86 1.51
ASC100.29+2% Cu+0.5% C+0.5% MnS 0.91 0.83
ASC100.29+2% Cu+0.5% C+0.3% MnX 0.79 1.05
Diffusion bonded
Distaloy AE (4% Ni, 1,5% Cu, 0,5% Mo)+0,5% C 1.17 1.36
Distaloy AE (4% Ni, 1,5% Cu, 0,5% Mo)+0,5% C+0,5%
MnS
0.96 1
Distaloy AE (4% Ni, 1,5% Cu, 0,5% Mo)+0,5% C+0,3%
MnX
1.07 1.37
15.
16.
Machining of P/M materials regarding Tapping
122
MnS
In the turning evaluation, the forces acting on the tool decreased with MnS addition (see
Chapter 3, gure 37, gure 38 and gure 39).
Comparison of the MnS effect on torque for emulsion and dry tapping revealed a
large decrease in torque under the dry condition. In tapping of ASC100.29+2% Cu+
0.5% C with applied emulsion, there was a small increase in torque.
With Distaloy AE+0.5% C, the torque decreased. The effect from MnS seems to
increase with hardness.
MnX
It is clear from the evaluation that MnX has no effect on tapping Distaloy AE +0.5% C
under a dry condition. For ASC100.29+2% Cu+0.5% C the effect is signicant.
Improved chip breaking would explain the difference in performance.
For material with a high amount of ferrite, MnX addition in combination with
lubrication by either oil impregnation or minimal applied lubricant, is believed to be
benecial. In the case of tapping with a cold forming tap, the thread is formed by plastic
deformation of the material. Internal lubrication (oil impregnation) or MnS addition is
believed to be benecial for the threading operation. Some kind of lubrication is very
important when using cold forming taps.
Selection of taps
123
5.3 Selection of taps
A range of taps was investigated for use with P/M materials. The four main taps tested
are shown in Table 17. Different types of tool materials inuence tap performance (see
Chapter 4, Section 4.5 for discussion of tool materials). Details of surface treatments and
coatings used with tool materials were also given in Chapter 4 (see Section 4.6).
Descriptive characteristics of taps used in these evaluations are shown in gure 90. The
illustrations serve as denitions for those characteristics that are important in the
performance of taps.
Table 16. Images of four types of taps evaluated for use with P/M alloys.
Spiral point tap Spiral ute tap Straight ute tap Cold forming tap
17.
Machining of P/M materials regarding Tapping
124
Figure 91. Dening characteristics of quality taps.
Five main hole congurations were considered for tapping. Figure 91 illustrates these
hole types. Guidelines for tap selection and general recommendations for tapping of
P/M materials are given below.
Figure 92. Five main type of holes in tapping operations.
1 2 3 4 5
91.
90.
Selection of taps
125
Straight uted taps
Straight utes are the most commonly used type of tap. Suitable for use on most
materials, straight-uted taps form the basis of most tapping operations. They are
recommended for hole types 1, 2 and 3. The E500 is the model of this type evaluated
here.
Spiral point taps A tap with a straight, fairly shallow ute is often referred to as a gun
nose or spiral point tap. The gun nose or spiral point is designed to drive the swarf
forward. The relatively shallow utes ensure that the section strength is maximised and
they also act to allow emulsion to reach the cutting edges. This type of tap is
recommended for threading through-holes and is used for hole types 1 and 2. It may also
may be used in blind hole applications where there is sufcient space to accommodate
the swarf, hole type 3. The model evaluated was the E509.
Spiral uted taps
Taps with spiral utes are intended primarily for threading in blind holes of type 3, 4 or
5. The helical ute transports the swarf back away from the cutting edges and out of the
hole thus avoids packing of swarf in the utes or at the bottom of the hole. In this way
the danger of breaking the tap or damaging the thread is minimised. The model
evaluated was the E507.
Cold forming taps
Cold forming taps differ from cutting taps in that the thread is produced by plastic
deformation of the component material rather than by the traditional cutting action.
Thus no swarf is produced by cold forming taps. The application range is materials with
good formability: tensile strength (Rm) should not exceed 1200 N/mm
2
and the
elongation factor (A5) should not be less than 10%. The model evaluated was the E565.
Cold forming taps without utes are suitable for normal machining and are
especially suitable when working with vertically tapped blind holes. Conversely, cold
forming taps with utes are especially suited for applications in horizontal holes and
vertical through-holes. The utes act to facilitate the supply of lubricant to the working
area. With difcult to machine materials, TiN coating has been shown to give
outstanding tool life.
Determination of hole width
The diameter of the hole prior to tapping is an extremely important factor in
determining both thread quality and the useful life of the tap. Normally, a drilled hole is
slightly larger than the diameter of the drill. The amount of oversize depends upon the
material being drilled, the cutting conditions selected and the condition of the
equipment being used. Note:
Machining of P/M materials regarding Tapping
126
If material is pushed up at the thread entry by the tap and/or the life of the tap is too
short - select a slightly larger drill diameter.
If on the other hand the prole of the thread formed is insufcient - select a slightly
smaller drill diameter.
Torque comparison
A selection of four taps of various types was tested for torque values on a range of P/M
materials. A tap dimension of M4 was used and emulsion was applied in each case.
Results in Nm values are shown in Table 18.
(Emulsion applied in each case; tap dimension M4; values in Nm.)
Table 17. Comparison of torque in tapping of 11 P/M materials with a selection
of four taps.
Material groups E565 E973 E507 E500
Iron base
ASC100.29 1.00 0.81
ASC100.29+0.5% C 1.81 1.16 1.31
ASC100.29+0.45% P+0.5% C 1.10
ASC100.29+2% Cu+0.25% C 1.06
ASC100.29+2% Cu+0.5% C 1.19
ASC100.29+2% Cu+0.8% C 1.38
Diffusion bonded
Distaloy AE (4% Ni, 1,5% Cu,
0,5% Mo)
1.50 1.31 1.00
Distaloy AE (4% Ni, 1,5% Cu,
0,5% Mo)+0.25% C
1.40
Distaloy AE (4% Ni, 1,5% Cu,
0,5% Mo)+0.5% C
1.31 1.62
Distaloy AE (4% Ni, 1,5% Cu,
0,5% Mo)+0.8% C
1.66
Pre-alloyed with 1,5% Mo
Astaloy Mo+0.5% C 1.70
18.
Hints on Optimal Tapping
127
5.4 Hints on Optimal Tapping
The success of any tapping operation depends on a number of factors all of which affect
the quality of the nished product. Brief guidelines for optimal tapping are given here,
followed by discussion of some important factors affecting performance:
Select the correct design of tap for the component material and type of hole (i.e.
through or blind). See cutting data recommendations for tapping in Section 5.6, at
the end of this chapter.
Ensure the component is securely clamped: lateral movement may cause tap breakage
or poor quality threads.
Select the correct size of drill from the tapping drill charts. Remember: drill sizes dif-
fer between cutting and forming taps.
Select the correct cutting speed as shown in the cutting data recommendations for
tapping.
Use appropriate cutting uid for each application.
In NC applications ensure that the pitch value chosen for the program is correct.
When using a tapping attachment, 95% to 97% pitch is recommended to allow the
tap to generate its own pitch.
Where possible hold the tap in a good quality torque-limiting tapping attachment.
This should ensure free axial movement of the tap and that it is presented squarely to
the hole. It also protects the tap from breakage if it is accidentally bottomed in a
blind hole.
Core hole dimensions
A correct thread can only be obtained if the hole is round and straight. The diameter of
the hole must never be smaller than the minor diameter of the thread. The larger the
hole diameter, the lower the generated torque will be on the tap. Recommended core
sizes are given in the concluding section of this chapter (see Table 18).
Lubrication
It is important that the cutting part of the tap is ensured a good supply of lubricant or
cooling uid. The need for good lubrication increases with the depth of the hole and the
hardness of the material being machined. Any cooling uid must have a lubricating
effect in order to reduce friction.
One solution to avoid applied emulsion is to use minimal lubrication. A small
amount of oil, (20-40 ml/h) can then be directed to the thread part of the tap.
Machining of P/M materials regarding Tapping
128
Guidelines when using equipment for minimal lubrication are:
Direct the nozzles to the tap and the core hole.
Use only oil recommended for minimal lubrication.
Dry tapping
When selection of the most suitable cutting uid is not possible, or when dry cutting,
the useful life of the tool will be shorter than normal. When tapping dry, cutting speeds
must be reduced.
Tapping attachment
In order to ensure the best possible result a high quality tapping attachment with axial
oat should be used. See Dormer catalogue for available tapping attachments.
Clamping and centring
The tap must be carefully centred with the work piece for the best result to be obtained.
When thin materials are to be threaded it is important that the work piece is properly
secured in order to prevent the formation of oblong holes.
5.5 Tapping Guidelines
The following conclusions have been drawn from experimental and practical experiences
in tapping of P/M materials. These are rules of thumb or a general guide to optimal
tapping:
For materials of lowest hardness use high spiral taps.
For materials of medium hardness use straight uted or low spiral taps.
For materials of highest hardness use surfaced-treated low spiral taps.
Lubrication should be used whenever possible. It is of particular importance with
materials of lowest and greatest hardness, and with cold forming taps.
Tap and Cutting Data Recommendations
129
5.6 Tap and Cutting Data Recommendations
Recommendations for tap application and related cutting data are presented in gure 92.
The speed rates shown are start values for tapping with emulsion of P/M materials with a
density of 7.0 g/cm
3
.
In Table 19 - Table 22 drill diameters recommended for cutting taps and cold
forming taps are stated. In each case drill diameter refers to ISO metric coarse thread.
Machining of P/M materials regarding Tapping
130
Selection of Taps Spiral point taps S
Recommendations and cutting data
for thread form M coarse. For other thread
forms contact Dormer Tools.
ISO E509 E511 E507 E
DIN 371 E214 E206 E208 E
DIN 376 E265 E257 E259 E
Excellent for application.
Acceptable for applications
Example:
15 = Peripheral speed m/min. mid range +/- 10%.
All recommendations with lubricants.
Material groups
HSS
-2.5 x D
Bright
HSS
-2.5 x D
TiN
HSS
-2 x D
Bright
H
-2
T
ASC 100.29
ASC 100.29 + 0.5% C
Iron base
ASC 100.29 + 0.45% P
ASC 100.29 + 0.45% P + 0.5% C
ASC 100.29 + 2% Cu
ASC 100.29 + 2% Cu + 0.25% C
ASC 100.29 + 2% Cu + 0.5% C
ASC 100.29 + 2% Cu + 0.8% C
Distaloy AE (4% Ni, 1.5% Cu ,0.5% Mo)
Distaloy AE (4% Ni, 1.5% Cu ,0.5% Mo) + 0.25% C
Diffusion bonded
Distaloy AE (4% Ni, 1.5% Cu ,0.5% Mo) + 0.5% C
Distaloy AE (4% Ni, 1.5% Cu ,0.5% Mo) + 0.8% C
Astaloy Mo + 0.5% C
Distaloy HP (4% Ni, 2% Cu) + 0.5% C
Pre-alloyed with 1.5% Mo
20
15
10
8
15
10
8
10
8
8
35
25
20
16
25
20
16
20
16
16
20
15
10
8
15
10
8
10
8
8
35
25
20
16
25
20
16
20
16