Guide to Machining Carpenter Specialty Alloys Guide to Machining Carpenter Special Ty All O Ys
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GUIDE TO MACHINING CARPENTER SPECIAL GUIDE TO MACHINING CARPENTER SPECIALTY ALLOYS Carpenter Technology Corporation TY ALL Wyomissing, PA 19610 U.S.A. 1-800-654-6543 Visit us at www.cartech.com O YS For on-line purchasing in the U.S., visit www.carpenterdirect.com GUIDE TO MACHINING CARPENTER SPECIALTY ALLOYS Carpenter Technology Corporation Wyomissing, Pennsylvania 19610 U.S.A. Copyright 2002 CRS Holdings, Inc. All Rights Reserved. Printed in U.S.A. 9-02/7.5M The information and data presented herein are suggested starting point values and are not a guarantee of maximum or minimum values. Applications specifically suggested for material described herein are made solely for the purpose of illustration to enable the reader to make his/her own evaluation and are not intended as warranties, either express or implied, of fitness for these or other purposes. There is no representation that the recipient of this literature will receive updated editions as they become available. Unless otherwise noted, all registered trademarks are property of CRS Holdings, Inc., a subsidiary of Carpenter Technology Corporation. ISO 9000 and QS-9000 Registered Headquarters - Reading, PA Guide to Machining CARPENTER SPECIALTY ALLOYS Contents Introduction ............................................................................. 1 General Stainless Material and Machining Characteristics .... 3 Classification of Stainless Steels .............................................. 5 Basic Families and Designations ........................................ 5 Austenitic Alloys ......................................................... 5 Ferritic Alloys ............................................................... 7 Martensitic Alloys ...................................................... 7 Duplex Alloys ............................................................. 8 Precipitation-Hardenable Alloys ................................. 8 Free-Machining Alloys ...................................................... 9 Project 70+® Stainless Enhanced-Machining Alloys ........ 12 Machinability of Stainless Steels ........................................... 15 Definitions of Machinability .............................................. 15 General Machining Properties .......................................... 16 Austenitic Alloys ........................................................ 16 Ferritic and Martensitic Alloys ................................... 18 Duplex Alloys ............................................................. 19 Precipitation-Hardenable Alloys ................................. 20 Relative Machinability of Stainless Steels and Other Alloys .................................................................. 22 The Carpenter Selectaloy® Method ......................................... 23 Criteria for Selecting ......................................................... 23 Selecting for Corrosion Resistance ................................... 26 Selecting for Mechanical Strength .................................... 26 Enhanced Selectaloy® Diagram ........................................ 27 Nitrogen Strengthened Grades ......................................... 27 Other Grades to Consider ................................................. 29 Guide to Machining CARPENTER SPECIALTY ALLOYS Traditional Machining Operations .......................................... 31 General Considerations and Guidelines ............................ 31 Turning ... Speeds & Feeds—Turning can be found on pages 37 to 40 Turning Parameters ........................................................... 35 Single-Point Turning Tools ................................................. 35 Cutoff Tools ...................................................................... 41 Form Tools ........................................................................ 41 Shaving Tools .................................................................... 42 Trouble-Shooting Check Chart .......................................... 43 Drilling ... Speeds & Feeds—Drilling can be found on pages 48 and 49 General Guidelines ............................................................ 45 Drilling Parameters ........................................................... 46 Grinding of Drills ............................................................... 46 Small-Diameter Drills ........................................................ 47 Special Drills ..................................................................... 49 Trouble-Shooting Check Chart .......................................... 51 Tapping ... Speeds & Feeds—Tapping can be found on pages 57 and 58 Types of Holes and Taps ................................................... 55 Percent of Thread ............................................................. 58 Grinding of Taps ................................................................ 60 Trouble-Shooting Check Chart .......................................... 61 Threading ... Speeds & Feeds—Threading can be found on page 65 to 66 Die Threading .................................................................... 63 Types of Chasers and Geometries .................................... 63 Die-Threading Parameters and Cutting Fluid .................... 65 Percent of Thread ............................................................. 66 Thread Rolling ................................................................... 67 Trouble-Shooting Check Chart .......................................... 68 Guide to Machining CARPENTER SPECIALTY ALLOYS Milling ... Speeds & Feeds - Milling can be found on pages 71 and 72 Types of Milling Cutters .................................................... 69 Grinding of Milling Cutters ................................................ 70 Milling Parameters and Cutting Fluid ................................ 73 Trouble-Shooting Check Chart .......................................... 74 Broaching ... Speeds & Feeds - Broaching can be found on pages 79 and 80 General Guidelines ............................................................ 77 Broach Design and Grinding ............................................. 77 Trouble-Shooting Check Chart .......................................... 81 Reaming ... Speeds & Feeds - Reaming can be found on pages 85 and 86 General Guidelines ............................................................ 83 Types of Reamers ............................................................. 83 Grinding and Care of Reamers .......................................... 84 Reaming Parameters ........................................................ 87 Alignment ......................................................................... 87 Trouble-Shooting Check Chart .......................................... 88 Sawing ... Speeds & Feeds - Sawing can be found on page 90 General Guidelines ............................................................ 89 Sawing Parameters ........................................................... 89 Grinding Wheels ........................................................................... 91 Grinding Parameters ....................................................... 91 Guide to Machining CARPENTER SPECIALTY ALLOYS Other Specialty Metals ... Speeds & Feeds—Other Carpenter Specialty Alloys can be found on pages 93 to 112 These include: • Carpenter Tool Steels • Carpenter High Temperature Alloys — Nickel-Base and Cobalt-Base • Carpenter Electronic Alloys Cutting Fluids ............................................................... page 113 • Stainless Steel Cutting Oils • Emulsifiable Fluids • General Practices Cleaning and Passivating ............................................... page 119 • Cleaning Before Heat Treating • Passivating • Citric Acid Passivation Nontraditional Machining Operations ............. pages 123 to 136 • Abrasive Jet Machining • Abrasive Water Jet Machining • Electrochemical Machining • Electrochemical Grinding • Electrical Discharge Machining • Electron Beam Machining • Laser Beam Machining • Plasma Arc Machining • Chemical Machining Guide to Machining CARPENTER SPECIALTY ALLOYS Helpful Tables ................................................... pages 137 to 167 • Automatic Machining Efficiency Index Table • Machine Hours Per 1,000 Pieces • Approximate Stock Required to Make 1,000 Pieces • Weights of Steel Bars Per Lineal Foot • Decimal Sizes of Drills & Length of Drill Points • Drills for Tapped Holes • Table of Cutting Speeds • Fractions, Decimal & Metric Equivalents • Hardness Conversion Table • Wire Gauges • Formulas Introduction Carpenter Technology Corporation (“Carpenter”) is a materials company making specialty alloys and engineered parts for dozens of industries with hundreds of applications. Specialty Alloys Operations, our specialty steel and alloy manufacturer and distributor, comprises the core business. Dynamet Incorporated, a Carpenter company, produces bar and coil products from titanium and other alloys. Carpenter Powder Products makes and sells tool and high speed steels and specialty alloy powder products. The Engineered Products Group is a consortium of companies that makes precision drawn products, complex ceramic parts, thin- wall tubing and other engineered materials. Since 1928, when Carpenter introduced the world’s first free- machining stainless steel, we have been concentrating on the business of making stainless and other specialty alloys more useful and more profitable to industry. Our record of accomplishment in this endeavor has been gratifying. Through never-ending research,