1.4 1.5 1.6

Alloy SteelApplication Material Group

For details on the full Dormer product range, please order a copy of our current tooling catalogue.

For correct tool selection and operation, please also refer to our Product Selector CD.

Further useful technical information can be found in our brand new 2005 Technical Handbook.

www.dormertools.com

Dormer ToolsShireoaks Road Worksop, S80 3HBUK

T: +44 (0)1909 534700F: +44 (0)1909 534701dormer.uk@dormertools.com

© DORMER 2006All rights reserved under the “Dormer” registered trademark. Although every effort has been made to ensure the accuracy of the information contained herein, no responsibility for loss or damage occasioned to any person acting from action as a result of any material in this publication can be accepted by the editors, publishers or product manufacturers.

2

BS

SSU

SAU

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1.4

708M

40/4

2, 8

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4053

4A99

, BM

2, B

T42

1672

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209

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44-0

2, 2

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2, 4

340

M42

, M2

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G41

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T301

02, T

1134

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CM

4,

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826

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40, 8

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5, 2

541-

03,

2550

, 272

2, 2

723

01, L

6, M

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3, A

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8630

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EN

DIN

1.4

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<850

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10

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7 - H

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3

Contents

Classification of workpiece materials 2Application Material Groups 4Introduction to Alloy Steels 5Machinability of Alloy Steels 6 Hints when machining Alloy Steels 6AMG 1.4 7AMG 1.5 8AMG 1.6 9General Hints on Drilling 10Drill Feed Chart 11Drill Selection 12General Hints on Tapping 14Drill diameters for cutting taps 15Tap Selection 16General Hints on Milling 18Milling parameters 19Applications 20Milling Feed Charts 20Milling Cutters Selection 24Table of cutting speeds 26

Gen

eral

Info

rmat

ion

4

Application Material Groups

Application Material Groups (“AMGs”) are designed to assist in the selection of the optimum cutting tool for a particular application.

Dormer classifies materials into 10 major Application Material Groups. Each major group is divided into sub-groups on the basis of material properties, such as hardness and strength, and chip formation. This booklet concentrates on sub-groups 1.4 – 1.6 – Alloy Steels.

Examples of national designations within each sub-group are shown on page 2.

This booklet contains a selection of tools that are rated “excellent” for machining Alloy Steels. Please see the Dormer catalogue or Product Selector for the full range, or contact your local Dormer representative or Technical Helpdesk if you need further advice.

Gen

eral

Info

rmat

ion

5

Introduction to Alloy Steels

Alloy steels are steels with alloying elements other than carbon and iron.When various alloying elements are added to steel, these usually become stronger and harder than plain carbon steels, such as AMG 1.1 – 1.3. The factors to consider when machining alloy steels are:1) The analysis of the steel – generally, the higher

the alloy addition, the more difficult it is to machine the material (see table on page 6).

2) The structure and hardness – often this group of steels will respond to heat treatment, so the hardness and metallurgical condition must be known before machining starts.

3) Surface finish – a poor surface finish (eg. heavy oxide, scale) will lead to rapid tool wear.

Machinability of Alloy SteelsThe actual alloying elements within a steel have a profound effect on its properties. The table below shows the effect on machinability.

Effects of Alloy AdditionNegative effect Positive effectManganese (Mn) Lead (Pb)Nickel (Ni) Sulphur (S)Cobalt (Co) Phosperous (P)Vanadium (V) Carbon between 0.3 to

0.6%Carbon (C) < 0.3 %Carbon (C) > 0.6 %Molybdenum (Mo)Niobium (Nb)Tungsten (W)

Gen

eral

Info

rmat

ion

6

When the various alloys are all added up together, if the total is less than 5%, the steel is considered as a “low alloy steel”. Above 5%, the steel is regarded as a “high alloy steel”.Carbon is regarded as the dominant element that determines much of the mechanical properties and machinability of a steel. For information specific to each sub-group, see pages 7 - 9.

Hints when machining Alloy Steels

• These sub-groups of steel materials are extensive, which makes it important to find out the properties of the material to be machined. Use the Dormer Product Selector to find the correct AMG classification, which in turn will help you to find the correct tool for the application.

• A high alloyed steel can be abrasive or hard. To reduce rapid wear on the cutting surface, use coated tools and carbide tools.

• Tool steels can be hardened to various degrees. It is important to be aware of both material grade and hardness in order to select the correct tool configuration for the application.

Gen

eral

Info

rmat

ion

7

1.4 Alloy Steel (generally low-alloy steels witha total alloy content of 2–4%) Hardness <250 HBTensile strength <850 N/mm2

Typical Composition

The very low-alloy steels within this group are generally high strength structural steels with a total alloy content of up to 2%. These steels are not usually heat-treated. Typical tensile strengths of 400 N/mm2 and hardness values of approximately 230 HB are normal. As the alloy content increases slightly, then generally ductility reduces and with a total alloy content of 2–4%, hardness of 250 HB and tensile strengths to 850 N/mm2

are found.

Examples of uses

Typical uses of AMG 1.4 are axles, shafts, structural steels, tubes and forgings.

Gen

eral

Info

rmat

ion

8

1.5Alloy steel – Hardened and tempered Hardness >250 <350 HBTensile strength >850 <1200 N/mm2

Typical Composition

Alloy steels within this range are those which have been hardened and tempered to give enhanced tensile strengths. Also included are the highly alloyed tool steels in their annealed condition.Nickel, chrome alloy steels, with a total alloy content of 3-4% can be heat treated to give various hardness and tensile strengths by tailoring the tempering temperature to give the desired balance between hardness and ductility.Alloy tool steels with high carbon levels and a total alloy content of more than 5% also fall into this grouping, provided they are in the fully annealed (softened) state.

Examples of uses

Typical uses of AMG 1.5 are gears, connecting rods, swivel arms and transmission parts.

Gen

eral

Info

rmat

ion

9

1.6 Alloy steel – Hardened and tempered Hardness >350 HB Tensile strength >1200 <1620 N/mm2

Typical Composition

This grouping covers alloy steels which are heat-treated to give more hardness but with the loss of toughness or ductility.Whilst many of the actual steel grades are similar to those within AMG 1.5, the heat treatment is designed to give higher tensile strengths.Also included are the wear-resistant or abrasion resistant alloy steels (eg. Hardox 400).The increased hardness of these steels will make machining more difficult, so care must be taken to select the optimum cutting conditions.

Examples of uses

Typical uses of these steels are gears, machine tool parts, dies, cylinders and cropping blades.

Gen

eral

Info

rmat

ion

10

General Hints on Drilling

1. Select the most appropriate drill for the application, bearing in mind the material to be machined, the capability of the machine tool and the coolant to be used.

2. Flexibility within the component and machine tool spindle can cause damage to the drill as well as the component and machine - ensure maximum stability at all times. This can be improved by selecting the shortest possible drill for the application.

3. Tool holding is an important aspect of the drilling operation and the drill cannot be allowed to slip or move in the tool holder.

4. The use of suitable coolants and lubricants are recommended as required by the particular drilling operation. When using coolants and lubricants, ensure a copious supply, especially at the drill point.

5. Swarf evacuation whilst drilling is essential in ensuring the correct drilling procedure. Never allow the swarf to become stationary in the flute.

6. When regrinding a drill, always makes sure that the correct point geometry is produced and that any wear has been removed.

Ø [m

m]

12

34

56

810

1215

1620

2530

4050

D0.

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0.03

80.

053

0.06

00.

068

0.07

80.

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0.11

90.

130

0.14

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155

0.18

80.

210

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80.

253

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0.01

70.

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20.

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0.08

00.

092

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50.

140

0.15

00.

173

0.18

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215

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50.

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50.

109

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80.

165

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80.

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50.

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90.

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190

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355

0.37

50.

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0.32

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0.38

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0.21

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0.48

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0.55

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580

11

mm

/rev

± 25

%

A117 A520 R022 R520

1.0 - 13.0

3.0 - 13.0

3.0 - 17/32

3.0 - 16.5

●27G ■32I ■55V ■80X■18F ■21G ■45U ■55X■11E ●11E ■45U ■45W

1.41.51.6

12

A551 A552

5.0 - 20.0 5.0 - 20.0

■40I ■40I■24G ■24G■13E ■13E

■ ●

ExcellentGood

1.41.51.6

13

A777 A510 A553 A554 R002 R510 R553 R570

0.3 - 16.0 3.0 - 14.0 5.0 - 20.0 5.0 - 30.0 3.0 - 14.0 3.0 - 14.25 5.0 - 20.0 3.00

- 5/8

●24F ■30H ■45H ■45H ■55U ■80W ■115U ■ 100U■17E ■21F ■28F ■28F ■45T ■55V ■90U ■ 80U■10D ●11D ■15D ■15D ■45T ■45V ■65T ■ 55T

14

General Hints on Tapping

1. Select the correct design of tap for the component material and type of hole, i.e. through or blind, from the Application Material Groups chart.

2. Ensure the component is securely clamped - lateral movement may cause tap breakage or poor quality threads.

3. Select the correct size of drill (see opposite). Always ensure that work hardening of the component material is kept to a minimum.

4. Select the correct cutting speed as shown in the tap selection pages, the catalogue or the Product Selector.

5. Use appropriate cutting fluid for correct application.

6. In NC applications ensure that the feed value chosen for the program is correct. When using a tapping attachment, 95% to 97% of the pitch is recommended to allow the tap to generate its own pitch.

7. Where possible, hold the tap in a good quality torque limiting tapping attachment, which ensures free axial movement of the tap and presents it squarely to the hole. It also protects the tap from breakage if accidentally ‘bottomed’ in a blind hole.

8. Ensure smooth entry of the tap into the hole, as an uneven feed may cause ‘bell mouthing’.

M mm mm mm1.6 0.35 1.321 1.25 3/641.8 0.35 1.521 1.45 542 0.4 1.679 1.6 1/162.2 0.45 1.833 1.75 502.5 0.45 2.138 2.05 463 0.5 2.599 2.5 403.5 0.6 3.010 2.9 334 0.7 3.422 3.3 304.5 0.75 3.878 3.8 275 0.8 4.334 4.2 196 1 5.153 5 97 1 6.153 6 15/648 1.25 6.912 6.8 H9 1.25 7.912 7.8 5/1610 1.5 8.676 8.5 Q11 1.5 9.676 9.5 3/812 1.75 10.441 10.3 Y14 2 12.210 12 15/3216 2 14.210 14 35/6418 2.5 15.744 15.5 39/6420 2.5 17.744 17.5 11/1622 2.5 19.744 19.5 49/6424 3 21.252 21 53/6427 3 24.252 24 61/6430 3.5 26.771 26.5 1.3/64

15

D = Dnom- P

M mm mm

4 0.70 3.405 0.80 4.306 1.00 5.108 1.25 6.9010 1.50 8.7012 1.75 10.4014 2.00 12.2516 2.00 14.25

Drill diameter can be calculated from:

METRIC COARSE THREAD

RECOMMENDED DIAMETERS WHEN USING DORMER ADX AND CDX DRILLS

The above table for drill diameters refer to ordinary standard drills. Modern drills such as Dormer ADX and CDX produce a smaller and more accurate hole which makes it necessary to increase the diameter of the drill in order to avoid breakage of the tap.Please see the small table to the left.

D = Drill diameter (mm)

Dnom = Tap nominal diameter (mm)

P = Tap pitch (mm)

METRIC COARSE THREAD FOR ADX/CDX

Max. DRILL DRILLInternal

Pitch Diam. Diam. Diam.inch

TAP DRILLPitch Diameter

Drill Diameters for Cutting Taps - Recommendation tables

1.41.51.6

DIN

16

E340 E341 E464 E465 E324 E326

M3 - M10 M12 - M20 M3 - M10 M12

- M20 M3 - M10 M12

■16 ■16 ■30 ■30●10 ●10 ■17 ■17 ■17 ■17●5 ●5 ●11 ●11 ■11 ■11

■ ●

ExcellentGood

Other thread forms available. Please see Dormer catalogue.

E342 E343 E314 E316 E402 E049 E050 E044

M3 - M10 M12 - M20 M3 - M10 M12 M3 - M30 M3 - M20 M3 - M20 M8 - M20

■16 ■16 ■20 ■30 ■16 ■16●10 ●10 ■17 ■17 ■15 ■17 ■11 ■10●5 ●5 ■11 ■11 ●11 ■5

ISO

1.41.51.6

17

Other thread forms available. Please see Dormer catalogue.

18

General Hints on Milling

1. Where possible, use climb milling (down milling) for longer tool life. Climb milling allows easier chip disposal, less wear, improved surface finish and lower power requirements compared to conventional milling (up milling).

2. Always use a cutter in good condition.

3. Use well-maintained machine tools with sufficient power.

4. Use correct clamping system according to working operation and type of tool.

5. Check for damage or wear on the tool shank or in the holder itself.

6. Use the shortest cutters recommended for your application and work as close to the machine head as possible.

7. For optimum productivity, use coated or Solid Carbide cutters.

19

Milling parameters

1. Identify the type of end milling to be carried out - type of end mill - type of centre

2. Consider the condition and the age of the machine tool.

3. Select the best end mill dimensions in order to minimize the deflection and bending stress

- the highest rigidity - the largest mill diameter - avoid excessive overhand of the tool from the tool

holder.

4. Choose the number of flutes - more flutes - decreased space for chips - increased

rigidity - allows faster table feed - less flutes - increased space for chips - decreased

rigidity - easy chip ejection.

5. Determining the correct cutting speed and feed rate can only be done when the following factors are known:

- type of material to be machined - end mill material - power available at the spindle - type of finish.

20

For details on how to use the feed charts in the tables which follow, please see below.

Slotting Roughing

Ball nose Finishing

Application

Ø m

mm

m/z

± 2

5%1

23

45

68

1012

1416

1820

2225

2830

3236

40↕

0,5D

↔ D

B0,

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0,00

70,

012

0,01

50,

022

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60,

039

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40,

065

0,07

60,

086

0,08

70,

086

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90,

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80,

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80,

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90,

045

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10,

058

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041

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60,

052

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80,

058

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043

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021

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80,

037

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062

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20,

082

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30,

103

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10,

093

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70,

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70,

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6

O0,

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065

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073

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069

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DT

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90,

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026

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50,

046

0,06

40,

077

0,09

00,

103

0,11

60,

129

0,10

20,

116

0,09

60,

103

0,11

00,

123

0,12

0

U0,

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081

0,09

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104

0,11

60,

092

0,10

40,

087

0,09

20,

099

0,11

10,

108

21

S24

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276,

S33

2, S

250,

S25

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S19

0, S

290

22

Z

Ø m

m

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0.6

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12

34

56

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1214

1618

20

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0.07

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080

0.09

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0

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0.05

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0.09

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0.03

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0.05

50.

065

0.07

50.

090

0.11

00.

120

0.13

00.

150

0.17

0

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0.14

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200

0.22

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↔ 0

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80.

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0.01

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70.

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0.05

50.

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070

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1.41.51.6

24

C353 C352 C907 C428 C921 S044 S017 S241 S276 S332 S250 S251 S503 S190 S290

z3 z3 z3-6 z3-6 z3-6 z4 z4 z4 z4 z4 z4 z4 z2 z2 z4

3.0 - 30.0 3.0 - 20.0 3.0 - 32.0 6.0 - 40.0 6.0 - 32.0 2.0 - 20.0 2.0 - 20.0 3.5 - 20.0 2.0 - 25.0 6.0 - 20.0 3.0 - 20.0 6.0 - 20.0 1.0 - 16.0 3.0 - 16.0 6.0 - 16.0

■87B ■79B ■79T ■79H ■79N ■153B ■153B ■153B ■153B ■80B ■175B ■145B ■250B ■250B ■250B■60C ■54C ■54U ■54I ■54O ■120B ■120B ■115B ■115B ■60B ■130B ■110B ■200B ■200B ■200B●26C ●24C ■24U ■24I ■24O ■77B ■77B ■92B ■92B ■105B ■85B ■180B ■180B ■180B

1.1 1.1 1.1 1.1 1.1 1 0.3 1 1 1 1 1 1 1 1■ ●

azExcellentGood

1.41.51.6

25

C353 C352 C907 C428 C921 S044 S017 S241 S276 S332 S250 S251 S503 S190 S290

z3 z3 z3-6 z3-6 z3-6 z4 z4 z4 z4 z4 z4 z4 z2 z2 z4

3.0 - 30.0 3.0 - 20.0 3.0 - 32.0 6.0 - 40.0 6.0 - 32.0 2.0 - 20.0 2.0 - 20.0 3.5 - 20.0 2.0 - 25.0 6.0 - 20.0 3.0 - 20.0 6.0 - 20.0 1.0 - 16.0 3.0 - 16.0 6.0 - 16.0

■87B ■79B ■79T ■79H ■79N ■153B ■153B ■153B ■153B ■80B ■175B ■145B ■250B ■250B ■250B■60C ■54C ■54U ■54I ■54O ■120B ■120B ■115B ■115B ■60B ■130B ■110B ■200B ■200B ■200B●26C ●24C ■24U ■24I ■24O ■77B ■77B ■92B ■92B ■105B ■85B ■180B ■180B ■180B

1.1 1.1 1.1 1.1 1.1 1 0.3 1 1 1 1 1 1 1 1 az

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