Technical Information - Speeds & Feeds charts
Contents
1. H PH P e DO Er 1 1 4 0 0040 nmm LHLS 1 01 0 0035 89 0 0030 77 0 0025 L7 1 O ULL ILL T 64 0 0020 4 A 2 GH Limits Steps of 0 0005 51 0 0015 IRI at12 7 pm 2 39 0 0010 26 TN em N GH number 0 0005 ao y D 1 3 0 0 basic pitch dia For Sutton Tools Metric mm Roll Fluteless Taps Limit same as the RH amp G Limits GH M ITS GH Limits Steps of 0 0127 mm Upper limit 0 0005 x N N GH number Lower limit 0 0005 x N 0 0005 390 www sutton com au Technical Information British Standard Threads Basic Profile for Whitworth BSW BSF and WHIT Thread forms Sutton Tools The sides of the thread form an angle of 55 with one another and the top and bottom of the full triangle are truncated one sixth of ZN h British Standard Whitworth Form H 6 the height The actual depth of the thread is equal to two thirds of the height of the generating triangle and is equal to 0 6403 times the pitch The crests and roots are rounded to a radius of 0 137329 times the pitch Fig 5 la _______ PitchP H 0 96049p 0 160082. 00 250 13 120 140 200 250 13 120 140 110 130 11 100420 11 60 80 10 110 130 15 120440 12 130450 12 100 120 11 130 150 140 16 180230 12 110 130 180230 12 110 130 00 1 120 140 8 130 140 190 11 90 110 140 190 11 90 110 80 100 70 90 40 60 90 110 100 120 Feed Table Feed No mm tooth Mill omm 0 001 0 001 0 001 0 002 0 002 0 004 0 005 0 006 0 007 0 008 0 010 0 012 0 014 0 016 0 03 0 016 0 018 0 022 0 026 0 030 0 036 0 046 0 048 0 052 0 059 0 063 0 072 0 079 0 085 0 15 0 020 0 023 0 027 0 031 0 038 0 045 0 052 0 059 0 063 0 071 0 079 0 087 0 095 0 100 0 18 5 0 6 jo 8 0 sess sos osse om wise oie s To www sutton com au 363 364 Application Guide Trouble Shooter HSS Drills Code Problem Tang Breaks HCH ES A EEE Solution Dull point ______ 00 ele __ f f Pemma LL emi el fe ere 0000000 amem 6 seem m ________ fey Drill web core diameter too big T NENNNNNNNUE NM controlled by the taper fit www sutton com au Ap
3. 10 pe ENTES EEC 15 15 8 00 25 _ as as lololo wf _ _ _ 3 pr fa Pe Pos 25 as 25 20 Calculations Example Tapping M6x1 18mm deep blind hole in 4140 annealed steel using R40 UNI spiral flute tap with length compensation tapping attachment _ 318 i 0 10m min LEO 530 _ RPM x Thread Feedrate mm min Pitch mm min 530 x 1mm Pitch 530mm min Short pitching allowance 530 x 0 95 length compensation attachment 503mm min m min Dia WWW Sutton com au 360 Application Guide Speeds amp Feeds Endmills IS SLOTTING PROFILING FINISHING Sutton Tools acy 0 5xD 1 5xD 1x D 0 02 0 05 0 0 1xD Discount Group 80502 80610 80402 80602 80502 80610 80502 80610 80610 Material Colour Ring amp Application Coolant Oil O Soluble Oil S Air A a aN i Steels sof fate dodo 45 5 m s 1917146 40 6 96 7 40 6 S ree cutting steel S1214L Leaded Steels tructural steels lloy steels 850 1200 N mm 4140 01 A2 D3 M42 EN26 01 L6 M42 D3
4. Application Guide Index Sutton Tools Contents page no General Application Workpiece materials table 0 2 0 000000 352 Speeds amp Feeds o e oie 354 356 LETOS TEE 358 A E UE OO COR e 360 Carbide ENCMIllS oo mnes 362 SN REOR RT TS 369 Trouble Shooting SEEE EE 364 Eo 365 Om 366 Endmills 367 368 350 www sutton com au Technical Information Index Sutton Tools Contents page no General Codtngs amp 1d Ge Wl AAA __ 370 AP 371 Ir 372 PP RUOTE 374 Manufacturing A 374 shank designs AS OO a 375 SI 376 Drills BINDS Ru orf T 377 Hints on use and Maintenance 378 Taps 777 7 7 379 Construction 0651005 380 i ES 300 i ccr 301 A o O OO 7 AA 381 382 Tapping Information OPOPOO_O ORO OO 383 Tapping Drill 5 2 0 383 777777 2 384 Fluteless taps Benefits amp 386 drill chart 387 ISO Metric Threa
5. Form D screwed shank centre hole Z in cut represented Thread Profile after in cut represented DIN ISO 228 Part 1 thread undercut or thread runout released centering borehole All measurements in millimetres www sutton com au 376 Technical Information Shank Types Sutton Tools Carbide Straight Shanks Form HA plain centre hole chamfer Ou 6mm to 20mm One Drive Flat centre hole 25mm amp 32mm Two Drive Flats without centre hole d All measurements in millimetres 1 without centre hole For d 6 to 20mm Chamfer For d 25 amp 32mm WWW Sutton com au Technical Information Drill Terminology Sutton Tools Drill Definitions FLUTED LA tt DIAMETER TANG POINT ANGL TANG DRIV LIP RELIEF ANGLE CLEARANCE DIAMETER CHISEL EDGE HEX ANGLE ANGLE AVETE SS SS DIAMETER b S e LAND E FLUTE LENGTH Lip WEB E sex ____ OVERALL LENGTH Drill Point Types DIN1412 THINNED CHISEL EDGE THINNED CHISEL EDGE SPLIT POINT WITH CORRECTED CUTTING LIPS Z On AS OA TYPE D POINT GROUND FOR CAST IRON BRAD POINT Drill Tolerances DIN ISO 286 Part 2 Drill Diameter at Point mm
6. 7 05 5 sen se s we s 00 s e 00 56 s awl s 50 7 964 EE T co 11 60 80 10 EA ZEN s n up m v pum al o mms w omo o eso n sem wv em ud pem lt gt c ns 2 Es gt TES cal TES n lt malis TEN CEN CENTS TEN gt T I lt gt LR c c gt lt gt ma c ce e ER gt c c ow T 11 lt gt gt c c co lt gt n2 c lt gt Y e gt e co 11 e m lt gt Sis gt a gt lt gt gt e gt 0 m nm no
7. 1 4 8 Lis 25 8 4 ee eee ES ASES ENTES A E E A Eee p 25 6 1 30 6 se ae ee fe ESA 77 6 52 5 5 120 9 7 6 4815 6 120 9 5 8 5 40 4 4 _ BEN EN E EN 90 80 6 UE pe EN MEM e 6 NEN Feed Table Feed No mm tooth Mill emm SSE Se SESE NN See SE NE UE EN UE UE d ME e o N www sutton com au 362 Application Guide Speeds amp Feeds Carbide Endmills Sutton Tools SLOTTING 1xD Cutting Depth 0 5xD Discount Group B0202 80202 80202 1 Steels _5 ma e e av 7 a jono w 567 70 56 7 TOGO 10 567 o 7 56 0 m3
8. Material Grade Characteristics of Material Short Chipping Long Chipping Tapping Hole Size Hole Type Hole Depth Machine Details Machine Type cnc SemiAuto Manual Tapping Attachment Tapping Chuck Tension Compression Machine Direction Vertical Horizontal Oblique _ Tapping Comp Tapping Attachment Work Piece Holder Stationary Rotating _ Tapping Tapping Chuck rigid Coolant Neat Oil Mist Dry Elton 50 Emulsion gt 10 Collet Chuck length compensating Feed Mechanical Pneumatic Hydraulic Manual Please copy and fax to our Special Sales Dept on 1800 804 084 Item No 499980185B SUTTON TOOLS 214 Coleraine Road Hamilton Vic 3300 Ph 1800 035 010 Fax 1800 804 084 Email specsales sutton com au APPLICATION MILLING SPECIAL ENQUIRY Sutton Tools Customer New Customer Address Date Basic Geometry O E 3 e 2 Shank to DIN 6535 0 3 0 to 10 0 from 10 0 to 20 0 0 3 0 to 10 0 from 10 0 to 20 0 0 3 0 to 6 0 from 6 0 to 20 0 No of c
9. Spark Plug ISO METRIC FINE 60 SUN 8 TPI UNIFIED NATIONAL FORM 60 Tapping Drill mm mm 8 8 8 8 8 8 8 8 www sutton com au THREAD FORMING FLUTELESS TAPS THREAD FORMING BSPT ISO Rc TAPER SERIES 1 16 55 FLUTELESS TAPS Drill amp Tapping Drill Tap TPL Tapping Drill Only Reamer Size mm Size mm 1 16 28 6 4 METRIC COARSE UNG Rc 1 8 8 4 M1 0 25 0 9 1 073 1 7 Re 1 4 10 8 M1 1 0 25 1 0 2 086 2 0 Re 3 8 14 5 1 2 0 25 11 3 099 23 Re 1 2 18 0 4 112 2 6 3 4 23 0 5 125 2 9 Re 1 29 0 6 138 3 2 Rc 1 1 4 38 0 8 164 3 8 1 1 2 44 0 1 8 0 35 1 65 10 190 4 4 Rc 2 55 0 M2 0 0 40 1 8 12 216 9 0 M2 2 0 45 2 0 1 4 5 8 5 16 7 3 6 BSPF M T ISO G PARALLEL SERIES 55 5 7 2 7 16 10 2 Tapping Drill M3 0 5 28 1 2 11 7 am M3 5 0 6 3 2 al 9 086 64 2 0 5 0 8 4 6 3 099 56 23 1 0 9 9 4 112 48 2 6 8 1 25 7 4 5 125 44 2 9 M10 1 5 9 3 6 138 40 3 2 12 1 75 11 2 8 164 36 3 9 10 190 32 4 5 12 216 28 5 1 1 4 28 6 0 5 32 32 3 6 3 16 24 4 3 3 9 24 90 1 4 20 5 8 7 16 20 10 6 5 16 18 7 3 1 2 20 121 3 8 16 8 8 BSPF 1 8 28 9 25 BSPPL NPT NPTF T SEALING PIPE THREAD PARALLEL 55 NATIONAL PIPE TAPER 1 16 60 1 2 14 200 Tapping Drill Drill
10. 2 5 2 5 2 5 2 5 5 is 5 26 Feed mm rev Drill SO EA ee Calculations Example Drilling 10mm 40mm deep in P20 steel using R40 UNI drill _ Vc x 318 40m min RPM ED x 8 1272 so 0060 0080 0 20 0 50 0180 0200 0250 56 oos 0080 0120 0 50 0200 0250 0200 0360 Feedrate _ RPM xf Feed No 5 refer feed table 0 20mm rev Feedrate _ 1272 x 0 20 254mm min mm min Vc m min Dia www sutton com au 356 Application Guide Speeds amp Feeds Carbide Drills Sutton Tools STUB JOBBER LONG orig pen aa Discount roup 0206 moma Material 7 VHM VHM VHM VHM VHM VHM VHM VHM VHM VHM surface Fish TEN TON TANTO TAN TH TANT TON Tanem TAM TAN Colour Ring amp Application UNI UNI UNI UNI UNI ceomety mes OX _ Coolant Oil O Soluble Oil S Air A Wats ette rt pt ly t i e i ote i n ly Fite ay Steels seem s 5 100 e 30 7 10 7 10 4 180 7 25 7 efso s _____ 5 100 o 6 7 7 4 wo 7 e 7
11. Discount Group A1002 A1004 A1006 A1130 A1502 A1502 A1502 A1124 Material Surface Finish StOx Bt TN TAN TAN TAN Colour Ring amp Application General Purpose VA UNI Geometry 30 Helix 40 Helix 40 Helix 40 Helix 40 Helix 40 Helix Steels 2515 20 5 25 5 30 5 6 6 7 7 85 4 5 17 5 2015 25 5 64 6 55 7 2514 5 12 5 15 5 25 5 62 5 55 7 4 6 20 4 4 12 4 15 4 45 6 a 5 3 General H Coolant Oil O Soluble Oil S Air A 2 olo 5 loa ee 5 ct i1 o 8 Sir Bis ez 3 3 3 V e 3 3 gt o lt n CD 1 2 n 3 gt Y o 5 2 2 o e puit D NEM Jia me Ev 39 _ 36 Po a 5 sls Free machining stainless steel 416 430F Le as ee es 2 Pol 4110157 Austentic stainless steels 317 321 Duplex Alloys Ferritic martensitic lt 1000 N mm S S A gt e x UJ GG10 6620 GG25 6640 Spheroidal graphite Malleable cast iron
12. EE 3 S 855 DI o 2518 os E o lt alloys 850 1150 N mm Coppers unalloyed hort chip brass phosphor bronze gun meta ong chip brass Aluminiums Mg unalloyed 21 e gt gt lt wn A o z N 3 3 N Al alloyed Si lt 5 Al alloyed Si gt 1 5 lt 10 alloyed Si gt 10 Alloys N o gt Notes on Milling 1 Above values are guidelines for the size and type of cut nominated 2 For coated tools speeds may be increased by 20 3 For long series tools reduce speed by 40 and feed by 20 Calculations Example Slotting 010mm 5mm deep in 1020 steel using S2 type R30 UNI Endmill 2 flutes _ 318 i 0 42m min 42 318 10 1335 _ RPMxfxZ Feed No 5 refer feed table 0 024mm tooth Dia f mm tooth _ 1335 x 0 024 x2 Bam Z No of teeth mm min www sutton com au BEI 0 5 D General General Purpose 25 Helix 25 Helix 30 Helix 30 Helix 30 Helix 30 Helix 0 0 50 Helix Coarse Pitch Fine Pitch Coarse Pitch 55 Helix m Helix Coarse Pitch Fine Pitch Fine Pitch Loans Aes Paes ES eet es eee E rarer 2 EN E EX es LL s S 28 8 30 8
13. HOOK Technical Information aps Sutton Tools Construction dimensions designs The construction dimensions amp designs of our taps are manufactured in accordance to the various international standards listed below The dimensions can be found in our catalogues respective leaflets amp our Expert Tool System situated on our website Standard Illustration Short Machine ISO 529 NT gt E 8 Hand Taps JIS J TYPE mumm AN oe Reinforced Shank Taps DIN371 mum 5 ac Reduced Shank Taps DIN374 DIN376 Exceptions are Pipe taps Rc BSPT G BSPF Rp BSPPL 1502284 Standard Pipe taps NPT NPTF NPSF ANSI B949 Standard Machine Nut Taps ANSI B949 Standard Chamfer Type Length Table below is in accordance with 1508830 DIN2197 Terminology Form Number of Approx Type of flute Main area of Illustration threads chamfer ame on lead angle application TAPER A 6 to 8 D Hand or Short through holes straight flutes INTERMEDIATE D 3 5105 89 Generally for Through straight holes BOTTOMING 1 5 to 2 23 Blind holes with very straight short thread runout umm Y flutes INTERMEDIATE B 3 5 to 5 10 Straight with Through holes in medium spiral point amp long chipping materials BOTTOMING C 2103 15 Spiral Generally for blind holes ON Wn Use of this type is not recommended 380 www sutto
14. 5 Ferritic martensitic lt 1000 N mm 5 20 20 gt Lo Spheroidal graphite Malleable cast iron EM o EM 6610 6620 S A Ti99 8 TAT TAG pl le ES _ 8 5 15 o 20 _ ls L 40 39 042148 45 ES EEES P 10 15 15 25 40 25 30 0 0 _ P ao fas as 25 25 _ eo 409 430 436 Duplex Alloys 1 Nickel 200 Ni99 6 Monel 400 Hastelloy C Inconel 600 Nimonic 80A Wasp alloy Inconel 7 18 Short chip brass phosphor bronze gun metal Long chip brass gt gt gt Y elem E Begs 5 SS 5 5 5 2 6 Ex SS ES els gt 9 EE 87 52 lt lt 5 27 VIAIS o lt lt D a ala lt lt olo 12 a e Ola lt de a A gla e
15. MAXIMUM INTERNAL PITCH DIAMETER BASIC PITCH DIAMETER MINIMUM INTERNAL at gauge plane PITCH DIAMETER 392 www sutton com au Technical Information Endmill Terminology Sutton Tools Endmill Definitions OVERALL LENGTH e SHANK LENGTH FLUTE LENGTH CUTTING LENGTH ENDTEETH For shank styles refer page 367 NGHE SHANK CUTTING DIAMETER AE RAISED LAND WIDTH Conventional milling versus climb milling A milling cutter can cut in two directions sometimes known as climb or conventional Conventional milling The depth of the cut starts at zero thickness and increases up to the maximum The cut is so light at the beginning that the tool does not cut but slides across the surface of the material until sufficient pressure is built up and the tooth suddenly bites and begins to cut This deforms the material at point A on the diagram left work hardening it and dulling the tool The sliding and biting behaviour leaves a poor finish on the material Climb milling Each tooth engages the material at a definite point and the width of the cut Starts at the maximum and decreases to zero The chips are disposed behind the cutter leading to easier swarf removal The tooth does not rub on the material and so tool life may be longer However climb milling can apply larger loads to the machine and so is not recommended for older milling machines or
16. M1 0 1 00 0 25 M1 1 1 10 0 25 0 35 0 35 1 2 1 25 1 45 1 55 1 4 1 6 1 7 1 65 0 35 1 8 1 80 2 0 2 00 0 45 2 2 2 10 11 2 3 2 90 2 30 2 40 2 75 0 45 0 45 1 8 A ea j M2 5 M2 6 M3 0 3 10 3 20 M3 5 3 60 e 3 70 3 80 4 30 4 30 5 55 po 7 40 5 80 5 80 7 30 1 25 3 8 8 80 a poo _ 8 80 9 30 M10 5 O c O o 388 Technical Information Thread Forms Components amp Tap Limits Sutton Tools Thread Systems The ISO standard is the international standard intended to be adopted throughout the world to unify and rationalise screw threads at an international level The ISO standard recognises two groups of screw threads a ISO metric a complete thread system in metric units and b ISO inch Unified which is covered by British Standard BS 1580 and American Standard ANSI B1 1 Unified screw thread systems The Whitworth and BA screw threads are obsolete but still widely used during the period of transition All measurements must have a controlling point or base from which to start In the case of a screw thread this control point is called BASIC or theoretically correct size which is calculated on the basis of a full thread form Thus on a given screw thread we have the Basic Majo
17. ES E lt E 5 E E v e a9 2 a9 gt gt o lt 2 e V bh Q 5 Mg Alloys Tl Q eed Table Feed No mm rev Calculations Example Drill 1 2 3 4 5 7 Drilling 10mm 40mm deep in P20 steel using 122310 drill 0190 318 0200 0220 o6 1 6 0 0 0 gt 8 0 060 0 080 0 100 0 120 0 150 0 200 0 250 0 300 0 350 Feedrate RPM x f Feed 7 refer feed table 10 0 0 080 0 100 0 120 0 150 0 200 0 250 0 300 0 350 0 400 mm min 12 0 0 080 0 100 0 120 0 150 0 200 0 250 0 300 0 400 0 500 Feedrate eon ceo a 0 30mm rev 16 0 0 100 0 120 0 150 0 200 0 250 0 300 0 400 0 500 0 600 Dista Poemas mm min 20 0 0 150 0 200 0 250 0 300 0 400 0 500 0 600 0 700 0 800 0250 10 5 www sutton com au Application Guide Hints on use Carbide Drills Sutton Tools GARANT carbide high performance drills The use of carbide high performance drills Fig 1 requires both high concentricity of the machine and rigid tool clamping and also performance machine technology to achieve high feed rate values Example of application drilling through holes Fig 1 Garant Carbide High Performance Drill Material GG 25 cast iron lt 240HB CS1045 carbon steels hole diamete
18. 4 For hole depths greater than 7 x 0 pre drill initially to pilot start for more accurate hole position and eliminate drill wandering The pilot can be drilled with short rigid drill approx 3 x in depth and reduced feed to ensure accurate pilot hole www sutton com au JOBBER LONG SERIES EXTRA LENGTH ame ama ano mo Vc Vc initi imi mimi mi 205 9 5 2 5 4 5 24 5 20 4 58 6 70 7 48 5 9 5 25 5 22 5 2 5 165 9 5 17 5 20 5 0 5 25 4 58 6 9 7 13 5 16 5 1 15 110 5 10 5 0 4 t 4 12 4 2 8 8 aletas ee Sleep ___ __ _ CR _ TT EX 8 4 10 tos 12 4 12 4 12 8 25 6 16 4 7 4 6 4 jajajesejajeyja ta 5 v EN _ __ __ _ 12 4 24 24 2 4 eje 20 6 25 6 0 6 4 6 24 6 9 5 4 6 1 165 225 0 5 0 5 9 5 0 5 3 6 13 5 116 6 20 6 20 6 20 6 20 6 20 6 40 5 k N O1 5 ING e 2 8 2 5 2 5 2 5 4 8 6 _ __ _ 5 5 5 48 5 5 4 38 p gt 6 6 6 6 12 5 27 38 gt gt fats 20 6 7 e
19. 4140 o a i o 416 430F 303 304 316 317 321 409 430 436 Duplex Alloys GG10 GG20 GG25 GG40 66650 GGG70 itanium unalloyed Ti99 8 Titanium alloys TiA164V4 TiA155n2 Nickels ickel unalloyed Nickel 200 Ni99 6 iudi Austenitic stainless steels erritic martensitic lt 1000 N mm Cast Irons ast iron lt 240 HB ast iron lt 240 HB pheroidal graphite Malleable cast iron 40 5 5 35 4 40 6 4 28 3 50 4 a 3 90 4 25 3 _ _ 23 2 40 3 22 2 25 3 TEA gt 5 E EJE 5 5 g 0 E 5 og P 6 N n CD o AS 3 3 o 5 3 77 min O Af Nh PO ojo o oa 6 6 6 pc cioe so 5 5 5 5 40 7 sols 80 6 96 6 115 6 85 6 10 6 70 6 96 7 80 6 170 8 944 5 101 5 6 84 7 70 6 60 5 72 5 86 5 5 72 6 60 5 40 6 48 6 48 6
20. 5 cobalt grade of high speed steel High heat resistance especially suited for roughing or when coolant insufficient Cobalt alloyed tungsten molybdenum high speed steel possessing high hardness excellent cutting properties high red hardness and good toughness 8 cobalt grade of high speed steel Increased heat resistance 4 hardness suitable for difficult to machine materials Available for applications that require a strong resistance to softening at elevated cutting temperatures The ability of the steel to maintain its red hot hardness is provided by the addition of cobalt The high hot hardness 15 required for machining difficult materials such as nickel base titanium and highly alloyed steel Premium grade of high speed steel Wide range of machine taps Vanadium grade gives high wear resistance and toughness for most tapping applications Powdered metallurgy vanadium grade of high speed steel Materials with hardness up to 40HR Difficult to machine materials eg stainless steels PM HSS V3 for higher performance tools incorporates very fine and uniform grain structure allowing a high hardness to be achieved whilst maintaining good toughness Powdered metallurgy 8 Cobalt grade of high speed steel Materials with hardness up to 45HR The addition of cobalt provides this material with the ability to maintain its strength and hardness level when exposed to extrem
21. 7 100 0 2795 10 084 0 3970 x 19 500 0 7677 CAST 0 2810 K 10 200 0 4016 19 844 25 32 0 7813 7 144 9 32 0 2813 10 262 0 4040 20 000 0 7874 7 200 0 2835 10 819 13 32 0 4063 20 241 51 64 0 7969 7 300 0 2874 10 490 0 4130 2 20 500 0 8071 7 366 0 2900 L 10 500 0 4134 20 638 13 16 0 8125 7 400 0 2913 10 716 27 64 0 4219 21 000 0 8268 7 493 0 2950 M 10 800 0 4252 21 034 53 64 0 8281 7 500 0 2953 11 000 0 4331 21 431 27 32 0 8438 7 541 19 64 0 2969 11 112 7 16 0 4375 21 500 0 8465 7 600 0 2992 11 200 0 4409 21 828 55 64 0 8594 7 671 0 3020 N 11 500 0 4528 22 000 0 8661 7 700 0 3031 11 509 29 64 0 4531 22 225 7 8 0 8750 7 800 0 3071 11 800 0 4646 22 500 0 8858 7 900 0 3110 11 906 15 32 0 4688 22 622 57 64 0 8906 7 938 5 16 0 3125 12 000 0 4724 23 000 0 9055 8 000 0 3150 12 200 0 4803 23 019 29 32 0 9063 8 026 0 3160 12 303 31 64 0 4844 23 416 59 64 0 9219 8 100 0 3189 12 500 0 4921 23 500 0 9252 8 200 0 3228 12 700 1 2 0 5000 23 812 15 16 0 9375 8 204 0 3230 P 12 800 0 5039 24 000 0 9449 8 300 0 3268 13 000 0 5118 24 209 61 64 0 9531 8 334 21 64 0 3281 13 097 33 64 0 5156 24 500 0 9646 8 400 0 3307 13 494 17 32 0 5313 24 606 31 32 0 9688 8 433 0 3320 Q 13 500 0 5315 25 000 0 9843 8 500 0 3346 13 891 35 64 0 5469 25 003 63 64 0 9844 8 600 0 3386 14 000 0 5512 25 400 1 1 0000 8 611 0 3390 R 14 288 9 16 0 5625 8 700 0 3425 14 500 0 5709 8 731 11 32 0 3438 14 684 37 64 0 5781 www sutton com au Technical Information Useful Tables Sutton
22. Al insertion run at low speed 300 rpm and low feed rate vy 400 mm min Shortly increase the feed to cycle feed rate Dril to the desired depth without clearing the chips Back out to about hole depth Withdraw from hole at normal rate of withdrawal w 1000 mm min For through holes sand all ante when approsching break through www sutton com au 358 Application Guide Speeds amp Feeds Taps FOR TAPPING BLIND HOLES Thread Depth lt 3x0 lt 3x0 Discount Group 00402 101201 00402 00408 00402 Material PM HSSE V HSSEV3 PM HSSEV3 PM HSSEV PLI HIMEN SEDE UE G Colour Ring amp Application UNI Al VA VA PM H eneral H Purpose Purpose Purpose p E 0 0 i 0 i o Geometry 0 e 4 Het 4c Ho Hel 45 Heli 50 Hox 9 e roe Coolant Oil O Soluble Oil S Air A Meals 0 0 Material examples Coolant Vc m min Vc m min Steels o 1020 1024 1045 1060 4140 01 A2 D3 M42 P20 EN26 01 L6 M42 D3 4140 416 430F 303 304 316 317 32 Alloy steels 850 1200 N mm Alloy steels hard temp 1200 1400 N mm High tensile alloy steels Free machining stainless steel Austenitic stainless steels nl ids il
23. amp 5 8 14 22 0 Size mm 5 Only Reamer 3 4 14 25 5 Rp 1 8 T T 7 8 1 4 ES 1 8 82 3 8 15 0 1 4 10 8 1 2 18 5 3 8 14 0 3 4 24 0 1 2 175 3 4 23 0 Tapping Drill Rp 1 1 4 39 0 um Rp 1 1 2 45 0 Rp 2 56 4 1 1 4 37 0 0 1 1 2 43 5 1 4 5 2 55 0 2 4 0 Pg 3 3 4 STEEL CONDUIT 80 4 3 0 wem NPSF 5 2 65 NATIONAL PIPE STRAIGHT 60 6 23 Tapping Drill f 2 05 ma 8 1 8 9 1 55 10 1 4 11 132 12 1 05 13 0 98 Taper pipe threads of improved quality 14 0 8 are obtained when taper is pre formed 15 0 7 using Sutton Taper Pipe Reamers 16 0 6 www sutton com au 386 Technical Information Fluteless Taps Sutton Tools Fluteless taps Fluteless taps do not cut threads in the same manner as conventional taps but actually FORM and FLOW the threads with an absence of chips Used under suitable conditions these taps produce threads with a high degree of finish not possible with ordinary taps Ductile materials are most appropriate for forming of threads and must have a minimum 10 elongation Benefits of thread forming suitable for wide range materials 1 No chips produced Low carbon steels 2 Higher tensile strength threads produced due to grain structure following the thread form Leaded steels 3 For use in through and blind holes applications Pa ca Alloy steels typically to 1200 N mm 36 Rc with a minimum 10 elongation 4 Higher speeds and tool life Aluminium di
24. some of which are listed Excessive speed Too much clearance on reamer Lack of rigidity in jig or machine Insecure holding of work Excessive overhang of reamer in spindle Excessive looseness in floating holder 7 light a feed Correcting the cause can materially increase both reamer life and the quality of the reamed holes PL Pa c Coolants for Reaming In reaming the emphasis is usually on finish and a lubricant is normally chosen for this purpose rather than for cooling Quite often this means a straight cutting oil The tolerance on the cutting diameter measured immediately behind the bevel or taper lead for parallel reamers listed is M6 as specified in BS122 PT2 1964 It is not practicable to standardise reamer limits to suit each grade of hole and the limits chosen are intended to produce 7 holes Nominal Diameter Range Up to and including Up to and including Cutting Edge Diameter 0 1181 3 0 2362 6 0 3937 10 0 7087 18 1 1181 30 1 9085 50 3 1496 80 www sutton com au Sutton 5 Tool System Finding the right cutting tool for your specific machining application has never been easier with Sutton Tools revolutionary Expert Tools System located at www suttontools com au The Sutton Tools Expert Tools System will recommend the right tool for the right application with everything from suitable co
25. 00050 66670 Ti99 8 TiA164V4 TiA155n2 5 00 8 9 5 5 22 te 3 3 S SS An B Nickels Nickel 200 Ni99 6 Nickel 400 Hastallo C Inconel 600 Nimonic 80A Waspalloy Inconel 71 lt gt lt JHE 1 2 _ 5 8 2 m bo n 5 3 ENS HEN REN REN MCN ENTES 30 5 9 8 5 0 3 33 4 28 5 40 5 40 5 4 5 E E REN EEN CAEN Coppers Copper unalloyed Shortchip brass phosphor bronze gun metal as 5 5 5 5 s 94 Pa ms ss s 7 Dep e Leite Long chip brass Aluminiums Al Mg unalloyed Al alloyed Si lt 5 Al alloyed Si gt 1 5 lt 10 Al alloyed Si gt 10 Mg Alloys RW EN Notes on Drilling 1 Step feeding or pecking is required for drilling greater than 3 x diameter 2 When drilling cast surface amp black ie not machined surface reduce drilling speed by 2096 3 For optimal positional accuracy and hole size the use of spot drills is recommended prior to drilling desired hole refer to our standard range Discount Group A1124
26. 6 60 6 S 5 75 7 4 v 7 7 8 40 5 75 6 66 7 7 os 7 s 3 5 3 732 3 3 3 3 3 2 DS ce 1 n 5 2 5 a ojan 2 o N 3 3 gt o lt lt a D2 gt gt e 3 o 3 3 m ce z gt CORREO 40 6 40 6 30 6 416 430F 0 P20 2 EXI E Austentic stainless steels 6 ne 1 5 3 EX CATRE E ETE IER EN IET RE EE EE ENEJ EE 6 4 35 3 25 3 fent maesti C A gt o x UJ e s FE 77 ENS jo lt E 5 2 KMS xs e o BO lt D o 5 5 D wn 5 V ce D 3 N 7 6 60 6 6 7 8 50 5 56 5 ___ _ _ 6 75 5 50 5 50 5 496 6 35 12 4 5 4 35 4 35 5 35 5 2512 25 a EE O ESA AER 20 1 890 4 2
27. have sufficient pressure to wash the chips away from the hole as much as possible Also if the flow is not continuous it should start before the tap enters the hole and continue until the tap is completely reversed out of the hole In this way ample oil is provided at the start of the cut and loose chips will be suspended in the oil so that they do not interfere with the tap backing out of the hole On machines where the work revolves and the tap is stationary it is desirable to use several streams of lubricant on opposite sides of the tap especially on horizontal tapping Cleanliness Tapping lubricants must always be clean If filter equipment is not used the lubricant must be replaced periodically to eliminate fine chips grit and foreign matter that accumulate in the tank Also it is very important that the piping and tank are thoroughly flushed and cleaned before filling with new lubricant The dilution of lubricants often changes during use so that additions may be necessary to maintain the recommended proportion of active materials Tapping drill The tapping drill hole diameter should be drilled as large as possible within the respective fitting just under the upper permissible dimension of the tolerance If the tapping drill hole diameter is too small then this will cause the thread root diameter minor diameter to cut the material This should be avoided because the small chips which derive from the root of thread clog the normal chip fl
28. it is obvious that the drill could not withstand a load of 0 013mm feed at this speed a penetration rate of 124mm min The correct procedure is to retain the feed but reduce the speed to obtain a penetration within the capacity of the strength of the drill Deep Hole Drilling When drilling deep holes speeds and feeds should be reduced as follows Depth of hole Reduction per cent Fe 6 to 8 times drill diameter 35 to 40 www sutton com au Technical Information lap Terminology Sutton Tools OVERALL LENGTH Tap Definitions LENGTH OF SHANK THREADED LENGTH LENGTH OF CHAMFER SQUARE PITCH LEAD LENGTH LEAD ANGLE SQUARE SIZE S DIAMETER EE DIAMETER DIAMETER DIAMETER Y SHEAR ANGLE INCLUDED ANGLE OF THREAD SEMI ANGLE OF THREAD LAND GUN NOSE SPIRAL POINT CUTTING CORE FACE FLUTE Thread Relief Types CONCENTRIC LAND RADIAL RELIEF RADIAL RELIEF CONCENTRIC THREADS No radial relief ECCENTRIC THREADS Relieved to cutting edge CON ECCENTRIC THREADS Relieved to a land Cutting Faces LAND P TANGENTIAL HOOK CHORDAL HOOK NEGATIVE RAKE ANGLE NEGATIVE RAKE www sutton com au RADIAL RAKE POSITIVE RAKE ANGLE POSITIVE RAKE
29. machines which are not in good condition This type of milling is used predominantly on mills with a backlash eliminator www sutton com au PERIPHERAL RELIEF ANGLE Center cutting endmill Conventional milling Point A may become work hardened Material to be removed by next tooth Cutting Depth ro feed per tooth Material A Feed Cutter Rotation Chip formation during climb milling feed per tooth Material Feed Cutter Rotation Technical Information Endmills Types Sutton Tools VA Al amp CU NR WR HR HRS Ti STF 394 Description Finishing Form Slotting amp Finishing Use in soft materials quick spiral 45 upto 600 N mm Optimized geometry for Austentic Stainless Steels amp other long chipping materials upto 1000 N mm For slotting wrought aluminium alloys with efficient chip evacuation due to high relief angles and 40 spiral Normal Roughing Form general purpose Coarse Form ideally suited to soft non ferrous materials Fine Pitch Roughing Form ideally suited to hard short chipping materials Special Fine Pitch Roughing Form Universal use Wave Form ideally suited to titanium amp nickel alloys Special tooth form Semi Roughing Form ideally suited to materials upto 1400 N mm Application Illustration www sutton com au Technical Inf
30. necessitate slower speeds while occasionally a very compact rigid operation may permit still higher speeds When close tolerances and fine finish are required it is usually found necessary to finish the reamer at considerably lower speeds In general reamers do not work well when they chatter Consequently one primary consideration in selecting a speed is to stay low enough to eliminate chatter Other ways of reducing chatter will be considered later but this one rule holds SPEEDS MUST NOT BE SO HIGH AS TO PERMIT CHATTER Limit of tolerance on cutting diameter a The following charts gives recommended surface feet per minute values which may be used as a basis from which to start m min Aluminium and its 2 2 74 9 e 20 35 20 35 PP 18 22 Monel ac Ca enne 8 12 Al 22 35 Cast iron emen 18 22 Cast Iron chilled seme 7 10 Malleable 18 20 O 13 18 wis MIN NR Ec 12 13 Steel Alloy 300 400 7 10 Stainless __ 5 12 Chatter The presence of chatter while reaming has a very bad effect on reamer life and on the finish of the hole Chatter may be the result of several causes
31. spindle or socket in which reamer is held clean spindle Misalignment of two or more parts of the set up E ejoj This condition can cause a bell mouthed hole ee e Too much or too little feed adjust Wrong type of coolant refer to lubricant supplier s literature ef No lubricant between guide bushing and reamer apply ojej je Lack of lubricant increase ef Bottoming in blind holes reduce depth travel of reamer el Lack of sufficient stock to ream drill smaller hole ojoj o Too much stock to ream drill larger hole slow down the approach feed until all cutting ej e Entering Work 100 Test edges are located in the hole Badly drilled holes too rough tapered or bell mouthed Bell mouthed holes may cause the reamer replace drill to wedge rather than cut ej e Oversize or undersize bushings Use suitable bush Lack of rigidity in machine or work holder improve rigidity 368 www sutton com au Application Guide Carbide Burs Sutton Tools Recommended Cutting Speeds RPM Standard Length Burs Double Cut Aluminium Cut Steels alloys amp Max RPM Diameter non ferrous 1 16 33 000 3 32 26 000 40 000 Stainless Steel Aluminium lt omm pom Note Recommend reduce speeds by 50 when using long shank carbide burs safety Tips e Eye protection must be worn at and aroun
32. tolerances of these three classes are determined in terms of a tolerance unit t the value of which is equal to the pitch tolerance value TD2 grade 5 of nut extrapolated up to pitch 0 2mm t TD grade 5 The value of the tap pitch diameter tolerance is the same for all three classes 1 2 and 3 it is equal to 20 of t The position of the tolerance of the tap with respect to the basic pitch diameter results from the lower deviation the values of which are See figure 3 for tap class 1 011 for tap class 2 0 31 for tap class 3 0 51 Choice of tolerance class of the tap with respect to the class of thread to be produced Figure 3 NUT LIMITS 8H oH Pitch Diameter of Basic Profile www sutton com au Unless otherwise specified the taps of classes 1 to 3 will generally be used for the manufacture of nuts of the following classes ISO Class 1 for nuts of limits 4H and 5H ISO Class 2 for nuts of limits 6H and 5G ISO Class 3 for nuts of limits 7H 8H and 6G ISO TAP CLASSES Class 2 Class 1 Technical Information Unified Screw Thread Tolerancing System Sutton Tools This system is well known It has now been accepted by ISO as the recommended tolerancing for 150 inch threads down to 0 06 inch nominal diameter The arrangement of the allowance and the various classes of pitch diameter tolerance for a normal length of engagement of the mating threads is shown in this diagram The p
33. 0 2165 0 889 0 0350 65 3 454 0 1360 29 5 556 7 32 0 2188 0 900 0 0354 3 500 0 1378 5 600 0 2205 0 914 0 0360 64 3 569 0 1405 28 5 613 0 2210 2 0 940 0 0370 63 3 572 9 64 0 1406 5 700 0 2244 0 965 0 0380 62 3 600 0 1417 5 791 0 2280 1 0 991 0 0390 61 3 658 0 1440 27 5 800 0 2283 1 000 0 0394 3 700 0 1457 5 900 0 2323 1 016 0 0400 60 3 734 0 1470 26 5 944 0 2340 1 041 0 0410 59 0 1495 25 5 953 15 64 0 2344 www sutton com au Technical Information Conversion Tables Sutton Tools 6 000 0 2362 8 800 0 3465 15 000 0 5906 6 045 0 2380 B 8 839 0 3480 5 15 081 19 32 0 5938 6 100 0 2402 8 900 0 3504 15 478 39 64 0 6094 6 147 0 2420 9 000 0 3543 15 500 0 6102 6 200 0 2441 9 093 0 3580 T 15 875 5 8 0 6250 6 248 0 2460 D 9 100 0 3583 16 000 0 6299 6 300 0 2480 9 128 23 64 0 3594 16 272 41 64 0 6406 6 350 1 4 0 2500 E 9 200 0 3622 16 500 0 6496 6 400 0 2520 9 300 0 3661 16 669 21 32 0 6563 6 500 0 2559 9 347 0 3680 U 17 000 0 6693 6 528 0 2570 F 9 400 0 3701 17 066 43 64 0 6719 6 600 0 2598 9 500 0 3740 17 462 11 16 0 6875 6 629 0 2610 G 9 525 3 8 0 3750 17 500 0 6890 6 700 0 2638 9 576 0 3770 17 859 45 64 0 7031 6 747 17 64 0 2656 9 600 0 3780 18 000 0 7087 6 756 0 2660 H 9 700 0 3819 18 256 23 32 0 7188 6 800 0 267 7 9 800 0 3858 18 500 0 7283 6 900 0 2717 9 804 0 3860 W 18 653 47 64 0 7344 6 909 0 2720 9 900 0 3898 19 000 0 7480 7 000 0 2756 9 922 25 64 0 3906 19 050 3 4 0 7500 7 036 O27 70 J 10 000 0 3937 19 447 49 64 0 7656
34. 0 230 0 0091 89 1 778 0 0700 50 4 200 0 1654 0 240 0 0094 88 1 854 0 0730 49 4 216 0 1660 19 0 254 0 0100 87 1 900 0 0748 4 300 0 1693 0 270 0 0106 86 1 930 0 0760 48 4 305 0 1695 18 0 280 0 0110 85 1 984 5 64 0 0781 4 366 11 64 0 1719 0 290 0 0114 84 1 994 0 0785 47 4 394 0 1730 17 0 300 0 0118 2 000 0 0787 4 400 0 1732 0 305 0 0120 83 2 057 0 0810 46 4 496 0 1770 16 0 317 0 0125 82 2 083 0 0820 45 4 500 0 1772 0 330 0 0130 81 2 184 0 0860 44 4 572 0 1800 15 0 343 0 0135 80 2 261 0 0890 4 600 0 1811 0 368 0 0145 79 2 375 0 0935 42 4 623 0 1820 14 0 397 1 64 0 0156 2 381 3 32 0 0938 4 700 0 1850 13 0 400 0 0157 2 438 0 0960 41 4 762 3 16 0 1875 0 406 0 0160 78 2 489 0 0980 40 4 800 0 1890 12 0 457 0 0180 77 2 527 0 0995 39 4 851 0 1910 11 0 500 0 0197 2 578 0 1015 38 4 900 0 1929 0 508 0 0200 76 2 642 0 1040 37 4 915 0 1935 10 0 533 0 0210 75 2 705 0 1065 36 4 978 0 1960 9 0 572 0 0225 2418 7 64 0 1094 5 000 0 1969 0 600 0 0236 2 794 0 1100 35 5 055 0 1990 8 0 610 0 0240 73 2 819 0 1110 34 5 100 0 2008 0 635 0 0250 72 2 870 0 1130 33 5 105 0 2010 7 0 660 0 0260 71 2 946 0 1160 32 5 159 13 64 0 2031 0 700 0 0276 3 000 0 1181 5 182 0 2040 6 0 711 0 0280 70 3 048 0 1200 31 5 200 0 2047 0 742 0 0292 69 3 100 0 1220 5 220 0 2055 5 0 787 0 0310 68 3 175 1 8 0 1250 5 300 0 2087 0 794 1 32 0 0313 3 200 0 1260 5 309 0 2090 4 0 800 0 0315 3 264 0 1285 30 5 400 0 2126 0 813 0 0320 67 3 300 0 1299 5 410 0 2130 3 0 838 0 0330 66 3 400 0 1339 5 500
35. 2 Fig 5 6 h 2 H 0 640327p 0 137329 The Whitworth Screw Thread Tolerance System Figure 6 MEDIUM CLASS NORMAL CLASS NORMAL CLASS NUT BASIC PITCH DIAMETER BOLT 3 4 DIA AND UNDER img n OVER 3 4 DIA 150 p 3 DIA AND UNDER OVER 3 4 DIA F UNDAMENTAL DEVIATION ALLOWANCE CLOSE CLASS MEDIUM CLASS FREE CLASS Pitch diameter tolerance zones of recommended combinations of classes of bolts and nuts having Whitworth screw threads Fig 6 British Tap Size Zone Limits British Standard Zone 3 and Zone 4 limits are normally applied to Whitworth Figure 7 and taps The values for position and tolerances are formulated and must be obtained from the standard s tables The accompanying chart shows the zone limits relationship for ground threads Fig 7 Basic Pitch Diameter WWW Sutton com au Technical Information 50 Pipe Thread Systems Sutton Tools The International Standard Pipe Tap Thread System ISO has been derived from the original Whitworth gas and water pipe tap threads formerly known as BSPF Fastening and BSPT Taper these systems have been so widely used throughout Europe and the United Kingdom that they have been metricated whilst still retaining the whitworth thread form These popular thread systems are the basis for the ISO parallel G series and the taper R series these systems are endorsed and in agreement with the current British and Australi
36. 3 EX 3 3 N k be be adjusted on application As a general rule f hole depth required is less than above mentioned increase speed If hole depth required is more than above mentioned reduce speed 2 For coated tools speeds may be increased by 20 3 Taps must be driven by the square to eliminate slippage eg ER GB collets square drive 4 When using spiral flute taps with length compensation tapping attachment it is recommended to short pitch the feed 9596 to eliminate tap cutting oversize eg M6x1 amp 1000RPM Feedrate 950mm min Denotes for use on fully computer controlled synchro machines with rigid tapping holder www sutton com au NC E553 en UNI pe LL LRL LL Lene ES 5 8 5 8 EK EK to 00 10 8 8 jio En J o E 5 5 J 3 ES a a aa i F fp 7 CEE E e 1 12 12 Pts
37. 5 4 90 4 25 __ ar 5 1804 9 200 5 100 9 wo 6 _ 5 160 4 _ 7 5 0e 0 6 _ ___ __ 120 5 150 8 120 6 fizo 260 5 240 9 200 5 240 9 7 200 7 200 5 4 _ 1 5 te 7 180 7 1 5 YA E ES ER _ 11001 5 4 jt20 7 120 7 140 5 O les Spheroidal graphite Malleable cast iron 45 20 04 20 EN 3 EX El 1 3 E pe peo a tz 110 90 10 3 80 1 90 3 80 40 5 40 6 y n 5 aL 313 S 2 E A lt c a UJ TiA164V4 TiA155n2 4 1200 5 6 5 6 50 6 40 5 40 5 65 50 1 Nickels DT Inconel 600 Inconel 718 515 5 olo 2 a 8 amp ei 1 Z eis o3 N 3 3 N Coppers Copper unalloyed Shortchip brass phosphor bronze gun metal Long chip brass i lt 5 E
38. 7 woj 4 sa 5 as e i 4 655 2 wa s 6 00 58 2 ET e ozod s 55 2 3 10 20 e 102013 55 2 Coolant Oil O Soluble Oil S Air A Free cutting steel 512141 Leaded Steels RO EN26 01 L6 M42 D3 4140 4140 01 2 D3 M42 4140 01 42 D3 M42 En 4140 01 2 D3 M42 Hardened materials 46 548 Hardened materials 54 628 DID OIO lt lt 5 5 5 gt Simo elg e 1 Sil 5 _ lt 5 N o e e 3 3 N o o High tensile alloy steels Stainless Steels 0 40 5 35 5 25 Free machining stainless steel 416 430F 1 aa s gt esas a fom 8 205 e 3 sas 2 ss o mas a ois 2 6 es u ss n oss 8 ____ ras s ____ 7 7 3 3 4 303 304 316 317 321 4 3 409 430 436 Duplex Alloys Austenitic stainless steels 70 80 50 60 S 85 95 Ferritic martensitic 1000 N mm Cast iron 240 HB Cast iron 240 HB Spheroidal graphite Mal
39. Diameter Tolerance h8 mm Back Taper mm Over Inclusive Plus Minus Tapering of Diameter 0 000 0 018 0 002 t 0 008 w _ t The Drill diameter usually reduces towards the shank end tolerance per 10mm of flute length www sutton com au 378 Technical Information Hints on Use and Maintenance Sutton Tools Web Thinning On most drills the web increases in thickness towards the shank with the result that as the drill is shortened by repeated sharpening the chisel edge will become wider As the chisel edge does not cut but forces the metal out of the way too wide a chisel edge will result in more pressure required for penetration leading to greater heat generation and a resultant loss of life HOLD ORIGINAL THICKNESS Cutting Fluids The use of cutting fluids is an advantage in most drilling operations and an essential in some The two main functions of the cutting fluid are lubrication and cooling The purpose of lubrication is to reduce friction by lubricating the surfaces tool and work to facilitate easier sliding of the chips up the flute and to prevent the chips welding to the cutting edges In production work particularly when drilling deep holes the cooling action of the fluid is often more important than the lubrication Overheating will shorten the life of the drill Intermittent feed on deep holes where possible not only clears the chips but permits more effec
40. Tools Approx Tensile Strength vs Hardness 374 Tensile Strength Hardness N mm Kg mm Tons Inch Brinell Hb Rockwell HR 400 40 8 26 0 119 69 HR 450 45 9 29 0 133 75 HR Conversion of values depends on the actual alloy content this chart therefore indicates a general conversion only Manufacturing Tolerances 1 Micron 0 001 Diameter and inmm including 1510 512 0 0 0 0 0 25 40 20 50 0 0 0 0 0 30 48 24 60 8 12 18 30 48 0 0 24 60 E m 0 0 0 0 0 36 58 29 75 9 15 22 36 58 0 0 29 75 0 0 0 0 0 43 70 35 90 7 pe 11 18 27 43 70 0 0 35 90 26 0 0 0 0 0 52 84 42 105 13 21 33 52 84 0 0 42 105 0 0 0 0 0 62 100 50 125 i D 16 25 39 62 100 0 0 50 125 0 0 0 0 0 74 120 60 150 P 19 30 46 4 120 0 0 60 150 Bn i2 0 0 0 0 0 87 140 70 175 22 35 54 87 140 0 0 70 175 Conversion 1 micron equals 00004 inches Technical Information Shank Types Sutton Tools High Speed Steel Straight Shanks DIN 1835 Form A plain centre hole chamfer centre hole form 1 R 0 DIN 332 part b aos _ _ m we 50 18 45 47 8 23
41. Vic 3300 Ph 1800 035 010 Fax 1800 804 084 Email specsalesOsutton com au APPLICATION TWIST DRILL SPECIAL ENQUIRY New Customer Order Contact Phone Fax Signature WITH Internal Cooling WITHOUT Internal Cooling Uncoated TiN Uncoated TIN NENNEN TICN TiALN TeClube TICN TIALN TeClube AAA 4 0 20 0mm 4 0 20 0mm Please and fax to our Special Sales Dept 1800 804 084 Item No 499980185 c SUTTON TOOLS 214 Coleraine Road Hamilton Vic 3300 Ph 1800 035 010 Fax 1800 804 084 Email specsales sutton com au APPLICATION TAP SPECIAL ENQUIRY Sutton Tools Customer No New Customer _ Order Contact Address Phone State Province Fax Country Email Tap Details Thread Cutting Thread Forming Existing Method Size 2 Thread Limit Dimensions 2 Coating C Uncoated 71 Steam Oxide Please Note If special thread form Toerane __ L Tian Li tic L TeClube please supply details on separate drawing Product No Speed o d I3 XO 1 sq a f Workpiece Details Drawing Notes Component Material Group
42. an standards For comparison the pitch diameter tolerance zones are given for both the parallel and taper systems G Fastening Parallel Pipe Threads ISO 228 AS1722 PT2 and BS2779 This parallel thread system has only one positive internal thread tolerance and two classes of external tolerances This series constitutes a fine series of fastening connecting pipe threads for general engineering purposes the assembly tolerances on these threads are such as to make them unsuitable for pressure tight seal by the threads themselves For the conveying of fluids the seal may be produced by gaskets flanges or O rings etc INTERNAL THREAD EXTERNAL BASIC PITCH THREAD DIAMETER Sealing Taper Pipe Threads 150 7 AS1722 PT1 BS21 The taper rate is 1 16 on diameter This series is for tubes and fittings where pressure tight joints are made by threads these threads therefore must have a full form profile no truncations The series include a taper external thread for assembly with either taper internal Rc or parallel internal Rp threads The Rp series has a unilateral tolerance which normally requires a special below basic low limit tap to allow for sizing deviations at the start of the internal thread the size is gauged at this position with an Rc taper gauge The low limit Rp tap size allows a minimum accommodation length to be machined with an equivalent material saving possible TAPER PARALLEL
43. d Systems 388 390 Whitworth Sie MS 391 ISO Pipe Thread Systems senes 392 Endmills 393 Climb amp Conventional nns 393 miel BU gt 394 Reamers HINTS USC 00 enn enne enn 395 liic O 395 Enquiry forms for special tools nn 397 o A E E o E 0 398 A eE E ro EEE O 399 ma NL 400 www sutton com au Application Guide Colour Band Selection Sutton Tools ELONGATION N mrm 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 Hardness 120 150 180 25 240 265 25 325 355 385 401 415 445 450 Rockwell C 71 6 7 1 44 48 47 46 Material Type yep bees JIS DIN Material Common examples 500 N mm Leaded Steels Leaded Steels RFFeb60 RFe100 1 1015 1 1013 750 N mm 1010 1012 1020 S10C S12C S20C St37 2 16MnCr5 St50 2 1 0112 1 1053 1 7131 900 N mm 1025 1060 S25C S45C S55C CK45 C60 1 1191 1 0601 42CrMo4 100Cr6 1 7225 1 3505 1 6582 2 3 J 3 1100 N mm 4140 A2 4340 M42 M2 SCM4 SCM5 SCM440 aACINIMOG 52 10 1 8 35217 1400 N mm 01 L6 M42 D3 SKD1 SNCM439 1 2510 1 271 90MnCrV8 1 2842 1 2379 gt 55 HR 02 A2 D2 D3 M2 SKD12 SKD11 SKD1 x100CrMgV5 1 1 2363 1 2080 Austenitic 303 416 430F SUS304L X10C
44. d bur application e For use in air amp electric die grinders do not use in conventional electric drills as insufficient speed can cause breakage e Chuck carbide bur to full capacity of machine chuck Do not use driving tool with worn bearings e Endeavour to use double cut wherever possible as standard cut can produce harmful slivers Hints for Use e Position bur in drive as close as possible to head of collet Allow tool to do its own cutting do not force the cut or use excessive pressure e Allow tool to be running at full speed before making contact with the work piece prevent loading on aluminium burs coat bur with bees wax or oven cleaner before use e f sparks are evident in use either bur is dull and should be replaced or material is too hard www sutton com au 0 8 1 0 Non ferrous metals and plastics Ferrous metals e g HSS Steam _ _ _ _ _ Blue e Prevents chip build up on the cutting edges St Ox Oxide Black Cutting sticky ferrous materials Increased corrosion resistance Ni oe 0 8 1 0 Abrasive materials cast iron and aluminium alloys Nitride Abrasive materials cast iron and heat treated steel Futura Nano Nano up to Violet e Difficult to machine materials such as stainless steel a 900 C Grey Higher speeds and feeds e Reduces or eliminates use of coolants Mone inde Bl
45. de Other Spiral RH LH Quantity Required Tools Please copy and fax to our Special Sales Dept on 1800 804 084 Item No 499980185A Sutton Tools Customer Company Address Date Solid Carbide Drill Without Step Carbide grade specify if known Norm 0 d Shank 0 d to DIN 6535 Shank length to DIN 6535 Shank form to DIN 6535 Drilling depth Flute length Total length Point angle Point geometry specify if known Surface finish coating Quantity Cost per tool Solid Carbide Step Drill Carbide grade specify if known Step 0 d ee Body 0 d Shank to DIN 6535 Shank length to DIN 6535 pue Uu rc MM Shank form to DIN 6535 Step length Drilling depth Flute length Total length Point angle Step angle Point geometry specify if known Surface finish coating Quantity Cost per tool SUTTON TOOLS 214 Coleraine Road Hamilton
46. dg de Eon E E aera 2 Above speeds amp feeds are based on UNCOATED tools regular length uncoated depth 15mm width 1mm 3 For COATED tools speeds may be increased _ _ 318 _ EMIR 0 215 1431 _ RPMxfxZ Feed No 9 refer feed table 0 044mm tooth Vc m min Dia f mm ooth _ 1431 x 0 044 x 4 Db IE Z No of teeth mm min www sutton com au PROFILING PROFILING SUPER ROUGHING p Cg oe ol _ _ 0 02 0 05 x D 0 02 0 05 x D 0 02 x D T 5 30 Helix 30 Helix 30 Helix 30 Helix 30 Helix 30 Helix 30 Helix 40 Helix 60 Helix gris 30 Helix 50 Helix gri Ede mus mm o ee w mew mm orm w wmm o mm mu o o sem w mm o 5s w w mm w s su m s mw ew o s pew w om s we s um es m me mem a mu 5 5m s mm w se ua 1 o ss a ss wn ss 9 se s tm s fom ss sew es ma a CEEE I esr foals nals fom mole _ E E E E OANA zu pem es pom e ss s emp s ps s wa x ss ma enl s sel
47. ditions unsuitable shape of cutting edge Non parallel or uneven surface Low stiffness of the cutter or of the workpiece loose Extreme flank wear Extreme crater wear Breaks and shelling due to thermal shock Unsuitable cutting conditions unsuitable shape of cutting edge Formation of built up edges Poor chip clearance chip blockage Lack of Rigidity End mill cutter breaks 1 2 3 4 5 6 7 8 9 10 001 Difficult cutting conditions clamping of the workpiece A O Unsuitable cutting conditions flute length of the cutter Solution Increase cutting speed Reduce cutting speed Increase feed rate Reduce feed rate Reduce cutting depth Change cutter diameter and cut width Check use of cooling lubricant flush swarf away Reduce number of teeth a Change shape of minor cutting edge 9 fe Cutter change radial run out jeje Change cutter stiffness flue length I D ratio re feof Select machine with higher power and stiffness Increase clearance angle Radial relief Increase wedge angle Rake angle Increase number of teeth www sutton com au Application Guide rouble Shooter Reamers HS Sutton Tools Code Problem Excessive wear AMEX Poor surface Finish Possible reason Solution Dirt or burrs in
48. e castings alloys low silicon 10 5 Reduced possibility of breakage due to no cutting edges and robust tool construction Wrought aluminium alloys Ductile Zinc die casting alloys Copper and copper alloys 2 Formed Cut Thread Thread BL Whats New New polygon profile 6 6 1 ES CX a New radiused blend on polygon profile 7 Thread profile with radius crest 8 Re Polished tool surface surface finish 9 Percentage of thread required Because the thread produced by a fluteless tap is substantially stronger than a conventional thread greater tool life and efficiency may be obtained when forming up to 65 thread Threads may be formed up to 80 of depth but tool life will be reduced and work clamping pressure necessarily increased Greater tapping speeds allow the metal to flow far more readily so 60 feet per minute minium may be used as a guide but this could increase with the type of material being tapped A depth of 65 is recommended for the ductile materials mentioned but this percentage will be reduced for less ductile materials to maintain all round efficiency Tapping drill formula for fluteless taps Refer Tapping Drill Size Chart for recommended sizes Suitable for Unified Whitworth and Metric sizes only The formula to calculate the theoretical hole size for a required percentage of thread is Formula Example Drill size for 65 of thread in a M6 x 1 0 threaded h
49. earest Standard Drill 5 4mm 2007 inch 1 4 UNC 75 thread required 1 30 19 Unified Form Threads 2221202 Drill size 250 440 T3 250 046 inch calculation Drill Size Nom Dia E X of thread depth Therefore Drill Size 201 Nearest Standard Drill 5 1mm 2007 inch www sutton com au 384 Technical Information Drill Size Chart Cut Thread ALL SIZES ARE SUGGESTED SIZES ONLY AND MAY BE VARIED SUIT INDIVIDUAL REQUIREMENTS Sutton Tools ISO METRIC COARSE 60 Tapping Drill mm UNIFIED NATIONAL COARSE 60 Tapping Drill Size BSW BRITISH STANDARD WHITWORTH 55 Tapping Drill mm 0 35 1 25 1 16 0 4 1 6 2 1 3 32 1 85 0 45 2 05 2 3 1 8 2 55 0 6 2 9 2 8 3 16 0 33 7 32 4 5 0 75 3 7 3 8 1 4 5 1 0 8 4 2 45 1 0 5 0 5 1 5 16 6 5 1 25 6 8 6 6 3 8 7 9 1 5 8 5 8 0 7 16 9 3 1 75 10 2 9 4 1 2 10 5 M14 2 0 12 0 9 16 12 1 M16 2 0 14 0 5 8 135 M20 2 5 17 5 M22 25 195 m 8 24 3 0 21 0 SETS 27 2 0 24 0 M30 3 5 26 5 1 1 4 28 0 33 3 5 99 5 33 5 36 4 0 32 0 1 3 4 39 0 M42 4 5 37 5 2 44 5 M45 45 40 5 WHIT Form M48 5 0 43 0 M52 5 0 47 0 M56 5 5 50 5 10 10 M12 M12 M14 M14 M16 M18 M20 M22 M24 M25 M32 M40 M50 Metric Conduit LI LI LI LI LI LI LI LI gt LI o a
50. ely high cutting temperatures This makes PM HSS Co suitable for heavy duty tapping in materials such as high alloyed steels to non ferrous metals like Ni base alloys amp Ti alloys Powdered metallurgy 11 Cobalt grade of high speed steel Special applications requiring very high edge hardness Cutting tools with the appropriate geometry can be applied to workpiece materials with hardness upto 55HR An excellent bridge material between high speed steel and carbide SPM offers very high red hardness wear resistance and the highest compressive strength of any high speed steel Solid carbide www sutton com au Materials with hardness up to 62HR also used in materials with very high abrasion such as Al Si gt 10 Ultra fine grain type with maximum toughness combine with high hardness therefore especially reccommended for rotating tools to machine hardened parts Technical Information Conversion Tables Sutton Tools 372 0 010 0 0004 1 0 0 0420 3 800 0 1496 0 100 0 0039 1 092 0 0430 57 3 861 0 1520 24 0 150 0 0059 97 1 181 0 0465 56 3 900 0 1535 0 160 0 0063 96 1 191 3 64 0 0469 3 912 0 1540 23 0 170 0 0067 95 1 321 0 0520 55 3 969 5 32 0 1563 0 180 0 0071 94 1 397 0 0550 54 3 988 0 1570 22 0 190 0 0075 93 2211 0 0595 53 4 000 0 1575 0 200 0 0079 92 1 588 1 16 0 0625 4 039 0 1590 21 0 210 0 0083 91 1 613 0 0635 52 4 089 0 1610 20 0 220 0 0087 90 1 702 0 0670 51 4 100 0 1614
51. i fan s faal s lea a laaf e fae o esl s e se s ss s ma s wm m0 6 mo sss oes 4 5 m w em s se w ea ow jew s rens e 0 60 0 50 0 40 oo c 38 35 4 e e e Y gt gt 4 cn 5 EN 5 es ep s m CINE es 5 4 0 4 0 3 gt lt gt Sis e gt gt lt gt EN TEN DIESE CEN gu 11 e e asja amp ce Y gt ceci 5 ar o e RUN RO mE as 7 s 5 56 e s Jem o e o 1 Jes 0 s 55 5 su 4 fowls 55 s 58 gt wal 5 e s s om 65 esr 5 56 o 60 e
52. itch diameter tolerance for Class 2A bolts is shown as 100 units and the fundamental deviation and other tolerances are shown as percentages of the Class 2A tolerance Fig 4 Figure 4 NUT CLASS 1B CLASS 2B CLASS 3B 4 195 BASIC 97 5 130 PITCH DIAMETER 75 da 100 CLASS 3A 0 30 150 CLASS 2A Y CLASS Unified Taps The System This system provides for a range of pitch diameters for each size of tap the height limit of pitch diameters being the basic pitch diameter plus increments or units of 0005 It is designated by the letter GH followed by a numeral indicating the number or units applying to the particular GH size The tap manufacturer s tolerance is applied as minus This is the limit which will normally be supplied Alternative GH limits other than those shown in the price list can be made to special order GH Limits for JIS Roll Taps GH Limits are applied to JIS Metric and Unified Thredflo Tap Threads due to market demands in the JIS standard Inch Micron um 0 0060 EEEE EEE EEA EIL 0 0055 SAA A A n 1 40 0 0050 P P Ie 1 27 0 0045 wnR
53. ke angle amp Low thread relief High rake angle High helix 2 Flutes Low thread relief TICN Plasma Nitride Ni Bright Steam Oxide Bright Steam Oxide TICN Bright CrN Bright Plasma Nitride www sutton com au Technical Information Tapping Information Sutton Tools Use Use of a suitable lubricant or cutting compound is necessary on most tapping operations The type of lubricant as well as the method of application is often of extreme importance and can be responsible for the success or failure of a tapping operation Recommendation The table on page 130 lists general recommendations for the type of lubricant However better results can sometimes be obtained by the use of one of the many modified or specialised lubricants recommended by cutting oil specialists The general principle is to have more EP Extreme Pressure additives added with the degree of difficulty usually hardness increase Oils stick and improve frictional properties essential in tapping tough applications Application Proper application of the lubricant is just as important as the type used To be effective ample quantities of lubricant must reach the chamfer or cutting portion of the tap during the entire tapping operation In many cases the lubricant must also aid in controlling or disposing of the chips Flow The flow of lubricant should be directed into the hole rather than at the tap and should
54. leable cast iron GG10 GG20 GG25 GG40 par e 42 k o o 66650 66670 Titaniums Ti99 8 40 50 30 40 _____ sas 8 es s as e map a 4 CEN s EEESERENZXESENEN w CIA TiA164V4 TiA155n2 5 25 EN EJER 72121 s 5 5 5 o 2 2 nio lt gt gt Nickel unalloyed Nickel 200 Ni99 6 Monel 400 Hastelloy C Inconel 600 Co Nickel alloys lt 850 N mm Nickel alloys 850 1150 N mm Nimonic 80A Waspalloy nconel 718 Copper unalloyed 60 80 co RO lt exl r pa oo s em Short chip brass phosphor bronze gun metal 5 4 e pe d EX NENNEN _____ 9 EIN Aluminiums oia 0 m o 5 Alaloyedsi gt 15 lt 10 ____ s TO o jono feos w Sm gt 10 _______5 9m woj o 1090 om0 0 s o0 7 Notes on Tapping m 1 Above speeds amp feeds are a guide only based on type of cut illustrated
55. n com au Technical Information laps Sutton Tools Tap Types Helix direction Helical pitch Fluteless The helix angle depends primarily upon the hole form eg Through hole blind hole deep blind hole etc but the material eg short chips long chips also has a strong influence on the direction of the helix The following basic forms have derived during the development of taps Description Illustration Straight Flutes Hand Suitable for through or blind holes The flutes only have room for a small amount of chips The chips are not transported axially Therefore it is not advisable to cut deep through or blind holes except in short chipping materials with this type Straight Flutes with spiral point Gun Suitable for through holes the spiral point curls the chip forward ahead of the tap amp out of the hole Therefore chip clogging is avoided and coolant can flow without problems Spiral Flutes LH Spiral Suitable for interrupted through holes where cross holes exist The direction of the flutes curls amp transports the chips forward of the tap similar to Gun taps also opposite to RH spiral flutes However in applications where another hole intersects with the tapped hole the helical flutes maintain the pitching of the thread 15 Spiral Flutes RH Spiral Suitable for blind holes best suited to tough short chipping materials upto 1 5 x D in depth This particular tap design has no advan
56. ngle is not correct The axial machine spindle movement is not free and easy a check workpiece clamping b check machine settings a use mechanical feed b use tap holder with length compensation Cold welding on the thread flanks of the tap a use a new tap b improve and check lubrication remove cold welding area from tap d use tap with surface treatment or coatings Poor guidance of the tap because of little thread depth a use mechanical feed b use tap that has better guiding characteristics Speed is too high improve lubrication lower speed Chip clogging use tap with different flute form use coated taps C use tap set a 0 0 The lubrication wrong additives or the coolant supply is not sufficient Make sure that the coolant is correct and that the supply is sufficient Spiral fluted taps are over pressured in the initial cutting phase retracting pulling force Spiral fluted taps should only be ony pushed into the tap hole until it ae to cut The tap holder should immediately begin to apply tension to the tap Spiral pointed taps gun taps are not receiving enough pressure in the initial cutting phase Spiral pointed taps and even left hand spiral flute taps must have a stronger pressure until they begin to cut The tap holder should immediately begin to apply pressure to the tap pushing force Tolerance on the tap 15 not identical to the tolerance
57. nout forms used at the bottom of the tap hole One form has a recessed diameter at the bottom of the hole and the other form has a standard runout Other types of holes are respective to construction designs eg a The bore is smaller than the tap hole diameter typical for pipes b As step hole where the following diameter Second step is smaller than the tap hole diameter www sutton com au Technical Information Tap Geometry Sutton Tools Geometry Abbrev Surface VA VAPM Al E ud 6 A elo Description For cast iron iron is a very abrasive material therefore to increase tool life the taps are always surface treated or coated to resist the abrasion The thread limit for this range 15 6HX which is high limit of the 6H tolerancte allowing for longer wear life For normal general purpose type materials suited to a wide range of materials with normal rakes relief s This is existing geometry that Sutton has historically manufactured For normal general purpose type materials suited to a wide range of materials with normal rakes amp high relief s However tap material is powder metal high speed steel PMHSS which due to its finer grain structure than that of conventional HSS higher hardness can be achieved with excellent toughness along with Teclube surface coating allowing for better tool life than normal taps For stainless and tough steels to avoid clogging in tough long chi
58. o for nuts These are designated g and for bolts and G and H for nuts As in the ISO System for limits and fits small letters are used to designate tolerance positions for bolts and capital letters are used for nut tolerance positions Also the letters h and H are used for tolerance positions having the maximum metal limit coincided with the basic size i e with a fundamental deviation of zero Fig 2 ISO Metric Tolerance Grades A series of tolerance grades designated 4 5 6 7 and 8 for nut pitch diameters An extended series of tolerance grades designated 3 4 5 6 7 8 and 9 for bolt pitch diameters An important factor here is that for the same tolerance grade the nut pitch diameter tolerance is 1 32 x the corresponding bolt pitch diameter tolerance Size and recommendations of fits can be obtained from the Australian Standards AS 1275 or AS 1721 Figure 1 NEN P EE Figure 2 p MAJOR ES 8H NUT 2 FUNDAMENTAL 6H E 6G DEVIATION 4H BASIC PITCH DIAMETER BOLT 79 9g FUNDAMENTAL DEVIATION 0 86603P 0 32476 8 0 21651 4 0 54127 y 8 0 10825 www sutton com au Technical Information 50 Metric Tap Class amp Tolerance Sutton Tools The ISO metric system of tap tolerances comprises three classes of tap sizes which are calculated from the Grade 5 nut tolerance irrespective of the nut grade to be cut as follows ISO Class 1 Class 2 Class The
59. olant choices through to recommended cutting calculations 0 Fast and easy to use tool selection system 0 High speed navigation 0 Quickly search by product description or catalogue number 0 Recommends most suitable tool and machining data based on the latest research 0 Animated demonstrations of machining processes Visit www suttontools com au to find the right tool for your job Sutton Tools SUTTON TOOLS 214 Coleraine Road Hamilton Vic 3300 Ph 1800 035 010 Fax 1800 804 084 Email specsales sutton com au APPLICATION HSS DRILLS SPECIAL ENQUIRY Sutton Tools Customer New Customer Order No Company Contact Address Phone State Province Fax Country Email Drill Details Tool Material Hss HSS E PMHSS E Other Tool Type Drill Step Dril Subland Drills Core Drills Countersinks Centre Drills Internal Cooling Without With Shank Design _ Reinforced _ Without Flat With Flat Parallel Straight Shank Morse Taper _ Other Number of Steps Without With Steps Total Length mm Step Diameter mm mm d mm mm mm mm Point Geometry Relieved Cone For Grey Cast Iron Centre Point Facet Point Grind Other Special Point Grind Form Without Other Coating Uncoated TeClube Steam Oxi
60. ole would be 007 x of thread Drill size 6 007 x 65 x 1 0 pitch 5 54m Use 5 50mm drill Stockable drill 76 Drill size nominal thread dia inch It is to be noted that the drill size for fluteless tapping is always larger than the P D of the thread A drill size equal to the P D of the thread would produce 100 of thread but this is NOT recommended As the additional driving torque 1 only up to 50 increase any conventional driving equipment using the square as a drive is suitable for fluteless tapping Lubrication Countersinking In general it is best to use a good cutting oil or lubricant rather than a coolant Because the fluteless tap displaces metal some metal will be displaced above for fluteless tapping Sulphur base and mineral oils along with most friction the mouth of the hole during tapping countersink or chamfer the hole prior to reducing lubricants recommended for use in cold extrusion or metal drawing tapping will reduce the extrusion within the countersink and not interfere with have proven best for this work Make sure lubricant is clean free from chips the mating part swarf and filings in suspension which produce a poor finish and jamming sometimes breakage extra filtration may be required www sutton com au Technical Information Tapping Drill Size Chart Fluteless Fluteless Roll Taps 2 5 e THREAD SIZE M C Screw Gauge 0 25
61. on the drawing or on the gauge Use a tap which has a correct tolerance Wrong initial cutting pressure has been used or the machine spindle is not moving along its axis free and easy a use mechanical feed b use tap holder with length compensation Tap is over loaded either from coarse pitch and or tough material Use set of taps Cold welding material build up pick up a improve coolant supply use taps with surface treatments or mE b check if surface treatment is correct for this application Hardened walls in drilled hole a use drill best suited to material being drilled b use new drill or boring tool c resharpen drilling or boring tools d if possible heat treatment and coatings should only be made after threading Over loading of teeth in the chamfer area use a longer chamfer check if the tap hole is blind hole or through l b use increased number of teeth in the chamfer area by selecting tap with increased number of flutes Tap hole chamfer is missing or wrong countersink tap hole chamfer with correct angle Tap crashed against the bottom of tap hole Use tap holder with length compensation and over load clutch www sutton com au Application Guide Trouble Shooter Endmills Sutton Tools Code Problem Possible reason Poor Workpiece Finish Cutting edge wear cutter radial run out Splintering of workpiece edge Unsuitable cutting con
62. ormation Reamers Sutton Tools Feeds In reaming feeds are usually much higher than those used for drilling The amount per feed may vary with the material but a good starting point would be between 0 038mm and 0 10mm per flute per revolution Too low a feed may result in glazing excessive wear and occasionally chatter Too high a feed tends to reduce the accuracy of the hole and may lower the quality of the finish The basic idea is to use as high a feed as possible and still produce the required accuracy and finish stock to be removed For the same reason insufficient stock for reaming may result in a burnishing rather than a cutting action It is very difficult to generalise on this phase as it is closely tied with the type of material the finish required depth of hole and chip capacity of the reamer For machine reaming 0 20mm for a 6mm hole 0 30mm for 12mm hole and 0 50mm for a 50mm hole would be a typical starting point guide For hand reaming stock allowances are much smaller partly because of the difficulty in hand forcing the reamer through greater stock A common allowance is 0 08mm to 0 13mm Speeds The most efficient speed for machine reaming is closely tied in with the type of material being reamed the rigidity of the set up and the tolerance or finish required Quite often the best speed is found to lie around two thirds the speed used for drilling the same material A lack of rigidity in the set up may
63. ow and rip pieces of material out of the finished thread Consequently the tap is overloaded and often breaks because of the high torque Another problem which occurs in certain materials due to thread root diameter cutting is when a chip bulge has been formed around the root radius The minor diameter of the tap is clogged with small chips which leads to a clamping of the tool teeth are ripped out which leads to tool breakage It is therefore necessary that the material which is to be tapped be taken into account when determining the tap hole diameter Typical materials which do not squeeze or clamp are iron brass and bronze and materials which squeeze are steels steel castings and malleable steels The tap cuts more economically when the tap drill hole diameter is within the upper range of the permissible tolerance Warning When drilling holes in materials which tend to work harden care is needed to ensure the drills are sharp otherwise tap life is decreased Tapping drill formula The correct size of drill to give the desired percentage of thread can be calculated by using the following formula Thread Type Formula Example Metric ISO Drill Size Nom Tap Dia in mm Pitch M6 x 1 5 00mm drill 1 4 BSW 75 thread required 1 28 5 Whitworth Form Threads 1 28 Drill Size 250 55 400 250 048 Drill Size Nom Tap Dia x of thread depth inch calculation 2 Therefore Drill Size 202 N
64. plication Guide rouble Shooter Carbide Drills Code Problem EL TE Burr formation at the drill hole exit 13 A eae The clearance angle at the drill centre should be greater than the relief Feed rate Enlargement of the clearance angle at the outer cutting edges _ fet 200 Se f emme __ maximum of 0 02 mm lbi QUIE eee ___ Greater tapering and smaller chamfered edge width Smaller edge preperation Lower feed rate Lower cutting speed Greater feed rate www sutton com au 366 Application Guide Trouble Shooter Taps Sutton Tools Problem Thread is oversize Axial miscutting of thread Thread is undersize Thread has bellmouthed entry Thread surface 15 rough and unclean Low tool life 1 2 3 4 5 6 7 2 3 4 5 6 7 Possible reason Wrong tap cutting geometry of the tap is not suitable for this operation Partial or complete tap breakage on FORWARD or BACKWARD movement Solution Use correct tap for the material group see Expert Tool System at www sutton com au Tap hole diameter is undersize Tap hole diameter should be in accordance to DIN336 or respective standard For cold forming taps a special hole diameter is needed Misalignment tap hole position or a
65. pping materials such as Stainless steel it is essential that the chip flows continuously in an axial direction Best suited to rigid tapping applications due to high thread relief TICN amp coating has proven to be best suited for these materials For stainless and tough steels geometry similar to VA range however tap material is powder metal high speed steel PMHSS which due to its finer grain structure than that of conventional HSS higher hardness can be achieved with excellent toughness allowing for better tool life than VA taps For hard materials forming short chips the low rakes amp relief s combined with a hard surface coating allow excellent tool life For soft materials due to the very high rake angle with a low thread relief allows for excellent chip flow amp gauging in soft materials For malleable aluminium with long chips to avoid clogging when threading in aluminium which forms long chips it is essential that the chip flows continuously in an axial direction Generally these taps have 1 less flute than normal taps amp therefore have larger flute space which more adequate for large volumes of chips to help avoid clogging Tap geometry Straight flutes with low rake angle Normal rake angle amp Normal thread relief Normal rake angle amp High thread relief High rake angle amp thread relief High rake angle amp thread relief Low rake angle amp thread relief High ra
66. r 10 0 mm hole depth 110 mm 11 Tool Carbide high performance drill 123100 10 For drilling up to 12 x d in cast iron spheroidal graphite iron malleable cast iron short chipping as well as corrosion and acid resistant steels Cutting data GG 25 CS1045 Cutting speed ve 50 m min vc 40 m min Speed n 1600 rom 1200 rpm Feed rate f 0 2 mm rev f 0 2 mm rev Feed rate speed vf 320 mm min vf 240 mm min Q Shrink fit clamping chuck Hydraulic chuck high precision chuck 200 Collets AR Side clamping chuck Influences on the drilling result 7P The actual quality of the completed bore hole depends on various factors A strong influence on the hole tolerance is exerted by the radial run out of the drill in the spindle Fig 2 shows the relationship between concentricity tolerance of the clamping holder and the life of the drilling tool 5 10um 5 20 25 um A medium influence on the drilling result is exerted by the general machine Radial run out condition as well as drill tip wear On the other hand the feed rate speed and Fig 2 the material only influence the bore hole tolerance very slightly Influence of the radial run out on the life of the drill related to the clamping method Use the deep hole drill correctly Pilot drill must have the same diameter 0 01 0 03 as the deep hole drill a Minimum depth of pilot hole 3xD recommend 5 0
67. r Diameter the Basic Pitch Diameter and the Basic Minor Diameter The Basic Profile is the profile to which the deviations which define the limits of the external and internal threads are applied While it is impossible in practice to form screw threads to their precise theoretical or BASIC sizes it is possible and practical to establish limits to which the deviation must not exceed These are called the Maximum and Minimum Limits If the product is no smaller than the Minimum Limit and no larger than the Maximum Limit then it is within the size limits required This difference between the Maximum and Minimum Limits is the TOLERANCE In actual practice the Basic size is not necessarily between Maximum and Minimum Limits In most cases the Basic Size is one of the Limits In general tolerances for internal threads will be above Basic and for external threads below Basic Basic Profile for ISO Inch Unified and ISO Metric The basic form is derived from an equilateral triangle which is truncated 1 8 of the height at the major diameter and 1 4 of the height at the minor diameter The corresponding flats have a width of P 8 and P 4 respectively Fig 1 In practice major diameter clearance is provided by the tap beyond the P 8 flat on internal threads and beyond the P 4 flat on external threads These clearances are usually rounded ISO Metric Tolerance Positions Three tolerance positions are standardised for bolts and tw
68. rNiS189 900 N mm SUS430F X12CrMoS17 Austenitic SUS304 SUS316 X10CrNiMoTi1810 5 189 Stainless Steel 2900 N mm d SUS321 X210CrNiTi189 Martensitic Ferritic 4108 430 436 420 Stavax 5529 SUS33 SUS43 gt 900 N mm i XBCITi12 1 gt 850 N mm 4901 4902 4921 4941 NENNEN Ti 99 5 Ti 99 771 99 8 3 7024 3 7034 3 7065 Grade 150 Grade 400 FC10 FC25 FC40 GG10 GG25 GG40 0 6025 0 6040 S G iron Mehanite 22040 FCD70 0 0740 0 7070 2 lt 850 N mm Black amp White Heart 66640 66670 9949506 BIWAS UT 0 08145 0 8045 350 N mm 101 C1020 C1011 E Cu57 SE Cu 2 0060 2 0070 gt 850 N mm C24000 C26800 634800 Long Chipping CuZn37 CuZn33 2 0321 2 0260 700 N mm Short Chipping 40A B124 C28000 CuZn39Pb2 CuZn40 2 0360 1500 N mm WE LMO 1B 1050A Magnesium Long Chipping ida IN90 IN99 A199 5 3 0255 7075 6061 AlCuMg2 1 92 0 8 3 1355 3 3525 Low silicon wrought amp cast aluminium 3 2162 05 4043 380 355 1 A356 2 ADC10 AC2B AC4A AC4D GD A1Ci8Cu G A1Si5Mg 3 2341 01 Polyurethane ABS Polycarbonate PUR elastomer Short Chipping Cast gt 10 Si 352 www sutton com au Ho iuit Hi lli Hull Hi iirmr se eel Application Guide Colour Band Selection Sutton Tools 353 5 O 2 5 o 354 Application Guide Speeds amp Feeds Drills Pe A Sutton Tools
69. tages for soft and long chipping materials especially over 1 5 x d in depth Due to the slow helix angle not transporting the chips well clogging is possible 40 to 50 Spiral Flutes RH Spiral Suitable for blind holes best suited to long chipping materials the high helix angle amp the direction of the flutes curls amp transports the chips back out of the hole This particular tap style is required to cut on reversal therefore flute rake is required on the both front amp back flute faces Thredflo Roll taps fluteless Suitable for blind amp through holes This type of tap internally rolls a thread therefore displacing the metal rather than cutting like the above mentioned styles Due to torque generated when producing roll threads much higher machine power is required Roll threads also produce much stronger threads than cut threads as the grain structure of the thread remains uniform through the thread form profile Note Tapping drill size is not the same as a cut thread tap The above basic tool types are available in different variations which have been designed amp developed in respect to the specific materials and working conditions Tap Hole Type The two basic types of tapping holes are blind holes and through holes Through Holes D D Upto 1xD lt 1 5xD eg nut thread exits one sided Blind Holes For blind holes there are generally two thread ru
70. tive cooling Speeds The speed of a drill is the rate at which the periphery of the drill moves in relation to the work being drilled As a rule with a drill working within its speed range for a specific material more holes between sharpenings will be achieved if the speed is reduced and less holes if the speed is increased Thus for each production run a speed must be established which will result in the highest rate of production without excessive breakdown time or drill usage The factors governing speed are Component material hardness of material depth of hole quality required condition of drilling machine efficiency of cutting fluid Feeds The feed of the drill is governed by the drill size and the component material As with speeds an increase in feed will lessen the number of holes produced sharpening but it is essential that a constant feed be maintained If a drill is allowed to dwell breakdown of the cutting edges will result small Drill Feeds and Speeds Breakdown of small drills can most often be attributed to two faults speed too high and feed too low A feed which will produce CHIPS not POWDER coupled with a speed compatible with the strength of the drill is essential for small hole drilling Feeds must be based on thickness of chip not mm min and speeds adjusted accordingly EXAMPLE A 1mm drill is to operate at a feed of 0 013mm rev drilling steel While the material may permit a speed of 30m min or 9 500 RPM
71. ue Low alloy steels and high tensile steels Alcrona AICrN 4 um 3200 HV 0 35 E 5 Hardened steels up to 54 HRC Layer 1 100 C Grey e Ideal for carbide endmills High performance applications Gradient up to Blue o Difficult to machine materials TICN TE Coating LE 2000 Ry on 400 C Grey e Abrasive materials cast iron and aluminium alloys Adhesive materials copper and copper based alloys General purpose use up to Gold e Wide range of materials TIN Layer 600 C Yellow 3 to 8 times longer tool life than uncoated tools e Higher tool speeds and feeds than uncoated tools Cutting and forming of copper nickel amp metal _ Enhanced thermal stability and oxidation resistance CrN CrN aradeni 3 5um 1750 HV 0 5 up gt Excellent corrosion resistance Coating 700 C Grey Low internal stress of coating results in excellent adhesion under high loads Latest advances in thin film Coatings to optimise your machining application www sutton com au Technical Information Materials Sutton Tools Abbreviations HSSE Co8 HSSE V3 Type Conventional high speed steel Application Standard tool material for most common applications Description Used for the manufacturing of cutting tools such as twist drills end mills and taps Yields consistent hardness levels following heat treatment providing for a reputable tool life
72. utting edges 0 3 0 to 6 0 Q 55 Shank Design Choice DIN 6535 C HB Peripheral Geometry 0 3 0 20 0mm 1 LI Chip Breaker 06 0 20 0mm C Coarse Fine N w chip breaker Coarse Fine Face Geometry Point angle w 180 5 Cutting to Choice Corner Prep 00 03 1 5mm x 45 0 0 3mm 2 3 x d hoice Sharp edge Corner protection Corner radius Ball nosed Pluse Internal Cooling 4 0 20 0mm C Yes C No 4 0 20 0mm C TiN C TiCN L Uncoated TeClube Tool Material Carbide specify grade if known PM HSSE specify grade if known Detail Regarding Application Material description Material hardness N mm or HR O Slotting C Finishingop Slotting Roughing 1 Copy Roughing op Finishing op milling Drawing Notes Please copy and fax to our Special Sales Dept on 1800 804 084 Item No 499980185 d
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