ENGINEERING RESEARCH INSTITUTE UNIVERSITY OF MICHIGAN ANN ARBOR REPORT NO. 3 EFFECT OF SIDE RAKE ANGLE ON TOOL LIFE IN TURNING TITANIUM (HIGH-SPEED-STEEL TOOLS) By L. V. COLWELL Project M993 U. S, ARMY, ORDNANCE CORPS CONTRACT NO. DAr20-18-ORD-11918 January, 1953

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SUNMARY SHEET I. Engineering Research Institute, University of Michigan, Ann Arbor, Michigan. II. U. S. Army, Ordnance Corps. III. Project No. TB4-15 Contract DA-20-018 ORD-11918, RAD No. ORDTB-1-12045. IV. Report No. WAL 401/109-3 V, Priority No. - None VI. Investigation of machinability of titanium-base alloys. VII. Object: The object is to investigate the machinability of commercially pure titanium and-three alloys of titanium. VIII. Summary: Turning tests were made with 18-4-1 high-speed steel tools ground to the shape O,Var,6,6,6,15,0.10. The rake angles studied varied between -8 degree and 40 degrees. Cutting speed tool life curves were determined for each of several rake angles in the above range. All cuts were made dry with a feed of 0.006 ipr. and a depth of 0.050 inch. Similar tests were carried out on SAE 1045 hot-rolled steel, type 304 stainless steel, grade Ti 150A titanium and grade RC 130B titanium, XI. Conclusions: The preliminary nature of these tests and the dependence of interpretation of the results upon the outcome of other tests yet to be conducted makes it inadvisable to speculate on- general application of the results reported herein. ii

TECHNICAL REPORT DISTRIBUTION LIST Copy No. 1 2-3 4 5 6 7 8 9-10 11-12 Contractor Department of the Army Office, Chief of Ordnance The Pentagon Washington 25, D. C. Attn: ORDTB - Res. and Matls. Same. Attn: ORDTA - Ammunition Div. Same. Attn: ORDTR - Artillery Div. Same. Attn: ORDTS - SmAll Arms Div. Same. Attn: ORDTT - Tank Automotive Same. Attn: ORDTU - Rocket Div. Same. Attn: ORDTX-AR - Executive Library Same. Attn: ORDIX Commanding General Aberdeen Proving Ground Aberdeen, Maryland Attn: ORDTE R. D. and E. Library Commanding General Detroit Arsenal Center Line, Michigan Commanding Officer Frankford Arsenal Bridesburg Station Philadelphia 37, Pa. Commanding Officer Picatinny Arsenal Dover, New Jersey Commanding Officer Redstone Arsenal Huntsville, Alabama Commanding Officer Rock Island Arsenal Rock Island, Illinois 13 16 17-18 19 iii

Copy No. Contractor 20 Commanding Officer Springfield Armory Springfield, Mass. 21 Commanding Officer Watervliet Arsenal Watervliet, New York 22-23 Central Air Documents Office U. B. Building Dayton 2, Ohio Attn: CADO-D 24-25 Commanding Officer Box CM, Duke Station Durham, North Carolina 26 Chief Bureau of Aeronautics Navy Department Washington 25, D. C. 27 Chief Bureau of Ordnance Navy Department Washington 25, D. C. 28 Chief Bureau of Ships Navy Department Washington 25, D. C. 29 Chief Naval Experimental Station Navy Department Annapolis, Maryland 30 Commanding Officer Naval Proving Ground Dahlgren, Virginia Attn: A. and P. Lab. 31 Director Naval Research Laboratory Anacostia Station Washington, D. C. iv

Copy No. Contractor 32 Chief Office of Naval Research Navy Department Washington, D. C. 33 Commanding General Air Materiel Command Wright-Patterson Air Force Base Dayton 2, Ohio Attn: Prbduction Resources MCPB and Flight Research Lab. 34 Commanding General Air Materiel Command Wright-Patterson Air Force Base Dayton 2, Ohio Attn: Materials Lab., MCREXM 35 Director U. S. Department of Interior Bureau of Mines Washington, D. C. 36 Chief Bureau of Mines Eastern Research Station College Park, Maryland.37 National Advisory Committee for Aeronautics 1500 New Hampshire Avenue Washington, D. C. 38 Office of the Chief of Engineers Department of the Army Washington 25, D. C. Attn: Eng. Res. and Dev. Div. Military Oper. 39 U. S. Atomic Energy Commission Technical Information Service P. 0. Box 62 Oak Ridge, Tennessee Attn: Chief, Library Branch v

Copy No. Contractor 40 District Chief Detroit Ordnance District 574 E. Woodbridge Detroit 31, Michigan 41 Masaachusetts Institute of Technology Cambridge, Massachusetts Via: Boston Ordnance District 42 Commanding Officer Watertown Arsenal Watertown 72, Massachusetts Attn: Technical Representative 43-44-45- Commanding Officer 46-47-48- Watertown Arsenal 49-50 Watertown 72, Massachusetts Attn: Laboratory 51 Dr. James E. Bryson Office of Naval Research 844 N. Rush Street Chicago 11, Illinois 52 Ford Motor Company 3000 Schaefer Road Dearborn, Michigan Attn: Mr. R. Lesman Supervisor, Development Section Manufacturing Engineering Department Engine and Foundry Division 53-54 Engineering Research Institute Project File University of Michigan Ann Arbor, Michigan Initial distribution has been made of this report in accordance with the distribution list. Additional distribution without recourse to the Ordnance Office may be made to United States military organizations, and to such of their contractors as they certify to be cleared to receive this report and to need it in the furtherance of a military contract. I vi

L ENGINEERING RESEARCH INSTITUTE * UNIVERSITY OF MICHIGAN EFFECT OF SIDE RAKE ANGLE ON TOOL LIFE IN TURNING TITANIUM (HIGH-SPEED-STEEL TOOLS) One of the more important factors of any metal cutting setup is the life of the cutting tools as influenced by variations in cutting speed, tool shape, size of cut, tool material, and cutting fluids. These variables are being studied separately in the titanium machining program. This report presents the results of a study of the influence of both cutting speed and tool side rake angle when cutting with 18-4-1 high-speed-steel tools. Reports on the effect of other variables follow later. WORK MATERIALS The overall program was set up to include machining studies of four grades of titanium: Ti 75A, Ti 150A, Ti 150B, and RC 130B. Hot-rolled SAE 1045 steel and type 304 stainless steel were added to the test group to be carried through the same testing program. This provides a basis for comparing the performance of titanium with metals for which machining practice has become fairly well established. Only the Ti 150A and the RC 130B titanium were available for the early part of the program. Results for the Ti 75A and Ti 150B will be given in supplementary reports. PROCEDURE The general procedure involved determining the tool life curve in turning for each material for each of several tool side rake angles. A tool life curve is determined by plotting the results of several tool life tests conducted at different cutting speeds. A tool life test consists of operating a tool at constant speed and size of cut until ultimate breakdown failure occurs and observing the elapsed cutting time. The elapsed time to total failure is known as the tool life. The tool life in minutes and the corresponding cutting speed in fpm are plotted on logarithmic coordinates. 1

ENGINEERING RESEARCH INSTITUTE * UNIVERSITY OF MICHIGAN - The resulting points can be represented by a straight line which in turn can be represented by an equation of the form VTn = C, where n is the slope of the line and C is a proportionality constant. When summarized in this manner the original data are readily analyzed to evaluate the effects of pertinent variables. TEST CONDITIONS For this phase of the program, the size of cut was fixed at 0.050 inch depth of cut and the feed at 0.006 ipr. The tool material selected for the tests was 18-4-1 high speed steel marketed as "Blue ChipV' by the FirthSterling Steel Company. The tools were in the form of 1/2-inch square by 4-inch long tool bits. Only those tools with hardness readings between 63.0 and 64.5 Rc were accepted for testing. The tool shape conformed with the ASA signature OVar.,6,66,6,15 0.010, wherein the side rake angle was varied in increments of 4 to 8~ from -8~ up to and including 40~. The work materials were in the form of 3-inch diameter bars except for the SAE 1045 steel, which was in 4-inch diameter bars. These bars were mounted in a 14-inch swing American "Pacemaker" lathe with one end held in a four-jaw chuck and the other end against a live center. The lathe was equipped with a Reliance Electric Company "V-S" Drive, making it possible to maintain constant cutting speed at any work diameter. All tests were run without a cutting fluid. TEST RESULTS Tool Life versus Rake Angle The test results are summarized in Figs. 1-12 inclusive. Figures 1-4 show the effect of side rake angle on tool life at constant cutting speed. Figure 1 is a curve for RC 150B titanium. It shows the tool life in minutes for a cutting speed of 48 fpm as affected by tool side rake angle. It will be noted that tool life increases as the rake angle is increased from -8~ up to an optimum in the vicinity of 30~. It then drops off very rapidly as the rake angle is further increased to 40~. The data points in Fig. 1 were obtained from the tool-life curves in Figs. 13-20 inclusive. The cutting speed of 48 fpm gives a 60-minute or 2

L ENGINEERING RESEARCH INSTITUTE - UNIVERSITY OF 'MCHI4IGA'N. --- 1-hour tool life with the optimum rake angle of 32~ as shown in Fig. 19. The other data points in Fig. 1 are the tool lives at the same speed as obtained from the other tool-life curves in Figs. 13-20. Similar curves showing the effect of rake angle on tool life are shown for Ti 150A, SAE 1045 steel and 304 stainless steel in Figs. 2, 3, and 4 respectively. In every case, the optimum is in the vicinity of 30~. It was concluded that the optimum is 28~ for the type 304 stainless steel and 32~ for the three other materials. The tool life drops off precipitously as the rake angle is increased beyond the optimum, so it is somewhat hazardous to attempt to operate in this range, particularly since slight reduction in rigidity of the setup can cause crumbling of the cutting edge, thus making it impossible to realize full advantage of the optimum rake angle. Since it may be desirable to operate somewhat below the optimum rake angle, the slope of the curves in the approach to the optimum takes on particular significance. It will be notdd that the tool life for the Ti 150A and the stainless steel drops off very rapidly as the rake angle is decreased from the optimum, while it decreases more slowly with the other two materials. Thus rigid specification of the rake angle is less important in the case of the 1045 steel and the RC 130B titanium. The cutting speeds shown in Figs. 1-4 are particularly significant, since they give similar performance in cutting each of the four work materials. These speeds are summarized in Table I. TABLE I CUTTING SPEED FOR ONE-HOUR TOOL LIFE AT OPTIMUM RAKE ANGLE.Cutting Speed Work Material Cting Speed RC 130B 48 25 Ti 150A 74 39 304 Stainless 99 53 SAE 1045 187 100 I

- ENGINEERING RESEARCH INSTITUTE * UNIVERSITY OF MICHIGAN Cutting Speed versus Rake Angle The cutting speed, tool life curves, Figs. 13-47 inclusive, are relatively flat (i.e., n is small), so it is possible to get an exaggerated impression of the importance of rake angle by considering only the tool life at constant speed. Therefore the cutting speed for a 1-hour tool life (V60) at each rake angle is plotted for each material in Figs. 5-8 inclusiveo It will be noted that the resulting curves show relatively broad optimums for all four materials and that the percentage change in cutting speed over the entire range of rake angles is relatively small except in the case of the SAE 1045 steel. Thus it may be concluded that standard tool shapes may be used satisfactorily on titanium with only a relatively small sacrifice in production rate over what could be obtained at optimum conditions. It should be emphasized that the rake angle referred to as the side rake angle in these tests is substantially the effective slope of the top of the tool in the direction of chip flow. Thus if it were decided to use a 300 effective rake angle on the teeth of a face mill cutting entirely on a 450 chamfer, then the radial and axial rake angles must'be such as to produce a slope of 30~ away from the chamfer, since the chip will flow in this direction. Slope of Tool Life Curve versus Rake Angle The slope of the tool life curve is an empirical indication of the relative effectiveness of temperature and abrasiveness in a metal cutting combination. The flatter the curve (i.e., the smaller the value of the slope n), the greater the influence of temperature. Similarly, temperature decreases in importance and abrasiveness increases in dominance as the slope approaches 450 or n approaches a value of 1.0. Figures 9-12 inclusive show corresponding values of the slope n for each material at the several rake angles The slope decreases for rake angles in the region of the optimum. This should be interpreted as the result of decreased abrasiveness accompanying the decrease in strain hardening which results from larger rake angles. The increased slope at rake angles beyond the optimum represents a virtual increase in abrasiveness brought about by superficial crumbling or fracture of the cutting edge. Original Data and Observations All original test data are plotted in Figs. 13-47. The following is a description of the sequence of events leading up to tool failure: I. SAE 10 Steel (Hot Rolled). At the start of cut, a long, straight, silver colored chip forms. The chip then begins curling slightly and although the degree of spiraling varies, it is obvious that the chip is 4

ENGINEERING RESEARCH INSTITUTE * UNIVERSITY OF MICHIGAN no longer straight. In due time, the curl gets much smaller and the chip forms in tight little spirals which consistently break off and then reform. Up to this point, the surface finish is quite consistent, the chip does not discolor, the shoulder of the work at the tool point has not changed, and the nose of the cutting tool does not show a red glow. A point is reached where the surface finish begins to change, the chip has a yellowish tinge, and it appears to be straightening (i.e., the small spiral disappears). Suddenly the nose of the tool becomes very red, a noise probably caused by rubbing can be heard, the chip turns blue, and the shoulder of the work at the tool point undergoes a definite change in shape in addition to being burnished. Failure occurs almost instantly at this point. II. Type 304 Stainless Steel. During the initial cutting stage, a long, straight silver colored chip forms. The cut itself presents a much noisier condition than was encountered with the SAE 1045 steel. The chip begins losing its straight formation and starts to form a slight spiral. In time the spiral decreases, but it does not get nearly as small as that which occurred on SAE 1045 steel. A slight change in surface finish can then be noticed and the chip formation that follows this event becomes quite inconsistant (that is, it curls, then becomes straight, then curls, etc.). This is followed by a very noticeable change in surface finish, at which time the nose of the tool turns red. As the chip is removed it has a definite pattern of discoloration; the portion nearest the work is much darker than the remainder. The shoulder of the work changes rapidly (becomes broad and burnished). Failure occurs immediately at this point. III. Ti 150A. From the instant the cut starts, the chip is silver colored and curled in a very irregular ribbon-like formation. It does not form the long, straight chip so noticeable in the turning of the steels. Surface finish is very consistent. These conditions prevail up to a point just before tool failure. At this point, the finish begins changing and the chip color changes from silver to yellow. Since the chip curls back towards the work, the area between chip and tool face is exposed and it is very easy to see a red glow at the nose of the tool. At this stage, the contact area between chip and tool is very small. The red glow at the nose of the tool increases in intensity and the chip becomes a dark yellow in color for a very short time: then the material being removed appears to be in a molten state. As it cools it forms a chip which becomes blue and then purple in color and very tight and irregular in shape. At the same time this event is taking place, the shoulder changes shape and tool failure occurs. The blue color is a reliable criterion to use as the point of tool failureo IV. RC 130B. During the initial cutting stage, the chip is silvercolored and has a slight spiral shape. It is not as long and straight as the chip formed in turning the steels, but it is not at all like the tight ly curled ribbon-like chip formed by Ti 150A. There ia a noticeable noise present from the beginning of the cut. The chip formation then becomes 5

- ENGINEERING RESEARCH INSTITUTE * UNIVERSITY OF MICHIGAN - similar to that encountered with Ti 150A, that is, irregular and ribbon-likeo Following this period, the chip breaks up into small, irregular pieces. A red glow can be observed between the chip and tool face at the nose of the toolo Suddenly, the tip of the tool becomes very red, a whining noise occurs, the surface finish changes, the shoulder changes shape, and there is a slight discoloration of the chip (silver to yellow). At this point the tool fails almost instantly. Tool Wear versus Time Figures 48 and 49 show the progress of tool wear as a function of elapsed time during typical tool life tests. Figure 48 gives the results obtained whlen cutting Ti 150A at a constant speed of 75 fpm with a feed of 0.006 ipr and a depth of cut of 0.050 inch. The speed was selected to give a life of 12 minutes and the tool failed at 11,9 minutes. The cut was stopped at intervals no greater than 1 minute and the width of the worn area beneath the cutting edge was measured with a toolmaker's microscope. The results show that the wear increased rapidly to about 0.007 inch during the first minute of cutting and progressed at a much slower rate up to about 0.015 inch, after which the tool became unstable and wear progressed rapidly up to a maximum of 0.052inch. This is typical of the performance of high-speedsteel tools when cutting ductile metals. The similarity to performance when cutting materials other than titanium is supported by the tool wear curve for SAE 1045 steel shown in Fig 49. Figure 50 shows pictures made of the cutting tools as they appeared halfway through the wear tests and again at failure. CONCLUSIONS Interpretation of the results of these tests and their application to commercial practice will be undertaken at the completion of the entire program. A final summary report will be devoted to this purpose. Such conclusions as have been made in the manuscript of this report are not likely to be modified by results from the later phases of the program, 1 - 6

TOOL LIFE vs. SIDE RAKE ANGLE cm ----- 0) 0 -x _ o I I) 0) 1 - ) Ch I-J -J 0 0 I-IIJ SIDE RAKE ANGLE - DEREES FIs. I

TOOL LIFE vs. SIDE RAKE ANGLE I - I I I - I - I a _ I - I - A a 3 2 I I IL 0 0 IC) 60 - _. _ S ' TI. - 150 A CUTTING SPEED: 74 FPM 50 s0 -I.....,,,, -, _ _ - - 40 30 20 I0 -8 0 +8 +16 +24 +32 +40 SIDE RAKE ANGLE - DEGREES FIG. 2

TOOL LIFE vs. SIDE RAKE ANGLE IIII _IIIIII I I 60. ---- SAE - 1045 CUTTING SPEED:187 FPM 50. w 2 I.-::i 40......... 20 o 20......... _" SIDE RAKE ANGLE - DEGREES FIG. 3

TOOL LIFE vs. SIDE RAKE ANGLE 60 _ ' _ - 304 STAINLESS STEEL CUTTING SPEED: 99 FPM 40 ". Z W 30..... ---- I0.J 0 o 20 go - 0 +16 +24 +32 SIDE RAKE ANGLE - DEGREES FIG. 4

CUTTING SPEED vs. SIDE RAKE ANGLE 100 f RC- 130 B w 0 z!fJ 1 1i 1 ' I, r1 r - ' 1 I I, I Il I l I I I!,il.....!.m,.... - '.....'... IIII l L i1 l i I I I.. A..~~ll —,.. _ _ A_____ _ _ _~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 50 0 - 0 +8 +16 +24 +32 +40 SIDE RAKE ANGLE-DEGREES FIG. 5

CD 0 -J < - --- I X1 I. l at II I lI I 1. UJ 1 C~i z + 4 Q 1 < I i I I w + a o 1 2 a. - - - -- — S 0')~U) o e. i -d- -- 033d- ~Nl —n - 09A

CUTTING SPEED vs. SIDE RAKE ANGLE 0: Iu' I 0 hJ UJ 0) 15' 10( 0 Ds SAE 1045 STEEL 3,.... I-I.......... —I --- —) I I.,.!, ' _ 1 I 0 z IF-: 0 '5( ( u +~ ~+1t +~. +5o 4 v SIDE RAKE ANGLE-DEGREES FIG. 7

CUTTING SPEED vs. SIDE RAKE ANGLE o10 304 STAINLESS STEEL ~~~~~)~~~~~~~~~~~~~~~~ I 8 - - 8 m 6 -2 - -I4 -I - -8 0 +8 +16 +2 4 +32 + z I0 5( ( SIDE RAKE ANGLE-DEGREES FIG. 8

SLOPE OF TOOL- LIFE LINE vs. SIDE RAKE ANGLE.15 0. -J V).104.05e RC -130 B 0 O) ) - - --- - D~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~.. ( -0 u -+-o +Ib3 +Z * +53 4t U SIDE RAKE ANGLE-DEGREES FIG@ 9

SLOPE OF TOOL-LIFE LINE vs. SIDE RAKE ANGLE.150 Um 0 J U).100.050 0 SIDE RAKE ANGLE-DEGREES FIG. 10

SLOPE OF TOOL- LIFE LINE vs. SIDE RAKE ANGLE SAE 1045 STEEL.150 '-. — 'r') a.oo.05.050 -I ----- -- SIDE RAKE ANGLE-DEGREES FIG. II

SLOPE OF TOOL- LIFE LINE vs. SIDE RAKE ANGLE *1;U,I.100 Q. 0.J 0 0 304 STAINLESS STEEL 7I I I i i I 2 771 7.~~~~~~~~~~ -i i i iii ii i ii iii~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ i I I I I ' ' ' ' J,,,,.., _ l,..,..,..IIII I...., i..... -8 0 +8 +16 +24 +32 +40 SIDE RAKE ANGLE-DEGREES FI G. 12

CUTTING SPEED-TOOL LIFE At% I " V ' m-1 I I- u i i i I * - I I II - n urm i* II i 300 - I ii 1: U: I a la 0. IU 20 e V. - I I. - I, — I XI I 4 150. 100. I i RC. 130 B SIDE RAKE ANGLE - 8 70. 50. I I I I I I MWQM I I I I - van NUNN I no i i a I --- - - i i I I an I %Flq. I I I I- I I, I - i i. t 1 -—. 1 I I |i., d I _ L 1 I L — ~_I I I n - ' r.6 1.0 2'0 3.0 5.0 10.0 20.0 TOOL LIFE-MINUTES FIG. 13

CUTTING SPEED -TOOL LIFE 40 n - I I II I- I r I IIII I -I1 1 I n _ - - nft IA I I I a VI _ I -II 1- I.. —I —I,,- - -II — - I I =i 0 a: I II al CO am 0 0 20 l _.I I I -— I --- —-— I I ------- 150. 100.: r: 1 RC. 130 B SIDE RAKE ANGLE: 0~ r 70. 50 s~~~~~~~~~~~~~~~~~~~~~~~~.. --. ~-,,__o ---v a —| I OR I I I I inIa &In m i iin4.6.6 1.0 2:0 3.0 5.0 10.0 20.0 40.0 O 0.O TOOL LIFE- MINUTES FIG. 14

CUTTING SPEED -TOOL LIFE 4 nl V - I I I a I - I I - P - - I - - 300. ai 0: Ils I a Ia 0 0 I0 200. 150. 100. RC. 130 B SIDE RAKE ANGLE + I I - 71 I I I I I I tT*t - I I -. I.N.. Pw-. I I -'% I I I - m -a MMM a i i i i i i. i i i i i i i i i 54 30 I a I I IIIIaI I II I I.. A Iiaaql - *~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ I A I I *; __.6 1.0 2O0 3.0 5.0 10O. 20.0 60.0 TOOL LIFE-MINUTES FIG. 15

CUTTING SPEED —TOOL LIFE,ANti _W - I -- I II I0l ' 11 II-V a A I I 'n3 - I _W F I I I i i i i i i I_ I I i i i-4.-4-I-4- 4 4 i I Q CW 0 z 1 - 200. 150. 100. 70. so5 14 -1 RC. I30 B SIDE RAKE ANGLE + 16~ t-I 1 t 1 i + -4-i- +i- + -i -i..- i i. I I I I I I I I pm- - ez I I I I.L I 6 mmm I m MENNEN- i i I I I I I I I I. i i - - - 'U I 30 1 ~ ~ ~ ~ ~ ~ ~ ~ ~ — I m — ~ L _I ~II I I I. I 1 a~1I1~s B -qb BIIr Ib- L - a 3 Is~~- 1.O 2:0 3.0 5.0 10.0 20.0 TOOL LIFE -MINUTES FIG. I 6

CUTTING SPEED -TOOL LIFE Ann -11'V m I 0 1 9 I - ~ ~,.,, I, - 'I I 300 vR lw 0: U: I a z 0. 0 I0.. 20 154 RC.130 B 0, SIDE RAKE ANGLE + 24 0- -__|__ _ _____ ___- ti '0f$ Wit; <Xt~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~. 101 71 50 I -ff I. momahre')ww - lw l I I I I I I I I I I I I1 I I ~1S-. m- C ll h _ I I a I i I ~ B 30 iHHC______ Wi ELJ IDI1_.6 1.0 2:0 3.0 5.0 10.0 20.0 40.0 60.0 TOOL LIFE —MINUTES FIG. 17

CUTTING SPEED-TOOL LIFE 40 A -II- - I -. I - - U - - I I - - P. - - IIa - - 300. f II 0 a 0 0 z 20 ft V_ t I i IIL I I I, i _ 4 1 - I I 150. I A L i 1.L RC. 130 B SIDE RAKE ANGLE + o 28 7 8 11 o.____ ___ _ I__ _______ ____ I_ 3.6 1.0 20 3.0 5.0 10.0 20.0 40.0 60.0 TOOL LIFE-MINUTES FiG. 8

CUTTING SPEED TOOL LIFE 400. 300 - i A: I I la I a.1 U I0 200. IgR 1 RC. 130 B SIDE RAKE ANGLE + 32 Inn 5 0 _ _ _ _ _ _ _ _ _ _ _ - - 3 0I _ _ _n o__ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _... mmr 1.... I.6 1.0 2.0 3.0 5.0 10.0 TOOL LIFE-MINUTES 20.0 40.0 60.0 FIG. 19

CUTTING SPEED-TOOL LIFE A ^S V.pwam - ml -. - Ii - m U br m! m 300. Ial z 0: I Q 0 200. 150. 100. RC- 130 B SIDE RAKE ANGLE:+40~ 7 5 0 — XI I Im iI ii I I I I I — ~ — - - 3.6 1.0 20o 3.0 5.0 10.0 20.0 40.0 60.0 TOOL LIFE-MINUTES FIG. 20

CUTTING SPEED -TOOL LIFE 400 -300. I a: I1: I l 0 CZ 0 0 1 -U 200 wv, 15 o,_l___ TI- 150 A SIDE RAKE ANGLE: - 8~ 0I- II I III_ I I I - 101 5 IaS __ I I I 0_ _ _____ _ _I _. ___ __- _ _ __ ___ ___I __ m m — 3.6 1.0 20 3.0 5.0 10.0 20.0 40.0 60.0 TOOL LIFE-MINUTES FIG. 21

CUTTING SPEED-TOOL LIFE 40 n a. 4a. I P P.... I 300. z Iw la I 0 200. 150. TI -150 A SIDE RAKE ANGLE ' - 4~ inn 0 ______I I I __ I ____1__ ___ w~~~~~~~~~~~~~~~~~OMNeI- o 5 o l< I I Ir|Em 30 i I I - I I I 1 11._ _I I I I I 1 11 1 1 1 1-..6 1.i 2:0 3.0 5.0 10.0 20.0 40.0 60.0 TOOL LIFE-MINUTES FIG. 22

CUTTING SPEED-TOOL LIFE 40 30 lo.u _,. -I* - a-.. 0. I I i a= 0: 1: I Q ht la IL 0 F0 U 9nfl ___-1~~~ _I ~ 1 -r 1 ~I, I 1 1 1 1 1 1 J ~.I I I,I 150I 100 - i TI - t50 A SIDE RAKE ANGLE t 0o i 5 0 ________ ____ _____ wmg -- -- --- 3.6 1.0 2CO 3.0 5.0 10.0 20.0 40.0 60.0 TOOL LIFE-MINUTES FIG. 23

CUTTING SPEED-TOOL LIFE AL#^A awl V ~ff'-^ B i i M ~ I i I * W ^ i i W W i i a I a I.ann 0 a U: I a a. I.. 0 z 3 -U TI. 150 A SIDE RAKE ANGLE:+ 4~ 10 50 ____ ______ _ I A I I l I A I II I I I I I A a I a.6 1.0 2.0 3.0 5.0 10.0 20.0 40.0 60.o TOOL LIFE-MINUTES Fie. 24

CUTTING SPEED-TOOL LIFE A LM M: k: i a a. I0 300 TI. 150 A SIDE RAKE ANGLE:+ 8 100- -- -- - I I I I I -1 r 0 W ____ 1__ _ _____ 0. _ _ _ __ ___ _ ___I _t* s I 1 1 7 nA 4 aV I ii 1 1i i 1 I I I I I I I UI I___ I, i. I I _I.6 1.0 2:0 3.0 5.0 10.0 20.0 40.0 60.0 TOOL LIFE-MINUTES FIG. 25

CUTTING SPEED -TOOL LIFE 400 - I i: la I a 0. 0 0 z I0. 20 I I...... Tl. 150 A 150 __..._ _ _.. _ SIDE RAKE ANGLE,+ 12 100 I..I. I I. __ I 74 ~~ E~,..-._,_-.__,_ —. - - _ _,_... T0 _ _ _ _ _ m UI I I I I I I 0 _ _ _ _ __ I I _ I I I I I IIA — ~~ ~~ ~~ ~~ ~~ ~~ ~~ ~~~~~~~~~.- 1...... - I,.O 51 I 30 I a a a 4I I I III - - I I -I- II.6 1.0 2:0 3.0 5.0 10.0 20.0 40.0 60.0 TOOL LIFE-MINUTES FIB. 26

CUTTING SPEED TOOL LIFE 4 A n - I - I - I -A a - - - a 300. zi a 0: CO I Q. hi I 200o 150. 100 TI. 150 A SIDE RAKE ANGLE + i6 W _ __ I m 1 I III I i + 4 I 5 *- m m. _ __ _ _______________ __ _ _ _ _ ______________ I _II I I I I I I II I I I ~I I -I 3.6 1.0 20 3.0 5.0 10.0 20.0 40.0 60.0 TOOL LIFE —MINUTES FlG. 27

CUTTING SPEED -TOOL LIFE 40 n I I II a I I I 300. I. li a I 0 ki w 0 20 L VI I I I I I I I I I I__ 4 I t I - 150. 100. TI. 150 A SIDE RAKE ANGLE + 20!-TM I s I I I —+ III I I I I 1 I 7 5 0_ ______ I I __ I I II I I I I I - 3.6 1.0 2:0 3.0 5.0 10.0 20.0 40.0 60.0 TOOL LIFE-MINUTES FIG. 28

CUTTING SPEED —TOOL LIFE 44 rn _ _ - X. - - _ I F I- _ ann I( Zffil lwI W WPIi i i i i i.. I I I I I I I I 0: a: i I a o0 0 z I0 200. I 50 TI. I0 A SIDE RAKE ANGLE 0 + 28 10I W _ -,. I I [- I I I I I I I I I I I I I I 0. I I I I I I I I I - - Nombld — -,% 0-4 I AP"'Ath, I I- I I -w I I I I I I i a m 2 2 0 a i i 50. 0o _ I i 4 I I I I _ a a 9 I I 5 - C I - I _.6 1.0 2:0 3.0 5.0 10.0 20.0 40.0 60.0 TOOL LIFE-MINUTES FIG. 29

CUTTING SPEED -TOOL LIFE 40 30 Amik. me *-me I I. I a. I I. I I - -7 U V I O ' - -I - I I I. A: td IU: Id 0 0 ee, ir 200 - I i L 1 I i I~~~~~ I I I I I I I l 150. TI. 150 A SIDE RAKE ANGLE I r r I.I I _ I l i + 32; I I 1 I 1 a Af AL O. _t -________ __ - )8 30_~~~~~~ I I I I I I I I I I I j I I I I I I I I I I - I I I I I 0 5 I I - - I I i i Nk.6 1.0 2:0 t 3.0 5.0 10.0 20.0 40.0 O0.0 TOOL LIFE —MINUTES FIG. 30

CUTTING SPEED —TOOL LIFE A nf i ld ld a. co 0 IU., 300_ 200_.__._ TI. 150 A SIDE RAKE ANGLE + 36 I - U -r —~~~~~~~~-0-11 I A 1 I I ~I~~~~~~~~~~~~~~ 74 o I IlII I I_ I F1 ___ 1 1 _ I — I I I 50. 30 - - - - - - - -- I- - - I- - - _ __ _ _ _ __ _ _ _ __ _~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ I i.6 1.0 2:0 3.0 5.0 10.0 20.0 40.0 60.0 TOOL LIFE-MINUTES FiG.31

CUTTING SPEED-TOOL LIFE 401 30 n M - -I I a I a I~ I I.- I m ~ I a A 5 0.:1 SAE 1045 STEEL SIDE RAKE ANGLE: - 8 0.a a: la 0 z F 0 200 -t1oo v I _ _IIL I - I I I- I I -I I I.I 4I I I - I *^ I wthhV I II It I I I 'I I I1 1 1 1 1_II A 7 -! - -= I - - -I I I I owQ!~~ I 3.6 I.0 3.0 TOOL 5.0 10.0 LIFE -MINUTES 20.0 40.0 -— r 60.0 FIG. 32

CUTTING SPEED -TOOL LIFE 'A Ak f I 9 U r -I. I- - * F - F I s t I I I 1 ^WVq --—. -. l l lll l _w__I I I I I SAE 1045 STEEL SIDE RAKE ANGLE: d a: I 0 0 20 15i k I V- I ~l4Wsv1.L 1 A0I I I 1 I 1 1 I 1J mm I I. k~ I I I I I 101 0% q)i I I I I I I I I I I I I I I _I I- I I I I W. I I I I I I I I I t__ I ii- I I I 11I I 1 i i 1 I I I I I 54 r WL_ I I I I I _____I____ I I-iw ~ ~~~~~ I i,.,, I I 1 I I I 1 I I I I I I I I I I - - I I- t I a, j IKO% JWV I I I4I I I I I I I I I I I I I I I I I I I I I L I I, I I I Il I I ~ I I ~ I I0r a 0.6 I.O 2o0 3.0 TOOL 5.0 10.0 LIFE -MINUTES - 9 - - -. - -. ' 20.0 40.0 60.0 go. FIG. 33

CUTTING SPEED-TOOL LIFE 404 30 n — ~~~~~~~~~~I I. aI.l I A I a, 0O a SAE 1045 STEEL SIDE RAKE ANGLE +I hi I Q C9 0i I0 z 0 IU 20 154 0~~~~~~~~~~~N0m I fm.a SID RAKE I ANL M.1 R W 100. I K I i I i i- -4 -I —4 i I 7 o_ __ — 0o,____I__e___1_____ ___ i - m _ _ _ - - - - -. -.6 1.0. 20 3.0 5.0 10.0 TOOL LIFE -MINUTES 20.0 40.0 60.0 FIG. 34

CUTTING SPEED-TOOL LIFE AnEr 300 L8________ S 1 AE 1045 STEEL 30.. SIDE RAKE ANGLE +16 20- I _ i A: U: I Q la Id a. 0 0 100 70. 50. i I IP - I I I 11 I m rT T T 1II 1 l I I I - l - I *j- - - -I......, I so I a I I I I I II ~ I a I I I I~ I I a I.6 1.0 2 0 3.0 5.0 10.0 TOOL LIFE-MINUTES 20.0 40.0 60.0 FIG. 35

CUTTING SPEED-TOOL LIFE 40 n m w~~~~- r1r1r r 30 C li 0 z 3.I Id 0.0 20 -I& — I I I IS I F I i.1 t SAE 1045 STEEL SIDE RAKE ANGLE I24 424: UffKP~f~.... ~-. kv tfan I I I I I I T I ISt_- I I 11 1I 50. ___ __ IO _____II I I - _ -_ __ I I I I i I I 1 J - i a i I I a I _. Ii I I a a 0 x D.A,.. 0o 3.0 5.0 10.0 TOOL LIFE-MINUTES 9 I. 5 20.0 40.0 60.0 FlI. 36

CUTTING SPEED -TOOL LIFE 404 f% In* -- u L u -I - * U U - -- 'i n I.f I IL SAE 1045 STEEL SIDE RAKE ANGLE 28 +2as. 0 G: aI: I Q li Il. I0 -____-_ -- I00. --- — -______________ --- - ____ — --- I I I I I I 7 5 0. _ ________ - -- -- _______ - — I - - - m - - m - - - - - - - - -~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 3.6 1.0 20 3.0 5.0 10.0 TOOL LIFE-MINUTES 20.0 40.0 60.0 Fie. 37

CUTTING SPEED-TOOL LIFE 'A A dlP ak t V t t 300. I I/ II III dol I: a L - SAE 1045 STEEL SIDE RAKE ANGLE' 4 32 I ___I _ I I I.. mm m N mm - I_ G: Il: I li a. 0 0 z 0.. 20 15 IA i~ I I I fT ~2 1 OL O i I I lk. -If I a k I I i I I i 1,,,,, I _,,I I, I I - I I I I WV_, _ i i i- I -+ i I ---I —I i-i - i-i- - -i I: I I I I I.1 I I I I I I I I I I V^ r0X I..-., I i I I 3 - - - - ---- - - -. - - I I - - -1 -.6 1.0 2:0 3.0 TOOL 5.0 10.0 LIFE -MINUTES 20.0 40.0 60.0 FlG. 38

CUTTING SPEED-TOOL LIFE AAA A: I: la I III OD SAE 1045 STEEL SIDE RAKE ANGLE + 4e0 t- - - —. -1 -*l_- = - - = ===______ - - 0 -L_________ I I _________ -- I I I s- I, I K.4 t.b 2.O 5.0 50 10o0 TOOL LIFE-MINUTES 60.o 40.0 60.0 Pie. 39

CUTTING SPEED-TOOL LIFE 40 30 n _a I I _ 1, I a I a b I l 1111 I I _.... _.__.. I a A: I Q li li Id a. 0 0 IU 200 - i. 304 STAINLESS STEEL I I I I I I I I I I I.I-I. + 4I I-I-f SIDE RAKE ANGLE - 8~ 150. I i Inn. 0 ________ ____ __ ________ __ 30 __,_______ ____ _______- - _-_______ ___ - - - I i I a i I I I IJ, I I I I I I a I -~ ff I1 m I..6 1.0 20 3.0 5.0 10.0 20.0 40.0 60.0 TOOL LIFE — MINUTES FIG. 40.

CUTTING SPEED -TOOL LIFE 404 ft I aI.. I I I I I a.. I 300. I 11 I I I I -' I I I I I - I I I - a: 0 0 200. IRf.. I.l I 304 STAINLESS STEEL SIDE RAKE ANGLE: 0 I I I- I r I I I I _ I i t 1 O ___0so. II____ L III II______ _ I___I_ I I I I I I I a I I I- I II I I I I I a II II - a a r I.6 1.0 20 3.0 TOOL 5.0 10.0 LIFE — MINUTES -, _ _, - 20.0 40.0 e' 60.0 FIe. 41

CUTTING SPEED —TOOL LIFE A 0%0 i a I Id a 0 0 )~~;OO;; i ii ________,iii 304 STAINLESS STEEL o00 ______ ---SIDE RAKE ANGLE + 8~ Ao __________ —., ~so,_ __ ______ _ - -___-. T I T I I I I I I I I~ I Il I Il I I I I I a I I - al - Amb r I_.6 a 1.0 2-0 3.0 TOOL 5.0 to. LIFE -MINUTES.~ ~ ~~~~~~~~~~~~~~~i __ Kl Id 20.0 40.0 0O.O FIl. 42

CUTTING SPEED-TOOL LIFE 404 r Y- a I a I I ~-I I.2 1 1 1 — 1 1 1 5 ar~ ~I -~I I a - r 300. a: 0 0I z Ilo 20 15 10 7 5 0 0 b In I I I I I. 304 STAINLESS STEEL 0 SIDE RAKE ANGLE +16 I I I.I 1111 I I _ __ I I - I - I I I I r p mi m lztz-Iz II I I I I I I I — _ I m ~~I I I t I I I I I I I I I A _- O 0. i I I I I - i I l 4 4 4 i - i - i - i 4 I. - - I, q - - U _-I -I -I*- I I - - 0 I.___ __ 34.6 1.0 2.0 3.0 TOOL 5.0 10.0 LIFE -MINUTES 20.0 40.0 60.0 FI. 43

CUTTING SPEED-TOOL LIFE 40 30 9% I. a I.I I, I I II, L% I 11111 I I I V I_ I I, I I,, I I r A: I Q 0. CO 0 z II 200. 150. I ~ I I I - I I 304 STAINLESS STEEL 0 SIDE RAKE ANGLE + 24, I I 1I I.I I I I I I I I I I I _I I i, _ Ii I I I JL -- I I I a I I... _ —..Ii i i1 1 I. I -. -- rI I * Ir -- I i kvTqw T I I -,. I I IIL L., II mf 00=I.LI I II — ~T B*.L I I I I I 71 61 0I_____ ___1_I__ I_-I-I — - _____- I I II — _ __ - ____ _____ _ _- -- - - Um - - - __ _ _____ _ _ _ _ ____- - - a.6 1.0 20 3.0 5.0 10.0 TOOL LIFE-MINUTES 20.0 40.0 60.0 FIG. 44

CUTTING SPEED-TOOL LIFE 401 a iI I I I F a IY 4II I a I IIY 300 - L 1111 304 SIDE a:: i: I Q 0 0 z I-.0 200. 150. STAINLESS STEEL RAKE ANGLE + 28 I r i - A * L I *^ I — I - I w - I I 10 I I I I I I I I I I~~~~~ I - 71 0ol.I I =I 7 __ __ __ I _ _ 0 _ _ _______ _ __ ___ - m - - U - - - - - m -. - - 3.6 1.0 3.0 5.0 10. TOOL LIFE-MINUTES 20.0 40.0 0O.C FPl. 45

CUTTING SPEED -TOOL LIFE 40 30 n N E. I I - I I I I I I I Ia I I W A: i I a Cl 0 z I 20 o0 ______________ - - - - - ---- -- 304 STAINLESS STEEL SIDE RAKE ANGLE: +32'.j044f __- -- m m m ImI I I I I.1I I I - I I I P I I 3 I i 10 I. I t I I 11f 1 I 1I I I I I I 1 I 1t I 7 0._____ _____ _____ 0 _________ _____ _ 5 30 I I a 0 I - I I I I I - ~ I I - - ~ ~ - I, '.6 1.0 2.0 3.0 5.0 10.0 20.0 40.0 60.0 TOOL LIFE -MINUTES FIG. 46

CUTTING SPEED- TOOL LIFE 44 A ak U 1" i, Ii. i i I I rI i 4m, 0% Aft I 1 1 1 1 1 I i A: a I Q In Io 304 STAINLESS STEEL 200 __ _ —0 --- SIDE RAKE ANGLE: +40~ 15, 10 m_______ *^ntnr*-H '4444^mi^^-^-. I I I I I mi I I I I I I 4 I I I _ _ i i I t I I I t 7 5 o.I_==1 I I I I z:f 1 -f O! 30 I — L- II I I III I I I - _~~~~~~~~~~~~~~~ _ _ -_ I _ _ _.!b _ _ __M, m Bk I.6 1.0 3.0 5.0 10.0 TOOL LIFE-MINUTES 20.0 40.0 60.0 FIG. 47

TOOL WEAR vs. TIME.030 02l9 0() IJ z I.J C. 0 0 I-.020.015.010.005 I -t- r — I I, 1, Ia * i,,f TI- 15 A CUTTING S - II I I [ [ - a m a N - - I I I I I I 19 IPEED: 75 I.- ~ --- FPM I I.052" AT 11.9 MIN. I I m 1.000 0 I 2 3 4 5 6 7 8 9 10 11 12 13 14 TIME - MINUTES FIG. 48

TOOL WEAR vs. TIME - I I I I - I aI I / I nnf SAE 1045 STEEL 1 t I.039" 10.73 I.r I AT MIN. I U) 0 z aml I J 0.025 CUTTING SPEED: 200 FPM.020.015.010.005,,OoQ 11 A I I I I.I % W I I I - -- 0 I 2 3 4 5 6 7 8 9 10 II 12 13 14 TIME - MINUTES FIG. 49

SAE 1045 STEEL GRADE Ti 150 A TITANIUM HALF LIFE FAILED clank wear at half life was.009 and.011 inches respectively for the steel and the titanium. Total tool life approximately 11 minutes for each material. Tool signature was 0~, 320, 6~, 60, 60, 150, and 0.010 inches, fee 0.006 ipr, depth = 0.050 inches, and cutting speed was 200 and 75 fpm respectively for the steel and the titanil wa