Boring Tools Cutting Data Tables

CUTTING DATA TABLES

For fine- and rough boring heads of BIG KAISER

BIG KAISER – the key to higher performance Since 1948 BIG KAISER manufactures high performance tooling solutions for the metal cutting industry. The products are developed to meet the highest standards and are fully produced in Switzerland and Japan. As part of the family owned BIG DAISHOWA Group with more than 800 employees, BIG KAISER has corporate headquarters in Switzerland, Germany and the United States.

Founded: 1967 Employees: 640 Location: Osaka and Awaji, Japan Production hall: 6 (Tool holders &Cutting tools), Central stock Asia, TechCenter

BIG KAISER Germany

Founded: 2010 Employees: 15 Location: Vöhringen, Germany

BIG Daishowa Japan

BIG KAISER Switzerland

BIG KAISER USA

Founded: 1948 Employees: 110

Founded: 1990 Employees: 45 Location: Chicago, USA Central stock North America TechCenter

Location: Zurich, Switzerland Production hall: 2 (Boring tools) Central stock Europe, TechCenter

INNOVATION Investment of 10% of sales in development and infrastructure

PRODUCTIVITY 500 000 produced collets per year and 320t processed steel per year

GLOBAL BIG KAISER has more than 200 sales reps and partners

KNOW-HOW Founded in 1948

QUALITY AND PRECISION Accuracy of Ø 1 μm

FLEXIBILITY Batch size 1 – 10 0000 as 20 000 standard products and 1 200 special tools

PERFORMANCE Production area size of 135 000m 2

SERVICE Stock levels at 95%

CONTENTS

GENERAL INFORMATION

Cutting Data App / Insert Development

4

Important formulas

5

Taper standards

6

Rough boring with rough boring heads SW

7 - 8

Fine boring with fine boring heads EWN/EWE

9

Special applications with fine boring heads EWN/EWE

10

CUTTING DATA

Drilling

11

DV/BT40, HSK-A63, Capto C6

12 - 35

DV/BT50, HSK-A100, Capto C8

36 - 61

EWN 04-7, EWN 04-15

62 - 67

EWN 04-22, EWN/EWE 2-32

68 - 105

EWN/EWE 2-152

106 - 141

Application data for CBN and PCD inserts

142

On the following pages, tables with recommended speeds and feeds are provided. The values in these tables are the result of practical experience and specific tests. They serve as guidelines to help operators use BIG KAISER boring tools efficiently. For tools in the diameter range from 15 to 340 / 620 mm, there are different tables for the tool shank sizes DV40, BT40, HSK-A63, Capto C6 and DV50, BT50, HSK-A100, Capto C8. The tool shanks and the machines on which these tools are used, have a decisive influence on the rigidity and available drive power, which are especially important for heavy rough boring operations. In the smaller diameter range from 0.4 – 50 mm, there are different tables for the different sizes of the fine boring heads, with their specific accessories, such as tool holders and boring cutters.

Every table has its specific colour. See table of contents.

3

Cutting Data App / Insert Development

A Cutting Data App for Smart Phones and Tablets

BIG KAISER has developed a smartphone and tablet app to enhance the user-experience when assembling and running cutting tools while providing extremely precise cutting data. This app will help operators fine tune the optimal cutting parameters for their tool assemblies. They can save their tool adjustment history in the app for future reference; this is an essential "piece-of-the-puzzle" for shops joining the smart manufacturing movement. 61 BIG KAISER boring heads, covering diameters from Ø.01575" (Ø 0.4 mm) up to Ø24.41" (Ø 620 mm), are currently supported by this app. Cutting data for rough and fine boring tools is available in both metric and imperial units. The key benefit that this app brings the user is that machine and tool data, parameters and settings are always available and can be monitored remotely in real-time. Comprehensive information is displayed on a large legible screen, providing greater comfort than the existing on-machine interface. More precise information should lead to improved decision-making, thereby contributing to the bottom line.

Convenience at Your Fingertips!

• • • • • • • •

Cutting data calculator

Calculator for adjusting tools Quick access to operating manuals

To the App

Tool overview Application data Store favorites

Tool Tips

Metric and imperial units available

Insert Development

The customer shall reach the best possible results in terms of performance, precision and cost efficiency for all boring operations with BIG KAISER twin cutter and precision boring tools. Therefore, not only outstanding boring tools are required, but also inserts, specially designed for boring, which fulfil the highest demands. BIG KAISER invests continuously in development and tests of new inserts. New geometries will be defined, coatings tested and different substrates evaluated, often also in co-operation with carbide- and coolant manufacturers.

Criteria

Workpiece Material

Machining Process

Cutting Condition

To be considered

Material group Crystalline structure

Rough boring Fine boring Bore diameter Depth of cut (ap)

Interrupted cut Continuous cut Depth of cut Precision HSC Workpiece chucking Rigidity of tool

Ralph Stadelmann, Head of Special Tooling & Testing BIG KAISER «The selection of the indexable insert is decisive for the machining process and reduces production costs.»

With effect on

Substrate of cutting material Coating

Shape of insert Size of insert

Cutting edge geometry Nose radius Rake and relief angle Chip breaker ground or sintered Circumference ground or sintered

Target

Indexable inserts for perfect chip control, maximum tool life and minimized costs

The results of the developments and tests are shown in the BIG KAISER cutting data table. In their, you’ll find the most suitable inserts for the vari- ety of workpiece materials and machining processes in relation to the tool configuration. The table shows precise cutting data for all applications.

4

Important formulas

Conversion table Metric/Inch

Spindle speed

Length dimensions

1000 x V c D c x π

(min -1 )

n =

mm 25.4

mm to Inch =

Cutting speed

n

n x D c x π 1000

m 0.3048

V c =

(m/min)

m to feet =

V f

Feed per min.

Cutting speed

f n V x n f = (mm/min)

m/min to SFM = m/min x 3.28

f n

Feed per revolution

SFM x 3.82 D

f z x Z

f n =

(mm)

RPM =

Cross section of chip

n

Feed

ap x f n A = (mm 2 )

V f

mm/rev 25.4

mm/rev to Inch/rev =

Material removal rate (Boring)

f n

A x V c Q = (cm

3 /min)

IPM = RPM x IPR

Cutting performance (Boring)

Workpiece material

Workpiece material No. k c 1.1 (N/mm 2 )

m

ap x f n x V c x k c 1000 x 60

c

P =

(kW)

St 37-2 St 50-2

1.0037 1.0050 1.1191 1.2312 1.4301 1.4401

1780 1990 2220 1800 2350 2600 1020 1005 1130

0.17 0.26 0.14 0.27 0.21 0.19 0.25 0.25 0.44 0.23 0.23 0.21

CK 45

Torque (Boring)

40CrMnMo S 8 6

(D c

2 - D

i 2 ) x f

n x k c

X5CrNi 18 10

M c =

(Nm)

8000

X5CrNiMo17 12 2

GG 20

Specific cutting force

GGG 40 GGG 80

k c 1.1 h m c

k c =

(N/mm

2 )

AL Wrought alloys

3.3535 3.2581 3.7164

780 830

AL Cast alloys

TiAI 6V4

1370

Thickness of chip

f z x sin κ h = (mm)

A

Cross section of chip

mm 2 mm mm mm

ap D c

Depth of cut

With an entering angle of 90° the chip thickness is equal to the feed per tooth (f z ).

Cutting diameter

D i F f

Diameter of starting bore

Feed force

N

Material removal rate (Drilling)

f n f z h

Feed per revolution Feed per tooth Thickness of chip Specific cutting force

mm mm mm

V f x π x D c 2 4 x 1000

(cm 3 /min)

Q =

k c

N/mm

2

Cutting performance (Drilling)

k c 1.1

Specific cutting force for a chip cross section of 1mm 2 and chip thickness h = 1mm

M c x 2 x π x n 60 x 1000

P =

(kW)

N/mm 2

m c M c

Increase of the k c curve

Torque

Nm

Feed force (Drilling)

n P Q

Spindle speed

min -1

0.63 x f n x D c x k c 2

F f =

(N)

Cutting performance Material removal rate

kW

cm 3 /min

V c V f

Cutting speed Feed per min. Number of teeth

m/min

Torque (Drilling)

mm/min

D c

2 x k

c x f n

M c =

(Nm)

Z

8000

5

Taper standards

L3

Steep taper shanks DIN 69871 / DV

L4 L5

L2

L1

DV

30

40

45

50

ØD1

31.75

44.45

57.15

69.85

ØD2 max.

45 50

50

63

80

ØD3

63.55

82.55

97.5

L1 L2

47.8 19.1

68.4 19.1

82.7 19.1

101.75

Form AD

19.1

Position of the cutting edge on single cutter tools

L3 min.

35

35

35

35

L4 L5

16.4

22.8

29.1 31.3 19.3 M20

35.5 37.7 25.7 M24

19

25

20˚

Form AD/B

b

16.1 M12

16.1 M16

M

Centre and flange through coolant

y

L1

L2

L3 L3

Steep taper shanks JIS B6339/BT

BT

30

40

45

50

ØD1 ØD2

31.75

44.45

57.15

69.85

46

63

85

100

y

2

2

3

3

L1 L2 L3

48.4

65.4

82.8

101.8

Form BT

20

25

30

35

16.3 16.1 M12

22.6 16.1 M16

29.1 19.3 M20

35.4 25.7 M24

b

20˚

M

Form BT/B

Centre and flange through coolant

Hollow taper interface DIN 69893, form A

L3

HSK-A 32

40 40

50 50

63 63

80 80

100 100

L1

L2

Ø10

ØD1 ØD2

32

24.007 30.007 38.009 48.010 60.012 75.013

ØD3 max. 26

34 20 20 35

42 25 26 42

53 32 26 42

68 40 26 42

88 50 29 45

L1 L2

16 20 35

L3 min.

b1

7.05 8.05 10.54 12.54 16.04 20.02 5.4 5.2 5.1 5.0 4.9 4.9

t1

Position of the cutting edge on single cutter tools

Hollow taper interface DIN 69893, form E

L3

L1

L2

HSK-E

32 32

40 40

50 50

63 63

25

ØD1 ØD2

25

19.006 24.007 30.007 38.009 48.010

ØD3 max. 20

26 16 20 35

34 20 20 35

42 25 26 42

53 32 26 42

L1 L2

13 10 20

L3 min.

L1

L2

Orientation groove

BIG CAPTO (compatible with ISO 26623-1, polygonal hollow shank taper with face contact)

C

4

5

6

8

ØD1

40 24 20

50 30 20

63 38 22

80 48 30

L1 L2

Position of the cutting edge on single cutting tools

6

Rough boring with rough boring heads SW

Rough boring methods

1. RSS Rotationally symmetrical rough boring The symmetrical cutter arrangement is the most used adjustment for twin cutter heads. Especially suitable for small to medium stock removal (up to 10% of the final bore diameter) with high feed rates. 2. DVS Double offset rough boring Diameter and height offset cutters allow the removal of twice the stock (20% of the final bore diameter), with half the feed rate and excellent chip control. 3. VPS Full profile rough boring Heavily offset cutter arrangement in dia- meter for largest stock removal (up to 40 % of the final diameter), with surprisingly low power requirement. Due to the use of inserts type WC, the boring head functions like an adjustable insert drill for rough boring.

Examples (Insert holders type CC, SC, SD and WC)

RSS/BAL.

Ød

ØD

Boring head

SW / 32 SW / 41 SW / 68

38 45 90

42 50

100

0.2 / 0.4

Examples (Insert holders type CC)

DVS/STEP

Ø d

Ø D1

Ø D2

Boring head

SW 25 SW 53 SW 100 SW 100

28 60

31.5 35 67.5 75

110

125

140

Examples (Insert holders type CC)

Ød

ØD1

ØD2

Boring head

SW / 41 SW / 53 SW / 68

38 45 67

52 63 90

62 75

RSS

110

Adjustment instructions for rough boring heads SW

Rotationally symmetrical rough boring Both cutting edges are adjusted to the same length and to the same diameter. Mount the long insert holder “L” on the short support “B2” of the tool body and the short insert holder to the long support “B1”. The reference line marking on both insert holders is aligned to the RSS mar- kings on the tool body.

L1

S (Short)

B1

X/2

RSS

B2

X/2 L (Long)

Double offset rough boring The cutting edges are displaced in length and diameter. The difference in length is achieved by mounting the insert holders in a 180° twisted position. The reference line marking on both insert holders is aligned to the DVS markings on the tool body. Adjust the cutting edge on insert holder “L” to half the stock allowance. (Pre-cutter)

L2

B1

X/2

L (Long)

X

DVS

B2

S (Short)

X/2

X

7

Rough boring with rough boring heads SW

Full profile rough boring – Application and adjustment instructions

Full profile rough boring permits rough boring with large stock allowances (30 mm and more in diameter) in a single operation, with relatively low drive consumption.

Adjustment instructions for insert holders type WC: • Mount the insert holders on mark "RSS“. • Set cutting edge 2 to the final bore diameter (D2).

• Set cutting edge 1 corresponding to the starting bore diameter, according to the table (column D1). • Both cutting edges must be located at exactly the same height. Use coolant in large quantities.

Table for optimum cut sharing in full profile rough boring operations VPS

For Boring Head Insert Holder Order No. Starting Bore Ø ØD1

ØD2

35 - 37.9

49 52 59 63 69 73 73 79 85 90 96

51 - 62 54 - 62 61 - 76 65 - 76 76 - 86 81 - 86 75 - 93 81 - 93 87 - 93 92 - 110 98 - 110 104 - 110 109 - 129 115 - 133 121 - 133 128 - 133 133 - 154 140 - 159 147 - 159 154 - 159 159 - 179 165 - 183 171 - 183 178 - 183 183 - 204 190 - 209 197 - 209 204 - 209

SW41

639.243

38 - 41

41 - 44.9

639.253

45 - 50

SW53

51 - 54.9

639.257

55 - 60

50 - 55.9 56 - 61.9

639.263

62 - 67

SW68

67 - 72.9 73 - 78.9

639.267

79 - 85

102 107 113 119 126 131 138 145 152 157 163 169 176 181 188 195 202

84 - 89.9 90 - 95.9 96 - 102.9 103 - 109 108 - 114.9 115 - 121.9 122 - 128.9 129 - 135 134 - 139.9 140 - 145.9 146 - 152.9

639.273

SW98

639.277

RSS

639.283

153 - 159

SW148

158 - 164.9 165 - 171.9 172 - 178.9 179 - 185

639.287

Driving power

kW 15

Vc = 100 m/min Material: St 60, Kc1 = 2110 N/mm 2 Efficiency ƞ = 0.8 Cutting data-guide values Cutting speed: Vc = 100 - 200 m/min Feed: fn = 0.05 - 0.15 mm/U

10

5

0

10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40

Machining allowance (mm/Ø)

8

Fine boring with fine boring heads EWN/EWE

Fine boring methods

There are two different methods of precision boring, machining with the fine boring cycle and machining with the reaming cycle. Both methods have advantages:

Fine boring cycle (G 76) boring – spindle stop – spindle orientation – displacement – retraction This cycle is used for: • deep bores with long tools

Reaming cycle (G 85) Forward – backward boring This cycle is used for: • short bores • small diameters

• low cutting speeds and low rpm • large boring diameter > 200 mm Ø • problems with tool life and surface quality

• high cutting speeds and high rpm • tight form and position tolerances

Extension of the boring range

Insert holder type E, with 87° approach angle For each one of the fine boring heads EWN 20 - EWN 100 and EWE 41 - EWE 100 there are two additional insert holders (size 2 and size 3) available for the extension of the boring range and for back boring. The boring range from Ø20 - 153 mm is covered with insert holder size 1 of each boring head.

E

87˚

ØD1

ØD1

ØD

ØD

ØD

Size 1

Size 2

Size 3

Size 3

Size 2

Insert holder Type C, with 90° approach angle For each of the fine boring heads EWN 25 - EWN 100 and EWE 41 - EWE 100, there are two insert holders with 90° approach angle available.

E

The cutting data given in the tables is valid for the insert holders type E and type C as well as for forward and back boring.

90˚

ØD1

ØD1

ØD

ØD

Size 2

Size 3

Size 3

Size 2

Caution: • Counter clockwise spindle rotation is required for back boring operations. • The cutting edge is at a shorter length than the boring head. Consider total length of tool. Check the space at the back side of the workpiece. Back boring For back boring, it is required to enter into the bore off centre, with a tool adjusted to the back bore diameter. In this respect, the back bore diameter "ØD" as well as the diameters of the entry bore "C" and the tool body "A", are related to each other. These values can be calculated as follows:

Min. entry bore diameter "C"

C

ØD1

ØD + ØD1 2

C =

Max. back bore diameter "ØD"

ØD =

2C - ØD1

Max. tool body diameter "A"

ØD1 =

2C - ØD

ØD

9

Special applications with fine boring heads EWN/EWE

Chamfering and recessing

Special insert holders for chamfering 30° and 45° as well as for recessing in stepped bores.

25°

Face grooving Ø 14 - Ø 3 040 mm

Face groving Ø 14 - 53 mm With EWN/EWE 2-152, series 112 and special tool and insert holder, groove width 2 – 3 mm, groove depth max. 5 mm

Tool holder

Holder for grooving insert

Grooving insert

Face grooving Ø 53 - 3 040 mm With EWN/EWE 53, 68. 100, series 310 and EWN/EWE 200, series 318 and with special insert holders, groove width 2.5 – 4 mm, groove depth 2.7 – 4.3 mm

Type 2

Type 2

Type 1

Type 1

EWN/EWE Series 310

EWN/EWE Series 318

Grooving insert

Groove dimensions Recommended groove dimensions for given cross section diameters of O-rings, for static sealing.

Cutting data The given data are guide values and have to be adjusted according to the actual working conditions.

ØD

Groove Width b

Groove Depth t

Workpiece Material

Vc m/min

fn mm/rev 0.01 - 0.03 0.01 - 0.02 0.02 - 0.04

Construction- heat treatable steels 120 - 200

1.78

2.5 2.5 3.3 3.5 4.0

1.3 1.6 1.9

Stainless steels

60 - 120 80 - 160

2.0 2.5

Cast iron

Aluminium

200 - 400

0.02 - 0.04

2.62

2.05

Non-ferrous metals

3.0

2.4

10

Cutting data

Boring

Ø 16-30 Ø 31-74

Cutting data for indexable insert drills serie 337 3xD and 4xD, Ø 16-30 mm

Cutting speed Vc (m/min) 1) Coolant

Feed fn (mm/U) Drill

from outside

trough the drill

Designation

No.

3xD / 4xD 160 - 200 140 - 160 140 - 160 120 - 160 100 - 140 100 - 140 100 - 140 130 - 170 130 - 170 120 - 160 200 - 300

3xD

4xD

Ø 16-20

Ø 21-30

St 37 St 60 CK 45

(1.0067) (1.0062) (1.1191) (1.7220) (1.2311) (1.2080) (1.4108)

240 - 280 220 - 280 220 - 280 180 - 220 160 - 200 160 - 200 160 - 200 220 - 260 220 - 260 180 - 220 250 - 500

200 - 240 180 - 220 180 - 220 160 - 200 140 - 180 140 - 180 140 - 180 170 - 210 170 - 210 160 - 210 250 - 500

0.08 0.08 0.08 0.08 0.06 0.05 0.05 0.10 0.10 0.08 0.06

0.10 0.10 0.10 0.10 0.08 0.07 0.07 0.12 0.12 0.10 0.08

34CrMo4

40CrMnMo7

X210Cr12

X100CrMo13 GG 20 - GG 40

GG 60

GGG 42

Aluminum 2)

1) The above cutting data are guide values and apply under normal working conditions when an ample supply of coolant is used. 2) Machining of aluminium: In case of unfavourable chipping, interrupt drilling cycle for chip removal. Max. drilling depth with flood coolant supply: 1xD

Cutting data for indexable insert drills serie 336 2xD and 3xD, Ø 31-74 mm

Cutting speed Vc (m/min) 1) Coolant

Feed fn (mm/U) Drill

Designation

No.

from outside

trough the drill

31.0 - 41.9

≥ 42 0.10 0.15 0.15 0.15 0.15 0.15 0.15 0.25 0.25 0.15 0.10

St 37 St 60 CK 45

(1.0067) (1.0062) (1.1191) (1.7220) (1.2311) (1.2080) (1.4108)

200 - 240 180 - 220 180 - 220 140 - 180 120 - 160 120 - 160 120 - 160 150 - 220 150 - 220 140 - 180 200 - 300

240 - 280 220 - 280 220 - 280 180 - 220 160 - 200 160 - 200 160 - 200 220 - 260 220 - 260 180 - 220 250 - 500

0.10 0.12 0.12 0.12 0.12 0.12 0.12 0.22 0.22 0.12 0.10

34CrMo4

40CrMnMo7

X210Cr12

X100CrMo13 GG 20 - GG 40

GG 60

GGG 42

Aluminum

1) The above cutting data are guide values and apply under normal working conditions when an ample supply of coolant is used. Max. drilling depth with flood coolant supply: 1xD

11

12

Cutting data DV/BT40, HSK-A63, Capto C6

Ø 15-340/390

With the exception of the diameter range 15 - 22 mm (page 14/15), which is covered by the fine boring heads EW 15 and EW 18, there is cutting data of one specific diameter range on each double page, which corresponds to the size of the rough- and the fine boring head. For the diameter range bigger than 200 mm, the data is valid for light weight boring tools series 318.

The diameter ranges shown in the headline of each page will be reached for rough boring with a second pair of insert holders and for fine boring with additional insert holders size 2 and size 3.

The maximum values of the cutting data given in the tables require spindle speed of 12 500 rpm and spindle power of approx. 20 kW. In case of lower available speeds and spindle power, the cutting data has to be adapted accordingly.

The cutting data is valid for rough boring heads type SW, and for the fine boring heads type EWN, EWB/EWB-UP and EWE. The max. permissible cutting speeds to operate these heads are listed below and may not be exceeded at any time: Rough boring heads SW: 1200 m/min Fine boring heads EWN/EWE: 1200 m/min Balanceable fine boring heads EWB/EWB-UP: 2 000 m/min

In the table the following terms and dimensions are used:

Workpiece material: Material no. according to DIN or generally used designation Boring depth X: Projection length according to picture 1 and picture 2 Insert:

Detailed information about the inserts is shown in the BIG KAISERmain catalogue.

R:

Nose radius Cutting speed

(mm)

Vc:

(m/min)

Stock allow.:

Sock allowance per cut in Ø

(mm)

fn:

Feed per revolution

(mm/U)

Ra:

Surface roughness (Ra 1.6 µm for N7) Rotationally symmetrical rough boring

RSS: DVS: VPS:

page 7 page 7 page 8

Double offset rough boring Full profile rough boring

Diameter-length ratio For long tool assemblies with different boring bar diameters, the boring depth X may not be the decisive factor for the cutting data to be ap- plied, but the total tool length. Should the diameter-length ratio in relation to taper gauge diameter be bigger than 1:6, the lowest cutting data (highest X-value) has to be applied.

x

x

L

Picture 1

Picture 2

Boring depth X including the useable length of the tool shank and the boring head.

Boring depth X including the useable length of the reduction and the corresponding boring head.

13

DV/BT40, HSK-A63 Capto C6

Fine boring head EW 15 Fine boring head EW 18

Ø 15-18.5 Ø 18-22

x

x

Ø 14 carbide

Ø 16 carbide

Ø 63.5

EW 15

EW 18

Fine boring EW 15

Fine boring EW 18

Inserts

Vc

Allow.

Feed

Inserts

Vc

Allow.

Feed

Workpiece material

Boring depth X [mm]

Std. val. Max.

Ra 1.6 µm

Std. val. Max.

Ra 1.6 µm

Order No.

R m/min mm/Ø mm/Ø mm/U Order No.

R m/min mm/Ø mm/Ø mm/U

Steel

50 60 80

655.602 655.602 655.602 655.602 655.606 655.606 655.602 655.602 655.602 655.602 655.606 655.606 655.602 655.602 655.602 655.602 655.606 655.606 655.602 655.602 655.602 655.602 655.606 655.606 655.602 655.602 655.602 655.602 655.606 655.606 655.603 655.603 655.603 655.603 655.605 655.605

0.2 400 0.2 330 0.2 250 0.2 180 0.1 90 0.1 40 0.2 400 0.2 330 0.2 250 0.2 180 0.1 90 0.1 40 0.2 320 0.2 280 0.2 240 0.2 170 0.1 90 0.1 40 0.2 280 0.2 280 0.2 240 0.2 170 0.1 90 0.1 40 0.2 250 0.2 250 0.2 225 0.2 160 0.1 90 0.1 40 0.2 350 0.2 310 0.2 240 0.2 180 0.1 90 0.1 40

0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.1 0.1

0.5 0.5 0.5 0.5 0.3 0.3 0.5 0.5 0.5 0.5 0.3 0.3 0.5 0.5 0.5 0.5 0.3 0.3 0.5 0.5 0.5 0.5 0.3 0.3 0.5 0.5 0.5 0.5 0.3 0.3 0.5 0.5 0.5 0.5 0.3 0.3

0.06 655.602 0.06 655.602 0.06 655.602 0.06 655.602 0.04 655.602 0.04 655.606

0.2 400 0.2 400 0.2 350 0.2 300 0.2 180 0.1 90 0.1 40 0.2 400 0.2 400 0.2 350 0.2 300 0.2 180 0.1 90 0.1 40 0.2 320 0.2 320 0.2 280 0.2 200 0.2 150 0.1 90 0.1 40 0.2 280 0.2 280 0.2 260 0.2 190 0.2 140 0.1 90 0.1 40 0.2 250 0.2 250 0.2 225 0.2 160 0.2 120 0.1 90 0.1 40 0.2 350 0.2 350 0.2 310 0.2 240 0.2 180 0.1 100 0.1 50

0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1

0.5 0.5 0.5 0.5 0.5 0.3 0.3 0.5 0.5 0.5 0.5 0.5 0.3 0.3 0.5 0.5 0.5 0.5 0.5 0.3 0.3 0.5 0.5 0.5 0.5 0.5 0.3 0.3 0.5 0.5 0.5 0.5 0.5 0.3 0.3 0.5 0.5 0.5 0.5 0.5 0.3 0.3

0.06 0.06 0.06 0.06 0.06 0.04 0.04 0.06 0.06 0.06 0.06 0.06 0.04 0.04 0.06 0.06 0.06 0.06 0.06 0.04 0.04 0.06 0.06 0.06 0.06 0.06 0.04 0.04 0.06 0.06 0.06 0.06 0.06 0.04 0.04 0.06 0.06 0.06 0.06 0.06 0.04 0.04

< 450 N/mm2

1.0037 1.0401 1.0715

100 120 140 160

P

655.606

Steel

50 60 80

0.06 655.602 0.06 655.602 0.06 655.602 0.06 655.602 0.04 655.602 0.04 655.606

450-850 N/mm2

1.0050 1.0503 1.1141 1.1191 1.5752

100 120 140 160

655.606

Steel

50 60 80

0.06 655.602 0.06 655.602 0.06 655.602 0.06 655.602 0.04 655.602 0.04 655.606

850-1200 N/mm2

1.2083 1.2294 1.2312 1.2344 1.2764

100 120 140 160

655.606

Stainless steels,

50 60 80

0.06 655.602 0.06 655.602 0.06 655.602 0.06 655.602 0.04 655.602 0.04 655.606

ferritic,

martensitic

1.4016 1.4024 1.4034

100 120 140 160

M 1.4762

655.606

50 60 80

0.06 655.602 0.06 655.602 0.06 655.602 0.06 655.602 0.04 655.602 0.04 655.606

Stainless steels,

austenitic

1.4301 1.4311 1.4401 1.4435 1.4571

100 120 140 160

655.606

Gray cast iron

50 60 80

0.06 655.603 0.06 655.603 0.06 655.603 0.06 655.603 0.04 655.603 0.04 655.605

K GG 15

GG 20 GG 25 GG 30

100 120 140 160

655.605

Caution: The given cutting data are guide values. In any case, they have to be adapted to the actual working conditions.

For cutting speeds above 240 m/min, we recommend to balance the complete and pre-set tool assembly or to mount a fine balanced tool shank.

14

DV/BT40, HSK-A63 Capto C6

Fine boring head EW 15 Fine boring head EW 18

Ø 15-18.5 Ø 18-22

x

x

Ø 14 carbide

Ø 16 carbide

Ø 63.5

Ø 52.5

EW 15

EW 18

Fine boring EW 15

Fine boring EW 18

Inserts

Vc

Allow.

Feed

Inserts

Vc

Allow.

Feed

Workpiece material

Boring depth X [mm]

Std. val. Max.

Ra 1.6 µm

Std. val. Max.

Ra 1.6 µm

Order No.

R m/min mm/Ø mm/Ø mm/U Order No.

R m/min mm/Ø mm/Ø mm/U

GGG

50 60 80

655.603 655.603 655.603 655.603 655.605 655.605 655.602 655.602 655.602 655.602 655.606 655.606 655.601 655.601 655.601 655.601 655.601 655.604 655.602 655.602 655.602 655.602 655.602 655.606 655.602 655.602 655.602 655.602 655.606 655.606 655.602 655.602 655.602 655.602 655.606

0.2 350 0.2 310 0.2 240 0.2 180 0.1 90 0.1 40 0.2 320 0.2 280 0.2 240 0.2 170 0.1 90 0.1 40 0.2 550 0.2 550 0.2 400 0.2 300 0.2 150 0.1 70 0.2 400 0.2 330 0.2 250 0.2 180 0.2 100 0.1 50 0.2 120 0.2 120 0.2 120 0.2 80 0.1 60 0.1 40 0.2 50 0.2 50 0.2 50 0.2 40 0.1 30

0.2 0.5 0.2 0.5 0.2 0.5 0.2 0.5 0.1 0.3 0.1 0.3 0.2 0.5 0.2 0.5 0.2 0.5 0.2 0.5 0.1 0.3 0.1 0.3 0.2 0.5 0.2 0.5 0.2 0.5 0.2 0.5 0.2 0.3 0.1 0.3 0.2 0.5 0.2 0.5 0.2 0.5 0.2 0.5 0.2 0.3 0.1 0.3 0.2 0.4 0.2 0.4 0.2 0.4 0.2 0.4 0.1 0.3 0.1 0.3 0.1 0.2 0.1 0.2 0.1 0.2 0.1 0.2 0.1 0.2

0.06 655.603 0.06 655.603 0.06 655.603 0.06 655.603 0.04 655.603 0.04 655.605

0.2 350 0.2 350 0.2 310 0.2 240 0.2 180 0.1 100 0.1 50 0.2 320 0.2 320 0.2 280 0.2 200 0.2 150 0.1 90 0.1 40 0.2 700 0.2 700 0.2 650 0.2 500 0.2 300 0.1 150 0.1 70 0.2 400 0.2 400 0.2 350 0.2 300 0.2 180 0.1 100 0.1 50 0.2 120 0.2 120 0.2 120 0.2 120 0.2 80 0.1 60 0.1 40 0.2 50 0.2 50 0.2 50 0.2 50 0.1 40 0.1 30

0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1

0.5 0.5 0.5 0.5 0.5 0.3 0.3 0.5 0.5 0.5 0.5 0.5 0.3 0.3 0.5 0.5 0.5 0.5 0.5 0.3 0.3 0.5 0.5 0.5 0.5 0.5 0.3 0.3 0.4 0.4 0.4 0.4 0.4 0.3 0.3 0.2 0.2 0.2 0.2 0.2 0.2

0.06 0.06 0.06 0.06 0.06 0.04 0.04 0.06 0.06 0.06 0.06 0.06 0.04 0.04 0.06 0.06 0.06 0.06 0.06 0.04 0.04 0.06 0.06 0.06 0.06 0.06 0.04 0.04 0.06 0.06 0.06 0.06 0.06 0.04 0.04 0.06 0.06 0.06 0.06 0.04 0.04

< 500 N/mm2

GGG 40 GGG 50

100 120 140 160

K

655.605

GGG

50 60 80

0.06 655.602 0.06 655.602 0.06 655.602 0.06 655.602 0.04 655.602 0.04 655.606

< 800 N/mm2

GGG 60 GGG 70 GGG 80

100 120 140 160

655.606

Aluminium

50 60 80

0.06 655.601 0.06 655.601 0.06 655.601 0.06 655.601 0.06 655.601 0.04 655.604

Wrought alloys

Si < 10%

3.1354 3.2315 3.3545

100 120 140 160

N 3.4365

655.604

Aluminium Cast alloys Si > 10% G-AlSi 12

50 60 80

0.06 655.602 0.06 655.602 0.06 655.602 0.06 655.602 0.06 655.602 0.04 655.606

100 120 140 160

G-AlSi17Cu4Mg

655.606

50 60 80

0.06 655.602 0.06 655.602 0.06 655.602 0.06 655.602 0.04 655.602 0.04 655.606

Titanium

3.7164

100 120 140 160

S

655.606

50 60 80

0.06 655.602 0.06 655.602 0.06 655.602 0.06 655.602 0.04 655.606

Ni-basic-, Co-basic-,

Alloys

100 120 140 160

655.606

Remark: The boring heads EW 15 and EW 18 will be screwed on carbide shanks 615.233 / 615.221 and 615.268 / 615.227 / 615.269 / 615.229. For chucking the carbide shanks, we recommend BIG MEGA Chuck collet holders.

15

DV/BT40, HSK-A63 Capto C6

Rough boring head SW 20 Fine boring head EWN 20

Ø 20-26/31 Ø 20-26/31/36

x

x

Ø 19

Ø 19

Ø 63.5

Rough boring SW 20

Fine boring EWN 20

Inserts

Vc

RSS

DVS

Inserts

Vc

Allow.

Feed

Workpiece material

Boring depth

Allow. fn Ra 1.6 µm X [mm] Order No. R m/min mm/Ø mm/U mm/Ø mm/U Order No. R m/min mm/Ø mm/Ø mm/U Allow. Feed Std. val. Max.

Steel

65 85

654.850A 0.4 220 3.00 0.35 5.0 654.850A 0.4 125 2.00 0.30 4.0 654.840A 0.2 60 1.50 0.25 3.0 654.850A 0.4 220 3.00 0.35 5.0 654.840A 0.2 125 2.00 0.30 4.0 654.840A 0.2 60 1.50 0.25 3.0 654.840A 0.2 25 1.00 0.25 2.0 654.850A 0.4 220 3.00 0.30 5.0 654.850A 0.4 125 2.00 0.25 4.0 654.840A 0.2 60 1.50 0.25 3.0 654.850A 0.4 220 3.00 0.30 5.0 654.840A 0.2 125 2.00 0.25 4.0 654.840A 0.2 60 1.50 0.25 3.0 654.840A 0.2 25 1.00 0.25 2.0 654.856 0.4 180 2.50 0.25 4.0 654.856 0.4 100 2.00 0.20 3.5 654.846 0.2 60 1.50 0.20 2.5 654.856 0.4 180 2.50 0.25 4.0 654.846 0.2 120 2.00 0.20 3.5 654.846 0.2 60 1.50 0.20 2.5 654.846 0.2 25 1.00 0.20 2.0 654.856 0.4 180 2.50 0.30 4.0 654.856 0.4 100 2.00 0.25 3.5 654.846 0.2 60 1.50 0.25 2.5 654.856 0.4 180 2.50 0.30 4.0 654.846 0.2 120 2.00 0.25 3.5 654.846 0.2 60 1.50 0.25 2.5 654.846 0.2 25 1.00 0.25 2.0 654.856 0.4 150 2.50 0.30 4.0 654.856 0.4 90 2.00 0.25 3.5 654.846 0.2 60 1.50 0.25 2.5 654.856 0.4 150 2.50 0.30 4.0 654.846 0.2 100 2.00 0.25 3.5 654.846 0.2 60 1.50 0.25 2.5 654.846 0.2 25 1.00 0.25 2.0 654.852 0.4 220 4.00 0.30 7.0 654.852 0.4 140 3.50 0.30 6.0 654.840A 0.2 60 3.00 0.25 5.0 654.852 0.4 220 4.00 0.30 7.0 654.840A 0.2 140 3.50 0.30 6.0 654.840A 0.2 60 3.00 0.25 4.0 654.840A 0.2 25 2.00 0.25 3.0

0.18 651.713 0.4 400 0.15 651.738 0.3 260 0.12 651.838 0.2 100 0.18 651.738 0.3 260 0.15 651.838 0.2 130 0.12 651.824 0.1 60 0.12 651.824 0.1 25 0.15 651.713 0.4 400 0.12 651.738 0.3 260 0.12 651.838 0.2 100 0.15 651.738 0.3 260 0.12 651.838 0.2 130 0.12 651.824 0.1 60 0.12 651.824 0.1 25 0.15 651.734 0.4 320 0.12 651.737 0.3 250 0.12 651.837 0.2 100 0.15 651.737 0.3 250 0.12 651.837 0.2 130 0.12 651.824 0.1 60 0.12 651.824 0.1 25 0.15 651.737 0.3 320 0.12 651.837 0.2 250 0.12 651.837 0.2 100 0.15 651.737 0.3 250 0.12 651.837 0.2 130 0.12 651.824 0.1 60 0.12 651.824 0.1 25 0.15 651.737 0.3 250 0.12 651.837 0.2 200 0.12 651.837 0.2 100 0.15 651.737 0.3 230 0.12 651.837 0.2 130 0.12 651.824 0.1 60 0.12 651.824 0.1 25 0.15 651.734 0.4 350 0.15 651.735 0.3 260 0.12 651.834 0.2 100 0.15 651.734 0.4 280 0.15 651.834 0.2 150 0.12 651.824 0.1 60 0.12 651.824 0.1 25

0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1

1.0 0.8 0.7 1.0 1.0 0.5 0.5 1.0 0.8 0.7 1.0 1.0 0.5 0.5 0.8 0.6 0.5 0.8 0.6 0.3 0.3 0.8 0.6 0.5 0.8 0.6 0.3 0.3 0.8 0.6 0.5 0.8 0.6 0.3 0.3 1.2 0.8 0.7 1.0 0.8 0.7 0.6

0.10 0.08 0.06 0.08 0.06 0.04 0.04 0.10 0.08 0.06 0.08 0.06 0.04 0.04 0.10 0.08 0.06 0.08 0.06 0.04 0.04 0.08 0.06 0.06 0.08 0.06 0.04 0.04 0.08 0.06 0.06 0.08 0.06 0.04 0.04 0.10 0.08 0.06 0.10 0.06 0.04 0.04

< 450 N/mm2

100 115 150 175 200

1.0037 1.0401 1.0715

Steel

65 85

450-850 N/mm2

1.0050

100 115 150 175 200

P 1.0503

1.1141 1.1191 1.5752

Steel

65 85

850-1200 N/mm2

1.2083 1.2294 1.2312 1.2344 1.2764

100 115 150 175 200

Stainless steels,

65 85

ferritic,

martensitic

100 115 150 175 200

1.4016 1.4024 1.4034

M 1.4762

Stainless steels,

65 85

austenitic

1.4301 1.4311 1.4401 1.4435 1.4571

100 115 150 175 200

Gray cast iron

65 85

GG 15

100 115 150 175 200

K GG 20

GG 25 GG 30

Caution: The given cutting data are guide values. In any case, they have to be adapted to the actual working conditions.

For cutting speeds above 240 m/min, we recommend to balance the complete and pre-set tool assembly or to mount a fine balanced tool shank with index “F”, e.g. 324.312F.

16

DV/BT40, HSK-A63 Capto C6

Rough boring head SW 20 Fine boring head EWN 20

Ø 20-26/31 Ø 20-26/31/36

x

x

Ø 19 carbide

Ø 19

Rough boring SW 20

Fine boring EWN 20

Inserts

Vc

RSS

DVS

Inserts

Vc

Allow.

Feed

Workpiece material

Boring depth

Allow. fn Ra 1.6 µm X [mm] Order No. R m/min mm/Ø mm/U mm/Ø mm/U Order No. R m/min mm/Ø mm/Ø mm/U Allow. Feed Std. val. Max.

GGG

65 85

654.852 0.4 220 3.50 0.30 6.0 654.852 0.4 140 3.00 0.30 5.0 654.840A 0.2 60 2.50 0.25 4.0 654.852 0.4 220 3.50 0.30 6.0 654.840A 0.2 140 3.00 0.30 5.0 654.840A 0.2 60 2.50 0.25 4.0 654.840A 0.2 25 2.00 0.25 3.0 654.856 0.4 180 2.50 0.25 4.0 654.856 0.4 100 2.00 0.20 3.5 654.846 0.2 60 1.50 0.20 2.5 654.856 0.4 180 2.50 0.25 4.0 654.846 0.2 120 2.00 0.20 3.5 654.846 0.2 60 1.50 0.20 2.5 654.846 0.2 25 1.00 0.20 2.0 654.888 0.4 350 3.00 0.30 6.0 654.888 0.4 200 3.00 0.30 5.0 654.877 0.2 100 2.00 0.25 4.0 654.888 0.4 350 3.00 0.30 6.0 654.888 0.4 220 3.00 0.30 5.0 654.877 0.2 100 2.00 0.25 4.0 654.877 0.2 50 2.00 0.25 3.0 654.889 0.4 250 3.00 0.30 6.0 654.889 0.4 200 3.00 0.30 5.0 654.879 0.2 100 2.00 0.25 4.0 654.889 0.4 250 3.00 0.30 6.0 654.889 0.4 220 3.00 0.30 5.0 654.879 0.2 100 2.00 0.25 4.0 654.879 0.2 50 2.00 0.25 3.0 654.847 0.4 120 3.00 0.25 5.0 654.847 0.4 80 2.00 0.20 3.5 654.847 0.4 120 3.00 0.25 5.0 654.847 0.4 120 2.00 0.20 3.5 654.837 0.2 80 2.00 0.20 3.0

0.15 651.734 0.4 350 0.15 651.735 0.3 260 0.12 651.834 0.2 100 0.15 651.734 0.4 280 0.15 651.834 0.2 150 0.12 651.824 0.1 60 0.12 651.824 0.1 25 0.15 651.734 0.4 320 0.12 651.737 0.3 250 0.12 651.837 0.2 100 0.15 651.737 0.3 250 0.12 651.837 0.2 130 0.12 651.824 0.1 60 0.12 651.824 0.1 25 0.15 651.723 0.3 650 0.15 651.723 0.3 350 0.12 651.825 0.2 120 0.15 651.723 0.3 450 0.15 651.723 0.3 240 0.12 651.823 0.1 150 0.12 651.823 0.1 60 0.15 651.737 0.3 650 0.15 651.737 0.3 350 0.12 651.837 0.2 120 0.15 651.737 0.3 450 0.15 651.737 0.3 240 0.12 651.824 0.1 150 0.12 651.824 0.1 60 0.12 651.737 0.3 120 0.10 651.837 0.2 80 0.12 651.737 0.3 120 0.10 651.837 0.2 70 0.10 651.824 0.1 40

0.2 1.00 0.2 0.80 0.2 0.70 0.2 1.00 0.2 1.00 0.1 0.50 0.1 0.50 0.2 0.80 0.2 0.60 0.2 0.50 0.2 0.80 0.2 0.60 0.1 0.30 0.1 0.30 0.2 1.20 0.2 1.00 0.2 0.70 0.2 1.20 0.2 1.00 0.1 0.90 0.1 0.80 0.2 1.20 0.2 1.00 0.2 0.70 0.2 1.20 0.2 1.00 0.1 0.90 0.1 0.80 0.2 1.00 0.2 0.80 0.2 1.00 0.2 0.80 0.1 0.50

0.10 0.08 0.06 0.10 0.06 0.04 0.04 0.10 0.08 0.06 0.08 0.06 0.04 0.04 0.08 0.08 0.06 0.08 0.08 0.04 0.04 0.08 0.08 0.06 0.08 0.08 0.04 0.04 0.08 0.06 0.08 0.06 0.04

< 500 N/mm2

GGG 40 GGG 50

100 115 150 175 200

K

GGG

65 85

< 800 N/mm2

GGG 60 GGG 70 GGG 80

100 115 150 175 200

Aluminium

65 85

Wrought alloys

Si < 10%

100 115 150 175 200

3.1354 3.2315 3.3545

N 3.4365

Aluminium Cast alloys Si > 10% G-AlSi 12

65 85

100 115 150 175 200

G-AlSi17Cu4Mg

65 85

Titanium

3.7164

115 150 175

S

65 85

654.847 0.4 50 3.00 0.20 4.0 654.837 0.2 30 2.00 0.15 3.0

0.10 651.839 0.2 50 0.10 651.839 0.2 30

0.1 0.50 0.1 0.50

0.06 0.06

Ni-basic-, Co-basic-, Alloys

115 150

654.847 0.4 50 3.00 0.20 4.0 654.837 0.2 30 2.00 0.15 3.0

0.10 651.839 0.2 40 0.10 651.839 0.2 25

0.1 0.50 0.1 0.50

0.06 0.06

Remark: For a cost effective high volume production with boring depth X of 115 mm and deeper, carbide bars have to be used.

Extension of the boring range with additional insert holders: • Rough boring: Pair of insert holders 639.417 for the range Ø 25 - 31 mm. • Fine Boring: Insert holder size 2, 626.112 for the range Ø 25 - 31 mm, insert holder size 3, 626.113 for the range Ø 30 - 36 mm The given cutting data are valid for insert holder size 1. When using insert holder size 2, the cutting data have to be reduced by 15%, and by 30% when using insert holder size 3.

17

DV/BT40, HSK-A63 Capto C6

Rough boring head SW 25 Fine boring head EWN/EWB 25

Ø 25-33/40 Ø 25-33/40/47

x

x

Ø 24

Ø 24

Ø 63.5

Rough boring SW 25

Fine boring EWN/EWB 25

Inserts

Vc

RSS

DVS

Inserts

Vc

Allow.

Feed

Workpiece material

Boring depth

Allow. fn Ra 1.6 µm X [mm] Order No. R m/min mm/Ø mm/U mm/Ø mm/U Order No. R m/min mm/Ø mm/Ø mm/U Allow. Feed Std. val. Max.

Steel

80

654.850A 0.4 220 654.850A 0.4 125 654.840A 0.2 60 654.850A 0.4 200 654.840A 0.2 100 654.840A 0.2 60 654.840A 0.2 25 654.850A 0.4 220 654.850A 0.4 125 654.840A 0.2 60 654.850A 0.4 200 654.840A 0.2 100 654.840A 0.2 60 654.840A 0.2 25 654.856 0.4 180 654.856 0.4 100 654.846 0.2 60 654.856 0.4 160 654.846 0.2 90 654.846 0.2 60 654.846 0.2 25 654.856 0.4 180 654.856 0.4 100 654.846 0.2 60 654.856 0.4 160 654.846 0.2 90 654.846 0.2 60 654.846 0.2 25 654.856 0.4 150 654.856 0.4 100 654.846 0.2 60 654.856 0.4 150 654.846 0.2 90 654.846 0.2 60 654.846 0.2 25 654.852 0.4 220 654.852 0.4 140 654.840A 0.2 60 654.852 0.4 220 654.840A 0.2 100 654.840A 0.2 60 654.840A 0.2 25

3.5 0.35 6.0 2.5 0.30 5.0 2.0 0.25 4.0 3.5 0.35 5.0 2.5 0.30 4.0 2.0 0.25 3.0 1.5 0.25 2.0 3.5 0.30 6.0 2.5 0.25 5.0 2.0 0.25 4.0 3.5 0.30 5.0 2.5 0.25 4.0 2.0 0.25 3.0 1.5 0.25 2.0 3.0 0.30 5.0 2.5 0.25 4.0 2.0 0.25 3.0 3.0 0.30 5.0 2.5 0.25 4.0 2.0 0.25 3.0 1.5 0.25 2.0 3.0 0.30 5.0 2.5 0.25 4.0 2.0 0.25 3.0 3.0 0.30 5.0 2.5 0.25 4.0 2.0 0.25 3.0 1.5 0.25 2.0 3.0 0.30 5.0 2.5 0.25 4.0 2.0 0.25 3.0 3.0 0.30 5.0 2.5 0.25 4.0 2.0 0.25 3.0 1.5 0.25 2.0 5.0 0.30 8.0 4.0 0.30 7.0 3.0 0.25 6.0 5.0 0.30 8.0 4.0 0.30 7.0 3.0 0.25 5.0 2.0 0.25 4.0

0.18 651.713 0.4 400 0.15 651.738 0.3 140 0.12 651.838 0.2 100 0.18 651.713 0.4 260 0.15 651.838 0.2 130 0.12 651.838 0.2 60 0.12 651.824 0.1 25 0.15 651.713 0.4 400 0.12 651.738 0.3 140 0.12 651.838 0.2 100 0.15 651.713 0.4 260 0.12 651.838 0.2 130 0.12 651.838 0.2 60 0.12 651.824 0.1 25 0.15 651.734 0.4 320 0.12 651.737 0.3 140 0.12 651.837 0.2 100 0.15 651.737 0.3 250 0.12 651.837 0.2 130 0.12 651.824 0.1 60 0.12 651.824 0.1 25 0.15 651.737 0.3 320 0.12 651.837 0.2 140 0.12 651.837 0.2 100 0.15 651.737 0.3 250 0.12 651.837 0.2 130 0.12 651.824 0.1 60 0.12 651.824 0.1 25 0.15 651.737 0.3 250 0.12 651.837 0.2 140 0.12 651.837 0.2 100 0.15 651.737 0.3 230 0.12 651.837 0.2 130 0.12 651.824 0.1 60 0.12 651.824 0.1 25 0.15 651.734 0.4 350 0.15 651.632 0.3 140 0.12 651.834 0.2 100 0.15 651.735 0.3 280 0.15 651.834 0.2 150 0.12 651.824 0.1 70 0.12 651.824 0.1 25

0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1

1.2 1.0 0.8 1.2 1.0 0.8 0.7 1.2 1.0 0.8 1.2 1.0 0.8 0.7 1.0 0.8 0.6 1.0 0.8 0.6 0.5 1.0 0.8 0.6 1.0 0.8 0.6 0.5 1.0 0.8 0.6 1.0 0.8 0.6 0.5 1.2 1.0 0.8 1.2 1.0 0.8 0.7

0.10 0.08 0.06 0.10 0.06 0.06 0.04 0.10 0.08 0.06 0.10 0.06 0.06 0.04 0.10 0.08 0.06 0.08 0.06 0.04 0.04 0.08 0.06 0.06 0.08 0.06 0.04 0.04 0.08 0.06 0.06 0.08 0.06 0.04 0.04 0.10 0.08 0.06 0.08 0.06 0.04 0.04

< 450 N/mm2

100 125 130 175 200 250

1.0037 1.0401 1.0715

Steel

80

450-850 N/mm2 100

1.0050

125 130 175 200 250

P 1.0503

1.1141 1.1191 1.5752

Steel

80

850-1200 N/mm2 100

1.2083 1.2294 1.2312 1.2344 1.2764

125 130 175 200 250

Stainless steels,

80

ferritic,

100 125 130 175 200 250

martensitic

1.4016 1.4024 1.4034

M 1.4762

Stainless steels,

80

austenitic

100 125 130 175 200 250

1.4301 1.4311 1.4401 1.4435 1.4571

Gray cast iron

80

100 125 130 175 200 250

GG 15

K GG 20

GG 25 GG 30

Caution: The given cutting data are guide values. In any case, they have to be adapted to the actual working conditions.

For cutting speeds above 240 m/min, we recommend to balance the complete and pre-set tool assembly or to use a balanceable fine boring head on a fine balanced tool shank, e.g. 309.201 and 324.322F.

18

DV/BT40, HSK-A63 Capto C6

Rough boring head SW 25 Fine boring head EWN/EWB 25

Ø 25-33/40 Ø 25-33/40/47

x

x

Ø 24

Ø 24 carbide

Rough boring SW 25

Fine boring EWN/EWB 25

Inserts

Vc

RSS

DVS

Inserts

Vc

Allow.

Feed

Workpiece material

Boring depth

Allow. fn Ra 1.6 µm X [mm] Order No. R m/min mm/Ø mm/U mm/Ø mm/U Order No. R m/min mm/Ø mm/Ø mm/U Allow. Feed Std. val. Max.

GGG

80

654.852 0.4 220 4.00 0.30 7.0 654.852 0.4 140 3.50 0.30 6.0 654.840A 0.2 60 3.00 0.25 5.0 654.852 0.4 220 4.00 0.30 7.0 654.840A 0.2 100 3.50 0.30 6.0 654.840A 0.2 60 3.00 0.25 5.0 654.840A 0.2 25 2.00 0.25 4.0 654.856 0.4 180 3.00 0.30 5.0 654.856 0.4 100 2.50 0.25 4.0 654.846 0.2 60 2.00 0.25 3.0 654.856 0.4 160 3.00 0.30 5.0 654.846 0.2 90 2.50 0.25 4.0 654.846 0.2 60 2.00 0.25 3.0 654.846 0.2 25 1.50 0.25 2.0 654.888 0.4 420 4.00 0.30 7.0 654.888 0.4 200 3.00 0.30 6.0 654.877 0.2 90 2.00 0.25 4.0 654.888 0.4 420 4.00 0.30 7.0 654.888 0.4 200 3.00 0.30 6.0 654.877 0.2 100 2.00 0.25 4.0 654.877 0.2 50 2.00 0.25 4.0 654.889 0.4 320 4.00 0.30 7.0 654.889 0.4 200 3.00 0.30 6.0 654.879 0.2 90 2.00 0.25 4.0 654.889 0.4 320 4.00 0.30 7.0 654.889 0.4 200 3.00 0.30 6.0 654.879 0.2 100 2.00 0.25 4.0 654.879 0.2 50 2.00 0.25 4.0 654.847 0.4 120 3.50 0.25 5.5 654.847 0.4 80 2.50 0.20 4.0 654.847 0.4 120 3.50 0.25 5.5 654.847 0.4 120 2.50 0.20 4.0 654.837 0.2 80 2.00 0.20 3.0

0.15 651.734 0.4 350 0.15 651.735 0.3 140 0.12 651.834 0.2 100 0.15 651.735 0.3 280 0.15 651.834 0.2 150 0.12 651.824 0.1 70 0.12 651.824 0.1 25 0.15 651.734 0.4 320 0.12 651.737 0.3 140 0.12 651.837 0.2 100 0.15 651.737 0.3 250 0.12 651.837 0.2 130 0.12 651.824 0.1 60 0.12 651.824 0.1 25 0.15 651.723 0.3 750 0.15 651.723 0.3 200 0.12 651.825 0.2 120 0.15 651.723 0.3 450 0.15 651.723 0.3 240 0.12 651.825 0.2 150 0.12 651.823 0.1 60 0.15 651.737 0.3 650 0.15 651.737 0.3 200 0.12 651.837 0.2 120 0.15 651.737 0.3 450 0.15 651.737 0.3 240 0.12 651.837 0.2 150 0.12 651.824 0.1 60 0.12 651.737 0.3 120 0.10 651.837 0.2 80 0.12 651.737 0.3 120 0.10 651.837 0.2 70 0.10 651.824 0.1 40

0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.2 0.1 0.2 0.2 0.2 0.2 0.2 0.2 0.1 0.2 0.2 0.2 0.1 0.1

1.2 1.0 0.8 1.2 1.0 0.8 0.7 1.0 0.8 0.6 1.0 0.8 0.6 0.5 1.2 1.2 1.0 1.2 1.2 1.0 0.8 1.2 1.2 1.0 1.2 1.2 1.0 0.8 1.2 1.0 1.2 1.0 0.8

0.10 0.08 0.06 0.08 0.06 0.04 0.04 0.10 0.08 0.06 0.08 0.06 0.04 0.04 0.08 0.08 0.06 0.08 0.08 0.06 0.04 0.08 0.08 0.06 0.08 0.08 0.06 0.04 0.08 0.06 0.08 0.06 0.04

< 500 N/mm2

100 125 130 175 200 250

GGG 40 GGG 50

K

GGG

80

< 800 N/mm2

100 125 130 175 200 250

GGG 60 GGG 70 GGG 80

Aluminium

80

Wrought alloys

100 125 130 175 200 250

Si < 10%

3.1354 3.2315 3.3545

N 3.4365

Aluminium Cast alloys Si > 10% G-AlSi 12

80

100 125 130 175 200 250

G-AlSi17Cu4Mg

80

Titanium

100

3.7164

130 175 200

S

80

654.847 0.4 50 3.00 0.20 4.0 654.837 0.2 30 2.00 0.15 3.0

0.10 651.839 0.2 50 0.10 651.839 0.2 30

0.2 0.1

0.8 0.8

0.06 0.06

Ni-basic-, Co-basic-, Alloys

100

130 175

654.847 0.4 50 3.00 0.20 4.0 654.837 0.2 30 2.00 0.15 3.0

0.10 651.839 0.2 40 0.10 651.839 0.2 25

0.1 0.1

0.6 0.6

0.06 0.06

Remark: For a cost effective high volume production with boring depth X of 130 mm and deeper, carbide bars have to be used.

Extension of the boring range with additional insert holders: • Rough boring: Pair of insert holders 639.427 for the range Ø 32 - 40 mm • Fine Boring: Insert holder size 2, 626.122 for the range Ø 32 - 40 mm, insert holder size 3, 626.123 for the range Ø 39 - 47 mm The given cutting data are valid for insert holder size 1. When using insert holder size 2, the cutting data have to be reduced by 15%, and by 30% when using insert holder size 3.

19

DV/BT40, HSK-A63 Capto C6

Rough boring head SW 32 Fine boring heads EWN/EWB 32

Ø 32-42/51 Ø 32-42/51/60

x

x

Ø 31 carbide

Ø 31

Ø 63.5

Rough boring SW 32

Fine boring EWN/EWB 32

Inserts

Vc

RSS

DVS

Inserts

Vc

Allow.

Feed

Workpiece material

Boring depth

Allow. fn Ra 1.6 µm X [mm] Order No. R m/min mm/Ø mm/U mm/Ø mm/U Order No. R m/min mm/Ø mm/Ø mm/U Allow. Feed Std. val. Max.

Steel

80

654.950 0.8 240 4.50 0.40 8.00 654.940A 0.4 240 4.50 0.35 7.50 654.940A 0.4 160 4.00 0.30 7.00 654.930A 0.2 80 3.50 0.30 5.50 654.940A 0.4 120 3.00 0.30 4.50 654.930A 0.2 70 2.00 0.25 3.50 654.930A 0.2 25 1.50 0.25 3.00 654.950 0.8 220 4.50 0.35 8.00 654.940A 0.4 220 4.50 0.30 7.50 654.940A 0.4 160 4.00 0.30 7.00 654.930A 0.2 80 3.50 0.30 5.50 654.940A 0.4 120 3.00 0.25 4.50 654.930A 0.2 70 2.00 0.25 3.50 654.930A 0.2 25 1.50 0.25 3.00 654.955 0.8 200 4.00 0.35 7.50 654.945 0.4 180 4.00 0.30 7.00 654.945 0.4 140 3.50 0.30 6.00 654.935 0.2 80 3.00 0.30 5.00 654.945 0.4 100 2.50 0.25 4.00 654.935 0.2 70 2.00 0.25 3.50 654.935 0.2 25 1.50 0.25 3.00 654.955 0.8 200 4.00 0.35 7.50 654.945 0.4 180 4.00 0.30 7.00 654.945 0.4 140 3.50 0.30 6.00 654.935 0.2 80 3.00 0.30 5.00 654.945 0.4 100 2.50 0.25 4.00 654.935 0.2 70 2.00 0.25 3.50 654.935 0.2 25 1.50 0.25 3.00 654.955 0.8 160 4.00 0.35 7.00 654.945 0.4 140 4.00 0.30 6.50 654.945 0.4 110 3.50 0.30 6.00 654.935 0.2 70 3.00 0.30 5.00 654.945 0.4 90 2.50 0.25 4.00 654.935 0.2 60 2.00 0.25 3.50 654.935 0.2 25 1.50 0.25 3.00 654.952 0.8 240 7.00 0.40 10.00 654.942 0.4 240 6.00 0.35 9.00 654.942 0.4 160 5.50 0.30 8.00 654.935 0.2 80 5.00 0.25 7.00 654.942 0.4 130 4.50 0.25 6.00 654.935 0.2 70 3.50 0.25 5.00 654.935 0.2 25 2.50 0.25 4.00

0.20 655.385 0.4 400 0.20 655.385 0.4 260 0.17 655.375 0.2 160 0.15 655.375 0.2 80 0.15 655.375 0.2 150 0.12 655.363 0.1 80 0.12 655.363 0.1 25 0.17 655.385 0.4 400 0.17 655.385 0.4 260 0.15 655.375 0.2 160 0.12 655.375 0.2 80 0.15 655.375 0.2 150 0.12 655.363 0.1 80 0.12 655.363 0.1 25 0.17 655.318 0.4 320 0.17 655.318 0.4 240 0.15 655.319 0.2 150 0.15 655.319 0.2 70 0.12 655.319 0.2 140 0.12 655.369 0.1 70 0.12 655.369 0.1 25 0.17 655.318 0.4 320 0.17 655.318 0.4 240 0.15 655.319 0.2 150 0.15 655.319 0.2 70 0.12 655.319 0.2 140 0.12 655.369 0.1 70 0.12 655.369 0.1 25 0.17 655.318 0.4 280 0.17 655.318 0.4 220 0.15 655.319 0.2 150 0.15 655.319 0.2 70 0.12 655.319 0.2 140 0.12 655.369 0.1 70 0.12 655.369 0.1 25 0.20 655.393 0.8 350 0.18 655.383 0.4 300 0.15 655.383 0.4 160 0.12 655.373 0.2 70 0.12 655.383 0.4 150 0.12 655.373 0.2 70 0.12 655.363 0.1 25

0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.1 0.1

1.2 1.2 1.0 0.8 1.2 0.9 0.7 1.2 1.2 1.0 0.8 1.2 0.9 0.7 1.0 1.0 0.8 0.6 1.0 0.7 0.6 1.0 1.0 0.8 0.6 1.0 0.7 0.6 1.0 1.0 0.8 0.6 1.0 0.7 0.6 1.3 1.3 1.1 0.8 1.2 1.0 0.7

0.10 0.10 0.06 0.06 0.06 0.04 0.04 0.10 0.10 0.06 0.06 0.06 0.04 0.04 0.10 0.10 0.06 0.06 0.06 0.04 0.04 0.10 0.10 0.06 0.06 0.06 0.04 0.04 0.10 0.10 0.06 0.06 0.06 0.04 0.04 0.14 0.10 0.10 0.06 0.10 0.06 0.04

< 450 N/mm2

110 130 160 190 230 275

1.0037 1.0401 1.0715

Steel

80

450-850 N/mm2

110 130 160 190 230 275

1.0050

P 1.0503

1.1141 1.1191 1.5752

Steel

80

850-1200 N/mm2 110

1.2083 1.2294 1.2312 1.2344 1.2764

130 160 190 230 275

Stainless steels,

80

ferritic,

110 130 160 190 230 275

martensitic

1.4016 1.4024 1.4034

M 1.4762

Stainless steels,

80

austenitic

110 130 160 190 230 275

1.4301 1.4311 1.4401 1.4435 1.4571

Gray cast iron

80

110 130 160 190 230 275

GG 15

K GG 20

GG 25 GG 30

Caution: The given cutting data are guide values. In any case, they have to be adapted to the actual working conditions.

For cutting speeds above 240 m/min, we recommend to balance the complete and pre-set tool assembly or to use a balanceable fine boring head on a fine balanced tool shank, e.g. 309.301 and 324.331F.

20

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