Surface generation - is there a clear-cut strategy?
One-cut and two-cut machining strategies have advantages and disadvantages. We clarify both alternatives.
Opting for a one-cut or a two-cut machining strategy is a matter of weighing the demands for surface accuracy against overall productivity. Both have their place in today’s HPT environment.
A one-cut ‘metal removal’ strategy is feasible for stable set-ups with a one times diameter (1xD) overhang in internal cutting. For good machining, we recommend chamfered, lightly-honed inserts (S-type) and moderate speed and feed.
Advantages of this approach are quickest possible machining time plus the use of only one tool. Disadvantages include diffi culties in meeting stringent dimensional tolerances, shorter tool life (than two-cut), tolerance deviations due to relatively rapid wear, and the fact that post-hardening shape deviations will impact that of the finished component. | S-type - Chamfer with light honing.
A one-cut machining strategy
removes metal quickly with just one insert. |
T-type - Chamfer with no honing.
A two-cut strategy gives a high quality finished surface with close tolerances. |
A two-cut strategy allows unattended machining of high-quality finished surfaces. We recommend the one-cut roughing inserts with a 1.2 mm radius plus finishing inserts with a chamfer only (T-type). Advantages include tooling optimized for roughing and fi nishing, greater security, closer tolerances and potentially longer runs to tool change. On the other hand, two inserts are needed and total machining time is longer.
To meet very demanding surface quality criteria, we strongly recommend WH wiper geometry, which is specially developed for HPT. |
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