156 180

6 OIL HOLE REAMERS ･･･ (3), (4)
6-1 REAMER GEOMETRY AND APPLICATION

OIL HOLE REAMERS ARE USED FOR CUTTING A SLOT. IF A SLOT CUTTING IS ATTEMPTED WITH AN ORDINAL
REAMER, A CUTTING FLUID DOES NOT REACH THE TIP OF CUTTING EDGE, WHICH LEAD TO A CUTTING
TEMPERATURE RISE AND BUILT-UP EDGE FORMATION. AS A RESULT, IT IS NOT POSSIBLE TO ENSURE
DESIRED CUTTING ACCURACY.
IN THE OIL HOLE REAMER, A CUTTING FLUID IS FED FROM ITS BACK END TO KEEP DOWN THE CUTTING
TEMPERATURE AND MAINTAIN THE CUTTING ACCURACY. CUTTING FLUID HOLE
6-2 MATERIAL
WORKPIECE CUTTING EDGE
Al K-10
6-3 CUTTING CONDITIONS
CUTTING SPEED MACHINING

WORKPIECE FEED mm/rev CUTTING FLUID
m/min ALLOWANCE
Al 40 0.2 WATER SOLUBLE 1 mm
6-4 CUTTING EDGE ANGLES
WORKPIECE RAKE ANGLE RELIEF ANGLE HELIX ANGLE CHAMFER ANGLE
LEFT HAND HELIX,

Al 0° 8° 45°
5-6°
6-5 ACCURACY
SURFACE WORKPIECE
OVERSIZE
ROUGHNESS TOLERANCE
12φH8 X 0.027
4 μ - 6μ 6.3 s
－0
A CUTTING FLUID, FED AT PRESSURE FROM THE BACK END TO THE CUTTING EDGE, HAS THE SIGNIFICANT
EFFECT ON DISPOSAL OF CHIPS.
7 MACHINE REAMER ･･･ (1), (2)

THE MACHINE REAMER HAS A LONG CUTTING PART. BECAUSE A CHAMFER ANGLE IS 45°, IT IS POSSIBLE
TO REAM THE BOTTOM OF A BLIND HOLE.
- 60 -
7-2 MATERIALS
WORKPIECE CUTTING EDGE
Al SKH2-SKH3
FC SKH2-SKH3
STEEL SKH2-SKH3
5-4 CUTTING EDGE ANGLES
CHAMFER
WORKPIECE RAKE ANGLE RELIEF ANGLE HELIX ANGLE
ANGLE
Al 0° 5° -10° STRAIGHT 45°
FC 0° 5° -10° ONE TYPE OF HELIX 45°
STEEL 0° 5° -10° REF. TO JIS 45°
8 HAND REAMERS ･･･ (1), (2)

HAND REAMERS ARE USED FOR REAMING A PILOT HOLE MADE BY A ROUGH REAMER FOR MACHINE. THEY
ARE TURNED BY HANDLE TO FINISH THE HOLE SURFACE.
IT IS IMPORTANT TO TURN THE HANDLE SMOOTHLY AT A CONSTANT SPEED. THE HAND REAMER GENERALLY
HAS A LONG CHAMFER AT THE ANGLE OF 1°FOR STABILIZED LEAD IN.
THE CUTTING EDGE ANGLES ARE SAME AS THE MACHINE REAMER, EXCEPT FOR THE CHAMFER ANGLE.
9 ADJUSTABLE REAMERS ･･･ (3), (4)

ADJUSTABLE REAMERS ARE CAPABLE OF REAMING HOLES IN A CERTAIN RANGE BY ADJUSTING THE CUTTING
BLADES. THE CUTTING BLADES ARE INSERTED IN THE TAPERED GROOVES OF THE BODY AND ADJUSTED BY
THE TIGHTENING NUTS ON THE BOTH SIDES TO A DESIRED SIZE. THE ADJUSTABLE REAMERS DESIGNED FOR
MACHINE OPERATION AND MANUAL OPERATION ARE AVAILABLE.
- 61 -
10 GUN REAMERS ･･･ (3), (4)
GUN REAMERS ARE USED FOR A DEEP HOLE CUTTING. A CUTTING FLUID IS FED MECHANICALLY AT HIGH
PRESSURE FROM THE BACK END TO THE TIP OF THE REAMER TO PREVENT BUILT-UP EDGE FORMATION DUE TO
CUTTING HEAT, MAINTAIN PREDETERMINED ACCURACY AND FLUSH AWAY CHIPS.
AS IMPLIED BY THE NAME, THE GUN REAMER IS ORIGINALLY DESIGNED FOR HIGH PRECISION REAMING OF A
GUN BARREL. THEREFORE, IT IS THE MOST SUITABLE TOOL FOR A DEEP HOLE REAMING.
THE GUN DRILL IS ALSO ORIGINALLY DESIGNED FOR GUN BARREL MACHINING ･･･ REF. TO SECTION 4-12 GUN
DRILL..
11 REGRINDING AND HANDLING PRECAUTIONS ･･･ (1), (2)

PRECAUTIONS FOR REGRINDING AND HANDLING
(1) MEASURE THE OUTSIDE DIAMETER OF (3)
REAMER ･･･ CHECK FOR WEAR.
REDUCE A RADIAL RUN-OUT TO 0.01 OR
BELOW BEFORE REGRINDING
FOR CEMENTED CARBIDE REAMER, DO
NOT HIT THE TIP DURING RUN-OUT
MEASUREMENT. USE THE GUIDE FOR
ADJUSTMENT.
NEVER CAUSE GRINDING BURNING (HSS
MATERIAL)
MAINTAIN THE RUN-OUT ON CHAMFER
WITHIN 0.03 AFTER GRINDING
(2) ENSURE THAT WEAR HAS BEEN REMOVED
THOROUGHLY.
12 TROUBLES AND CHECK POINTS ･･･ (3), (4)

①　　　TROUBLE
LARGE DIAMETER ○ ○
○
○
SMALL DIAMETER ○ ○
○
○
POOR SURFACE ○ ○
ROUGHNESS ○
○
BREAKAGE ○ ○
○
SEIZURE (GUIDE) ○ ○
○
○
○
○
○
○
- 62 -
HOLE CUTTING. A CUTTING FLUID IS FED MECHANICALLY AT HIGH
HE TIP OF THE REAMER TO PREVENT BUILT-UP EDGE FORMATION DUE TO
INED ACCURACY AND FLUSH AWAY CHIPS.
EAMER IS ORIGINALLY DESIGNED FOR HIGH PRECISION REAMING OF A
MOST SUITABLE TOOL FOR A DEEP HOLE REAMING.
ESIGNED FOR GUN BARREL MACHINING ･･･ REF. TO SECTION 4-12 GUN
NEARLY 100% OF REAMERS USED BY HONDA ARE MADE

OF CEMENTED CARBIDES
HARDNESS AND BRITTLENESS ARE THE
CHARACTERISTICS OF CEMENTED CARBIDE REAMERS.
CARE SHOULD BE TAKEN TO AVOID THUMPS AND

BUMPS.
CHECK POINTS
CHECK CUTTING FLUID FOR ADEQUATE FLOW
CHECK CUTTING FLUID FOR SUFFICIENT AMOUNT
CHECK CHAMFER FOR LARGE RUN-OUT
CHECK GUIDE BUSH FOR LOOSENESS
CHECK CLAMP FOR INSUFFICIENT FORCE
CHECK FEED FOR INADEQUATE SPEED
CHECK REAMER FOR INADEQUATE DIAMETER
CHECK REAMER CUTTING EDGE FOR CHIPPING
CHECK CUTTING FLUID FOR ADEQUATE BRAND
CHECK CUTTING SPEED FOR ADEQUATE RATE (RPM)
CHECK CUTTING EDGE FOR CHIP CLOGGING
CHECK FEED FOR TOO FAST RATE
CHECK PILOT HOLE AND REAMER FOR CONCENTRICITY
CHECK WORKPIECE FOR FOREIGN MATERIAL
CHECK REAMER GUIDE FOR REDUCED DIAMETER
CHECK THE REAMER AND BUSH DIAMETERS FOR MATCHING
CHECK FOR BUILT-UP EDGE
CHECK REAMER FLUTE FOR SUFFICIENT DEPTH
- 62 -
[7] FACE MILLING CUTTERS
= TABLE OF CONTENTS =
1. TYPES AND APPLICATION OF FACE MILLING CUTTERS (1), (2)
2. PART NAMES (1), (2)
3. TERMINOLOGY FOR CUTTER ANGLES AND FUNCTIONS (3), (4)
4. TIPS ON THROWAWAY CUTTER ADJUSTMENT AND RUN-OUT

TOLERANCE (3), (4)
5. CUTTER AND TOOL MATERIAL SELECTION BY WORKPIECE

MATERIALS (3), (4)
6. CUTTING CONDITIONS (3), (4)
7. CUTTER ACCURACY AND WORKPIECE PRECISION (3), (4)
8. SURFACE FINISH ACCURACY (3), (4)
9. BUTTON CUTTERS (3), (4)
10. DEBURRING (3), (4)
11. TROUBLESHOOTING (3), (4)
- 63 -
S
PAGE
64
65
65
66
67
67
69
69
70
71
72
- 63 -
[7] FACE MILLING CUTTERS
FACE MILLING CUTTERS HAVE CUTTING TEETH ON THE END FACE AND THE RIM. THE MILLING HEAD ARBOR AND
THE CUTTER HAVE A CENTERING LOCATION TO ENSURE INSTALLATION ALIGNMENT WITH A SPINDLE. FACE
MILLING CUTTERS ARE GENERALLY USED FOR SURFACE CUTTING.
BECAUSE OF LARGE SIZE, INSERT TYPE OR THROWAWAY TYPE ARE COMMONLY USED.
1 TYPES AND APPLICATION OF FACE MILLING CUTTERS ･･･ (1), (2)
THROWAWAY
TYPE SHAPE APPLICATION MACHINE

THROWAWAY NEGATIVE FOR CUTTING OF WORKPIECE HAVING MANY NOT SUITABLE FOR
INTERRUPTED AREAS. MACHINES WITH LOW
STIFFNESS
FOR AN OPERATION WHERE CUTTING EDGES ARE
SUBJECTED TO A SIGNIFICANT SHOCK.
EXTRA HARD WORKPIECE MATERIAL SUCH AS CAST

IRON, STEEL.
POSITIVE GENERAL CUTTING & ROUGH CUTTING OF SOFT STEEL SUITABLE FOR
MACHINES WITH LOW
STIFFNESS
FINISHING OF LIGHT ALLOY, STEEL ALLOY, STAINLESS
STEEL
NEGATIVE- FOR AN OPERATION WITH GENERAL STEEL AND STEEL

POSITIVE ALLOY WHERE CUTTING WIDTH AND DEPTH
ROUGH CUTTING OF DIE STEEL AND STAINLESS STEEL
FOR A PROCESS WHERE CHATTER MARKS TEND TO

OCCUR
FOR A PROCESS WHERE POOR CHIP DISPOSAL IS

POSSIBLY ENCOUNTERED.
BUTTON SUPER FINISHING OF CAST IRON, LIGHT ALLOY
- 64 -
RIM. THE MILLING HEAD ARBOR AND
NMENT WITH A SPINDLE. FACE
NLY USED.
REMARKS
CUTTERS OF φ200 OR
LESS ARE INSTALLED
TO ARBOR. A
CENTERING LOCATION
IS USED AS
REFERENCE FOR φ200
OR OVER
APPLICABLE FOR
CUTTER OF φ250 OR
OVER
- 64 -
2 PART NAMES ･･･ (1), (2)
CUTTER BODY OUTSIDE DIA.
BOSS OUTSIDE DIA.
HOLE DIA
KEY WAY WIDTH
BODY
KEY WAY DEPTH
AXIAL RAKE ANGLE
BACK RING
REFERENCE RING
TRUE RAKE
ANGLE
TIGHTENING BOLT FACE RELIEF ANGLE
THROWAWAY INSERT
CHIP POCKET
PERIPHERAL
CUTTER DIA. (NOMINAL) RELIEF ANGLE
LOCATOR
CHUCK
PORTION A, ENLARGED
REFERENCE RING
FACE CUTTING EDGE ANGLE
RADIAL RAKE ANGLE
FACE CUTTING EDGE

(FLAT DRAG)
NEGATIVE-POSITIVE CUTTER DOUBLE POSITIVE CUTTER DOUBLE NEGATIVE CUTTER
POSITIVE POSITIVE
NEGATIVE POSITIVE
3 TERMINOLOGY FOR CUTTER ANGLES AND FUNCTIONS ･･･ (3), (4)

TERM CODE FUNCTION
(1) AXIAL RAKE ANGLE A.R HAS INFLUENCE ON CHIP FLOW DIRECTION,
ADHESION, THRUST, ETC.
(2) RADIAL RAKE ANGLE R.R
(3) PERIPHERAL CUTTING A.A HAS INFLUENCE ON CHIP THICKNESS AND

EDGE ANGLE FLOW DIRECTION
(4) TRUE RAKE ANGLE T.A ACTUAL RAKE ANGLE
(5) INCLINATION ANGLE I.A HAS INFLUENCE ON CHIP FLOW DIRECTION
- 65 -
(6) FACE CUTTING EDGE F.A HAS INFLUENCE ON FINISHED SURFACE
ANGLE ROUGHNESS
(7) RELIEF ANGLE HAS INFLUENCE ON CUTTING EDGE
STRENGTH, TOOL LIFE, CHATTER MARKS,
ETC.
- 65 -
PERIPHERAL CUTTING
EDGE ANGLE
CUTTER HEIGHT
CUTTING EDGE
TRUE RAKE
INCLINATION
ANGLE
ANGLE
PORTION A
PERIPHERAL
RELIEF ANGLE
PORTION A, ENLARGED
PERIPHERAL CUTTING EDGE ANGLE

(MAJOR CUTTING EDGE)
CHAMFER
FACE CUTTING EDGE
(FLAT DRAG)
DOUBLE NEGATIVE CUTTER
NEGATIVE
NEGATIVE
EFFECT
BOTH ANGLES ARE POSITIVE OR NEGATIVE. TYPICAL
COMBINATIONS ARE POSITIVE-NEGATIVE, POSITIVE-
POSITIVE AND NEGATIVE-NEGATIVE.
WHEN LARGE ･･･ REDUCES CHIP THICKNESS AND

CUTTING LOAD
WHEN POSITIVE (LARGE) ･･･ IMPROVES CUTTING

AND ADHESION RESISTANCE, REDUCES CUTTING
EDGE STRENGTH
WHEN NEGATIVE (SMALL) ･･･ ENHANCES CUTTING

EDGE STRENGTH AND ADHESION RESISTANCE
WHEN POSITIVE (LARGE) ･･･ IMPROVES CHIP

DISPOSAL, REDUCES CUTTING RESISTANCE AND
INSERT CORNER STRENGTH
- 65 -
WHEN SMALL ･･･ IMPROVES SURFACE ROUGHNESS
ACCURACY
- 65 -
4 TIPS ON THROWAWAY CUTTER ADJUSTMENT AND RUN-OUT TOLERANCE ･･･ (3), (4)
4-1 PART NAMES
a CLAMP SCREW
INSERT
b WEDGE A REPLACEMENT
c CLAMP SCREW
d WEDGE B
FRONT RUN-OUT
e FRONT PLATE ADJUSTMENT
f SUPPORTER
4-2 HOW TO INSTALL

* WHEN INSTALLING AN INSERT, CARE SHOULD BE TAKEN NOT
TO CAUSE FOREIGN MATERIALS TO ENTER BETWEEN THE JIG
AND THE REFERENCE SURFACE OF BODY.
* AIR BLOW FOREIGN MATERIALS FROM THE SUPPORT.
* PRESS DOWN THE INSERT IN THE DIRECTION (A) IN THE (B)
MANNER THAT FORCE IS EXERTED EVENLY ON TO THE TWO
POINTS OF REFERENCE SURFACE. (A)
THEN, PRESS DOWN THE INSERT IN THE DIRECTION (B).

PRESSING FORCE SHOULD BE EVENLY EXERTED ON TO THE
THREE POINTS OF REFERENCE SURFACE.
* HOLD THE INSERT WITH THE LEFT HAND AND A WRENCH WITH
THE RIGHT HAND. CLAMP THE WEDGE A.
4-3 RUN-OUT TOLERANCES
ITEM OUTSIDE DIAMETER FACE RUN-OUT
ROUGH CUTTER 0.05 MAX 0.03 MAX
FINISH CUTTER 0.03 MAX 0.01 MAX
4-4 HOW TO INSTALL WIPER INSERT
* A WIPER INSERT IS SO INSTALLED THAT IT PROTRUDES 0.03-
0.05 mm FROM THE INSTALLATION LEVEL OF OTHER INSERTS.
IT SMOOTHED THE SURFACES THAT MAY HAVE BEEN CUT BY
OTHER INSERTS.
* THE LENGTH AND GEOMETRY OF MINOR CUTTING EDGE ARE
VERY IMPORTANT.
MACHINING ALLOWANCE, 0.03-0.05 mm THE LENGTH SHOULD BE LARGER THAN A FEED PER
REVOLUTION OF CUTTER.
4-5 HOW TO INSTALL BUTTON INSERT * A BUTTON INSERT IS SO INSTALLED THAT IT PROTRUDES 0.03-
0.05 mm FROM THE INSTALLATION LEVEL OF OTHER INSERTS.
IT SMOOTHES THE SURFACES THAT MAY HAVE BEEN CUT BY
OTHER INSERTS.
- 66 -
5 CUTTER AND TOOL MATERIAL SELECTION BY WORKPIECE MATERIALS ･･･ (3), (4)
5-1 MATERIALS GENERALLY USED
ROUGHING FINISHING
NEGATIVE- TOOL NEGATIVE-

NEGATIVE POSITIVE NEGATIVE POSITIVE
POSITIVE MATERIAL POSITIVE
LOW-CARBON STEEL ○ P20 ○

ORDINAL CARBON STEEL ○ P20 ○
STEEL
HARDENED STEEL ○ P30 ○

STAINLESS STEEL ○ P20 ○
ORDINAL CAST IRON ○ K10 ○
CAST
IRON
HARD ALLOY CAST IRON ○ K10 ○

FERROUS
ALUMINUM ALLOY ○ K20 ○

NON-
COPPER ALLOY ○ K20 ○
(1) WHEN PREMATURE CHIPPING OF CUTTING EDGE IS ENCOUNTERED.

* CHANGE THE TOOL MATERIAL TO A MATERIAL WITH HIGHER TOUGHENS, e.g. K10 → K20
(2) WHEN PREMATURE WEAR OF CUTTING EDGE IS ENCOUNTERED.
* CHANGE THE TOOL MATERIAL TO A MATERIAL WITH HIGHER HARDNESS, e.g. P20 → P10
6 CUTTING CONDITIONS ･･･ (3), (4)

6-1 HOW TO DETERMINE CUTTING CONDITIONS
TO IMPROVE THE MILLING EFFICIENCY, IT IS NECESSARY TO INCREASE THE CUTTING SPEED AND THE FEED
RATE PER TOOTH AT THE SAME TIME. IF ONLY THE CUTTING SPEED IS INCREASED, THE NUMBER OF CUTS
INCREASES. THE EFFICIENCY DECREASES INSTEAD.
IT IS VERY IMPORTANT TO FACTOR IN THE CUTTING SPEED, CUT AND FEED PER TOOTH TO DETERMINE PROPER
CUTTING CONDITIONS FOR MILLING.
(1) WORKPIECE MATERIALS

* WORKPIECE MATERIALS HAVE SIGNIFICANT INFLUENCE ON CUTTING CONDITIONS
TYPES OF MATERIALS, HEAT TREATMENT BEFORE CUTTING, HARDNESS AND MACHINABILITY ARE
IMPORTANT FACTORS.
IN GENERAL, THE CUTTING FORCE IS RELATED TO BRINELL HARDNESS OF WORKPIECE MATERIAL. THE
MORE THE HARDNESS INCREASES, THE LOWER THE CUTTING CONDITIONS BECOME.
(2) MILLING CUTTER MATERIALS

* CEMENTED CARBIDES ARE AVAILABLE IN THREE TYPES: P, M, K. IF A FIGURE ASSOCIATED WITH THE
CHARACTER CODES IS SMALL, THE WEAR RESISTANCE IS LARGE, AND THUS SUITABLE FOR HIGH-SPEED
CUTTING. IF A FIGURE IS LARGE, THE TOUGHNESS INCREASES. IN THIS CASE, THE FEED RATE CAN BE
INCREASED.
* DIAMOND WIPER INSERTS ARE LATELY USED FOR FINISHING Al MATERIAL WORKPIECES.
- 67 -
FINISHING
TOOL
MATERIAL
P20
P20
P20
P20
K10
K10
K20
K20
SPEED AND THE FEED

HE NUMBER OF CUTS
TH TO DETERMINE PROPER
ONS
MACHINABILITY ARE
RKPIECE MATERIAL. THE

ECOME.
ASSOCIATED WITH THE

UITABLE FOR HIGH-SPEED
, THE FEED RATE CAN BE
RKPIECES.
- 67 -
(3) MACHINE OUTPUT AND STIFFNESS
* IF A MACHINE LACKS IN POWER AND STIFFNESS, THE CUTTING EDGE OF A MILLING CUTTER
TENDS TO CHIP.
USE A MILLING CUTTER WITH LESS CUTTING EDGES AND INCREASE THE FEED PER TOOTH.
(4) STIFFNESS OF WORKPIECE AND MILLING CUTTER HOLDERS

* IF HOLDERS FOR WORKPIECE AND MILLING CUTTER LACK IN STIFFNESS, VIBRATION AND
DEFORMATION TEND TO OCCUR, WHICH AFFECTS THE SERVICE LIFE OF MILLING CUTTER AND
MILLING ACCURACY.
(5) SERVICE LIFE OF CUTTING EDGE

* ENSURE THAT THE CUTTING EDGE OF A MILLING CUTTER CUTS INTO WORKPIECE AT AN ANGLE
OF 30°OR BELOW (CHAMFER ANGLE).
IF THE ANGLE EXCEEDS 30°, THE SERVICE LIFE OF CUTTING EDGE BECOMES SHORT RAPIDLY.
(6) GENERAL PRINCIPLE FOR DETERMINING CUTTING CONDITIONS

CUTTING SPEED FEED PER TOOTH CUT
ROUGHING LOW LARGE DEEP
FINISHING HIGH SMALL SHALLOW
HARD MATERIAL LOW SMALL SHALLOW
6-2 DETERMINATION OF CUTTING CONDITIONS

(1) CUTTING SPEED (2) FEED D: MILLING CUTTER DIA. (mm)
N: NUMBER OF MAIN SPINDLE
* MILLING CUTTER PERIPHERAL * FEED OF TABLE, R [m/min] REVOLUTION (RPM)
VELOCITY, V [m/min] T: FEED TIME PER TABLE
D ・π ROTATION
R= 1
π・D・ T D1: TABLE DIA.
V= N Z: NUMBER OF TOOTH
1000 R= N ・ Z ・ Sz
(3) CUTTING TIME
* CUTTING TIME, T [min]
* FEED PER REV., F [m/rev]
L
T = R = L1+D+R1+R2 R
R F= N
THE LENGTH OF TABLE FEED * FEED PER TOOTH, Sz [mm/TOOTH]
F R
Sz = Z = Z・N
- 68 -
6-3 GENERAL CUTTING CONDITIONS
WORKPIECE MATERIAL CUTTING CONDITIONS ROUGHING
CUTTING SPEED (m/min) 100 - 140
LOW-CARBON STEEL
FEED PER TOOTH (mm/tooth) 0.1 - 0.3
ORDINAL CARBON STEEL
STEEL

HARDENED STEEL
STAINLESS STEEL
CAST IRON
ORDINAL CAST IRON

HARD ALLOY CAST IRON
ALUMINUM ALLOY
FERROUS

NON

COPPER ALLOY
7 CUTTER ACCURACY AND WORKPIECE PRECISION ･･･ (3), (4)

7-1 IRREGULARITY OF CUTTING EDGE WORKPIECE
* IT LEAVES IRREGULAR FEED MARKS ON THE MACHINED SURFACE.
7-2 RUN-OUT OF MILLING MACHINES ONE REVOLUTION
* IT LEAVES UNDULATING SURFACE CORRESPONDING TO THE

AMOUNT OF RUN-OUT PER REVOLUTION.
WORKPIECE
8 SURFACE FINISH ACCURACY ･･･ (3), (4)

8-1 DEPENDING ON THE FEED PER TOOTH
* SURFACE ROUGHNESS BECOMES FINER BY REDUCING THE FEED
PER TOOTH.
8-2 CUTTING SPEED (1) CHANGE TOOL MATERIAL TO
* SURFACE ROUGHNESS BECOMES FINER BY INCREASING THE THOSE OF LESSER Co CONTENT.
SPEED. (2) INCREASE THE CUTTING
SPEED AND REDUCE THE CUT.
8-3 MINOR CUTTING EDGE ANGLE (3) REDUCE THE FEED PER TOOTH
* DECREASE THE ANGLE TO THE EXTENT THAT CHATTER DOES NOT TO MAKE CHIPS THINNER.
OCCUR. (4) INCREASE THE RAKE ANGLE.
8-4 MAINTAIN THE ACCURACY OF CUTTING EDGE RUN-OUT.
8-5 USE INSERTS (WIPER INSERTS) DESIGNED SPECIFICALLY FOR FINISHING.
8-6 PREVENT THE BUILT-UP EDGE FORMATION.
- 69 -
FINISHING
130 - 160
0.05 - 0.1
100 - 140
0.05 - 0.1
60 - 90
0.05 - 0.1
50 - 100
0.07 - 0.1
80 - 120
0.05 - 0
60 - 80
0.05 - 0.1
400 - 800
0.03 - 0.08
400 - 800
0.03 - 0.08
WORKPIECE
ONE REVOLUTION
WORKPIECE
HANGE TOOL MATERIAL TO

HOSE OF LESSER Co CONTENT.
NCREASE THE CUTTING
PEED AND REDUCE THE CUT.
EDUCE THE FEED PER TOOTH
O MAKE CHIPS THINNER.
NCREASE THE RAKE ANGLE.
- 69 -
9 BUTTON CUTTERS ･･･ (3), (4)
BUTTON CUTTERS ARE USED FOR MILLING OPERATIONS WHERE THE MACHINED SURFACE HAS TO BE IN A
LARGE RADIUS SHAPE AND THE SURFACE FINISH OF 6.3 S OR LESS IS REQUIRED.
THEY ARE ORIGINALLY DESIGNED BY HONDA FOR THESE PURPOSES.
THE BUTTON CUTTER HAS ELIMINATED BOTTLENECKS SUCH AS SURFACE FINISH ACCURACY, WORK
SIMPLIFICATION, COST REDUCTION OF TOOLS THAT HAD BEEN ENCOUNTERED WITH CONVENTIONAL
INSERTS USED FOR FINISHING OPERATIONS.
9-1 R-SHAPE ON THE CUTTING EDGE

* STUDY
WHEN A ROUND BAR IS TILTED, THE END FACE OF ROUND BAR THAT IS TANGENT TO THE WORKPIECE
SURFACE BECOMES A CIRCULAR ARC PROFILE OF A LARGE GENERATED CURVE.
THE WORKPIECE SURFACE CAN BE MACHINED INTO A LARGE RADIUS SHAPE DEPENDING ON ANGLES
OF TILT.
FEED OF TABLE
3 mm
CONDITION 1) SURFACE ROUGHNESS: 6.3 S OR LESS

2) FEED OF TABLE: 3 mm/rev
(CUTTER 1 rev/FEED)
(CUT AGAINST FEED)

WHEN H = 4μ, HOW MANY DEGREES SHOULD θ°TILTED?
(CUTTER 1 rev/FEED)
9-2 MACHINED SURFACE GEOMETRY

FEED: 3 mm/rev
FEED SURFACE ROUGHNESS 4μ
TILTING ANGLE OF BUTTON CUTTER: 1°30'
- 70 -
9-3 HOW TO USE BUTTON CUTTERS
* BUTTON CUTTERS
FINISHING TOOTH
ROUGHING
TOOTH
0.05mm(MACHINING ALLOWANCE OF FINISHING TOOTH)

FINISHING
ROUGHING TOOT
TOOTH
(THROWAWAY INSERTS)
0.03 ～ 0.05mm(MACHINING ALLOWANCE OF BUTTON CUTTER)
10 DEBURRING ･･･ (3), (4)

(1) MILLING OPERATION ON WORKPIECE MADE OF Al AND Fc LEAVES BURRS IN THE DIRECTION OF CUTTING.
A BUFF INSTALLED TOGETHER WITH THE FINISHING CUTTER IS USED FOR DEBURRING.
FINISHING CUTTER
BUFF
STAINLESS STEEL WIRES
WORKPIECE
DIRECTION OF FEED
- 71 -
BUTTON INSERTS ARE INSTALLED AT 2 POSITIONS, WHICH HAS
MADE THE SETUP EASY AND REDUCED THE TOOL COST.
BECAUSE OF THE DOUBLE-TOOTH CUTTING, THERE IS SOME

LIMITATIONS ON WORKPIECE GEOMETRY DUE TO CUTTING
RESISTANCE AND THE POSITION OF INSTALLATION DUE TO
JIGS.
FINISHING TOOTH)
THE COMBINED USE WITH THROWAWAY INSERTS HAS

PROVIDED A WAY TO USE THE BUTTON CUTTER IN CUTTING
OPERATIONS WHERE THE USE OF BUTTON CUTTER HAD BEEN
IMPRACTICABLE.
AS SHOWN IN THE FIGURE AT LEFT, THE BUTTON CUTTER IS

NOW USED FOR MACHINING OF Fc MATERIAL WORKPIECES.
OF BUTTON CUTTER)
WORKPIECE MADE OF Al AND Fc LEAVES BURRS IN THE DIRECTION OF CUTTING.
THER WITH THE FINISHING CUTTER IS USED FOR DEBURRING.
BUFF
STAINLESS STEEL WIRES
* A BUFF USES STAINLESS STEEL WIRES OF φ 0.18.

* BUFFS ARE INSTALLED AT 2 TO 4 POSITIONS PER MILLING
CUTTER.
- 71 -
11 TROUBLESHOOTING ･･･ (3), (4)
TROUBLE CAUSES COUNTERMEASURE
* TOO FAST CUTTING SPEED (INCREASE IN THE NUMBER OF * REDUCE THE CUTTING SPEED
IMPACT LOAD RECEIVING)
* TOO SLOW CUTTING SPEED (FALLING OF MACHINE * INCREASE THE CUTTING SPEED
TOOTH)
* INAPPROPRIATE CUTTING EDGE GEOMETRY (RAKE * CHANGE THE INSERTS (NEGATIVE)

CHIPPING
ANGLE)
* VIBRATION OCCURRENCE * ENHANCE THE STIFFNESS OF MACHINE AND JIG, CHANGE

THE NUMBER OF TOOTH
* INAPPROPRIATE TOOL MATERIAL (HARD) * CHANGE TO MATERIALS WITH MORE TOUGHNESS

* POOR CHIP REMOVAL (COPPER) * REDUCE THE CUTTING WIDTH
* CHANGE THE INSERTS (NEGATIVE)
* TOO MUCH FEED (OVERLOAD) * REDUCE THE FEED
* TOO MUCH CUT (OVERLOAD) * REDUCE THE CUT
FRACTURE
* VIBRATION OCCURRENCE * ENHANCE THE STIFFNESS OF MACHINE AND JIG

* INSUFFICIENT MACHINE POWER * INCREASE THE POWER
* EXCESSIVE OVERHANG OF INSERTS * REDUCE THE OVERHANG OF INSERTS
* INAPPROPRIATE TOOL MATERIAL * CHANGE TO MATERIALS WITH MORE TOUGHNESS
* TOO FAST CUTTING SPEED * REDUCE THE CUTTING SPEED
FLANK WEAR
* TOO SMALL FEED * INCREASE THE FEED

* INAPPROPRIATE TOOL MATERIAL * CHANGE TO HARD MATERIALS
* INSUFFICIENT STIFFNESS OF WORK HOLDER * ENHANCE THE WORK HOLDING FORCE
* INSUFFICIENT NUMBER OF TOOTH WORKING * CHANGE TO A MILLING CUTTER HAVING MORE TEETH
SIMULTANEOUSLY (CAST IRON)
* INCREASE THE CUTTING WIDTH

CHATTER
* TOO SMALL FEED * INCREASE THE FEED

* TOO FAST OR TOO SLOW CUTTING SPEED * REDUCE OR INCREASE THE CUTTING SPEED
* INSUFFICIENT ACCURACY OF CUTTER * ADJUST RUN-OUT
* INAPPROPRIATE INSERT GEOMETRY (SMALL MINOR * INCREASE THE MINOR CUTTING EDGE ANGLE
CUTTING EDGE ANGLE)
* BUILT-UP EDGE FORMATION * ELIMINATE THE CAUSES OF BUILT-UP EDGE

POOR SURFACE FINISH
* TOO MUCH FEED * REDUCE THE FEED

* TOO SLOW CUTTING SPEED * INCREASE THE SPEED TO THE EXTENT THAT ABNORMAL WEAR DO
NOT OCCUR ON THE CUTTING EDGE.
* INAPPROPRIATE CUTTING EDGE * REDUCE THE MINOR CUTTING EDGE ANGLE TO THE
EXTENT THAT CHATTER MARKS DO NOT OCCUR.
* EXCESSIVE RUN-OUT * INSTALL INSERTS PROPERLY
- 72 -
[8] GENERAL CUTTERS
1. COUNTER BORING TOOLS

1-1 GEOMETRY AND APPLICATION (1), (2)
1-2 TOOL MATERIALS (1), (2)
1-3 INCLUDED ANGLE (1), (2)
1-4 CUTTING ACCURACY (3), (4)
1-5 CUTTING CONDITIONS (3), (4)
1-6 TROUBLESHOOTING (3), (4)
1-7 TIPS ON REGRINDING (1), (2)
2. END MILLS
3. SIDE MILLING CUTTERS

3-3 CUTTING DIRECTION (1), (2)
3-8 CENTERING OF GRINDING WHEEL AND MILLING CUTTER (1), (2)
- 73 -
S
S=
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- 73 -
4. KEYWAY CUTTERS
5. METAL SAWS
6. PLAIN MILLING CUTTERS

- 74 -
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- 74 -
[8] GENERAL CUTTERS
GENERAL CUTTERS ARE CUTTING TOOLS THAT HAVE A SINGLE- OR MULTI-TOOTH CUTTER. A CUTTER,
ROTATING AT A CONSTANT SPEED, REMOVES MATERIAL FROM FLAT, CURVED OR INSIDE SURFACES.
THE FOLLOWING TOOLS ARE CALLED AS GENERAL CUTTERS AT HONDA.
1. COUNTER BORING TOOL 2. END MILL 3. SIDE MILLING CUTTER
4. KEY-SLOT CUTTER 5. METAL SAW (SCREW SLOTTING CUTTER) 6. PLAIN MILLING CUTTER
1 COUNTER BORING TOOLS

1-1 GEOMETRY AND APPLICATION ･･･ (1), (2)
(1) GEOMETRY… THE BODY, AVAILABLE IN VARIOUS SHAPES, HAS CUTTING
TEETH ON ITS END FACE AND RIM.
(2) APPLICATION… -1 TO PRODUCE DEPRESSIONS IN SURFACE TO
ACCOMMODATE THE HEADS OF SCREWS.
-2 COUNTERBORING OF THE SURFACES OF BOSSES.
-3 TO MAKE EXISTING HOLES OR CORED HOLES WIDER.
EXAMPLE
-4 TO MAKE STEPPED HOLES IN VARIOUS SHAPES
1-2 TOOL MATERIALS ･･･ (1), (2)
(1) TYPE……… HIGH-SPEED STEEL AND CEMENTED CARBIDES TOOLS ARE AVAILABLE. CEMENTED
CARBIDES TYPES ARE COMMONLY USED LATELY TO MEET DEMANDING CUTTING
CONDITIONS; VARIOUS WORKPIECE MATERIAL AND GEOMETRY, IMPROVED
PERFORMANCE OF MACHINE TOOLS.
(2) BY AS SPECIFIED BY THE HES STANDARDS, K10 OR K20 ARE USED FOR Al, Fc OR Fe
WORKPIECE WORKPIECE. TOOL MATERIALS OTHER THAN K10 AND K20 ARE USED DEPENDING ON
MATERIAL… WORKPIECE AND CUTTING CONDITIONS.
1-3 INCLUDED ANGLE ･･･ (1), (2)

(1) RAKE ANGLE AND RELIEF ANGLE
MAKE BOTH THE RAKE AND RELIEF ANGLES SMALLER FOR HARD MATERIALS AND LARGER FOR SOFT
MATERIALS.
(BY WORKPIECE MATERIAL)

RAKE ANGLE RELIEF ANGLE * LARGE RAKE ANGLE * LARGE RELIEF ANGLE
Al 10°　-　15° 6° a) SMALL CUTTING RESISTANCE

a) LESSER FRICTION WITH MACHINED
SURFACE, LESSER WEAR
Fc 0°　-　3° 6° b) IMPROVED SHARPNESS
b) POORER HEAT RELEASE, CUTTING

Fe 6° 6° c) WEAK CUTTING EDGE, SHORT LIFE
EDGE WEAKENS
- 75 -
TH CUTTER. A CUTTER,
R INSIDE SURFACES.
3. SIDE MILLING CUTTER

6. PLAIN MILLING CUTTER
EXAMPLE
E AVAILABLE. CEMENTED
DEMANDING CUTTING
METRY, IMPROVED
USED FOR Al, Fc OR Fe

ARE USED DEPENDING ON
IALS AND LARGER FOR SOFT
- 75 -
* LAND: GENERALLY, THE COUNTER BORING TOOL HAS A CUTTING
EDGE ON THE OUTER CORNER OF TOOTH. TO STABILIZE
RELIEF ANGLE DIAMETER AND PREVENT CHATTER MARKS AT START OF
CUTTING, THE TOOL USED AT HONDA HAS A ROUNDED LAND OF
0.3-0.5 mm.
LAND WIDTH
RAKE ANGLE
1-4 CUTTING ACCURACY ･･･ (3), (4)

ACCURACY (SURFACE ROUGHNESS AND OVERSIZE) IS DEPENDENT ON THE FOLLOWING FACTORS.
* CUTTING CONDITIONS * TOOL * WORKPIECE MATERIAL * MACHINE TOOL * CUTTING FLUID
(1) SURFACE ROUGHNESS
THE SURFACE ROUGHNESS IN THE RAGE OF 12.5-100 S CAN BE OBTAINED. BY CHANGING CUTTING
CONDITIONS (CUTTING SPEED, FEED, ETC), IT IS POSSIBLE TO REDUCE THE RANGE TO 1.6-6.3 S.
(THE END FACE ONLY)
(2) OVERSIZE
OVERSIZE IS ALMOST SAME FOR Al, Fc OR Fe MATERIALS. SUPPOSE A DIAMETER OF HOLE IS φ10-
20, THE OVERSIZE IS 0-1.2.
1-5 CUTTING CONDITIONS ･･･ (3), (4)
(1) CUTTING SPEED, FEED AND CUTTING FLUID
(BY WORKPIECE MATERIAL)
CUTTING SPEED (m/min) FEED (mm/rev) CUTTING FLUID
Al 50-80 0.1-0.2 WATER SOLUBLE
Fc 15-40 0.05-0.15 NOT REQUIRED
Fe 10-30 0.05-0.10 WATER INSOLUBLE
* SOME WORKPIECES MANUFACTURED BY HONDA REQUIRE
THE SURFACE ROUGHNESS OF 1.6-6.3 S.
TO PREVENT THE BUILT-UP EDGE FORMATION AND THE

CUTTING SPEED (m/min)
BUILT-UP EDGE
ABRASION ON MACHINED SURFACE CAUSED BY WORKPIECE DOES NOT TAKE
PLACE
MATERIAL BUILDING UP, A SLIGHTLY HIGHER CUTTING SPEED
(100-150 m/min) IS OFTEN ADOPTED WHILE THE RAKE ANGLE IS
INCREASED. BY DOING SO, CUTTING OPERATION IS BUILT-UP
EDGE TAKES
PERFORMED UNDER MARGINAL CONDITION IN WHICH BUILT-UP PLACE
EDGE FORMATION CAN BE ELIMINATED.
FEED (mm)
MARGINAL CONDITION TO ELIMINATE BUILT-UP EDGE FORMATION ON Al ALLOY
- 76 -
1-6 TROUBLESHOOTING ･･･ (3), (4)
(1) CHATTER ON THE EDGE

-1 CHECK THE RAKE ANGLE IF IT IS APPROPRIATE FOR WORKPIECE MATERIAL
-2 CHECK THE SPINDLE FOR DEFLECTION IN THRUST OR AXIAL DIRECTION
-3 CHECK THE SPINDLE FOR STIFFNESS
-4 CHECK THE CLAMP FOR INSUFFICIENT FORCE WITH RESPECT TO WORKPIECE
-5 CHECK THE CUTTING WIDTH FOR INADEQUATE LARGENESS ･･･ INSERT CHIP BREAKER IN THE END FACE
INSERTS TO REDUCE THE CUTTING WIDTH PER TOOTH.
(2) CHATTER ON INSIDE SURFACE
-1 CHECK THE SPINDLE BEARING FOR LOOSENESS ･･･ TORQUE OR REPLACE WITH NEW PARTS.
-2 CHECK THE CUTTING EDGE FOR EXCESSIVE SHARPNESS ･･･ ROUND LAND OF MINOR CUTTING EDGE OR
NEGATIVE CUTTING EDGE ANGLE TO OVERCOME LEAD IN.
-3 CHECK THE MINOR CUTTING EDGE FOR TOO MUCH CONTACT ･･･ INCREASE THE BACK TAPER
(3) LARGE INSIDE DIAMETER
-1 CHECK FOR EXCESSIVE BUILT-UP EDGE ･･･ CHECK THE CUTTING FLUID FOR DISTRIBUTION AND THE
CUTTING SPEED
-2 CHECK THE CUTTING EDGE FOR RUN-OUT ･･･ ENSURE ALIGNMENT OF THE GUIDE AND BUSH
-3 CHECK FOR DOUBLE CUTTING
(4) OVERLOAD
-1 CHECK THE THRUST FORCE OF MACHINE
-2 CHECK THE TEETH FOR APPROPRIATE RAKE ANGLE
-3 CHECK THE CUTTING WIDTH FOR INADEQUATE LARGENESS ･･･ INSERT CHIP BREAKER IN THE END FACE
INSERTS TO REDUCE THE CUTTING WIDTH PER TOOTH.
(5) DRILL BREAKAGE (INDEXABLE DRILL)
-1 CHECK THE HELICAL GROOVE FOR APPROPRIATE LOCATION ･･･ ALIGN THE CUTTER FLUTE AND DRILL
FLUTE TO IMPROVE THE FLOW OF CHIPS. INCREASE THE CHIP POCKET SIZE OF CUTTER FOR BETTER
FLOW OF CHIPS.
-2 CHECK THE DRILL SHANK FOR ADEQUATE THICKNESS
-3 THE ALIGNMENT OF GUIDE AND BUSH ･･･ REPLACE WHEN TOO LOOSE
(6) ABNORMAL WEAR

-1 CHECK THE TOOL MATERIAL IF IT IS APPROPRIATE WITH RESPECT TO WORK MATERIAL
-2 CHECK THE CUTTING CONDITIONS FOR ADEQUACY
-3 CHECK THE CUTTING FOR HANGING.
-4 CHECK THE TOOL IF ITS SERVICE LIFE HAS BEEN EXPIRED.
- 77 -
F IT IS APPROPRIATE FOR WORKPIECE MATERIAL
DEFLECTION IN THRUST OR AXIAL DIRECTION
NSUFFICIENT FORCE WITH RESPECT TO WORKPIECE

TH FOR INADEQUATE LARGENESS ･･･ INSERT CHIP BREAKER IN THE END FACE
CUTTING WIDTH PER TOOTH.
RING FOR LOOSENESS ･･･ TORQUE OR REPLACE WITH NEW PARTS.

E FOR EXCESSIVE SHARPNESS ･･･ ROUND LAND OF MINOR CUTTING EDGE OR
ANGLE TO OVERCOME LEAD IN.
NG EDGE FOR TOO MUCH CONTACT ･･･ INCREASE THE BACK TAPER
UILT-UP EDGE ･･･ CHECK THE CUTTING FLUID FOR DISTRIBUTION AND THE
E FOR RUN-OUT ･･･ ENSURE ALIGNMENT OF THE GUIDE AND BUSH
PPROPRIATE RAKE ANGLE

TH FOR INADEQUATE LARGENESS ･･･ INSERT CHIP BREAKER IN THE END FACE
CUTTING WIDTH PER TOOTH.
OVE FOR APPROPRIATE LOCATION ･･･ ALIGN THE CUTTER FLUTE AND DRILL
LOW OF CHIPS. INCREASE THE CHIP POCKET SIZE OF CUTTER FOR BETTER
FOR ADEQUATE THICKNESS

E AND BUSH ･･･ REPLACE WHEN TOO LOOSE
CHECK THE BUSH IF IT IS IN ACTION DURING MACHINING.
AL IF IT IS APPROPRIATE WITH RESPECT TO WORK MATERIAL

DITIONS FOR ADEQUACY
ERVICE LIFE HAS BEEN EXPIRED.
- 77 -
1-7 TIPS ON REGRINDING ･･･ (1), (2)
(1) AREAS TO BE REGROUND
RAKE FACE AND FLANK
(2) TIPS
-1 PERFORM REGRINDING IN A STATE SIMILAR TO ACTUAL USE.
(e.g. IN THE CASE OF TAPER SHANK, USE THE TAPER AS REFERENCE.)
-2 IF THE END FACE OF CUTTING EDGE IS GROUND, GRIND THE BODY AS WELL SO THAT ADEQUATE SIZE
OF CHIP POCKET IS MAINTAINED.
-3 REMOVE THE BUILT-UP EDGE ON THE RAKE FACE THOROUGHLY WITH OIL STONES OR BY GRINDING.
-4 IF PARALLELISM OR RUN-OUT OF THE CUTTING EDGE ON THE END FACE SEEM TO BE CLOSER TO THE
TOLERANCES, MEASURE THEM WITH A SMALL TEST TO ENSURE THAT THEY ARE WITHIN THE
TOLERANCES.
-5 AS FOR CUTTERS THAT NEED PROFILE SHAPE, GRIND ONLY THE RAKE FACE AND CHECK THE PROFILE
WITH THE PROJECTION DRAWING (e.g. SEAT CONTERBORING CUTTER)
-6 WHEN ROUGHING, DO NOT PRESS THE TOOL STRONGLY; OTHERWISE CHIPPING OCCURS.
- 78 -
2 END MILLS
(1) GEOMETRY
THE END MILL HAS THE CUTTING TEETH ON ITS END FACE AND RIM.
(2) APPLICATION
(1) SLOT MILLING, (2) LATERAL FACE MILLING, (3) NARROW PLAIN SURFACE MILLING
* HONDA USES SEVERAL END MILLS FOR MASS-PRODUCTION. MOST OF END MILLS POSSESSED BY
HONDA ARE USED FOR JIG OR DIE MACHINING.
(3) TYPES
-1 STRAIGHT SHANK TWO-FLUTE END MILL
-2 SHELL END MILL
-3 TAPER
-4 BALL NOSE END MILL FOR DIESINKING
-5 TAPER END MILL FOR DIESINKING
-6 STRAIGHT SHANK END MILL
-7 TAPER SHANK END MILL
ESPECIALLY FOR DIE MACHINING, END MILL ROUGHING CUTTER WITH CHIP BREAKER IS USED.
(1) TYPES
(2) INSERT MATERIAL BY WORKPIECE MATERIAL
-1 Al ･･･ K10
-2 Fc ･･･ K10
-3 Fe ･･･ K10
2-3 INCLUDED ANGLE ･･･ (1), (2)
(1) CUTTING EDGE
-1 STRAIGHT FLUTE
-2 HELICAL FLUTE
- 79 -
(2) PERIPHERAL RELIEF GEOMETRY
THE PERIPHERAL RELIEF CAN BE MADE IN FOLLOWING 3 SHAPES DEPENDING ON GRINDING WHEEL
SHAPES AND POSITIONS FOR USE.
a. CONCAVE TYPE WHEEL
b. FLAT TYPE
c. EXOCENTRIC TYPE
EXOCENTRIC
FLAT
CONCAVE c
b
a
THE SERVICE LIFE OF A TOOL WITH THE PERIPHERAL RELIEF OF EXOCENTRIC SHAPE CAN BE 1.5 TO
2 TIMES LONGER.
NOTE: HOW TO MAKE EXOCENTRIC SHAPE

SPECIAL GRINDING MACHINES ARE NOT NECESSARY. THE WIDTH OF GRINDING WHEEL IS
DETERMINED BY THE DIAMETER AND HELIX ANGLE OF END MILLS.
IF THE GRINDING WHEEL WIDTH IS AT LEAST 25% OF THE DIAMETER OF END MILL, THERE IS NO
INTERFERENCE BETWEEN TEETH.
ALIGN THE GRINDING WHEEL AXIALLY PARALLEL TO THE TOOL. IN PARALLEL TO THE TOOL
PERIPHERY, CARRY OUT A DRESSING ON THE WHEEL PERIPHERY ON THE SKEW ACCORDING TO THE
REQUIRED AMOUNT OF RELIEF. OR ALIGN THE GRINDING WHEEL AXIS ON THE SKEW TO THE TOOL
AXIS.
REFER TO THE FOLLOWING FIGURE FOR THE CALCULATION OF ANGLE OF INCLINATION.
GRIND WHEEL AXIS
θ: ANGLE OF INCLINATION
GRIND WHEEL WITH AN ANGLE H: HELIX ANGLE
β: RELIEF ANGLE
GRIND WHEEL AT Tan θ = Tan β X Tan H

AN ANGLE
BY MAKING THE PERIPHERAL MINOR RELIEF ANGLE IN THE EXOCENTRIC SHAPE WITH THE ABOVE
PROCEDURE, A LONGER SERVICE LIFE OF TOOL CAN BE EXPECTED. IN THIS CASE, THE THIRD
ANGLE IS NOT GROUND GENERALLY. IF A NARROWER RELIEF WIDTH IS NEEDED, IT IS DESIRABLE TO
MAKE THE THIRD ANGLE WHICH IS A 5-DEGREE LARGER THAN THE RELIEVING ANGLE.
- 80 -
(3) HELIX ANGLE AND RELIEF ANGLE
HELIX ANGLE (α) RELIEF ANGLE (r)
Al 40° 10-12°
Fc 30° 4-7°
Fe 45° 5-6°
-1 DEFINITION OF TOOTH AND HELIX

ROTATION OF CUTTER TOOTH HELIX
LEFT HAND
ROTATION LEFT HAND CUT LEFT HAND HELIX
DRIVE SIDE
END MILL
RIGHT HAND
ROTATION RIGHT HAND CUT RIGHT HAND HELIX
LEFT HAND
ROTATION LEFT HAND CUT RIGHT HAND HELIX
DRIVE SIDE
RIGHT HAND
ROTATION
RIGHT HAND CUT LEFT HAND HELIX

(1) SURFACE ROUGHNESS: 12.5 S - 100 S
(2) OVERSIZE: 0.2 - 0.4 (UP TO φ20) * HONDA ALSO ADOPTS THE TOLERANCE ±0.05
DEPENDING ON MACHINE ACCURACY AND CUTTING
PURPOSES.

Fc 15-40 0.18-0.20 NON

(1) AREAS TO BE REGROUND
THE CUTTING TEETH ON THE END FACE AND RIM.
(2) TIPS
-1 IF THE CUTTER DIAMETER HAS TO BE MAINTAINED, GRIND ONLY THE END FACE.
-2 MAKE THE CUTTING EDGE AT AN ANGLE SUITABLE FOR RESPECTIVE WORK MATERIALS TO IMPROVE
SHARPNESS.
- 81 -
* GUIDELINES FOR TROUBLESHOOTING
TROUBLE BASIC COUNTERMEASURE EXAMPLES
EXCESSIVE WEAR ON TOOL MATERIAL * USE MATERIAL WITH BETTER WEAR *
PERIPHERAL CUTTING EDGE RESISTANCE
OR END CUTTING EDGE
CUTTING * REDUCE THE CUTTING SPEED.
CONDITIONS INCREASE THE FEED.
* ANALYZE CUTTING FLUIDS *
CHIPPING OF CUTTING EDGE CUTTING * REDUCE THE FEED

CONDITIONS
DAMAGE ON CUTTING EDGE
* ADOPT DOWN CUT SYSTEM

MACHINE OR * ELIMINATE BACKLASH OF MACHINE
OTHERS
* SECURE WORKPIECE
* REDUCE THE OVERHANG
BREAKAGE DURING CUTTING CUTTING * INCREASE THE CUTTING SPEED *
CONDITIONS
* REDUCE THE FEED AND CUT.

TOOL DESIGN * SHORTEN THE LENGTH OF CUTTING
TOOTH
* REDUCE THE OVERHANG AT
INSTALLATION
POOR SURFACE FINISH TOOL MATERIAL * USE MATERIALS WITH HIGHER
YOUNG'S MODULUS
* POOR ROUGHNESS TOOL DESIGN * INCREASE THE HELIX ANGLE *
* POOR UNDULATION * INCREASE THE NUMBER OF CUTTING *

TOOTH
* POOR STRAIGHTNESS * REDUCE THE LENGTH OF CUTTING
TOOTH
POOR SURFACE FINISH
CUTTING * REDUCE THE FEED

CONDITIONS
* REDUCE THE CUT
* ADOPT UP CUT SYSTEM
OTHERS * PREVENT BUILT-UP EDGE FORMATION
CHATTER CUTTING * REDUCE THE CUTTING SPEED

CONDITIONS
* ADOPT DOWN CUT SYSTEM
* USE CUTTING FLUID
OTHERS * SECURE WORKPIECE AND END MILL *
CLOGGING OF CHIPS TOOL DESIGN * REDUCE THE NUMBER OF CUTTING

TOOTH
OTHERS
CUTTING * REDUCE THE FEED

CONDITIONS
* REDUCE THE CUT
- 82 -
EXAMPLES
CHANGE SOLID SPIRAL END MILL TO
COATING END MILL
CHANGE IT FROM WATER BASE TO

NON WATER BASE.
IN THE CASE WHERE A MACHINE HAS

LIMITATION ON RPM, USE A SPEED-UP
ARBOR.
USE A HIGH-LEAD SPIRAL END MILL
CHANGE THE NUMBER OF CUTTING

TOOTH: 2 → 4
CHECK THE CHUCK AND COLLETS

FOR CLEARANCE.
CHECK THE COLLETS AND END MILL
FOR CLEARANCE
- 82 -
3 SIDE MILLING CUTTERS
(1) GEOMETRY
CUTTING TEETH ARE PROVIDED ON THE RIM AND THE
BOTH END FACES IN A RADIAL PATTERN.
(2) APPLICATION
SIMALTANIOUS CUTTING OF SURFACES THAT MAKE A
RIGHT ANGLE EACH OTHER.
* MAINLLY USED FOR WIDETH MAKING PROCESS AT
HONDA.
(1) TYPE
1. HIGH-SPEED STEEL 2. CEMENTED CARBIDES
* MOST OF MILLING CUTTERS USED BY HONDA FOR MASS-PRODUCTION ARE MADE OF CEMENTED
CARBIDES.
(2) BY WORKPIECE MATERIAL
1. Al ･･･ K10, 　2. Fc ･･･ K10, 　3. Fe ･･･ K10
3-3 CUTTING DIRECTION ･･･ (1), (2)
(1) UP CUT MILLING AND (2) DOWN CUT MILLING ARE AVAIRALBE TO COVER VARIOUS COMBINATIONS OF TOOL
AND WORKPIECE FEED DIRECTIONS. THE UP CUT MILLING IS THE CONVENTIONAL TYPE.
UP CUT MILLING
CUTTING DIRECTION
FEED
- 83 -
(EXAMPLE OF OPERATION)
BY HONDA FOR MASS-PRODUCTION ARE MADE OF CEMENTED
LLING ARE AVAIRALBE TO COVER VARIOUS COMBINATIONS OF TOOL

UP CUT MILLING IS THE CONVENTIONAL TYPE.
DOWN CUT MILLING
FEED
- 83 -
UP CUT MILLING DOWN CUT MILLING
-1 NO INTERFERENCE BETWEEN CHIPS AND -1 THE TOOL HOLDERS CAN BE SIMPLE.
CUTTING EDGE DOWNWARD FORCE MAKES IT POSSIBLE TO
PROCESS THIN-WALL WORK WHICH IS DIFFICULT
-2 THE CUTTER FEED DIRECTION AND THE TO MAINTAIN HOLDING.
WORK FEED DIRECTION RUN COUNTER,
WHICH ELIMINATES THE BACKLASH OF FEED
MECHANISM AND ENABLES SPONTANEOUS -2 THE CUTTER TEETH CUT IN FIXED POSITIONS,
ADVANTAGES
CUTTING. WHICH MAKES TOOL SERVICE LIFE LONGER AND

POWER CONSUMPTION LOWER.
CONSEQUENTLY, CUTTING CAPACITY IMPROVES.
-3 GOOD SURFACE FINISH, IMPROVED CUTTING

ACCURACY
-4 LARGE CUTTING AMOUNT
-5 LESSER HEAT FORMATION AT CUTTING EDGE
-1 BECAUSE CUTTING TEETH PUSH UP -1 CHIPS CLOG IN CUTTING EDGES AND IMPEDE
WORKPIECE WHEN CUTTING, WORKPIECE CUTTING.
HAS TO BE SECURELY CLAMPED.
-2 BECAUSE THE CUTTING TEETH AND WORK TRAVEL IN
DISADVANTAGES
THE SAME DIRECTION, THE BACKLASH TENDS TO

-2 CUTTING TEETH WANDER ON THE WORK INCREASE AND WORKPIECE TENDS TO BE PULLED IN
SURFACE AT START OF CUTTING BEFORE THEY
BY THE TEETH, WHICHH RESULTS IN LOOSENESS AND
ATTAIN ENOUGH CONTACT PRESSURE. THE
CHATTERS, AND DAMAGE OF WORKPIECE AND TOOL.
CONTACT PRESSURE CAUSES CUTTING EDGE
FURTHERMORE, BECAUSE THE ARBOR IS BENT, A
WEAR, SHORTER TOOL LIFE AND WASTEFUL
BACKLASH ELIMINATING DEVICE IS REQUIRED FOR
POWER CONSUMPTION.
DOWN CUT MILLING.
-3 MACHINE SURFACE IS ROUGH.
3-4 CUTTING EDGE ANGLE ･･･ (1), (2)

(1) CUTTING EDGE
THE RAKE ANGLE AND RELIEF ANGLE ARE SAME AS COUNTERBORING TOOL.
(2) RAKE ANGLE AND RELIEF ANGLE LAND WIDTH
PERIPHERAL RELIEF ANGLE
FLUTE ANGLE
BY WORKPIECE
RAKE ANGLE RELIEF ANGLE
Al 20° - 40° 10° - 12°
Fc 8° - 10° 4° - 7°
SIDE RELIEF
RAKE ANGLE
Fe 10° - 15° 5° - 8°
SIDE CUTTING EDGE
ANGLE

(1) SURFACE ROUGHNESS
ANGLE
SURFACE ROUGHNESS OF 12.5 S TO 100 S CAN BE

ATTAINED.
SURFACE ROUGHNESS CAN BE IMPROVED ON THE

FOLLOWING CONDITION WHERE THE BUILT-UP EDGE
FORMATION IS PREVENTED BY (a) REDUCED FEED, (b)
INCREASED SPEED, (c) INCREASED NUMBER OF TEETH.
(2) OVERSIZE
DIMENSIONAL ACCURACY IS ENSURED BY FEED OF TABLE. OVERSIZE VARIES DEPENDING ON MACHINE
PRECISION AND CUTTING CONDITIONS WHEN SIDE MILLING CUTTER IS USED FOR WIDTH MAKING
PROCESS OR GROOVE CUTTING.
- 84 -
(1) CUTTING SPEED, FEED AND CUTTING FLUID BY WORKPIECE MATERIAL
CUTTING SPEED FEED CUTTING FLUID
Al 150-300 0.30 WATER SOLUBLE
Fc 10-20 0.25 NON
Fe 15-28 0.18 WATER INSOLUBLE

(1) FLUTE WIDTH BECOMES LARGE
CHECK FOR POOR INSTALLATION INTO A MACHINE, WHICH MIGHT HAVE CAUSED LATERAL RUN-OUT.
(2) SHORT TOOL LIFE
CHECK INSERT MATERIALS AND CUTTING SPEED.
(3) CHATTERS OF PERIPHERAL CUTTING TEETH
CHECK MACHINE FOR STIFFNESS AND ARBOR FOR RUN-OUT, ETC.
3-8 ALIGNMENT OF GRINDING WHEEL AND MILLING CUTTER ･･･(1), (2)
h = D sin β
Z
D: DIAMETER OF SURFACE GRINDING WHEEL (WHEN

SURFACE GRINDING MACHINE IS USED)
DIAMETER OF MILLING CUTTER (WHEN CUP TYPE
WHEEL IS USED)
β: RELIEF ANGLE OF CUTTING EDGE (DEGREE)
SURFACE GRINDING WHEEL
TOOTH REST
CUP TYPE GRINDING WHEEL
TOOTH REST
- 85 -
(1) POINTS OF REGRINDING
THE LAND AND THE RELIEF ANGLE OF THE TEETH ON THE RIM.
(2) REGRINDING METHOD
1. USE OF SURFACE GRINDING WHEEL, 　　2. USE OF CUP TYPE GRINDING WHEEL
(3) CHARACTERISTICS OF GRINDING WHEELS
-1 SURFACE GRINDING WHEEL
A DEPRESSION DEVELOPS IN THE LAND. A GOOD SHARPNESS CAN BE MAINTIANED AFTER GRINDING.
WHEN THE EDGE BECOMES BLUNT, HOWEVER, THE RELIEF ANGLE SOON BECOMES OUT OF SPECIFIED
ANGLE. THUS, THIS GRINDING WHEEL IS NOT SUITABLE FOR CUTTERS WITH WIDER LAND.
-2 CUP TYPE GRINDING WHEEL

BECAUSE THE LAND REMAINS THE FLATNESS AFTER GRINDING, THE RELIEF ANGLE IS ALSO REMAINED.
4 KEYWAY CUTTERS
(1) GEOMETRY
THE CUTTER HAS CUTTING TEETH ON THE RIM AND A SHANK.
(2) APPLICATION
A SPECIAL CUTTER USED FOR SPECIFIC CUTTING OPERATIONS SUCH AS KEYWAY CUTTING IN A SHAFT.
HONDA USES THE CUTTER FOR KEYWAY CUTTING IN CRANKSHAFT.
SKH - 4 (WORKPIECE MATERIAL S48-C)
(1) RAKE ANGLE 0°, (2) RELIEF ANGLE 6°
KEYWAY WIDTH REQUIRES ACCURACY. TO ENSURE THAT ACCURACY, LATERAL RUN-OUT OF CUTTER HAS TO
BE CONTROLLED. THUS, MACHINE ACCURACY AND TOOL HOLDING ACCURACY HAVE A GREAT INFLUENCE
ON THE PRECISION OF MACHINED KEYWAY.

1. CUTTING SPEED ･･･ 30-40 m/min, 2. FEED ･･･ 0.08-0.1 mm/rev. 3. CUTTING FLUID ･･･ NON WATER BASE.
(1) WHEN KEYWAY WIDTH TENDS TO BECOME LARGER, CHECK THE MACHINE ACCURACY.
(LATERAL RUN-OUT OF CUTTING TEETH WHILE BEING HELD TO THE MACHINE. RELATIONSHIP
BETWEEN SLEEVE AND TAPER SHANK.)
- 86 -
AS CUTTING TEETH SHOULD HAVE A CERTAIN WIDTH, GRIND ONLY THE CUTTING TEETH ON THE RIM. DO NOT
INCREASE THE RELIEF ANGLE UNNECESSARILY: OTHERWISE TOOL SERVICE LIFE COULD BECOME SHORT.
5 METAL SAWS (INCLUDING SLITTING CUTTERS)

(1) GEOMETRY
THIN CUTTING TEETH ARE PROVIDED ONLY ON THE RIM.
SLITTING CUTTERS HAVE RELATIVELY LARGER NUMBER OF
TEETH, CONSIDERING DIAMETERS. (i.e. THEY ARE ARBOR
TYPE)
(2) APPLICATION
1. GROOVE CUTTING, 2. NARROW GROOVE CUTTING, 3. CUTTING (EXAMPLE OF OPERATION)
(1) TYPE
1. HIGH-SPEED STEEL, 2. CEMENTED CARBIDES. HONDA USES BOTH TYPES.
(2) BY WORKPIECE MATERIAL
1. Al ･･･ K10, 2. Fc ･･･ K10, 3. Fe ･･･ K10
SAME AS THE KEYWAY CUTTERS.
BY WORKPIECE MATERIAL
Al 60-80 0.13 WATER SOLUBLE
Fc 30-40 0.10 NON
Fe 30-40 0.08 WATER INSOLUBLE

WHEN GROOVE WIDTH TENDS TO BECOME LARGER, CHECK THE MACHINE ACCURACY (LATERAL RUN-OUT OF
TOOL WHILE BEING INSTALLED TO THE MACHINE)
SAME AS THE KEYWAY CUTTERS.
- 87 -
6 PLAIN MILLING CUTTERS
(1) GEOMETRY
CUTTING TEETH ARE PROVIDED ON A CYLINDRICAL SURFACE.
(2) APPLICATION
MAINLY USED FOR CUTTING OF A PLAIN SURFACE PARALLEL TO AXIS. HONDA USES PLAIN MILLING
CUTTERS FOR JIG MACHINING.
HIGH-SPEED STEEL AND CEMENTED CARBIDE PLAIN MILLING CUTTERS ARE AVAILABLE.
(1) CUTTING TOOTH
-1 STRAIGHT (OVERALL LENGTH IS 20 mm OR LESS) ･･･
TENDS TO CAUSE CHATTER AND ROUGH SURFACE RAKE ANGLE WITH CROSS-SECTION THAT
MAKE A RIGHT ANGLE WITH THE CUTTING
FINISH. EDGE
-2 HELICAL (OVERALL LENGTH IS 20 mm OR OVER) ･･･

CAUSES LESSER CHATTER AND GOOD SURFACE FINISH.
RAKE ANGLE
-3 RAKE ANGLE, HELIX ANGLE AND RELIEF ANGLE
RELIEF
RAKE ANGLE HELIX ANGLE RELIEF ANGLE ANGLE
Al 25° 45° 8°
CLEARANCE
Fc 15° 45° 5°
Fe 8° 45° 3°

SURFACE ROUGHNESS IS DEPENDENT ON MACHINE STIFFNESS.
RANGE OF SURFACE ROUGHNESS: 12.5 S TO 100 S
CUTTING SPEED, FEED AND CUTTING FLUID
Fc 10-18 0.18-0.25 NON
- 88 -
S. HONDA USES PLAIN MILLING
RELIEF ANGLE WITH CROSS-

SECTION THAT MAKE A RIGHT
ANGLE WITH THE CUTTING EDGE
HELIX ANGLE
- 88 -
(1) WHEN FLATNESS CANNOT BE ATTAINED
-1 THE MACHINE USED LACKS IN STIFFNESS.
-2 BACKLASH AND WEAR OF MAIN SPINDLE AND MAIN SPINDLE BEARING.
-3 BACKLASH AND WEAR OF ARBOR BEARING.
(2) CHATTERS
-1 CHECK WORKPIECE HOLDING METHODS.
-2 CHANGE NUMBER OF TEETH AND ANGLE OF TEETH.
-3 CHANGE THE CUTTING CONDITIONS.
-4 CHECK ARBOR FOR LOOSENESS AND POOR INSTALLATION.
-5 INSERT A CHIP BREAKER IN CUTTING TOOTH.
(1) POINTS OF GRINDING
GRIND ONLY THE CUTTING TEETH ON THE RIM. DO NOT GRIND THE RAKE FACE.
MAKE THE RELIEF ANGLE SUITABLE FOR RESPECTIVE WORKPEICE MATERIALS.
- 89 -
[9] GEAR HOBS
1. CLASSIFICATION OF GEAR HOBS (1), (2)

2. TYPES OF GEAR HOBS (3), (4)
3. DESIGNATION AND CODES (3), (4)
4. CUTTING CONDITIONS AND CUTTER DESIGN PARAMETERS (3), (4)
5. REGRINDING PARAMETERS (1), (2)
- 91 -
S=
PAGE
92
94
96
98
101
- 91 -
[9] GEAR HOBS
A GEAR-CUTTING HOB IS A WORM MADE INTO A GEAR-GENERATING TOOL BY MACHINING A SERIES OF

LONGITUDINAL SLOTS INTO IT TO FORM THE CUTTING TEETH.
THE HOB IS INSTALLED TO A HOBBING MACHINE IN THE WAY THAT THE THREAD HELIX OF THE HOB MESHES WITH
THE TOOTH TRACE OF THE GEAR BLANK.
ROTARY MOTION AND FEED ARE GIVEN TO THE HOB AND THE GEAR BLANK UNTIL ALL TEETH ARE CUT.
A ROTATING HOB DRAWS AN ENVELOPE CURVE IN THE SURFACE OF GEAR BLANK DURING TOOTH CUTTING. A
SUITABLE TYPE OF HOB TOOTH HAS TO BE CHOSEN SO THAT THE ENVELOPE CURVE APPEARS ALONG THE
PROFILE OF THE GEAR BLANK.
THE PRINCIPLE OF GEAR CUTTING BY HOB IS SIMILAR TO THAT OF RACK SHAPER.
HOB CUTTER, TERMINOLOGY
OVER-ALL LENGTH
TOOTH LEAD ANGLE
FLUTE TREAD HELIX LINE

FLANK
CUTTING EDGE
HOB OUTSIDE DIA.
PITCH DIA.
KEYWAY
RAKE FACE
PITCH
RIGHT CUTTING EDGE
LEFT CUTTING EDGE
1 CLASSIFICATION OF GEAR HOBS ･･･ (1), (2)

1-1 CLASSIFICATION BY TYPES
(1)
AT FABRICATION OF INSERTED BLADE HOB ･･･
BLADES
BLADE -1
BODY
EFFECTIVE -2
TOOTH WIDTH
PERIPHERAL RELIEF ANGLE
AT ASSEMBLY OF HOB
(2)
SOLID HOB ･･･
- 92 -
-1
- 92 -
[9] GEAR HOBS
RM MADE INTO A GEAR-GENERATING TOOL BY MACHINING A SERIES OF

TO FORM THE CUTTING TEETH.
OBBING MACHINE IN THE WAY THAT THE THREAD HELIX OF THE HOB MESHES WITH
AR BLANK.
E GIVEN TO THE HOB AND THE GEAR BLANK UNTIL ALL TEETH ARE CUT.
NVELOPE CURVE IN THE SURFACE OF GEAR BLANK DURING TOOTH CUTTING. A
H HAS TO BE CHOSEN SO THAT THE ENVELOPE CURVE APPEARS ALONG THE
ING BY HOB IS SIMILAR TO THAT OF RACK SHAPER.
BASIC THREAD FACE

HOB
OVER-ALL LENGTH
TOOTH LEAD ANGLE HUB LENGTH
TREAD HELIX LINE

HUB FACE PROJECTED
PROFILE
(RACK SHAPER)
BEAR BLANK
HUB OUTSIDE
DIA.
MECHANISM OF GEAR CUTTING BY HOB
HOB TOOTH
BEARING
RELIEF
PITCH
PITCH CIRCLE
BEAR BLANK
TEETH GENERATION BY HOB
INSERTED BLADE HOB: BODY AND BLADES ARE MADE

SEPARATELY AND ASSEMBLED FOR USE.
HIGH-GRADE HIGH-SPEED STEEL WITH LARGE FORGING RATIO
IS USED FOR BLADES, WHICH HAS BETTER HARDENING
PROPERTY AND CAN BE USED IN MOST OPTIMAL CAPABILITIES.
(BODY IS MADE OF HIGH-CARBON CHROMIUM STEEL).
EFFECTIVE THE CUTTER IS INSTALLED TO GRINDING JIG FOR CYLINDRICAL

TOOTH WIDTH THREAD GRINDING. THEREFORE, THE CUTTING TOOTH IS USED
EFFECTIVELY IN FULL LENGTH, WHICH ENABLES TOOL SERVICE
LIFE OF 1.5 TO 2 TIMES LONGER THAN A SOLID TYPE GEAR HOB.
GOOD ACCURACY FOR TOOTH PROFILE AND SURFACE
ROUGHNESS CAN BE ATTAINED.
SOLID HOB: A SINGLE-PIECE CONSTRUCTION FOR RELIEVING

CUTTING.
- 92 -
AS THE TOOL IS DESIGNED FOR RELIEVING CUTTING, THE GRIND
WHEEL IS RETRACTED BEFORE IT GRINDS THE FULL LENGTH OF
CUTTING TOOTH TO AVOID THAT THE GRINDING WHEEL
TOUCHES A NEXT CUTTING TOOTH. ACCORDINGLY, THE
EFFECTIVE LENGTH OF CUTTING TOOTH IS SHORTER THAN THAT
OF THE INSERTED BLADE HOB.
- 92 -
-2 BECAUSE OF NO ASSEMBLY ERROR, SOLID GEAR HOBS ARE USED FOR GEAR CUTTING OPERATIONS
WHICH REQUIRES HIGHER ACCURACY OR FOR SPECIAL GEAR CUTTING. THEY ARE ALSO USED FOR
SMALL GEAR CUTTING USED FOR SMALL MODULE MACHINES.
1-2 CLASSIFICATION BY MATERIALS

(1) HIGH-SPEED STEEL HOB (HSS HOB)
CHARACTERISTICS
CLASS MATERIAL APPLICATION
WEAR RESISTANCE HIGH TEMP. TOUGHNESS MACHINABILITY
W BASE SKH 3 6 7 4 8 HIGH-SPEED HEAVY CUTTING
HIGHER TOUGHNESS FOR

SKH 9 5 6 8 5
GENERAL PURPOSE
RELATIVELY HIGHER
SKH 55 6 7 6 5
TOUGHNESS
Mo BASE HM 35 8 8 5 3 HIGH-SPEED HEAVY CUTTING
HM 33 7 7 4 8 HIGH TOUGHNESS
HM 34 7 8 5 8 HIGH-SPEED HEAVY CUTTING
(2) POWDER HIGH-SPEED STEEL

MOLTEN HIGH-SPEED STEEL IS SPRAYED AT PRESSURE OF INERT GAS AND COOLED DOWN TO BECOME
POWDER METAL. THE POWDER METAL OBTAINED IS COMPRESSED AND SINTERED IN HIGH TEMPERATURE
AND PRESSURE GAS ATMOSPHERE.
-1 UNIFORM DISTRIBUTION OF CARBIDE PARTICLES, HIGH TOUGHNESS, HIGH RESISTANCE TO CHIPPING AND
WEAR.
-2 GOOD MACHINABILITY AND EASY REGRINDING.
(3) PVD COATING
TOOL ACTS AS A CATHODE IN THIS PHYSICAL-VAPOR DEPOSITION TECHNIQUE. TITANIUM IS VAPORIZED
AND IONIZED IN VACUUM AND ATTRACTED IN TOOL SURFACE, WHICH FORMS A COATING OF HARD
CHEMICAL COMPOUND SUCH AS TiN, TiC IN THICKNESS OF SEVERAL μ.
THE HIGHER SURFACE HARDNESS (HV 2000 - 4000) CONTRIBUTES TO LESSER VB WEAR.
TOOL: INSERTED BLADE HOB
m 2.5, PA 20, 1 TH, KMC4
CUTTING CONDITIONS:
V = 62 m/min
MAX FLANK WEAR
F = 2.5 mm/rev
CLIMB CUTTING
CUTTING FLUID = NON WATER BASE
GEAR BLANK: SCM 415, HB 150
NUMBER OF WORKPIECE
φ82.5 X 25 l X Ng 31 (DOUBLE)
- 93 -
2 TYPES OF GEAR HOBS ･･･ (3), (4)
2-1 STAGGERED TOOTH HOBS
A STAGGERED TOOTH HOB HAS THE RIGHT CUTTING TEETH AND LEFT CUTTING TEETH LOCATED IN AN
ALTERNATING SEQUENCE TO REDUCE THE CHIP INTERFERENCE AND ABRASION, VB WEAR ON THE CORNER
AND IMPROVE TOOL SERVICE LIFE.
POINTS OF CHIP INTERFERENCE
HOB SPEC.
DP 10, PA 20°, 2 THREADS
MAX. FLANK WEAR (mm)

ORDINAL HOB GEAR FLANK SPEC.
XT 44, SXCM8, HB 200
CUTTING CONDITIONS
ARROWS SHOW DIRECTION OF CHIP FLOW
57 m/min, 1.5 mm/rev
CHIPS PRODUCED BY ORDINAL HOB
ORDINAL STAGGERED TOOTH HOB CLIMB CUTTING
NO SHAFT
HOB MACHINE: WF 10
A VERY LITTLE
INTERFERENCE OF
CHIP
NO INTERFERENCE OF CHIP
OFF-SET STAGGERED
POINT OF CUTTING EDGE TOOTH HOB
OF INTERFERENCE
NUMBER OF WORKPIECE
CHIPS PRODUCED BY SEMI-

STAGGERED TOOTH HOB ※1) EQUIPMENT: KASHIFUJI KS-300 (671 M3G, H4G)
2) CUTTING CONDITIONS: F-4.0 mm/rev,
CUTTING FLUID YUSHIRON M1
400 PC PROCESSING (GEAR 800
PC.)
・ TiC COATED CUTTER
3) CUTTER SPEC.: Mn = 200 DIVIDED INTO 3LH, L = 125
× WITHOUT COATING
B TYPE NORMAL
4) WORK SPEC: 671 M3 Mn = 2.00, Z-22, HA=36°L
X = 0.170, B = 12.0 (NITRIDING)
671 M4 Mn = 2.00, Z=26 CUTTER WITHOUT COATING
WEAR(mm)
MA = 36°L, X = 0.173
B = 12.0
TiC COATED CUTTER
CUTTING
FIG 3. WEAR IN TiC COATED CUTTER AND CUTTER WITHOUT COATING SPEED(m/min)
2-2 PROTUBERANCE GEAR HOBS (PB) CUTTER WORK

A SPECIAL CUTTER HAVING A KNOT ON THE
CUTTING EDGE WHICH HOLLOWS OUT THE
TOOTH ROOT OF GEAR BLANK, MAINLY USED
FOR GEAR ROLLING OF TOOTH GRINDING.
2-3 SPLINE HOBS

GENERALLY, A SPLINE HOB IS USED FOR CUTTING OPERATIONS TO ENGAGE A SHAFT WITH A GEAR OR
SPROCKET IN WHICH ROTARY MOTION (POWER) IS TRANSMITTED FROM ONE SHAFT TO ANOTHER BY THE
MEDIA OF GEAR OR SPROCKET.
AS FOR METHODS OF MACHINING, SHAFTS ARE MADE MAINLY BY PINION HOBBING, FORM ROLLING AND
FORGING AND HOLES ARE MADE BY BROACHING OR SINTERING.
* INVOLUTE SPLINE HOB
- 94 -
(1) PARALLEL SPLINE HOB (2)
PARALLEL SPLINE CUTTING BY GENERATING GEAR

CUTTING
CUTTER WORK
CHAMFER
2-4 SPROCKET HOBS

THIS IS MOST COMMON TYPE OF CHAIN DRIVE IN WHICH POWER IS TRANSMITTED BY A PAIR OF SPROCKETS AND
A CHAIN. THE SPROCKET HOB IS A TOOL TO MAKE SPROCKETS BY GENERATING GEAR CUTTING.
(1) ROLLER CHAIN SPROCKET (2)
ROLLER CHAIN SPROCKET HAS THE TOOTH
PROFILE TO WHICH A ROLLING CONFIGURATION OF
ROLLER IS COPIED FOR SMOOTH TRANSMISSION
OF POWER BY CHAIN. THESE TYPE OF
SPROCKETS ARE WIDELY USED AT HONDA FOR ASA
STANDARD PRODUCTS.
[FEATURES OF CHAIN]
IN GENERAL, CHAIN DRIVE HAS FOLLOWING FEATURES:
* THERE IS NO RESTRICTION ON DISTANCES BETWEEN CENTERS, WHICH ELIMINATES DESIGN RESTRICTIONS
WITH RESPECT TO SHAFT LOCATIONS.
* BECAUSE CHAIN IS ENGAGED WITH SPROCKET, THE LOAD IS BORNE BY A NUMBER OF TEETH. A SPECIAL
CONSIDERATION OF TOOTH STRENGTH AND HIGH-GRADE TOOTH MATERIAL ARE NOT NECESSARY.
* IMPACT TORQUE IS ABSORBED AND CUSHIONED BY CHAIN WHICH ACTS AS ELASTIC BODY.
- 95 -
INVOLUTE SPLINE HOB
MADE OF A PART OF GEAR TOOTH LENGTH (ABOUT

1/2)
CUTTER
WORK
E IN WHICH POWER IS TRANSMITTED BY A PAIR OF SPROCKETS AND

MAKE SPROCKETS BY GENERATING GEAR CUTTING.
SILENT CHAIN SPROCKET
(HY-VO CHAIN)
CHAIN SPROCKET EMPLOYS AN INVOLUTE CURVE
WHERE POWER IS TRANSMITTED BY BLOCKS IN
COMBINATION INSTEAD OF ROLLER. GENERALLY,
THEY ARE USED AT PLACES THAT REQUIRE HIGH
POWER AND SILENCE.
CES BETWEEN CENTERS, WHICH ELIMINATES DESIGN RESTRICTIONS
ROCKET, THE LOAD IS BORNE BY A NUMBER OF TEETH. A SPECIAL

AND HIGH-GRADE TOOTH MATERIAL ARE NOT NECESSARY.
SHIONED BY CHAIN WHICH ACTS AS ELASTIC BODY.
- 95 -
3 DESIGNATION AND CODES ･･･ (3), (4)
GEAR HOB SPLINE HOB SPROCKET HOB
RACK OF HOB FIG OF STRAIGHT SPLINE WORK
HOB OUTSIDE DIA. D St r. s N X D X d ーA

HOB INSIDE DIA. d (STRAIGHT SPLINE)
MEDIUM, L = 125 N ･･･ NUMBER OF FLUTE ROLLER CHAIN SPROCKET
HOB OVER-ALL LENGTH L ･･･
LONG, L = 150 B ･･･ FLUTE WIDTH C・P ･･･
MODULE m D ･･･ OUTSIDE DIA. R・D ･･･
PRESSURE ANGLE PA d ･･･ ROOT DIA. M・D ･･･
CUTTING DEPTH D+f A ･･･ CODE OF ENGAGEMENT D・D ･･･
WHOLE DEPTH h O・D ･･･
CUTTER DENDENDUM hk Inv. s. D X N X m ーA TOOTH PROFILE
CUTTER ADDENDUM hf (INVLUTE SPLINE) * HONDA USES ASA I AND II
BOTTOM CLEARANCE CK D ･･･ OUTSIDE DIA. TOOTH PROFILES AND
HONDA'S SPECIAL TOOTH
PITCH pitch N ･･･ NUMBER OF FLUTE
PROFILES.
TOOTH THICKNESS S m ･･･ MODULE
TOOTH LEAD ANGLE HA A ･･･ CODE OF ENGAGEMENT
(HOB HELIX ANGLE)
NUMBER OF THREAD OF HOB TH
- 96 -
SPROCKET HOB
ROLLER CHAIN SPROCKET

CHAIN PITCH
ROLLER DIA.
BOTTOM DIA.
PITCH CIRCLE
OUTSIDE DIA.
* ASA
* HONDA USES ASA I AND II

TOOTH PROFILES AND
HONDA'S SPECIAL TOOTH
PROFILES.
- 96 -
3-1 STANDARD RACK PROFILE FOR HM PRE-SHAVING GEAR HOBS
mn
PA
PRESSURE ANGLE 20° GAM

PITCH
LAND
ADD
DDM
He
D+F
RC
RX
- NORMAL TOOTH PROFILE -
(UNIT OF TOLERANCE: 0.001)
MODULE TYPE
NOT LESS
THAN BELOW
NOTE:
1. PRESSURE ANGLE: PA20°
2. TOOTH PROFILE ERROR: 10μ FOR mn 1.75-2.5 AND 12μFOR 2.75
3. ACCURACY OF ITEMS UNLESS OTHERWISE SPECIFIED IS JIS CLASS I.
- 97 -
NORMAL MODULE
PRESSURE ANGLE
SEMI-TOPPING ANGLE
PITCH
BASIC TOOTH THICKNESS
CUTTER ADDENDUM
CUTTER DEDENDUM
WORKING DEPTH
CUTTING DEPTH
TOP CORNER RADIUS
ORIGINATING POINT OF TO CORNER RADIUS
NOT LESS
THAN BELOW
- 97 -
4 CUTTING CONDITIONS AND CUTTER DESIGN PARAMETERS ･･･ (3), (4)
4-1 CUTTING CONDITIONS FOR HOBS
2πr X N
CUTTING SPEED ･･･ V= 1000 m/min
FEED ･･･ FEED PER REVOLUTION OF GEAR BLANK

CUTTER SHIFT ･･･ TRAVEL DISTANCE OF HOB PER ONE CYCLE OF GEAR BLANK.
CUTTING DIRECTION
* DOWNWARD ･･･
CONVENTIONAL HOBBING
* UPWARD ･･･ CLIMB
HOBBING
* CUTTING CONDITIONS FOR HOBS ARE DETERMINED BASED ON REQUIRED SPECIFICATIONS AND ACCURACY
OF GEAR TO BE CUT, STIFFNESS OF A HOB MACHINE, ETC.
4-2 HOB CUTTER DESIGN PARAMETERS
GEAR BLANK
CUTTER DESIGN
HOB CUTTER MATERIALS ･･･
5 REGRINDING PARAMETERS ･･･ (1), (2)

5-1 HOB CUTTER WEAR
* TERMINOLOGY
CUTTING
RAKE FACE EDGE
LEFT FLANK RIGHT FLANK
5-2 TIPS ON REGRINDING

GRIND AWAY WEAR ON THE CUTTING EDGE FROM THE BOTH SIDES OF CUTTING TEETH.
HONDA USES GRINDING MACHINES DESIGNED FOR HOB REGRINDING, WHICH ENABLES THOROUGH REMOVAL OF
WEAR WITH AUTOMATIC SPACING AND FEEDING FUNCTIONS.
- 98 -
ITIONS AND CUTTER DESIGN PARAMETERS ･･･ (3), (4)
ITIONS FOR HOBS
2πr X N r = CUTTER RADIUS mm
V= 1000 m/min N = NUMBER OF REVOLUTION
FEED PER REVOLUTION OF GEAR BLANK

TRAVEL DISTANCE OF HOB PER ONE CYCLE OF GEAR BLANK.
CUTTER
WORK
WORK
CUTTER
FEED (CUTTER) SHIFT (CUTTER)
CONDITIONS FOR HOBS ARE DETERMINED BASED ON REQUIRED SPECIFICATIONS AND ACCURACY
TO BE CUT, STIFFNESS OF A HOB MACHINE, ETC.
ESIGN PARAMETERS
(SPEC) m. PA, HLα, TOOTH PROFILE, ACCURACY
(EQUIPMENT) TYPE (STANDARD, HEAVY DUTY) EFFECTIVE SHIFT LENGTH
CUTTER TYPE ΦD X φd X L. TH
TOOTH PROFILE
BECAUSE HOBBING IS AN INTERRUPTED CUTTING OPERATION, THE TOOL
MATERIAL HAS TO HAVE STIFFNESS AS WELL AS HIGH HARDNESS AND
RESISTANCE TO WEAR.
ARAMETERS ･･･ (1), (2)
* POINT OF WEAR
CUTTING EDGE WEAR
EDGE PERIPHERY CRATER WEAR (CHIPPING)
FLANK WEAR
EAR ON THE CUTTING EDGE FROM THE BOTH SIDES OF CUTTING TEETH.
RINDING MACHINES DESIGNED FOR HOB REGRINDING, WHICH ENABLES THOROUGH REMOVAL OF
TOMATIC SPACING AND FEEDING FUNCTIONS.
- 98 -
* BEFORE STARTING GRINDING, CHECK THE CUTTING EDGE AND FLANK TO DETERMINE WHERE THE WEAR
HAS DEVELOPED MOST AND HOW MUCH MACHINING ALLOWANCE IS NECESSARY TO GRIND AWAY THE
WEAR.
WEAR + 0.1 mm IS A REASONABLE AMOUNT OF REGRINDING.
* REGRINDING LEAVES BURRS ON THE RIGHT AND LEFT FLANK. REMOVE BURRS FROM THEM WITH A BRUSH
AFTER COMPLETION OF REGRINDING.
WEAR OF REGRINDING
MAX. PERIPHERAL BODY CLEARANCE WEAR
MODULE
ROUGHING FINISHING
0.5 0.13-0.18 0.08-0.1
0.5-1.5 0.15-0.25 0.1-0.2
1.5-2.5 0.25-0.4 0.2-0.3
2.5-6 0.4-0.5 0.25-0.4
6-12 0.5-0.65 0.4-0.5
5-3 ACCURACY
* INFLUENCES ON TOOTH PROFILES OF GEAR BLANKS
REGRINDING ACCURACY TOOTH PROFILE OF HOB
PITCH ERROR
RADIAL ALIGNMENT OF
CUTTING FACE
FLUTE LEAD ERROR
- 99 -
EDGE AND FLANK TO DETERMINE WHERE THE WEAR
ALLOWANCE IS NECESSARY TO GRIND AWAY THE
T FLANK. REMOVE BURRS FROM THEM WITH A BRUSH
CORRECT TOOTH PROFILE

ACTUAL TOOTH PROFILE
TOOTH PROFILE OF GEAR BLANK
- 99 -
5-4 POINTS TO BE MEASURED AFTER REGRINDING
ITEM MEASURING METHOD FIGURE
DEFINITION ･･･ DIFFERENCE BETWEEN THE ACTUAL LINE AND THE STRAIGHT
LINE THAT RUNS THROUGH THE CENTER OF THE CROSS
SECTION PERPENDICULAR TO THE AXIS OF CUTTING FACE
(CUTTING DEPTH OF HOB).
H = RAKE ANGLE
HONDA HOB CUTTERS ARE DESIGNED TO HAVE RAKE ANGLES OF
STANDARD ･･･ 6°OR 8°(0°IS ALSO AVAILABLE). MEASURE ACTUAL HEIGHT
RADIAL
AND CHECK IT AGAINST A SPECIFIED HEIGHT OF RESPECTIVE
ALIGNMENT OF
HOB CUTTER OUTSIDE DIAMETERS SHOWN IN THE
CUTTING FACE
CROSSCHECK TABLE (MADE BY HONDA) TO DETERMINE
(RAKE ANGLE)
ERRORS.
MEASURING USE AN INSTRUMENT DESIGNED BY HONDA FOR RADIAL

INSTRUMENT ･･･ ALIGNMENT ERROR MEASUREMENT.
DEFINITION ･･･ DIFFERENCE BETWEEN THE ACTUAL PITCH MADE BY TWO

CORRESPONDING THREADS ON A PITCH LINE THAT RUNS
SINGLE PITCH ALONG ANY GIVEN FLUTE AND THE SPECIFIED (CORRECT)
ERROR PITCH.
DEFINITION ･･･ DIFFERENCE BETWEEN THE SUM OF ACTUAL PITCHES MADE

BY ANY GIVEN TWO CORRESPONDING THREADS AND THE
SPECIFIED FIGURES.
HONDA PUT MEASURING INSTRUMENTS ON (A) AND (B). AFTER ZERO

STANDARD ･･･ ADJUSTMENT, TURN THE HOB IN THE DIRECTION SHOWN BY
THE ARROW. READ AND RECORD THE READINGS GIVEN BY
THE MEASURING INSTRUMENT (H) ONE BY ONE. CHECK THE
CUMULATIVE READINGS AGAINST THE FIGURES SHOWN IN THE SPEC EXAMPLE OF SHEET ENTRY
PITCH DEVIATION SHEET TO DETERMINE ERRORS. BLADE NO. 1 2 3 4
VALUE OF (A) 0 +2 +1 0
SINGLE PITCH ERROR -1 +1 0 -1
INTEGRATED PITCH ERROR -1 0 0 -1
MEASURING USE AN INSTRUMENT DESIGNED BY HONDA FOR PITCH CUMULATIVE PITCH ERROR
INSTRUMENT ･･･ ERROR MEASUREMENT
SUM OF (A) + 5 ≒ + 1
DEFINITION ･･･ DIFFERENCE BETWEEN THE ACTUAL FLUTE LEAD WITH

RESPECT TO THE LENGTH OF HOB FLUTE (CUTTING FACE) AT
THE VICINITY OF PITCH CIRCLE AND THE SPECIFIED
ACTUAL FLUTE
(CORRECT) LEAD. (RAKE ANGLE) LEAD ERROR
HONDA FIX A HOB ON THE SURFACE TABLE OF MICROMETER WITH

STANDARD ･･･ THE AXIS PARALLEL TO AND THE CUTTING FACE HORIZONTAL
LEAD ERROR TO THE MICROMETER. MEASURE THE HOB CUTTING FACE TO
DETERMINE HEIGHT ERROR.
CORRECT ANGLE
(POINTS OF MEASUREMENT ･･･ A, B, C ON PCD) (RAKE ANGLE)
MEASURING USE AN INSTRUMENT DESIGNED BY HONDA FOR LEAD ERROR

INSTRUMENT ･･･ MEASUREMENT.
- 100 -
FIGURE
H = RAKE ANGLE
+2
+1
LEAD ERROR
- 100 -
5-5 REGRINDING ACCURACY
QUALITY OF RE-GROUND TOOLS IS ASSURED BY THE MEASURING METHOD MENTIONED IN THE PREVIOUS
PAGE, ITEM 5-4 AND THE x~CONTROL CHART AT HONDA.
HOB RADIAL ALIGNMENT SINGLE SPACING CUMULATIVE

HOB REGRINDING LEAD ERROR
ACCURACY OF CUTTING FACE ERROR SPACING ERROR
TOLERANCE GRADE 0 12 20 40 25
UNIT ･･･ μ GRADE 1 20 25 50 25
- 101 -
HE PREVIOUS
- 101 -
[10] PINION-SHAPED CUTTERS
1. GEAR CUTTING BY PINION-SHAPED CUTTERS (1), (2)

AND COMPARISON WITH GEAR CUTTING BY HOBS
2. CLASSIFICATION OF PINION-SHAPED CUTTERS (1), (2)
3. TYPES AND APPLICATIONS (3), (4)
4. TERMINOLOGY OF CUTTERS (3), (4)
5. CUTTING CONDITIONS (3), (4)
6. REGRINDING PARAMETERS (1), (2)
- 103 -
TERS
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PAGE
104
104
105
105
106
106
- 103 -
A PINION-SHAPED CUTTER IS A GEAR CUTTING TOOL THAT EMPLOYS THE GEAR MESHING MECHANISM. ONE OF
THE GEARS (PINION-SHAPED CUTTER) ROTATES WITH THE OTHER GEAR (GEAR BLANK) AT THE SAME PITCH-
CIRCLE VELOCITY IN AN AXIAL RECIPROCATING MOTION.
TYPICAL EXAMPLES OF PINION-SHAPED CUTTERS USED AT HONDA ARE LORENTZ GS MACHINE, HONDA GS
MACHINE (MADE BY HONDA ENGINEERING). THOSE MACHINES ARE USED FOR GEAR CUTTING OF SPUR GEAR,
HELICAL GEAR, SPROCKET AND SPLINE.
1 GEAR CUTTING BY PINION-SHAPED CUTTERS AND COMPARISON WITH GEAR CUTTING BY HOBS ･･･(1), (2)
1-1 ADVANTAGES
(1)
(2)
(3)
1-2 DISADVANTAGES
(1)
(2)
(3)
2 CLASSIFICATION OF PINION-SHAPED CUTTERS ･･･ (1), (2)
* DESK TYPE
- 104 -
A PINION-SHAPED CUTTER IS A GEAR CUTTING TOOL THAT EMPLOYS THE GEAR MESHING MECHANISM. ONE OF
THE GEARS (PINION-SHAPED CUTTER) ROTATES WITH THE OTHER GEAR (GEAR BLANK) AT THE SAME PITCH-
CIRCLE VELOCITY IN AN AXIAL RECIPROCATING MOTION.
TYPICAL EXAMPLES OF PINION-SHAPED CUTTERS USED AT HONDA ARE LORENTZ GS MACHINE, HONDA GS
MACHINE (MADE BY HONDA ENGINEERING). THOSE MACHINES ARE USED FOR GEAR CUTTING OF SPUR GEAR,
HELICAL GEAR, SPROCKET AND SPLINE.
GEAR CUTTING BY PINION-SHAPED CUTTERS AND COMPARISON WITH GEAR CUTTING BY HOBS ･･･(1), (2)
ADVANTAGES
STEPPED GEAR AND INTERNAL GEAR CANNOT BE CUT BY HOBS. THE PINION-SHAPED CUTTERS CAN MAKE
THOSE GEARS EASILY.
BECAUSE GEAR CUTTING BY HOBS USES SEVERAL TEETH, IT IS DIFFICULT TO ATTAIN SMOOTH TOOTH
PROFILE. HOWEVER, IN GEAR CUTTING BY PINION-SHAPED CUTTERS, ONE TOOTH GENERATES ONE
GROOVE, WHICH ENABLES TO ATTAIN MORE PRECISE ACCURACY FOR TOOTH PROFILE.
REGRINDING ERROR OF A HOB WILL AFFECT THE TOOTH PROFILE GENERATED BY THAT HOB. IN THE CASE
OF PINION-SHAPED CUTTERS, THE POINT TO BE CHECKED AFTER REGRINDING IS ONLY THE RAKE ANGLE.
THEREFORE, IT IS NOT DIFFICULT TO STABILIZE THE PRECISION AND TO CONTROL THE QUALITY.
DISADVANTAGES
IN GEAR CUTTING BY HOBS, THE CUTTER ACCURACY DOES NOT AFFECT THE PITCH OF FINISHED
PRODUCTS. ON THE OTHER HAND, IN GEAR CUTTING BY PINION-SHAPED CUTTERS, THE PITCH OF TEETH
GENERATED IN THE GEAR BLANK IS A COPY OF THE PITCH OF PINION-SHAPED CUTTER. GENERALLY, THE
HOB IS SUPERIOR TO THE PINION-SHAPED CUTTER IN PITCH ACCURACY.
WHILE GEAR CUTTING BY HOBS IS CONTINUOUS ROLL CUTTING, GEAR CUTTING BY PINION-SHAPED
CUTTERS IS SHAPING BY RECIPROCATING MOTION. THE MACHINING EFFICIENCY OF PINION-SHAPED
CUTTER IS NOT AS GOOD AS THAT OF HOB (ABOUT 1/2).
HOB MACHINE ALLOWS EASY HELICAL GEAR CUTTING. HOWEVER, PINION-SHAPED CUTTERS REQUIRE THE
INSTALLATION OF SPECIAL JIGS SUCH AS HELICAL GUIDE. THUS, CHOICE OF HELIX ANGLES ARE LIMITED.
CLASSIFICATION OF PINION-SHAPED CUTTERS ･･･ (1), (2)
* SHANK TYPE
* DESK TYPE * BELL TYPE * HUB TYPE TAPERED SHANK TYPE
STRAIGHT SHANK TYPE
- 104 -
3 TYPES AND APPLICATION ･･･ (3), (4)
3-1 PINION-SHAPED CUTTER FOR GEAR
(1) FOR SPUR GEAR (2)
USED FOR CUTTING A SPUR GEAR WHICH CANNOT
BE CUT BY HOB.
[TYPES OF TOOTH PROFILE]

FULL DEPTH TOOTH ･･･････････････････････････ MOST COMMON TOOTH PROFILE, USED FOR CUTTING
OPERATIONS BASED ON JIS FULL DEPTH TOOTH.
GENERALLY, GEARS PRODUCED BY THIS TOOL DO NOT
UNDERGO SUBSEQUENT FINISHING.
PRE-SHAVING TOOTH PROFILE ･･････････････････ AS IMPLIED BY THE NAME, IT IS USED FOR SHAVING
OPERATIONS PRIOR TO SV MACHINING.
IT IS CALLED AS "PS" FOR HIGH ADDENDUM.
WITH THIS TOOTH PROFILE, IT IS POSSIBLE TO CUT
SEMI-TOPPING TOOTH PROFILE ･････････････････････
TOOTH AND CHAMFER THE TOOTH EDGE AT A TIME.
3-2 PINION-SHAPED CUTTER FOR SPLINE (INV-SPL)
(1) PINION-SHAPED CUTTER FOR STRAIGHT-SIDED (2)
SPLINE
GENERALLY, SPLINE IS USED TO MESH A GEAR (ESPECIALLY SPROCKET) AND A SHAFT FOR POWER
TRANSMISSION FROM ONE SHAFT TO THE OTHER.
SPLINE IS MADE PREDOMINANTLY BY HOB, ROLL FORMING OR FORGING. IN THE CASE WHERE IT IS NOT
POSSIBLE TO CUT SPLINE WITH THOSE TOOLS, PINION-SHAPED CUTTERS ARE USED.
3-3 PINION-SHAPED CUTTER FOR SPROCKET (SP)
(1) PINION-SHAPED CUTTER FOR ROLLER CHAIN SPROCKET
(2) PINION-SHAPED CUTTER FOR SILENT CHAIN SPROCKET
THEY ARE MOST COMMON TYPES OF CHAIN DRIVE THAT EMPLOYS A PAIR OF SPROCKETS AND A CHAIN.
PINION-SHAPED CUTTERS ARE USED FOR CUTTING OPERATIONS WHICH CANNOT BE DONE BY HOBS.
4 TERMINOLOGY OF CUTTERS ･･･ (3), (4)

4-1 PART NAMES
FRONT OUTSIDE DIA

RELIEF ANGLE
PITCH CIRCLE RIGHT FLANK
ANGLE
INSIDE DIA
CLAMP FACE
RAKE ANGLE
BOTTOM
FACE
- 105 -
FOR HELICAL GEAR
USED FOR CUTTING A HELICAL GEAR WHICH
CANNOT BE CUT BY HOB.
MOST COMMON TOOTH PROFILE, USED FOR CUTTING

OPERATIONS BASED ON JIS FULL DEPTH TOOTH.
GENERALLY, GEARS PRODUCED BY THIS TOOL DO NOT
UNDERGO SUBSEQUENT FINISHING.
AS IMPLIED BY THE NAME, IT IS USED FOR SHAVING

OPERATIONS PRIOR TO SV MACHINING.
IT IS CALLED AS "PS" FOR HIGH ADDENDUM.
WITH THIS TOOTH PROFILE, IT IS POSSIBLE TO CUT
TOOTH AND CHAMFER THE TOOTH EDGE AT A TIME.
PINION-SHAPED CUTTER FOR INVOLUTE SPLINE
A GEAR (ESPECIALLY SPROCKET) AND A SHAFT FOR POWER

THE OTHER.
HOB, ROLL FORMING OR FORGING. IN THE CASE WHERE IT IS NOT
E TOOLS, PINION-SHAPED CUTTERS ARE USED.
CHAIN SPROCKET
CHAIN DRIVE THAT EMPLOYS A PAIR OF SPROCKETS AND A CHAIN.

OR CUTTING OPERATIONS WHICH CANNOT BE DONE BY HOBS.
CUTTER
ADDENDUM CUTTING
SIDE RELIEF
ANGLE DEPTH
LEFT FRANK
ANGLE
WHOLE
DEPTH
CUTTER
DEDENDUM
- 105 -
4-2 DESIGNATION AND CODE OF CUTTERS
FOR SPUR GEAR

m PA NT HL TOOTH STIPULATED BY
(MODULE) (PRESSURE ANGLE) (NUMBER OF TOOTH HELIX ANGLE PROFILE DIN (JIS)
FOR HELICAL
GEAR OF CUTTER)
φD NT m PA
FOR INVOLUTE (OUTSIDE DIA OF (NUMBER OF TEETH (MODULE) (PRESSURE ANGLE)
SPLINE WORK) OF WORK)
STIPULATED BY
MESH CODE
N φD φd JIS,HES
FOR STRAIGHT (NUMBER OF (OUTSIDE DIA OF (INSIDE DIA OF
SPLINE GROOVE OF WORK) WORK) WORK)
C・P RD
FOR ROLLER (PITCH) (ROLLER DIA) TOOTH STIPULATED BY
CHAIN SPROCKET PROFILE ASA
5 CUTTING CONDITIONS ･･･ (3), (4)

IN GEAR CUTTING BY PINION-SHAPED CUTTERS WHERE THE CUTTER CUTS A GEAR AT ONE DIRECTION IN AN
AXIAL RECIPROCATING MOTION, THE SPEED OF STROKE IS THE CUTTING SPEED AND THE FEED OF WORKPIECE
WITH RESPECT TO THE CUTTER STROKE IS THE FEED.
THE CUTTING SPEED AND FEED ARE DETERMINED BASED ON THE REQUIRED ACCURACY AND CONDITIONS FOR
WORKPIECE BY SHIFTING THE CHANGE GEAR OF MACHINE.
5-1 CUTTING SPEED (m/min)
N: NUMBER OF STROKE PER MIN.
S= 2XLXN S: CUTTING SPEED, m/min
1000 L: LENGTH OF STROKE, mm
5-2 MACHINING TECHNIQUE
GEAR CUTTING BY PINION-SHAPED CUTTERS
WORK
ALLOWS INDEPENDENT ADJUSTMENT OF THE
FEED, THE ROTATION AND THE DEPTH OF CUT
DURING ROUGHING AND FINISHING OPERATIONS. LENGTH OF STROKE
PINION-SHAPED
CUTTER
(1) 1-CUT CUTTING ･･･ GEAR CUTTING
COMPLETES IN ONE ROTATION OF
WORKPIECE RAKE FACE
(2) 2-, 3-CUT CUTTING ･･･ GEAR CUTTING POINTS OF WEAR
COMPLETES IN TWO OR THREE ROTATIONS
OF WORKPIECE.
6 REGRINDING PARAMETERS ･･･ (1), (2)

6-1 WEAR OF PINION-SHAPED CUTTERS
6-2 TIPS ON REGRINDING
GRIND AWAY WORN PART IN THE CUTTING EDGE OR THE FLANK OF CUTTER FROM THE RAKE FACE SIDE.
(1) PINION-SHAPED CUTTER FOR SPUR GEAR (SPLINE,
WEAR IN CUTTING EDGE
SPROCKET) AMOUNT OF WEAR (CHIPPING)
A GRINDING MACHINE DESIGNED FOR PINION-SHAPED
CUTTER GRINDING IS USED AT HONDA.
PROCEDURE: PLACE THE CUTTER AT A SPECIFIED RAKE
ANGLE (5°IN GENERAL) ON THE TABLE. ADJUST THE FLANK
WEAR
AUTOMATIC CUT DEPTH CONTROLLER BASED ON THE
AMOUNT OF WEAR IN THAT TOOL. THEN, GRIND AWAY THE
WORN PART FROM THE RAKE FACE SIDE.
- 106 -
6-3 PINION-SHAPED CUTTER FOR HELICAL GEAR
A GRINDING MACHINE DESIGNED FOR GRINDING OF PINION-SHAPED CUTTER FOR HELICAL GEAR IS USED. THE
CUTTER IS PLACED ON THE TABLE AT AN SPECIFIED RAKE ANGLE AND CUTTING EDGE ANGLE. WITH AUTOMATIC
CONTROL FUNCTIONS OF SPACE, FEED AND DEPTH OF CUT, WORN PART IS GROUND AWAY FROM THE RAKE FACE
SIDE.
(1) REGRINDING
-1 BEFORE STARTING REGRINDING, CHECK THE CUTTING EDGE
AND THE FLANK OF CUTTER FOR A POINT WITH MOST SEVERE
WEAR TO DETERMINE THE MACHINING ALLOWANCE FOR
REGRINDING.
GRINDING ALLOWANCE
-2 AS REGRINDING LEAVES BURRS ON THE RIGHT AND LEFT FLANK,

MAKE SURE TO REMOVE BURRS WITH A BRUSH AFTER
REGRINDING.
GRINDING WHEEL
GRINDING ALLOWANCE
-3 BEFORE COMPLETING REGRINDING WORK, MAKE SURE THAT
THE WORM PART HAS BEEN THOROUGHLY GROUND AWAY.
-4 WHEN A MAGNET CHUCK IS USED, MAKE SURE TO DEMAGNETIZE

THE GROUND TOOL.
6-4 POINTS OF MEASUREMENT AFTER REGRINDING
ITEM MEASURING METHOD
PLACE THE CUTTER ON THE SINE BAR WHICH IS
TILTED AT AN ANGLE CORRESPONDING TO THE RAKE
ANGLE. MOVE THE MICROMETER IN RADIAL
DIRECTION OF THE RAKE FACE TO OBTAIN A READOUT.
RAKE FACE
PLACE THE JIG ON THE SURFACE PLATE. TURN THE

CUTTER ABOUT THE REFERENCE OF THE BOTTOM
FACE AND THE HOLE DIAMETER
RUN-OUT OF
RAKE FACE
- 107 -
INION-SHAPED CUTTER FOR HELICAL GEAR IS USED. THE
AKE ANGLE AND CUTTING EDGE ANGLE. WITH AUTOMATIC
F CUT, WORN PART IS GROUND AWAY FROM THE RAKE FACE
TABLE
STROKE
GRINDING WHEEL
GRINDING ALLOWANCE
GRINDING WHEEL
GRINDING ALLOWANCE
FIGURE
SINE BAR PINION-

SHAPED
CUTTER
BLOCK GAUGE
TURN THE CUTTER
JIG
- 107 -
6-5 REGRINDING ACCURACY
* REGRINDING TOLERANCE FOR PINION-SHAPED CUTTER (UNIT: μ)

PINION-SHAPED CUTTER ACCURACY RAKE ANGLE RAKE FACE RUN-OUT
GRADE 0 ±10' 10
GRADE 1 ±10' 10
- 108 -
[11] SHAVING CUTTERS [(3), (4) ALL]
1. INTRODUCTION
2. TERMINOLOGY AND MATERIALS OF CUTTERS
3. CUTTING THEORY OF SHAVING CUTTERS
4. CUTTING METHODS
5. CUTTING CONDITIONS
6. ACCURACY OF CUTTERS AND FINISHED GEARS
7. INTERPRETATION OF GEAR DATA
8. GRINDING OF SHAVING CUTTERS
9. TOOTH PROFILE OF CUTTERS
10. SERVICE LIFE
- 109 -
, (4) ALL]
S=
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110
111
111
111
113
114
116
116
118
119
- 109 -
[11] SHAVING CUTTERS ･･･ [(3), (4) ALL]
1 INTRODUCTION
GEARS PRODUCED FOR AUTOMOBILE APPLICATIONS UNDERGO VARIOUS FINISHING PROCESSES AFTER THE
GEAR CUTTING OPERATION BY HOBS AND PINION-SHAPED CUTTERS IN ORDER TO ELIMINATE NOISE THAT
GEARS CAUSE WHEN THEY ARE ENGAGED.
THE FOLLOWING ARE GEAR FINISHING TECHNIQUES.
1-1 GEAR GRINDING (G/G)
A THREADED GRINDING WHEEL MESHES WITH A GEAR TO GRIND THE TOOTH FLANK.
(ALTHOUGH IT IS HIGHLY ACCURATE PROCESS, A LONG PROCESSING TIME AND HIGH COST ARE INVOLVED.
THUS, IT IS SUITABLE FOR SMALL-LOT PRODUCTION.)
1-2 GEAR ROLLING (G/Ro)
A PAIR OF HIGH-PRECISION ROLLERS IS ENGAGED CONCENTRICALLY WITH A GEAR. THE ROLLERS ARE
ROTATED AND THE PRESSURE OF 3 t TO 5 t IS EXERTED FROM THE RIGHT AND LEFT SIDES.
(HIGH ACCURACY CAN BE OBTAINED AT A SHORT PROCESSING TIME. NO CHIPS ARE GENERATED. TOOL
SERVICE LIFE IS SUPERIOR; IT COULD CUT SEVERAL HUNDREDS OF THOUSAND OF WORKPIECE.)
1-3 SHAVING (Sv OR G/SV)
THE TOOL IS IN THE SHAPE OF A HELICAL GEAR OF WHICH CROSSED AXES ANGLE WITH A GEAR IS 5° TO 15°.
IT UTILIZES THE SLIPPING FORCE THAT IS GENERATED WHEN THE GEARS COME INTO ENGAGEMENT TO
FINISH THE TOOTH SURFACE BY SHAVING.
(HIGH ACCURACY CAN BE OBTAINED AT A SHORT PROCESSING TIME. MOST COMMONLY USED TECHNIQUE AT
HONDA.)
1-4 GEAR HORNING (G/H)
A GRINDING WHEEL IN THE SAME SHAPE AS THE ABOVE SHAVING CUTTER COME INTO ENGAGEMENT WITH A
GEAR TO FINISH THE TOOTH SURFACE.
(ALTHOUGH TOOTH PROFILE ACCURACY DOES NOT IMPROVE, THE SURFACE ROUGHNESS IMPROVES. THUS,
WORKPIECES UNDERWENT SHAVING AND HEAT TREATMENT ARE FINISHED WITH THIS TOOL TO ELIMINATE
DENT MARKS.)
AMONG THE ABOVE TOOLS, WE EXPLAIN THE FINISHING TECHNIQUE BY SHAVING CUTTER, WHICH IS MOST
COMMONLY USED AT PRESENT.
THE FEATURE OF SHAVING CUTTER IS THAT IT CAN PROCESS HIGH-PRECISION GEARS AT A SHORT
PROCESSING TIME. IT IS ALSO POSSIBLE TO CHOOSE TOOTH PROFILE AND TOOTH TRACE ARBITRARILY.
HOWEVER, THERE ARE SOME DISADVANTAGES:
(1) SUSCEPTIBLE TO HEAT TREATMENT DEFORMATION.
(2) COME UNDER THE INFLUENCE OF THE ACCURACY OF PRECEDING GEAR CUTTING.
(3) LONG TOOL REGRINDING TIME.
- 110 -
2 TERMINOLOGY AND MATERIALS OF CUTTERS CUTTING EDGE
SERRATION
(1) MATERIALS KEYWAY TEETH
SKH-3 DRILL HOLE
SKH-9 PUNCH MARK CUTTING TEETH
SKH-52 GROOVE
SKH-53
TOOTH
3 CUTTING THEORY OF SHAVING CUTTERS

THE FIGURE AT RIGHT SHOWS A SHAVING PROCESS OF
SPUR GEAR. WHEN THE GEAR IN MESH WITH THE
CUTTER IS ROTATED TO THE DIRECTION VS1, THE GEAR
TENDS TO COME OFF THE ENGAGEMENT WITH THE
CUTTER. TO MAINTAIN THE ENGAGEMENT, THE GEAR IS
ROTATED BACK IN THE DIRECTION VS2, WHICH
GENERATES A SLIPPAGE IN THE AXIAL DIRECTION OF
GEAR. IN SHORT, TO ROTATE THE GEAR IN THE
DIRECTION VSt1, AN INTEGRATED FORCE OF ROTATING
FORCE (Vs1) AND SLIPPAGE FORCE (Vt1) HAS TO BE
EXERTED ON THE GEAR. AT THIS TIME, THE ROTATING
FORCE EXERTED IN THE DIRECTION OF GEAR INVOLUTE
AND THE SLIPPAGE FORCE EXERTED IN THE CUT FEED
DIRECTION CAUSE THE SERRATIONS OF GEAR TO CUT
THE WORKPIECE. UP TO THIS STEP, ONLY ONE SIDE OF
THE TOOTH FLANK IS CUT BECAUSE THE SLIPPAGE
FORCE IS EXERTED ONLY IN ONE DIRECTION. TO FINISH CUTTER AXIS
THE OTHER SIDE OF THE TOOTH FLANK, IT IS
NECESSARY TO ROTATE THE GEAR IN THE OPPOSITE GEAR AXIS
DIRECTION AND REVERSE THE DIRECTION OF SLIPPAGE GEAR CROSSED AXES
(THE CUTTER ROTATES IN REVERSE AT CUTTING ANGLE
OPERATION). CUTTER
ONLY WITH THE CUTTER'S ROTATING MOTION, THE

CENTER AREA OF TOOTH FLANK IS CUT ELLIPTICALLY.
THERFORE, THE GEAR IS RECIPROCATED IN THE AXIAL
DIRECTION (L1 L2) TO CUT THE TOOTH FACE WIDTH
EVENLY.
THIS IS THE BASIC MECHANISM OF SHAVING CUTTER,

WHICH IS REFERRED TO AS "CONVENTIONAL SHAVING."
4 CUTTING METHODS
4-1 CONVENTIONAL SHAVING
AS DESCRIBED IN THE ABOVE, THE GEAR AXIS IS FED IN THE AXIAL DIRECTION.
4-2 DIAGONAL SHAVING
THE WORKTABLE IS FED AT AN ANGLE OF 10°TO
35°TO THE GEAR AXIS. BECAUSE THE POINT OF
CUTTING MOVES, THE CUTTER WIDTH IS
EFFECTIVELY USED, THE TOOL SERVICE LIFE
BECOMES LONGER AND THE PROCESSING TIME
BECOMES SOMEWHAT SHORT.
- 111 -
4-3 UNDER-PASS SHAVING
THE WORKTABLE IS FED AT RIGHT ANGLES TO THE GEAR AXIS. THIS METHOD
IS USED FOR A CASE WHERE THE DIAGONAL SHAVING METHOD CANNOT BE
APPLIED, e.g. A GEAR ASSEMBLED WITH ANOTHER GEAR RIGHT NEXT TO IT.
THE ADVANTAGE IS SAME AS THE DIAGONAL SHAVING. THE CUTTER HAS

4° ～ 7°
HELICAL SERRATIONS. THEREFORE, WHEN IN ROTATION, IT ACTS ON
WORKPIECE IN THE SAME MANNER THAT THE WORKTABLE IS FED IN THE AXIAL
DIRECTION.
CONFIGURATION OF
SERRATION
THOSE HELICAL SERRATIONS ARE CALLED AS "DIFFERENTIAL SERRATIONS."
CONVENTIONAL SERRATIONS (FOR CONVENTIONAL SHAVING AND DIAGONAL SHAVING)
DIFFERENTIAL SERRATIONS (FOR UNDER-PASS SHAVING)
4-4 CROWNING SHAVING

THE BOTH SIDES OF TOOTH FLANK ARE CUT IN CONVEX TO OVERCOME
CUTTER POSSIBLE DEFORMATION AT HEAT TREATMENT AND TO SHAFT THE IMPACT OF
GEAR ENGAGEMENT ON TO THE CENTER AREA OF TOOTH FACE.
THE WORKTABLE IS MOVED IN A SEESAW MOTION ALONG WITH THE
CONVENTIONAL FEEDING MOTION.
CROWNING OF CUTTER
CONTRARY TO THE CROWNING OF GEAR, THE
TOOTH FLANK OF CUTTER IS MADE INTO
CONCAVE AT THE CENTER AREA.
THIS METHOD IS APPLIED PREDOMINANTLY TO
THE UNDER-PASS SHAVING.
(THE CONCAVE TOOTH FLANK IS CALLED AS MACHINED TOOTH
"HOLLOW LEAD" AND THE CONVEX TOOTH FLANK
IS CALLED AS "CROWNING READ".)
- 112 -
4-5 PLUNGE CUT SHAVING
THE MAJOR DIFFERENCE FROM THE DIAGONAL OR CONVENTIONAL
SHAVING IS THAT CUTTING IS DONE ONLY BY THE CUTTING FEED AND
CUTTER CROSS-FEEDING OF WORKTABLE IS NOT EMPLOYED.
THEREFORE, THE CUTTER HAS DIFFERENTIAL SERRATIONS IN MOST

OPTIMUM PITCH AND CONFIGURATION PRECISELY CALCULATED BASED ON
SUCH PARAMETERS AS CROSSED AXES ANGLE, NUMBER OF CUTTER
TOOTH.
THE WIDTH OF CUTTER SHOULD BE LARGER THAN THAT OF WORKPIECE TO
BE MACHINED.
WORKPIECE IN ACTUAL CUTTING OPERATIONS, THE CUTTER IS PROVIDED WITH A
CUTTING FEED HOLLOW-LEAD TO MAKE THE TOOTH FLANK OF GEAR STRAIGHT OR
CROWNING LEAD.
THE PROCESSING TIME IS SHORTER THAN THAT OF THE CONVENTIONAL SHAVING BY 1/2 TO 1/3. THUS, THIS
METHOD IS THE MAINSTREAM OF SHAVING PROCESSING.
5 CUTTING CONDITIONS
5-1 THE CUTTING CONDITIONS OF SHAVING CONSISTS OF THE FOLLOWING THREE FACTORS.
(1) NUMBER OF REVOLUTION OF CUTTER (RPM): 80 - 280
(2) TABLE FEED RATE (mm/min): 30 - 150 + MACHINING ALLOWANCE
(3) TABLE STROKE (STROKE): 2 - 3
THE CUTTING CONDITIONS ARE DETERMINED BY SELECTING FIGURES FROM THE ABOVE 3 FACTORS BASED
ON GEAR DEVELOPMENT, ETC.
FOR YOUR INFORMATION, THE SUITABLE VALUE FOR MODULE 1.75 IS 0.04 mm - 0.06 mm AND FOR 2.0, IT IS
0.05 mm TO 0.07 mm.
OUTSIDE DIA OF WORK CUTTER RPM TABLE FEED RATE (mm/min) TABLE STROKE
φ30 95 - 140 80 - 110 2
φ100 120 - 200 50 - 110 2
φ150 160 - 250 45 - 90 2 OR 3
MAJOR CUTTING CONDITIONS FOR PLUNGE CUT SHAVING

CUTTER RPM PLUNGE FEED RATE FINISHING TIME DWELL TIME BACK MOVEMENT
(RPM) (mm/min) T1 (sec) T2 (sec) (mm)
180 - 230 0.8 3-4 3-4 0 - 0.03
- 113 -
R CONVENTIONAL
CUTTING FEED AND
ED.
RATIONS IN MOST
CALCULATED BASED ON
UMBER OF CUTTER
THAT OF WORKPIECE TO
PROVIDED WITH A
AR STRAIGHT OR
BY 1/2 TO 1/3. THUS, THIS
ABOVE 3 FACTORS BASED
mm AND FOR 2.0, IT IS
- 113 -
(4) RELATIONSHIP BETWEEN NUMBER OF STROKE AND CUTTING FEED
F
NO CUTTING
NO CUTTING
E
D
C
CUTTING FEED
B
START OF CUTTING
G A (START)
STROKE WIDTH
IN THE CASE OF 3 STROKES, THE WORKTABLE PROCEED TO MAKE ONE MORE STROKE FROM THE POINT
(F), IN WHICH CUTTING DOES NOT TAKE PLACE.
(5) CUTTING CURVE OF PLUNGE CUT SHAVING
0 STARTING POINT
0-1 QUICK TRAVERSE
1-2 PLUNGE FEED
2 PLUNGE FEED STOPS, DWELL TIME: T1 TAKES PLACE
2-3 AFTER DWELL TIME: T1, THE CUTTER ROTATES IN REVERSE DIRECTION AND THE FEED IS EITHER
BY PLUNGE OR QUICK TRAVERSE
3-4 THE CUTTER RETRACTS BY PLUNGE FEED -- BACK MOVEMENT
4 DWELL TIME: T2 TAKES PLACE
4-0 AFTER DWELL TIME: T2, IT RETURNS TO START POINT BY QUICK TRAVERSE
6 ACCURACY OF CUTTERS AND FINISHED GEARS

THE ACCURACY OF GEARS IS STANDARDIZED BY EACH COUNTRY. BECAUSE IT CONTAINS SOME POINTS THAT
ARE DIFFICULT TO DEFINE THEORETICALLY, HOWEVER, THERE ARE A NUMBER OF POINTS THAT DO NOT AGREE
WITH CONCEPT OR FIGURES.
IN JAPAN, GEARS FOR AUTOMOBILE APPLICATION ARE MANUFACTURED UNDER JIS OR DIN, DEUTSCHE
INDUSTRIAL NORMEN.
- 114 -
NUMBER OF STROKE AND CUTTING FEED
THE CUTTER AND WORKPIECE ARE IN MESH WITH SOME
BACKLASH (LOOSENESS BETWEEN TEETH). AT THE START
POINT (A), THE CUTTER ROTATION, THE TABLE FEED, AND THE
CUTTING FEED (INCLUDING QUICK TRAVERSE) TAKE PLACE. AT
THE POINT (C), THE CUTTER AND THE TABLE REVERSE THEIR
DIRECTION SIMULTANEOUSLY TO PROCEED TO THE 2ND STAGE
OF A CUTTING CYCLE WHERE ALL TEETH ARE CUT TO SPECIFIED
CUTTING FEED DIMENSION. AT THE POINTS (D) AND (E), CUTTING DOES NOT
TAKE PLACE BUT THE EACH SIDE OF TOOTH FLANK IS FINISHED
RESPECTIVELY. AT THE POINT (F), THE CUTTER ROTATION AND
THE TABLE FEED STOP. THE TABLE RETURNS TO THE POINT (G),
WHICH IS THE FINISH OF A CYCLE. (THIS MEANS THAT THE
TABLE HAS MADE 2 STROKES.)
ES, THE WORKTABLE PROCEED TO MAKE ONE MORE STROKE FROM THE POINT
OES NOT TAKE PLACE.
NGE CUT SHAVING
STOPS, DWELL TIME: T1 TAKES PLACE

TIME: T1, THE CUTTER ROTATES IN REVERSE DIRECTION AND THE FEED IS EITHER
R QUICK TRAVERSE
RETRACTS BY PLUNGE FEED -- BACK MOVEMENT
TIME: T2, IT RETURNS TO START POINT BY QUICK TRAVERSE
STANDARDIZED BY EACH COUNTRY. BECAUSE IT CONTAINS SOME POINTS THAT

ORETICALLY, HOWEVER, THERE ARE A NUMBER OF POINTS THAT DO NOT AGREE
OBILE APPLICATION ARE MANUFACTURED UNDER JIS OR DIN, DEUTSCHE
- 114 -
6-1 GEAR ACCURACY AFTER SHAVING
DIN JIS
TOOTH PROFILE ERROR 2μ - 8μ GRADE 2 - 6 GRADE 0 -2
ACCUMULATED PITCH ERROR 10μ - 40μ GRADE 6 - 10 GRADE 3 - 7
(JIS GRADE 1 IS EQUIVALENT TO DIN GRADE 4)
(UNIT: μm)
NORMAL MODULE
NO. ITEM 1.25 OR OVER EXCEEDING 4 EXCEEDING 6
4 OR LESS 6 OR LESS 10 OR LESS
+5
1 LIMITED DEVIATION TOLERANCE OF HOLE DIA (d)
0
+ 90
LIMITED DEVIATION TOLERANCE OF WIDTH (F)
KEYWAY
0
2
+ 300
LIMITED DEVIATION TOLERANCE OF HEIGHT (E)
0
3 LIMITED DEVIATION TOLERANCE OF OUTSIDE DIAMETER (3) ±400
4 LIMITED DEVIATION TOLERANCE OF WIDTH (b) ± 200
5 TOLERANCE OF RADIAL RUN-OUT 15
6 TOLERANCE OF AXIAL RUN-OUT 5
225 mm MAX. 20
7 TOLERANCE OF TOOTH SPACE RUN-OUT
NOMINAL DIMENSION
300 mm 25
225 mm MAX. 5
TOLERANCE OF PITCH VARIATION
300 mm 6
PITCH
8
225 mm MAX. 10
TOLERANCE OF MUTUAL ERROR
300 mm 12
9 TOLERANCE OF TOOTH PROFILE (5) ±3 ±3 ±4
0
10 TOLERANCE OF TOOTH THICKNESS (6)
- 25
TOOTH TRACE (4) TOLERANCE OF DIRECTIONAL ERROR ±7
11
(PER 25 mm) TOLERANCE OF SYMMETRY 5
NOTE: (5) CAN BE APPLIED CORRESPONDINGLY TO THE CUTTER TOOTH PROFILE RECONDITIONING
(6) TOLERANCE OF TOOTH THICKNESS IN CORRESPONDENCE WITH OUTSIDE DIA.
- 115 -
7 INTERPRETATION OF TOOTH PROFILE DATA
THE INVOLUTE CURVE OF TOOTH IS REFERRED TO AS "TOOTH PROFILE". THE TOOTH PROFILE IS JUDGED
BASED ON THE DATA RECORDED BY THE TOOTH PROFILE MEASURING DEVICE.
(MEASURING
ROOT OF MAGNIFICATION) 500x
TOOTH ROOT OF TOOTH
(MAGNIFICATION IN
DIRECTION) 2x
NORMAL LINE
CORRECT INVOLUTE CURVE TOOTH TOP
TOOTH TOP
AS SHOWN ABOVE, IF THE INVOLUTE CURVE OF A TOOTH MEASURED IS CORRECT, A STRAIGHT LINE IS DRAWN
IN A RECORDING CHART OF THE MEASURING DEVICE. THIS IS REFERRED TO AS "TOOL INVOLUTE," THE BASIS
OF A GEAR. THE TOOL INVOLUTE ACTS AS THE TARGET OF WORKPIECE TOOTH PROFILE IN SHAVING
OPERATIONS AS WELL. AS A RULE, THE MEASURING MAGNIFICATION IS 500 TIMES AND THE FEEDING
MAGNIFICATION IS 2 TIMES (AT SUZUKA FACTORY). THE FEEDING MAGNIFICATION OF 4 TIMES OR 8 TIMES IS
SOMETIMES USED.
PRESSURE ANGLE CONCAVE AND CORRUGATION CHAMFER OF

PLUS CONVEX TOOTH TOP
8 GRINDING OF SHAVING CUTTERS

THERE ARE TWO GRINDING METHODS FOR SHAVING GRINDING WHEEL
CUTTERS.
8-1 PITCH CIRCLE ROLLING
THE CUTTER IS ROLLED ON A PITCH CIRCLE OR A
GENERATING ROLL CIRCLE WHICH IS SLIGHTLY SMALLER
THAN THE PITCH CIRCLE TO GRIND THE TOOTH FLANK.
BECAUSE THE FLAT SURFACE OF GRINDING WHEEL ACTS

ON THE CUTTER;
(1) FALL OF GRIT IS LESS.
(2) THERE IS NO LIMITATION ON THE TOOTH PROFILE
FOR GRINDING.
(3) IF THERE IS NOT LARGE DIFFERENCE IN THE
CUTTER PITCH CIRCLE, IT IS POSSIBLE TO GRIND GENERATING PITCH
CUTTERS WITH THE SAME GENERATING ROLL CIRCLE
CIRCLE. (GENERATING ROLL
FIG. 1 CIRCLE)
OWING TO THOSE ADVANTAGES (RATHER

REQUIREMENTS), THIS METHOD IS ADOPTED BY MANY
MANUFACTURERS.
- 116 -
FIG. 1 SHOWS THE GEAR CUTTING BY A RACK CUTTER. VIEW A PART OF RACK CUTTER AS A GRINDING
WHEEL. WHEN THE GRINDING WHEEL IS ROTATED IN THE DIRECTION (V), THE TOOTH IS GROUND FROM
THE TOOTH TOP TO THE ROOT OF TOOTH.
A MINOR ERROR IN A GENERATING ROLL CIRCLE DIAMETER CAN BE CORRECTED BY AN ANGLE OF
INCLINATION OF GRINDING WHEEL.
8-2 BASE CIRCLE ROLLING

THIS METHOD EMPLOYS THE INVOLUTE CURVE DRAWING
IN REVERSE. THE GENERATING ROLL CIRCLE DIAMETER IS
THE SAME AS THE CUTTER'S BASIC CIRCLE.
BECAUSE THE GRINDING WHEEL ACTS ON THE TOOTH

FLANK OF CUTTER AT A POINT;
(1) FALL OF GRIT IS RATHER RAPID.
(2) IT IS NOT POSSIBLE TO GRIND TOOTH PROFILE THAT
HAS BEEN MODIFIED OR IN SHAPE OTHER THAN
STRAIGHT.
(3) IT IS NOT POSSIBLE TO SHARE THE GENERATING

ROLL CIRCLE.
THUS, THIS METHOD IS SCARCELY ADOPTED.

8-3 GENERATION BY OFF-SET GRINDING
THE PRESSURE ANGLE OF WORKPIECE OF THE TOP,
MIDDLE AND BOTTOM PART OF TOOTH ARE MACHINED
WITH A CUTTER OF THE SAME TOOTH PROFILE VARIES
GRADUALLY ALONG THE TOOTH TOP TO THE TOOTH ROOT
AND TOWARD THE TOOTH WIDTH DIRECTION BECAUSE OF
SURFACE PRESSURE EXERTED DURING CUTTING. (FIG AT
RIGHT)
TO CORRECT THIS VARIATION, IT IS NECESSARY TO GIVE A

PRESSURE ANGLE TO THE CUTTER IN ACCORDANCE WITH
THE PRESSURE ANGLE OF WORKPIECE.
GENERALLY, THE CENTER OF GENERATING ROLL CIRCLE

BY 0.5 mm TO 2.5 mm IS SHIFTED FROM THE CENTER OF
THE CUTTER AND THE GENERATING ROLL MOTION. (THIS
IS CALLED AS OFFSET.) THIS ENABLES A GRADUAL
CHANGE IN PRESSURE ANGLE ALONG THE TOOTH TOP TO
THE TOOTH ROOT AND TOWARD THE TOOTH WIDTH
DIRECTION.
IN ACTUAL CUTTING OPERATIONS, THIS OFFSET METHOD

IS COMBINED WITH A TEMPLATE.
- 117 -
Y A RACK CUTTER. VIEW A PART OF RACK CUTTER AS A GRINDING
EL IS ROTATED IN THE DIRECTION (V), THE TOOTH IS GROUND FROM
OOTH.
OLL CIRCLE DIAMETER CAN BE CORRECTED BY AN ANGLE OF
PERPENDICULAR TO DIRECTION (V)
GRINDING WHEEL ACTS ON

WORKPIECE AT THIS LINE
BASIC CIRCLE DIAMETER

(GENERATING ROLL
CIRCLE DIA)
THEORETICAL TOOTH
BOTTOM
MIDDLE
TOP
PROFILE
GROUND
TOOTH
PROFILE
BOTTOM, MIDDLE, TOP

ROLL
GENERATING
AMOUNT OF OFFSET
- 117 -
EXAMPLES OF TOOTH PROFILE CUT BY OFFSET GRINDING
BOTTOM, MIDDLE, TOP BOTTOM, MIDDLE, TOP
TOOTH TOP
LEFT HAND HELIX
8-4 MACHINING ALLOWANCE FOR GRINDING
MACHINING ALLOWANCE FOR GRINDING VARIES DEPENDING ON THE NUMBER OF TOOL TO BE GROUND AND WEAR
CONDITION. FOR BASE TANGENT LENGTH, IT IS 0.02 mm - 0.07 mm.
8-5 GRINDING TIME
IT TAKES 1.5 - 2.5 HOURS TO GRIND SIMPLE TOOTH PROFILE. IN THE CASE OF DOUBLE-FOLDED OR CHEVRON
TOOTH PROFILE, IT TAKES 2.5 - 3.0 HOURS. IT IS ALSO NECESSARY TO CONTROL THE GRINDING TIME IN
ACCORDANCE WITH THE AMOUNT OF WEAR, NUMBER OF CUTTER TOOTH AND TOOTH WIDTH.
8-6 GRINDING OF OUTSIDE DIAMETER

TOOTH BECOMES THINNER BY THE AMOUNT OF GRINDING. IF A CUTTER WITH SUCH TEETH IS ENGAGED WITH A
GEAR, THE OUTSIDE DIAMETER OF THE CUTTER TOUCHES THE TOOTH ROOT OF THE GEAR. THUS, THE OUTSIDE
DIAMETER HAS TO BE GROUND.
BECAUSE IT IS STRONGLY RELATED TO THE ASSURANCE OF TOOTH PROFILE, THE OUTSIDE DIAMETER GRINDING
IS CONTROLLED BY THE CONSTANT WORKING RATIO.
9 TOOTH PROFILE OF CUTTERS

TO SATISFY THE REQUIRED ACCURACY OF TOOTH PROFILE OF GEARS, CUTTERS ARE OFTEN GROUND BY
MODIFIED TOOTH PROFILE. GRINDING WHEELS ARE CUT AND SHAPED WITH TEMPLATES FOR MODIFICATION OF
TOOTH PROFILE.
9-1 THE FIGURES SHOW A RELATIONSHIP BETWEEN MODIFIED TOOTH PROFILE AND TEMPLATE
GRINDING
WHEEL
TEMPLATE
CUTTER
TOOTH
TOP
PRESSURE
ANGLE
AMOUNT OF
MODIFICATION MODIFICATION
- 118 -
BY OFFSET GRINDING
BOTTOM, MIDDLE, TOP
RIGHT HAND HELIX
ARIES DEPENDING ON THE NUMBER OF TOOL TO BE GROUND AND WEAR

IT IS 0.02 mm - 0.07 mm.
E TOOTH PROFILE. IN THE CASE OF DOUBLE-FOLDED OR CHEVRON

IT IS ALSO NECESSARY TO CONTROL THE GRINDING TIME IN
R, NUMBER OF CUTTER TOOTH AND TOOTH WIDTH.
NT OF GRINDING. IF A CUTTER WITH SUCH TEETH IS ENGAGED WITH A

UTTER TOUCHES THE TOOTH ROOT OF THE GEAR. THUS, THE OUTSIDE
E ASSURANCE OF TOOTH PROFILE, THE OUTSIDE DIAMETER GRINDING

ING RATIO.
TOOTH PROFILE OF GEARS, CUTTERS ARE OFTEN GROUND BY

EELS ARE CUT AND SHAPED WITH TEMPLATES FOR MODIFICATION OF
WEEN MODIFIED TOOTH PROFILE AND TEMPLATE

FOR THE PRESSURE ANGLE MODIFICATION, SINCE ITS
CURVE IS STRAIGHT, TEMPLATE IS NOT MODIFIED BUT
THE INCLINATION ANGLE OF GRINDING WHEEL IS
MODIFIED.
THE FIGURE SHOWS AN EXAMPLE OF PRESSURE

ANGLE PLUS.
- 118 -
10
10-1
10-2
- 119 -
GRINDING
WHEEL
TEMPLATE
LENGTH
DOUBLE-FOLD
AMOUNT
TOOTH PROFILE MODIFIED IN
COMBINATION OF PRESSURE ANGLE
AND TEMPLATE
GRINDING
WHEEL
PRESSURE ANGLE
MODIFICATION
TEMPLATE
MODIFICATION
BY TEMPLATE
CHEVRON
SERVICE LIFE
SERVICE LIFE OF CUTTERS
A PIECE OF SHAVING CUTTER CAN BE GROUND 15 TO 20 TIMES. ELIMINATION OF SERRATIONS INDICATES THAT
THE CUTTER IS AT END OF SERVICE LIFE.
CUTTING LIFE OF CUTTERS

THE NUMBER OF WORKPIECES THAT A CUTTER CAN LAST AFTER EACH GRINDING OPERATION REANGES
BETWEEN 1,000 PC TO 15,000 PC, DEPENDING ON SIZE OF GEAR AND THE SPECIFIED ACCURACY OF TOOTH
PROFILE.
- 119 -
[12] BROACHES
1. CLASSIFICATION OF BROACHING (3), (4)

2. CLASSIFICATION BY TYPES OF BROACH MACHINES (3), (4)
3. COMPONENTS OF BROACH (3), (4)
4. BROACH MATERIALS AND CUTTING CONDITIONS (3), (4)
5. TIPS ON REGRINDING (1), (2)
- 121 -
S=
PAGE
122
122
123
124
124
- 121 -
[12] BROACHES
A BROACH IS A LONG MULTI-TOOTH CUTTING TOOL WHERE TEETH ARE CUT IN THE SAME SHAPE AS TEETH TO BE
CUT IN WORKPIECE. THE TOOL TRAVELS IN AXIAL DIRECTION (OR THE TOOL IS FIXED WHILE WORKPIECE
TRAVELS) THROUGH A GROOVE OR HOLE OF WORKPIECE TO REMOVE MATERIAL LITTLE BY LITTLE AND CUT A
DESIRED SHAPE BY USING THE ENTIRE LENGTH OF TOOL.
BROACHING DOES NOT REQUIRE SKILLS AND IS SUPERIOR TO OTHER CUTTING TOOLS IN EFFICIENCY. THUS, IT
IS WIDELY USED AS AN IMPERATIVE TOOL FOR HIGH-QUANTITY PRODUCTION RUNS.
1 CLASSIFICATION OF BROACHING ･･･ (3), (4)

1-1 TYPES OF DRIVING FORCE
(1) HYDRAULIC
(2) CHAIN
1-2 TYPES OF CUTTING
(1) PULLING ･･･ WORKPIECE IS FIXED AND BROACH IS PULLED.
(2) CONTINUOUS ･･･ BROACH IS FIXED AND WORKPIECES ARE FED CONTINUOUSLY.
1-3 TYPES OF OPERATION
(1) INTERNAL BROACH ･･･ TO CUT INTERNAL SURFACE OF WORKPIECE.
USED TO CHANGE THE SHAPE OF A HOLE OR CUT A SERIES OF GROOVES
(2) SURFACE BROACH ･･･ TO CUT SURFACE OF WORKPIECE.
USED TO MAKE CURVED SURFACE OF SPECIAL SHAPE. TOOLS OF VARIOUS SHAPES ARE
ASSEMBLED IN A TOOL HOLDER (JIG). (IT IS POSSIBLE TO CUT A WORKPIECE OF
COMPLICATED SHAPE WITH THIS BROACH.)
2 CLASSIFICATION BY TYPES OF BROACH MACHINES ･･･ (3), (4)

2-1 SINGLE-PIECE BROACH
THIS IS THE MOST COMMONLY USED TYPE. ROUGHING TEETH, SEMI-FINISHING TEETH AND FINISHING
TEETH ARE ARRANGED LONGITUDINALLY IN A SINGLE BODY.
[AT HONDA]
* ROUND BROACH * INVOLUTE SPLINE BROACH * SPECIAL SHAPE BROACH
* STRAIGHT-SIDED SPLINE BROACH * SERRATION BROACH * KEYWAY BROACH
2-2 COMBINATION BROACH
ROUND BROACH, FLAT BROACH AND OTHER TYPES OF BROACHES ARE INSTALLED TO A TOOL HOLDER OF A
BROACH MACHINE TO CUT VARIOUS SHAPES.
- 122 -
[AT HONDA]
* SURFACE BROACH (CHAIN BROACH)
[OTHERS]
* POT BROACH
2-3 INSERTED BLADE BROACH
GENERALLY USED FOR A LARGE SCALE BROACH MACHINE AND A SURFACE BROACH MACHINE.
HIGH-SPEED STEEL BLADES OR CEMENTED CARBIDE BLADES ARE BRAZED OR INSERTED (THROWAWAY
BLADES) IN THE CUTTING TEETH PORTION. THEY ARE USED FOR A BROACHING MACHINE OF LARGE SCALE OR
LARGE CUTTING AMOUNT, WHICH IS DIFFICULT TO FABRICATE.
3 COMPONENTS OF BROACHES ･･･ (3), (4)

3-1 GEOMETRY AND TERMINOLOGY OF BROACH
(1) SINGLE-PIECE BROACH
PULLING SIDE
LIFTING SIDE
FRONT PILOT
REAR PILOT
SEMI-FINISHING
FRONT SHANK ROUGHENING TEETH REAR SHANK
TEETH
FINISHING TEETH
OVERALL LENGTH
(2) COMBINATION BROACH
ROUND BROACH FLAT BROACH
CHAMFERING ROUGHENING TEETH FINISHING

TEETH
TEETH
THE ABOVE COMBINATION BROACH IS USED AT HONDA FOR ONNECTING RODS OF SEPARATE TYPE.
* CHAIN BROACH (CURL LINK): CONTINUOUS BROACH MACHINE USES 19 BROACHES COMBINED.
WEDGE
INSERT
CEMENTED CARBIDE INSERT
CEMENTED CARBIDE
THROWAWAY BROACH
BRAZED
HOLDER
BODY
- 123 -
4 BROACH MATERIALS AND CUTTING CONDITIONS ･･･ (3), (4)
4-1 MATERIALS OF BROACH
MATERIAL OF BROACH IS SELECTED BASED ON THE MATERIAL, HARDNESS, MACHINABILITY AND SHAPE OF
WORKPIECE.
MO HIGH-SPEED STEEL WHICH HAS HIGH TOUGHNESS HAS BEEN THE MAIN BROACH MATERIAL AT HONDA.
HOWEVER, OWING TO THE RECENT DEVELOPMENT IN CEMENTED CARBIDES, CEMENTED CARBIDE BROACHES
WITH INDEXABLE INSERTS ARE NOW USED FOR PRECISION FINISHING OPERATIONS.
TYPE MATERIAL APPLICATION FEATURES

Mo BASE HRC 64 - 66
SKH-9
SKH-55 (HM 35) GENERAL PURPOSE BROACH
Hi-V BASE FLAT BROACH WITH ROUGHING FOR HRC 65 - 67
HIGH-SPEED STEEL HEAVY CUTTING
SKH-57 (HS 93 R) BECAUSE OF HIGHER HARDNESS THAN
Mo BASE METAL, REGRINDING CAN ONLY
BE DONE WITH DIAMOND TOOL
ULTRA-FINE PARTICLE FLAT BROACH WITH ROUND FINISHING 1. HIGHER TOUGHNESS EVEN AT THE
BLADES FOR FINISHING SAME HARDNESS AS CEMENTED
CARBIDES.
CEMENTED CARBIDES (UF20) 2. CLOSE TO HIGH-SPEED STEEL IN

CUTTING TOOL MATERIAL CATEGORY.
4-2 CUTTING CONDITIONS

* CUTTING METHODS
BECAUSE A BROACH IS A MULTI-TOOTH CUTTING TOOL WHERE ROUGHING, SEMI-FINISHING AND FINISHING
TEETH ARE ARRANGED LONGITUDINALLY, IT IS PULLED TO REMOVE MATERIAL.
MACHINING
ALLOWANCE FINISHING TEETH
SEMI-FINISHING TEETH
ROUGHENING TEETH
ROUNDING TEETH
CONNECTING ROD (CUT BY COMBINATION

BROACHES)
* CUTTING SPEED
GENERAL STEEL (CARBON STEEL) ･･･ 5 - 10 m/min, Al ･･･ 15 m/min
5 TIPS ON REGRINDING ･･･ (1), (2)

5-1 WEAR OF BROACHES
FLANK WEAR FACE WEAR TOOTH CHIPPING
- 124 -
5-2 REGRINDING TIMING
PROPER DETERMINATION OF REGRINDING TIMING IS VERY IMPORTANT FOR BROACHING.
IF A BLUNT BROACH IS USED, THE WARE IN CUTTING TEETH FURTHER DEVELOPS. ACCORDINGLY, THE
AMOUNT THAT HAS TO BE GROUND AWAY BY REGRINDING INCREASES, RESULTING IN A SHORTER SERVICE
LIFE OF THE BROACH.
(1) [AT HONDA]

REGRINDING TIMING IS GENERALLY DETERMINED BY NUMBER OF WORKPIECE MACHINED UNDER
NORMAL CUTTING OPERATIONS.
(2) [GENERAL]
-1 WHEN THE SURFACE FINISH OF WORKPIECE TENDS TO BE POOR.
-2 WHEN THE CUTTING LOAD HAS BECOME LARGE (BY 30 - 40 % INCREASE FROM THE INITIAL PERIOD
OF USAGE.)
-3 WHEN WORKPIECE TENDS TO SUFFER FRACTURES AT THE TIME OF PULLING OUT THE TOOL.
-4 WHEN THE THOROUGH SIDE OF A LIMIT GAUGE DOES NOT GO THROUGH.
-5 WHEN WHIT WEAR APPEARS ON THE TEETH AND IT BECOMES 0.05 - 0.2 mm.
5-3 REGRINDING METHODS
(1) INTERNAL BROACH
HOLD IT WITH A SENSOR. USE A SIDE ANCHOR TO PREVENT DEFLECTION OR RUN-OUT OF A LONG
BROACH.
-1 MAKE SURE TO GRIND ONLY THE RAKE FACE.
-2 GRIND THE ROUNDED AREA OF CHIP POCKET PROPERLY.
-3 IN ORDER TO REGRIND AT CORRECT RAKE ANGLE, MAKE THE AXIAL INCLINATION ANGLE OF
GRINDING WHEEL LARGER THAN THE RAKE ANGLE.
-4 USE A GRINDING WHEEL AS LARGE DIAMETER AS POSSIBLE. HOWEVER, TOO LARGE GRINDING
WHEEL INTERFERES WITH THE TOOL, AND THE RAKE ANGLE MAY BECOME SMALL.
USE A GRINDING WHEEL AS 1.5 TO 2 TIMES AL LARGE AS THE BROACH DIAMETER.
HOW TO GRIND THE ROUND AREA * R-SHAPE OF CHIP PACKET

OF CHIP POCKET
(a) WRONG (b) CORRECT
(a) ･･･ BROKEN CHIPS ACCUMULATE

IN THE POCKET, RESULTING IN POOR
SURFACE FINISH AND BREAKAGE OF
BROACH.
(B) ･･･ CHIPS CURL IN THE POCKET
(2) SURFACE BROACH

FIX THE SURFACE BROACH TO THE TABLE (MAGNET, ETC.). GRIND THE RAKE FACE, AND THE BODY
CLEARANCE IF NECESSARY.
-1 MAKE THE AXIAL INCLINATION ANGLE OF GRINDING WHEEL SAME AS THE RAKE ANGLE.
- 125 -
-2 R-SHAPE OF CHIP POCKET IS SAME AS THAT OF THE INTERNAL BROACH.
-3 IF THE BODY CLEARANCE IS GROUND, MODIFY THE DIMENSION WITH A LINER TO MAKE UP THE REDUCED
AMOUNT OF TOOTH HEIGHT.
5-4 STANDARD RAKE ANGLE AND RELIEF ANGLE OF BROACH AGAINST WORKPIECE
RELIEF ANGLE
WORKPIECE MATERIAL RAKE ANGLE
ROUGHING FINISHING
MILD STEEL 13 - 15° 2° 1°
HARD STEEL 10 - 13° 2° 1°
CAST STEEL 10° 2° 1 1/2
CAST IRON (MILD) 10° 2° 1 1/2
CAST IRON (HARD) 5° 2° 1 1/2
ALUMINUM ALLOY 15 - 20° 2° 1 - 1 1/2
5-5 POINTS TO BE CHECKED AFTER REGRINDING OF BROACHES

(1) AFTER REGRINDING, ENSURE THAT WEAR AND CHIPPING ARE THOROUGHLY GROUND AWAY.
(2) ENSURE THAT THE R-SHAPE OF RAKE FACE IS A SMOOTH CURVE.
(3) MEASURE THE OUTSIDE DIAMETER WITH A MICROMETER ･･･ INTERNAL BROACH
(4) MEASURE THE PARALLELISM OF HEIGHT WITH A MICROMETER ･･･ SURFACE BROACH (FINISHING TEETH)
(5) REMOVE BURRS WITH A WIRE BRUSH.

(6) DEMAGNETIZE THE TOOL ･･･ SURFACE BROACH (STRAIGHT-SIDED)
- 126 -
ME AS THAT OF THE INTERNAL BROACH.
OUND, MODIFY THE DIMENSION WITH A LINER TO MAKE UP THE REDUCED
NGLE OF BROACH AGAINST WORKPIECE
* INCLINATION ANGLE OF GRINDING

WHEEL
MAKE THE RELIEF ANGLE AS SMALL AS

POSSIBLE
(FOR LESSER DIMENSIONAL REDUCTION IN DIAMETER AND

HEIGHT AFTER REGRINDING.)
NDING OF BROACHES
HAT WEAR AND CHIPPING ARE THOROUGHLY GROUND AWAY.
RAKE FACE IS A SMOOTH CURVE.
ER WITH A MICROMETER ･･･ INTERNAL BROACH
HEIGHT WITH A MICROMETER ･･･ SURFACE BROACH (FINISHING TEETH)
RFACE BROACH (STRAIGHT-SIDED)
- 126 -
[13] FROM ROLLING TOOLS ･･･ (ALL (1), (2))
1. TYPES OF ROLLER DIES (ROLLERS)

2. FEATURES OF FORM ROLLING ROLLERS
3. MATERIALS OF FORM ROLLING ROLLERS
4. HARDNESS OF ROLLERS
5. ROLLING FLUIDS
6. PRECISION OF ROLLED THREADS
7. REGRINDING PROCEDURE
- 127 -
(ALL (1), (2))
S=
PAGE
128
128
129
129
129
129
129
- 127 -
[13] FORM ROLLING TOOLS ･･･ (ALL (1), (2))
THREAD MAKING BY FORM ROLLING PROCESS IS A PLASTIC FORMING TECHNIQUE BY WHICH THREADS ARE FORMED
ON MATERIAL.
ROLLING TOOLS ARE (1) ROLL FORMING ROLLERS, (2) ROLL FORMING TAP (REF. TO SECTION "TAPS"), (3) ROLL
FORMING RACK.
ROLLERS FLAT DIES ･･･ MATERIAL IS HELD BETWEEN A PAIR OF FLAT DIES AND ROLLED
(DIES) WITH STROKE OF DIES.
ROLLER DIES ･･･ MATERIAL IS FED BETWEEN A PAIR OF ROLLERS WHICH ARE
(ROUND ROLLERS) ROTATED BY HYDRAULIC PRESSURE. (FIG. BELOW)
1 TYPES OF ROLLER DIES (ROLLERS)

TYPE DESCRIPTION
THREAD ROLLER USED FOR THREAD-ROLLING PROCESS
WORM ROLLER THREAD-ROLLING FOR WORM GEAR
SMALL MODULE AND LARGE PRESSURE

SERRATION ROLLER ANGLE WITH LOW TOOTH DEPTH
A KIND OF SPLINE
MODULE AND PRESSURE ANGLE ARE SAME AS

SPLINE ROLLER
GEAR. TOOTH DEPTH IS 1/2 OF GEAR
GEAR ROLLER USED FOR GEAR FINISHING
2 FEATURES OF FORM ROLLING ROLLERS

2-1 HIGH COST EFFICIENCY COMPARED TO THREAD CUTTING PROCESS
2-2 SKILLS ARE NOT REQUIRED AND PROCESSING TIME IS SHORT.
2-3 HIGH ACCURACY AND STRENGTH OF ROLLED THREADS.
2-4 BEAUTIFUL SURFACE FINISH
- 128 -
TOOLS ･･･ (ALL (1), (2))
IC FORMING TECHNIQUE BY WHICH THREADS ARE FORMED
LL FORMING TAP (REF. TO SECTION "TAPS"), (3) ROLL
AL IS HELD BETWEEN A PAIR OF FLAT DIES AND ROLLED

TROKE OF DIES.
AL IS FED BETWEEN A PAIR OF ROLLERS WHICH ARE

ED BY HYDRAULIC PRESSURE. (FIG. BELOW)
ROLLERS
WORKPIECE
(SUPPORTED AT THE CENTER)
ILLUSTRATION
- 128 -
3 MATERIAL OF FORM ROLLING ROLLERS
3-1 TOUGHNESS AND WEAR RESISTANCE ARE REQUIRED FOR ROLLERS. GENERALLY, SKD 11 IS USED.
3-2 FOR FORM ROLLING OF HIGH HARDNESS MATERIAL, D2 WITH SOME VANADIUM CONTENT IS USED.
4 HARDNESS OF ROLLERS ･･･ HRC 59 - 62
5 ROLLING FLUIDS ･･･ USED TO REDUCE FRICTION BETWEEN ROLLERS AND WORKPIECE, AND
FOR COOLING DOWN.
TO ENSURE THAT THE FLUID PENETRATES AND KEEP THE METALS
APART, ROLLING FLUIDS WITH HIGH PRESSURE RESISTANCE SHOULD
BE USED.
6 PRECISION OF ROLLED THREADS ･･･ THE PRECISION OF ROLLED THREADS IS DEPENDING ON THE
ACCURACY OF ROLLERS AND THE DIAMETER OF WORKPIECES. THUS,
CAREFUL CONSIDERATION MUST BE GIVEN TO THE DIAMTER OF
WORKPIECES.
IF WORKPIECES ARE OF INFERIOR IN ANY OF THE FOLLOWING POINTS;

(1) VARIATION, (2) CYLINDRICITY, (3) CIRCULARITY, (4) SURFACE FINISH,
SUCH INFERIORITY APPEARS EXACTLY IN THE PRECISION OF ROLLED
THREADS. IT ALSO AFFECTS THE SERVICE LIFE OF DIES.
7 REGRINDING PROCEDURE ･･･ WHEN A TOOTH OF ROLLER IS FOUND WITH CHIPPING OR WEAR, GRIND
AWAY IT BEFORE USING THE ROLLER FOR OPERATION.
(TO IMPROVE LEAD-IN AND ELIMINATE CHIPPING OF ROLLER, CHAMFER
THE BOTH SIDES OF ROLLER.)
- 129 -
[14] GRINDING WHEELS
1. 3 PARAMETERS OF GRINDING WHEELS (1), (2)

2. SELECTION OF GRINDING WHEELS (1), (2)
3. SELF-SHARPENING EFFECT OF GRINDING WHEELS (1), (2)
4. PHENOMENON OF LOADING, GRAIN FRACTURE,
AND BOND FRACTURE (1), (2)
5. GRINDING TEMPERATURE (1), (2)
6. GRINDING RESISTANCE (3), (4)
7. CONSTRUCTION OF GRINDING WHEELS (1), (2)
8. APPLICATION OF GRINDING WHEELS (3), (4)
9. GRINDING CONDITIONS (1), (2)
10. DRESSING (1), (2)
11. GRINDING FLUIDS (3), (4)
12. HANDLING PRECAUTIONS AND SAFETY (1), (2)
- 131 -
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132
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133
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133
137
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- 131 -
GRINDING IS ONE OF ABRASIVE MACHINING PROCESSES, WHICH USES GRINDING WHEELS ROTATING AT HIGH SPEEDS.
THE BONDED ABRASIVE GRAINS OF GRINDING WHEEL ACT AS NUMEROUS CUTTING EDGES AND REMOVE MATERIAL OF
WORKPIECE OF ANY TYPE FOR FINE AND PRECISE SURFACE FINISH.
1 3 PARAMETERS OF GRINDING WHEELS ･･･ (1), (2)

1-1 GRAINS
ABRASIVE GRAINS ARE EQUIVALENT TO CUTTING EDGE.
THE GRAINS WEAR OUT AND FRACTURE SO THAT NEW
SHARP CUTTING EDGES ARE PRODUCED CONTINUOUSLY
DURING GRINDING. THE GRAINS ARE BROADLY
CLASSIFIED AS THE SILICON CARBIDE AND THE
ALUMINUM OXIDE, AND ALSO CLASSIFIED BASED ON
MATERIALS AND GRAIN SIZES.
1-2 BOND
THE ABRASIVE GRAINS ARE HELD TOGETHER IN SHAPE
BY A BONDING MATERIAL (BOND). THE COMMON BOND
TYPES ARE SODIUM SILICATE, NATURAL RESIN AND
SYNTHETIC RESIN.
1-3 POROSITY
POROSITY IS CLEARANCE BETWEEN GRAINS, WHICH
ACCOMMODATE THE CHIPS BEING PRODUCED. THE SIZE
AND AMOUNT OF POROSITY DETERMINES THE
STRUCTURE OF GRINDING WHEEL.
THE ABOVE ARE 3 PARAMETERS OF GRINDING WHEEL.

GRINDING WHEELS ARE CLASSIFIED BASED ON THE
COMBINATION OF THOSE PARAMETERS.
2 SELECTION OF GRINDING WHEELS ･･･ (1), (2)

SELECTION OF GRINDING WHEELS IS MADE BASED ON THE FOLLOWING PARAMETERS (1) GRAIN TYPES, (2) GRAIN
SIZE, (3) GRADE (BONDING STRENGTH), (4) STRUCTURE, (5) BOND TYPES, (6) SIZE AND SHAPE OF GRINDING
WHEEL. THOSE ARE CALLED 6 PARAMETERS OF GRINDING WHEEL.
3 SELF-SHARPENING EFFECT OF GRINDING WHEEL ･･･ (1), (2)

DURING GRINDING, THE GRAINS FRACTURE OR FRAGMENT SO THAT NEW SHARP CUTTING EDGES ARE PRODUCED
CONTINUOUSLY TO MAINTAIN THE SAME SHARPNESS. THIS CHARACTERISTIC IS REFERRED TO AS "SELF-
SHARPENING EFFECT" OF GRINDING WHEEL.
4 PHENOMENON OF LOADING, GRAIN FRACTURE, AND BOND FRACTURE

4-1 LOADING
LOADING IS WHEN THE POROSITY ON THE SURFACE OF A GRINDING WHEEL BECOME FILLED OR CLOGGED WITH
CHIPS.
LOADING TENDS TO OCCUR WHEN GRINDING SOFT MATERIALS.
- 132 -
PROCESSES, WHICH USES GRINDING WHEELS ROTATING AT HIGH SPEEDS.
G WHEEL ACT AS NUMEROUS CUTTING EDGES AND REMOVE MATERIAL OF
ECISE SURFACE FINISH.
GRINDING WHEEL
GRAINS
POROSITY
BOND
GRAINS
BOND
POROSITY
ADE BASED ON THE FOLLOWING PARAMETERS (1) GRAIN TYPES, (2) GRAIN
(4) STRUCTURE, (5) BOND TYPES, (6) SIZE AND SHAPE OF GRINDING
TERS OF GRINDING WHEEL.
G WHEEL ･･･ (1), (2)

URE OR FRAGMENT SO THAT NEW SHARP CUTTING EDGES ARE PRODUCED
SHARPNESS. THIS CHARACTERISTIC IS REFERRED TO AS "SELF-
HEEL.
CTURE, AND BOND FRACTURE
HE SURFACE OF A GRINDING WHEEL BECOME FILLED OR CLOGGED WITH
DING SOFT MATERIALS.
- 132 -
4-2 GRAIN FRACTURE
THE PHENOMENON THAT THE CUTTING EDGES WEAR OUT.
IF A GRINDING WHEEL WITH GRAIN FRACTURE IS USED, THE SURFACE FINISH OF WORKPIECE IS BRIGHT, LOOKS
LIKE A MIRROR. HOWEVER, THE GRAIN FRACTURE IS A CAUSE OF SURFACE DAMAGE SUCH AS BURNING AND
CRACK.
4-3 BOND FRACTURE

THE GRAINS FALL OFF DUE TO GRINDING FORCE AND IMPACT FORCE, RESULTING IN PREMATURE WEAR OF
GRINDING WHEEL AND POOR SURFACE FINISH.
5 GRINDING TEMPERATURE ･･･ (1), (2)

BECAUSE A NUMBER OF GRAINS ACT ON THE SURFACE OF WORKPIECE AT HIGH SPEEDS AND AT A TIME, THE
TEMPERATURE RISE IN GRINDING OPERATION IS INCOMPARABLY GREATER THAN THAT OF TURNING OR MILLING
OPERATIONS. IT IS SAID THAT AN INSTANTANEOUS TEMPERATURE RISE COULD EXCEEDS 1,000℃.
6 GRINDING RESISTANCE ･･･ (3), (4)

GRINDING RESISTANCE IS A FORCE OCCURS BETWEEN THE GRINDING WHEEL AND WORKPIECE THAT TENDS TO
OPPOSE THE MOTION OF GRINDING WHEEL WITH THE MUTUAL INTERFERENCE OF THE GRINDING WHEEL AND
THE WORKPIECE.
CUTTING RESISTANCE IS INDICATED BY 3 COMPONENTS OF FORCES. AS FOR GRINDING RESISTANCE, THEY ARE
INDICATED BY TANGENTIAL GRINDING RESISTANCE (MAJOR FORCE), NORMAL GRINDING RESISTANCE (BACK
FORCE) AND FEED FORCE.
TANGENTIAL GRINDING
RESISTANCE
WORKPIECE
NORMAL
GRINDING
RESISTANCE
7 CONSTRUCTION OF GRINDING WHEELS ･･･ (1), (2)

7-1 GRAIN TYPES
CRYSTAL
BASE TYPE COLOR FEATURES MAJOR WORKPIECES
TYPE
HIGH TOUGHNESS, LOW
A FUSED DARK BROWN ROUGH GRINDING OF STEELS
SHARPNESS
HIGHER PURITY THAN TYPE A FOR

ALUMINA
FINISH GRINDING OF HARDENED

WA FUSED WHITE IMPROVED SHARPNESS, BUT
STEELS
TOUGHNESS IS SLIGHTLY LOW

PA FUSED PINK HIGHER PURITY THAN TYPE WA SPECIAL STEELS SUCH AS HSS
STEEL.
HIGHER HARDNESS BUT LOWER
SILICON CARBIDE
C BLACK
TOUGHNESS THAN TYPE A
GC GREEN HIGHER HARDNESS THAN TYPE C
- 133 -
SILICON CARBIDE
- 133 -
URFACE FINISH OF WORKPIECE IS BRIGHT, LOOKS
OF SURFACE DAMAGE SUCH AS BURNING AND
FORCE, RESULTING IN PREMATURE WEAR OF
RKPIECE AT HIGH SPEEDS AND AT A TIME, THE

BLY GREATER THAN THAT OF TURNING OR MILLING
URE RISE COULD EXCEEDS 1,000℃.
RINDING WHEEL AND WORKPIECE THAT TENDS TO

INTERFERENCE OF THE GRINDING WHEEL AND
RCES. AS FOR GRINDING RESISTANCE, THEY ARE

RCE), NORMAL GRINDING RESISTANCE (BACK
GRINDING WHEEL
NORMAL
GRINDING
RESISTANCE
MAJOR WORKPIECES
ROUGH GRINDING OF STEELS

STEELS

SPECIAL STEELS SUCH AS HSS
STEEL.
GRINDING OF Fc MATERIAL
ROUGH GRINDING OF
CEMENTED CARBIDES
- 133 -
GRINDING OF NONFERROUS
ALLOY SUCH AS ALUMINUM
- 133 -
7-2 GRAIN SIZE
GRAIN SIZE IS THE DIMENSION OF A GRAIN. IT IS IDENTIFIED BY GRIT NUMBER, WHICH IS A FUNCTION OF
SIEVE SIZE.
TABLE OF GRAIN SIZE

COARSE 10 12 14 16 20 24
MEDIUM 30 36 46 54 60
FINE 70 80 90 100 120 150 180 220
EXTRA FINE 240 280 320 400 500 600 700 800
FINE POWDER 1,000 1,200 1,500 2,000 2,500 3,000
RELATIONSHIP BETWEEN GRAIN SIZE AND CUTTING CONDITIONS

GRAIN SIZE
COARSE FINE
CUTTING CONDITION
MACHINING ALLOWANCE LARGE SMALL
FINISHED SURFACE COARSE FINE
WORK MATERIAL SOFT HARD
7-3 GRADE
THE GRADE INDICATES THE STRENGTH OF HOLDING ABRASIVE GRAINS TOGETHER, NOT THE STRENGTH OF A
GRAIN OR A BONDING MATERIAL.
TABLE OF GRADE
EXTRA RELATIONSHIP BETWEEN GRADE AND CUTTING
EXTRA MILD MILD MEDIUM HARD
HARD CONDITION
E H L P T GRADE
SOFT HARD
F I M Q U CUTTING CONDITION
G J N R V WORK MATERIAL HAD SOFT
K O S W ADHESIVE AREA WIDE NARROW
X
Y WHEEL PERIPHERAL VELOCITY HIGH LOW
Z WORK PERIPHERAL VELOCITY LOW HIGH
7-4 STRUCTURE
THE STRUCTURE OF A BONDED ABRASIVE IS A MEASURE OF THE POROSITY (SPACING BETWEEN THE GRAINS),
IDENTIFIED BY NUMERICAL WHERE SMALL FIGURES INDICATE DENSE STRUCTURE.
TABLE OF STRUCTURE
STRUCTURE OPEN MEDIUM DENSE
FIGURE 12, 11 10, 9, 8, 7 6, 5, 3, 2, 1, 0
- 134 -
OPEN (c) MEDIUM (m)
7-5 BOND TYPES

VITRIFIED [V] ･･･ THE MAIN COMPONENTS ARE FELDSPAR AND FUSIBLE CLAYS. THEY ARE FIRED SLOWLY
UP TO A TEMPERATURE OF 1,300℃ TO HOLD TOGETHER THE ABRASIVE. IT IS THE MOST
COMMON AND WIDELY USED BOND.
RESINOID [B] ･･･ SYNTHETIC RESIN OF CARBOL-FOLMALINE BASE IS HEATED UP TO A TEMPERATURE OF

ABOUT 200℃. RESINOID WHEELS ARE MORE FLEXIBLE THAN VITRIFIED WHEELS. IT HAS
HIGHER SAFETY AGAINST WHEEL BREAKAGE. IT IS USED FOR FREE GRINDING (CUTTING,
OFFSET) ETC.
SHELLAC [E] ･･･ NATURAL RESIN CONSISTING OF SHELLAC IS HEATED UP TO A TEMPERATURE OF ABOUT
170℃. IT IS USED FOR LAPPING OPERATIONS.
RUBBER [R] ･･･ ABRASIVE GRAINS ARE MIXED IN NATURAL/SYNTHETIC RUBBER AND HEATED UP TO A
TEMPERATURE OF ABOUT 180℃. (IT IS USED FOR CHAMFERING OF CRANKSHAFT OIL
HOLE OF CIVIC)
7-6 SHAPE AND SIZE OF GRINDING WHEELS

SHAPE GRINDING WHEELS ARE CLASSIFIED UNDER 4 TYPES BY SHAPE.
FLAT ROUND) WHEEL
BUILT-UP WHEEL
SIZE HOW TO INDICATE THE DIMENSIONAL SPECIFICATION FOR GIRDING WHEELS
OUTSIDE DIAMETER X THICKNESS (FULL THICKNESS FOR SPECIAL SHAPE) X HOLE DIAMETER
INDICATION OF SHAPE OF GRINDING WHEELS
MEDIUM TYPE, OR TYPE 1
RING, OR TYPE 2 CUP TYPE, OR TYPE 6
- 135 -
MEDIUM (m) DENSE
DENSE (w)
E MAIN COMPONENTS ARE FELDSPAR AND FUSIBLE CLAYS. THEY ARE FIRED SLOWLY
TO A TEMPERATURE OF 1,300℃ TO HOLD TOGETHER THE ABRASIVE. IT IS THE MOST
MMON AND WIDELY USED BOND.
NTHETIC RESIN OF CARBOL-FOLMALINE BASE IS HEATED UP TO A TEMPERATURE OF

OUT 200℃. RESINOID WHEELS ARE MORE FLEXIBLE THAN VITRIFIED WHEELS. IT HAS
HER SAFETY AGAINST WHEEL BREAKAGE. IT IS USED FOR FREE GRINDING (CUTTING,
FSET) ETC.
TURAL RESIN CONSISTING OF SHELLAC IS HEATED UP TO A TEMPERATURE OF ABOUT

℃. IT IS USED FOR LAPPING OPERATIONS.
RASIVE GRAINS ARE MIXED IN NATURAL/SYNTHETIC RUBBER AND HEATED UP TO A

MPERATURE OF ABOUT 180℃. (IT IS USED FOR CHAMFERING OF CRANKSHAFT OIL
LE OF CIVIC)
WHEELS ARE CLASSIFIED UNDER 4 TYPES BY SHAPE.

SQUARE WHEEL
SHAFT MOUNTED WHEEL
DICATE THE DIMENSIONAL SPECIFICATION FOR GIRDING WHEELS
AMETER X THICKNESS (FULL THICKNESS FOR SPECIAL SHAPE) X HOLE DIAMETER
PE OF GRINDING WHEELS
H
DOUBLE-CUP
ONE-SIDE DEPRESSED, TYPE, OR TYPE 9
OR TYPE 5
CUP TYPE, OR TYPE 6 DOVETAIL, OR TYPE 10
- 135 -
SINGLE TAPER, OR TYPE 3
TAPERED CUP, OR TYPE 11
DOUBLE TAPER, OR SAFETY TYPE,

TYPE 4 OR TYPE 8 DISH-SHAPED, OR TYPE 12
7-7 TYPES AND STANDARD MARKING SYSTEM (1), (2)
WA
GRAIN TYPE WA, A, MA, STA, RA, GC, C, A/WA, C/GC, A/C
60
GRAIN SIZE 10, 12, 14, 16, 20, 24, 30, 36, 46, 54, 60, 70, 80, 90, 100, 120, 150, 180, 220
240, 280, 320, 400, 500, 600, 700, 800, 1000, 1200, 1500, 2000, 2500, 3000
H
GRADE EFGH IJKLMNOPQRSTUVWXYZ
10 DENSE MEDIUM OPEN
STRUCTURE 0123456 7 8 9 10 11 12
V VITRIFIED RESINOID RUBBER SILICATE SHELLAC OXYCHLORIDE
BOND
=
V B R S E OM
BOND TYPES MARKING DIFFERS BY MANUFACTURERS
P B S P O F
SUPPLEMENTARY BAKE SULFER POROSITY O-COATING FIBER CONTENT ･･･ ETC.
TREATMENT TREATMENT
DOVETAIL
SINGLE TAPER
DOUBLE TAPER
DISH-SHAPED
DISH-SHAPED FOR
FLAT
RING
OFF-SET
SINGLE CONCAVE
CUP
BOTH-SIDE CONCAVE
SAFETY
DOUBLE CUP
TAPER CUP
SAWS
OTHERS
I
SHAPE
TYPE 1 TYPE 2 TYPE 3 TYPE 4 TYPE 5 TYPE 6 TYPE 7 TYPE 8 TYPE 9 TYPE 10 TYPE 11 TYPE 12 TYPE 13 TYPE 14
A
SHAPE OF A B C D E F M N P
GRINDING WHEEL
FACE
405 x 70 x 1524
DIMENSION OUTSIDE DIA. X THICKNESS X HOLE DIAMETER
- 136 -
8 APPLICATION OF GRINDING WHEELS ･･･ (3), (4)
8-1 CYLINDRICAL GRINDING
CYLINDRICAL GRINDING OPERATION IS TO GRIND THE EXTERNAL CYLINDRICAL SURFACE OF WORKPIECE. THE
WORKPIECE IN CYLINDRICAL GRINDING IS HELD BETWEEN CENTERS.
CYLINDRICAL
GRINDING
OPERATIONS
GRINDING
WHEEL
CENTER OF ROTATION
WORKPIECE
(TRAVERSE)
TRAVERSE GRINDING:
PLUNGE GRINDING:
8-2 INTERNAL GRINDING

INTERNAL GRINDING IS USED TO GRIND THE INSIDE DIAMETER OF A HARDENED STEEL OR TO ATTAIN DIMENSIONAL
PRECISION OF THE INSIDE DIAMETER.
INTERNAL GRINDING OPERATIONS
NORMAL TYPE
WORKPIECE
GRINDING
WHEEL
(1) NORMAL TYPE:
(2) PLANETARY TYPE:
- 137 -
ON OF GRINDING WHEELS ･･･ (3), (4)
CAL GRINDING OPERATION IS TO GRIND THE EXTERNAL CYLINDRICAL SURFACE OF WORKPIECE. THE
CE IN CYLINDRICAL GRINDING IS HELD BETWEEN CENTERS.
INDEX PLATE GRINDING WHEEL

(WHEEL AXIS)
CENTER OF ROTATION
CHUCK
STEADY REST
CENTER OF ROTATION JOURNAL
(MULTI-WHEEL)
CENTER OF
WORKPIECE
(ANGULAR) PLUNGE GRINDING
(DEPTH OF CUT)
(USED FOR CRANKSHAFT IN-HOUSE MACHINING)
THE RELATIVE MOVEMENT OF THE WHEEL IS ALONG THE SURFACE OF THE WORKPIECE
WHICH RECIPROCATES LONGITUDINALLY.
THE RELATIVE MOVEMENT OF THE WHEEL IS RADIALLY INTO THE WORKPIECE WHICH
DOES NOT RECIPROCATE.
GRINDING IS USED TO GRIND THE INSIDE DIAMETER OF A HARDENED STEEL OR TO ATTAIN DIMENSIONAL
N OF THE INSIDE DIAMETER.
GRINDING OPERATIONS
PLANETARY TYPE CENTERLESS
HOLDING WHEEL
WORKPIECE
GRINDING WHEEL
GRINDING
WHEEL
REGULATING
WORKPIECE
WHEEL
RAPID
(USED AT HONDA)
THE WORKPIECE IS HELD IN A ROTATING CHUCK AND THE GRINDING WHEEL ROTATES
AT A HIGH SPEED IN THE INSIDE DIAMETER OF THE WORKPIECE.
THE WORKPIECE IS FIXED AND THE GRINDING WHEEL TRAVELS ALONG THE SURFACE
OF WORKPIECE.
- 137 -
8-3 SURFACE GRINDING (DISC GRINDING WHEEL)
THE SURFACE GRINDING CAN GRIND WIDER SURFACE DIMENSIONS THAN ANY OTHER GRINDING
OPERATIONS.
SUCH GRINDING WHEELS ARE AVAILABLE: NUT, WASHER OR STUD IS MOUNTED IN WHEEL AND A COPPER
MOUNTING PLATE IS ATTACHED TO WHEEL.
MACHINING METHOD
CARRIER TYPE THROUGH FEED TYPE

GRINDING WHEEL
USE TWO WHEELS
GRINDING WHEEL
WORKPIECE
WORK FEED RAIL
WORKPIECE
(1) CARRIER TYPE: THE WORKPIECES HELD BY THE COPPER MOUNTING PLATE IS
TRANSFERRED FROM PERIPHERY TO INNER SIDE FOR GRINDING.
(2) THROUGH FEED TYPE: THE WORKPIECES ARE FED LINEARLY TO THE GIRDING WHEEL.
8-4 REGRINDING OF TOOLS

WHEN CUTTING TOOLS HAVE BECOME DULL DUE TO CUTTING EDGE WEAR, THEY ARE REGROUND TO
RESTORE SHARPNESS.
GRINDING WHEEL (ABRASIVE TYPE,
TOOL POINT OR REGRINDING SHAPE OF WHEEL
GRAIN SIZE, GRADE)
TURNING TOOL FLANK (ROUGH GRINDING) FLAT A36P, GC60G

DRILL CUTTING EDGE FLAT WA60M
TAP THREAD PORTION FLAT PA100U
MILLING CUTTER FACE CUTTING EDGE FLAT GC80I
PINION-SHAPED CUTTER RAKE FACE FLAT, CUP PA60J
SHAVING CUTTER TOOTH FLANK (SERRATION) DISH PA80J
HOB TOOTH FLANK (FLUTE) SINGLE TAPER H60I
8-5 HONING
HONING IS AN OPERATION USED TO GIVE THE INTERNAL CYLINDRICAL SURFACE A FINE SURFACE FINISH.
THE HONING TOOL CONSISTS OF A SET OF BONDED ABRASIVES, CALLED HONING STONES. THEY ARE
MOUNTED ON A MANDREL THAT ROTATES ALONG THE INTERNAL CYLINDRICAL SURFACE, APPLYING A
RADIAL FORCE WITH A RECIPROCATING AXIAL MOTION. A FLUID IS FED DURING HONING.
GRINDING WHEEL
WORKPIECE
GRINDING
WHEEL
HORNING ATTACHMET (SHOE) HONING HEAD
- 138 -
9 GRINDING CONDITIONS ･･･ (1), (2)
9-1 MACHINE CONDITIONS
INFLUENCE OF DEPTH OF CUT INFLUENCE OF FEED
DEPTH OF CUT FEED
SMALL LARGE SMALL LARGE
CONDITION CONDITION
GRINDING RESISTANCE SMALL LARGE GRINDING RESISTANCE SMALL LARGE
HEAT SMALL LARGE HEAT LARGE SMALL
SURFACE FINISH FINE ROUGH SURFACE FINISH FINE ROUGH
GRAIN GRAIN
WHEEL SURFACE LOADED WHEEL SURFACE LOADED
FRACTURE FRACTURE
WHEEL WEAR SMALL LARGE WHEEL WEAR SMALL LARGE

*GENERALLY, THE FEED IS INCREASED FOR ROUGHING AND
REDUCED FOR FINISHING.
SPEED OF GRINDING WHEEL
RANGE OF PERIPHERAL INFLUENCE OF PERIPHERAL VELOCITY
TYPE OF OPERATION
VELOCITY (ORDINAL USE)
EXTERNAL CYLINDRICAL SURFACE 1,700 - 2,000 m/min FEED

SMALL LARGE
INSIDE SURFACE 600 - 1,800 m/min CONDITION
FLAT SURFACE 1,200 - 1,800 m/min GRINDING RESISTANCE LARGE SMALL
TOOL REGRINDING 1,400 - 2,000 m/min GRINDING WEAR LARGE SMALL
CUTTING 2,700 - 3,700 m/min HEAT SMALL LARGE
HIGH SPEED GRINDING SAFETY GOOD BAD
2,700 - 3,600 m/min
(HONDA STANDARD)
10 DRESSING ･･･ (1), (2)

DRESSING IS THE PROCESS OF PRODUCING SHARP NEW EDGES ON GRAINS BY DIAMOND TOOL AFTER
CONDITIONING.
TYPE - SINGLE STONE MULTIPLE STONE ROTARY DIAMOND
10-1 PURPOSE OF DRESSING

(1) TO REMOVE DULL CUTTING EDGES FROM THE SURFACE OF A GRINDING WHEEL AND PRODUCE SHARP
NEW EDGES ON IT.
(2) TO REMOVE CHIPS CLOGGED ON THE SURFACE OF A GRINDING WHEEL.
(3) TO PRODUCE A NEW SURFACE ON A GRINDING WHEEL FOR IMPROVED SURFACE FINISH.
(4) TO CONDITION WORN GRAINS ON THE SURFACE OF A GRINDING WHEEL RESULTING FROM BOND
FRACTURE.
- 139 -
11 GRINDING FLUIDS ･･･ (3), (4)
11-1 CHARACTERISTICS OF GRINDING FLUIDS
(1) COOLING ･･･ HEAT PRODUCED BY GRINDING IS REMOVED BY COOLING EFFECT AND
TEMPERATURE IS KEPT LOW. ESPECIALLY, FLUIDS PREVENT A TEMPERATURE RISE
IN THE GRINDING ZONE AND THUS GRINDING FRACTURE. THEY ALSO PREVENT
THERMAL EXPANSION OF THE WORKPIECE AND IMPROVE DIMENSIONAL ACCURACY.
(2) LUBRICITY ･･･ FLUIDS RETARD WEAR OF CUTTING EDGE, MAINTAIN THE SHARPNESS OF GRAINS,
AND PREVENT GRAIN FRACTURES; CONSEQUENTLY THEY IMPROVES THE GRINDING
WHEEL SERVICE LIFE. FLUIDS ALSO REDUCE GRINDING RESISTANCE, RESULTING IN
LOW GRINDING ENERGY, INCREASED GRINDING AMOUNT AND IMPROVED SURFACE
FINISH.
(3) WETTABILITY ･･･ FLUIDS PENETRATE INTO THE CLEARANCE BETWEEN GRAINS (POROSITY) DUE TO
PERMEABILITY, WHICH PREVENT SEIZURE OF BOND AND CHIPS. CENTRIFUGAL
PERMEABILITY FORCE HELPS REMOVE CHIPS AND REDUCE THE POSSIBILITY OF LOADING
(CLOGGING)
WASHABILITY
(4) ANTI-CORROSION ･･･ FLUIDS ACTS AS RUST INHIBITOR FOR GRINDING WHEEL AND GROUND WORKPIECES.
(5) OTHERS ･･･ REFER TO SECTION 17. CUTTING FLUIDS FOR DETAILS.
11-2 TYPES OF GRINDING FLUIDS

EMULSION TYPE ･･･
WATER SOLUBLE TRANSPARENT EMULSION

GRINDING FLUIDS TYPE ･･･
LIQUID TYPE ･･･
WATER INSOLUBLE GRINDING FLUIDS ･･･
- 140 -
ODUCED BY GRINDING IS REMOVED BY COOLING EFFECT AND
ATURE IS KEPT LOW. ESPECIALLY, FLUIDS PREVENT A TEMPERATURE RISE
RINDING ZONE AND THUS GRINDING FRACTURE. THEY ALSO PREVENT
L EXPANSION OF THE WORKPIECE AND IMPROVE DIMENSIONAL ACCURACY.
ETARD WEAR OF CUTTING EDGE, MAINTAIN THE SHARPNESS OF GRAINS,

VENT GRAIN FRACTURES; CONSEQUENTLY THEY IMPROVES THE GRINDING
ERVICE LIFE. FLUIDS ALSO REDUCE GRINDING RESISTANCE, RESULTING IN
NDING ENERGY, INCREASED GRINDING AMOUNT AND IMPROVED SURFACE
ENETRATE INTO THE CLEARANCE BETWEEN GRAINS (POROSITY) DUE TO

BILITY, WHICH PREVENT SEIZURE OF BOND AND CHIPS. CENTRIFUGAL
ELPS REMOVE CHIPS AND REDUCE THE POSSIBILITY OF LOADING
NG)
CTS AS RUST INHIBITOR FOR GRINDING WHEEL AND GROUND WORKPIECES.
O SECTION 17. CUTTING FLUIDS FOR DETAILS.
MILK WHITE COLOR. DILUTED BEFORE USE.

LUBRICITY IS GOOD. BUT PERMEABILITY IS NOT SO
GOOD.
CONTAINS ANTICORROSIVE AND PRESERVATIVE AGENTS.
TRANSLUCENT WATER-SOLUBLE FLUIDS WITH GOOD
PERMEABILITY. GENERALLY USED FOR FINISH GRINDING.
SUPERIOR IN ANTI-ADHESION, ANTI-CORROSION AND

WASHABILITY.
USED WITHOUT DILUTION AND THUS SUPERIOR IN

PERMEABILITY, LUBRICITY AND SURFACE FINISH
ACCURACY. USED FOR SUPER FINISHING.
INFERIOR IN COOLING EFFECT; THUS NOT SUITABLE FOR

HEAVY GRINDING.
- 140 -
12 HANDLING PRECAUTIONS AND SAFETY ･･･ (1), (2)
12-1 HANDLING PRECAUTIONS FOR GRINDING WHEELS
(1) HANDLE WITH CARE NOT TO DROP OR BUMP A GRINDING WHEEL.
(2) DO NOT ROLL OVER A GRINDING WHEEL.
(3) DO NOT PLACE ANYTHING HEAVY ON A GRINDING WHEEL.
(4) IN CASE OF ACCIDENTAL DROP OF A GRINDING WHEEL, CHECK FOR CRACKS AND DAMAGES.
12-2 DIRECTIONS FOR USE
1. VISUAL EXAMINATION ･･･
(1) CHECK FOR CRACKS ･･･ IN THE ORDER OF END FACE, PERIPHERY AND HOLES.
(2) CHECK FOR A LABEL AND PACKING, AND ALSO ANOMALY.
(3) CHECK THE MATING SURFACE OF FLANGE FOR FOREIGN MATERIALS.
(4) CHECK FOR MOISTURE, OIL, CHIPPING, FLAWS, ETC.
2. HAMMERING TEST ･･･
(1) USE A WOOD HAMMER AS AN INSPECTION TOOL.
(2) TO DETECT A HAIR CRACK, HAMMER THE ENTIRE PERIPHERY.
(3) VITRIFIED GRINDING WHEEL SOUNDS CLEAR METALLIC SOUND. RESINOID GRINDING
WHEEL SOUNDS SLIGHTLY DULL SOUND.
(4) IF A GRINDING WHEEL IS WITHOUT A CRACK, SOUNDS BY HAMMERING ARE SAME
WHEREVER IT IS HAMMERED.
(5) IF A GRINDING WHEEL IS WITH A CRACK, SOUNDS BY HAMMERING CHANGE SUDDENLY.
BEAR IN MIND THAT MOISTURE AND BACKLASH OF BUSH ALSO CAUSE CHANGES IN SOUND.
(6) HAMMER A GRINDING WHEEL WITH A MINIMUM REQUIRED FORCE.
FULCRUM
HAMMERING POINTS
3. ROTATION TEST ･･･ MAKE SURE TO PERFORM IDLING OF GRINDING WHEEL FOR 3 MIN OR
OVER BEFORE EVERY USE TO ENSURE SAFETY.
* GRINDING WHEEL BREAKAGE MEANS THAT A LARGE STONE ROTATING AT A SPEED OF 2,000
TO 3,000 m/min FLIES TO YOU. OBSERVE THE RULES FOR PROPER OPERATION.
- 141 -
12-3 HANDLING PRECAUTIONS FOR GRINDING WHEELS
VARIOUS GRINDING WHEELS IMPERATIVE FOR OUR DAILY OPERATIONS SEEM TO BE ROTATING
WITHOUT ANY CHANGES. HOWEVER, IF A GIRDING WHEEL ROTATING AT A HIGH SPEED IS BROKEN, THE
BURSTING SPEED COULD REACH 120 - 160 km/h. THEREFORE, CERTAIN PROCEDURES MUST BE
CAREFULLY FOLLOWED IN THEIR HANDLING, STORAGE AND USE.
THE FOLLOWING ARE MAJOR HANDLING PRECAUTIONS:

(1) NEVER LAY DOWN THE GRINDING WHEELS; OTHERWISE THEY MAY GET DAMAGE.
(2) PERFORM HAMMERING INSPECTION PRIOR TO EVERY USE.
(3) NEVER REMOVE THE FLANGE REST PAPERBOARD.
(4) USE PROPER FLANGE. TO AVOID TIGHTENING DEVIATION, TIGHTEN IN AN EVEN, CRISSCROSS
PATTERN.
(5) ENSURE A BALANCE OF GRINDING WHEELS.
(6) BEFORE STARTING THE MACHINE, ROTATE THE WHEEL WITH HAND TO ENSURE THAT IT DOES
NOT TOUCH THE COVER, ETC.
(7) AVOID A FULL-ROTATION BY ONE PRESS OF START BUTTON. INSTEAD OF THAT, INCREASE THE
ROTATING SPEED GRADUALLY.
(8) MAKE SURE TO PERFORM IDLING OF WHEEL FOR 3 MIN OR OVER BEFORE EVERY USE AND
AFTER EVERY WHEEL SETUP. NEVER STAND IN FRONT OF GRINDING MACHINE DURING IDLING.
(9) NEVER GRIND ON OTHER SURFACES THAN THE GRINDING FACE.

(10) FOR WET GRINDING OPERATION, ROTATE THE WHEEL BEFORE FEEDING A GRINDING FLUID. IF
GRINDING FLUID FEEDING IS TO BE INTERRUPTED, IDLE THE WHEEL FOR 2 MIN OR OVER
BEFORE STOPPING IT.
(11) FOR A DUPLEX GRINDER, PROVIDE A CLEARANCE OF 3 mm BETWEEN THE REST AND THE WHEEL
AND 3 - 10 mm OR LESS BETWEEN THE REGULATING PIECE AND THE WHEEL.
REGULATING PIECE
3 mm OR LESS
REST
- 142 -
[15] DIAMOND TOOLS
1. WHAT IS DIAMOND?
2. CHARACTERISTICS OF DIAMONDS (1), (2)
3. CLASSIFICATION (1), (2)
4. TYPES OF TOOLS AND CLASSIFICATION (1), (2)
5. APPLICATION OF DRESSING TOOLS (1), (2)
6. DRESSING MECHANISM (1), (2)
7. KEY POINTS OF DRESSING TOOLS (1), (2)
8. DIAMOND WHEELS (1), (2)
9. BORAZON GRINDING WHEELS (3), (4)
10. ULTRA GRINDING WHEELS (3), (4)
11. PERFORMANCE COMPARISON, GENERAL GRINDING
WHEEL VS. BORAZON GRINDING WHEEL (3), (4)
- 143 -
S
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144
144
144
145
146
146
147
151
153
154
155
- 143 -
[15] DIAMOND TOOLS
1 WHAT IS DIAMOND?･･･ (1), (2)
DIAMOND IS THE CRYSTALLINE FORM OF CARBON OCCURRING IN ROCKS FOUND DEEP IN THE GROUND
BY HIGH TEMPERATURE (APPROX. 3,000℃) AND HIGH ATMOSPHERIC PRESSURE (SEVERAL THOUSANDS).
SYNTHETIC DIAMONDS PRODUCED ARTIFICIALLY ARE ALSO USED AS CUTTING TOOL MATERIALS.
2 CHARACTERISTICS OF DIAMOND ･･･ (1), (2)

2-1 HARDNESS (MOHS HARDNESS 10)
OF ALL KNOWN MATERIALS, THE HARDEST SUBSTANCE IS DIAMOND, THE PRIMARY CHARACTERISTIC OF
IT. BECAUSE OF ITS HARDNESS, DIAMOND IS WIDELY USED AS A DRESSING TOOL FOR GRINDING
WHEELS, AND DIAMOND WHEELS AND HONING STONES FOR INDENTER OF HARDNESS SCALE, TURNING
TOOL, DIES AND CEMENTED CARBIDES.
2-2 CRYSTAL FIG 1, PATTERN OF CRYSTAL

DIAMOND CRYSTAL BELONGS
TO THE ISOMETRIC SYSTEM
(CUBIC SYSTEM) AND COME
IN AS OCTAHEDRON OR
DODECAHEDRON. DIAMOND
CRYSTAL IS SOMETIMES
FOUND IN PIECES OR AS
TWIN CRYSTAL.
OCTAHEDRON DODECAHEDRON
CUBIC
2-3 SPECIFIC GRAVITY

ALTHOUGH THE SPECIFIC GRAVITY VARIES DEPENDING ON TYPES, IT IS GENERALLY BETWEEN 3.01 AND
3.5
SPECIFIC GRAVITY OF BLACK LEAD AND AMORPHOUS CARBON IS 1.5 - 2.0.
* DIAMOND IS MEASURED BY CARAT, A UNIT OF WEIGHT. (1 CARAT = 0.2 g)
3 CLASSIFICATION ･･･ (1), (2)

3-1 GEM-QUALITY DIAMONDS ･･･ COLORLESS OR TRANSPARENT, HIGH GRADE IN TERMS OF COLOR AND
CLEARNESS.
3-2 INDUSTRIAL DIAMONDS ･･･ COLORED WITH MANY FLAWS, CONTAINS IMPURITIES, NOT SUITABLE FOR
GEM.
* BECAUSE INDUSTRIAL DIAMONDS WEAR OUT WHEN USED, THERE IS ALWAYS DEMAND FOR
SUPPLEMENT. THUS, INDUSTRIAL DIAMOND ACCOUNTS FOR 80% OF TOTAL DIAMOND
PRODUCTION IN THE WORLD.
- 144 -
4 TYPES OF TOOLS AND CLASSIFICATION
4-1 TOOLS THAT USE ROUGH DIAMOND STONES
(1) DRESSING TOOLS SINGLE CRYSTAL
(2) DRILL AND BIT POLYCRYSTALLINE
(3) GLASS CUTTING TOOL AND OTHERS (ROLLER DIAMOND) IMPLEMENT

BOND
ROTARY
4-2 SHAPED TOOLS

(1) TURNING TOOL
(2) DIES CONE PYRAMID FORMING
(3) INDENTER FOR HARDNESS TEST
(4) FORMING POINT
4-3 TOOLS THAT USE POWDER DIAMONDS

(1) POWER (ABRASIVE GRAINS)
(2) WHEEL METAL, RESIN, BIT
(3) OTHERS
DRY
WET
- 145 -
FORMING
DRY
- 145 -
5 APPLICATION OF DRESSING TOOLS ･･･ (1), (2)
TYPE
SINGLE CRYSTAL
DIAMOND
POLYCRYSTALLINE
DIAMOND
IMPLEMENT DIAMOND
BOND DIAMOND
FORMING DIAMOND
ROTARY DIAMOND
GRINDING WHEEL
ROTARY DIAMOND
BUTT DIAMOND
6 DRESSING MECHANISM ･･･ (1), (2)

(1) DRESSING (TOOTING, GRAIN CONDITIONING)
DRESSING IS THE PROCESS OF CRUSHING THE DULL GRAINS OF LOADED OR GRAIN FRACTURED
SURFACE OF A GRINDING WHEEL AND PRODUCING SHARP NEW EDGES ON GRAINS.
(2) TRUING (SHAPE RESTORING AND CONDITIONING)
TRUING IS AN OPERATION BY WHICH A WHEEL IS RESTORED TO ITS ORIGINAL SHAPE. SOME ARE
STRAIGHT ON THE GENERATING LINE AND SOME ARE IRREGULAR (GENERATING GRINDING)
TRUING REMOVES THE SURFACE OF GRINDING WHEEL AND THUS THE DRESSING IS DONE AT THE SAME
TIME. HOWEVER, THE PURPOSE IS DIFFERENT. (TODAY, TRUING IS A PREDOMINANT DRESSING
METHOD.)
(GRAIN CONDITIONS BEFORE DRESSING)
UNCONDITIONED GRAIN
GRAINS WEAR
- 146 -
TION OF DRESSING TOOLS ･･･ (1), (2)
APPLICATION
CONDITIONING FOR GENERAL GRINDING SURFACE AND TOOL GRINDING WHEELS
MADE BY NIPPEI, HIRAKEN, TOYOTA AND OTHERS.
GRINDING OF CYLINDER, INTERNAL SURFACE, CENTERLESS, CONVEX SURFACE AND
DRESSING OF GRINDING WHEEL SIDE FACES.
CONDITIONING FOR THIN GRINDING WHEEL, ESPECIALLY DISH-SHAPED WHEEL.
GRINDING OF BROACHES AND THE BODY CLEARANCE OF CUTTERS AND DRILLS.
CONDITIONING OF FINE GRINDING WHEEL, CENTERLESS GRINDING AND CAM.
CONDITIONING OF GRINDING WHEEL OF COMPLEX SHAPE, SUCH AS STEPPED

WHEELS. CRANKSHAFT, TOYOTA JUDDLE SHADOW, NIPPEI.
WHEEL CONDITIONING TOOL IN NEW FIELD. IN GENERAL, THE ROTARY DIAMOND
TOOL HAS THE SAME SHAPE TO BE CUT IN WORKPIECE. THE WHEEL AND THE TOOL
ROTATE SIMULTANEOUSLY TO MAKE THE FORMS AND TO PERFORM DRESSING AT A
TIME.
IMPROVED GRINDING EFFICIENCY WITH PROCESSING TIME OF 3 - 4 sec. WIDELY

USED AT HONDA FOR CRANKSHAFT, PIN, JOURNAL. IMPERATIVE FOR CONTINUOUS
PROCESSING OF MACHINES.
USED FOR CUTTING OF SOFT METAL AND NONMETAL AND PROCESSING OF PLASTICS.
LONG SERVICE LIFE AND GOOD SURFACE FINISH.
G MECHANISM ･･･ (1), (2)

RESSING (TOOTING, GRAIN CONDITIONING)
RESSING IS THE PROCESS OF CRUSHING THE DULL GRAINS OF LOADED OR GRAIN FRACTURED
URFACE OF A GRINDING WHEEL AND PRODUCING SHARP NEW EDGES ON GRAINS.
RUING (SHAPE RESTORING AND CONDITIONING)
RUING IS AN OPERATION BY WHICH A WHEEL IS RESTORED TO ITS ORIGINAL SHAPE. SOME ARE
RAIGHT ON THE GENERATING LINE AND SOME ARE IRREGULAR (GENERATING GRINDING)
RUING REMOVES THE SURFACE OF GRINDING WHEEL AND THUS THE DRESSING IS DONE AT THE SAME
ME. HOWEVER, THE PURPOSE IS DIFFERENT. (TODAY, TRUING IS A PREDOMINANT DRESSING
ETHOD.)
RAIN CONDITIONS BEFORE DRESSING)
DRESSING
GRAIN GRAIN BOND

WEAR FRACTURE FRACTURE
- 146 -
(3) PURPOSE OF DRESSING
-1 REMOVE DULL GRAINS AND PRODUCE SHARP NEW EDGES ON GRAINS.
-2 REMOVE CHIPS CLOGGING IN THE POROSITY OF GRINDING WHEEL SURFACE.
-3 PRODUCE NEW POROSITY.
(4) DRESSING CONDITIONS

DEPTH OF PHENOMENON
FEED REMARKS
CUT DRESSING DIAMOND SURFACE FINISH
* FEED = mm/rev SHORT TOOL LIFE AND ROUGH
LARGE LARGE RAPID WEAR ROUGH SURFACE FINISH
LARGE 0.2 = 400 mm/min
MEDIUM 0.1 = 200 mm/min MEDIUM LARGE MEDIUM
SMALL 0.05 = 100 mm/min LONG DRESSING INTERVALS AND
SMALL LARGE FINE REDUCED EFFICIENCY
* DEPTH OF CUT = mm
LARGE 0.02 - 0.04 LARGE SMALL RAPID WEAR ROUGH
MEDIUM 0.01 MEDIUM SMALL FINE
SMALL 0.005 REDUCED EFFICIENCY FOR MASS
SMALL SMALL LONG LIFE MEDIUM PRODUCTION
* SURFACE FINISH (μ)
ROUGH 6 - 8 LARGE MACHINING ALLOWANCE, GOOD
EFFICIENCY FOR SEMI-FINISHING
MEDIUM 3 - 5 LARGE MEDIUM TENDS TO BREAK ROUGH
FINE 1- 2
MEDIUM MEDIUM FINE

HIGH STIFFNESS AND PRECISION
GRINDING MACHINE - GRADE OF
SMALL MEDIUM FINE WHEEL CAN BE SLIGHTLY OPEN.
7 KEY POINTS OF DRESSING TOOLS ･･･ (1), (2)

7-1 POLYCRYSTALLINE-DIAMOND TOOLS
POLYCRYSTALLINE-DIAMOND TOOLS ARE BASICALLY CATEGORIZED INTO THE SINGLE LAYER
POLYCRYSTALLINE-DIAMOND TOOL AND THE MULTI-LAYER POLYCRYSTALLINE-DIAMOND TOOL.
DIAMONDS OF A RELATIVELY SMALL AND UNIFORM SIZE
RANGING BETWEEN 1/20 ct AND 1/2 ct ARE FIRMLY
MOUNTED IN THE LONGITUDINAL DIRECTION.
AS THE FIGURE ILLUSTRATES, THE TOOL ENABLES A

UNIFORM OPERATION UNTIL THE DIAMONDS MOUNTED
WEAR AWAY. IT IS NOT NECESSARY TO MODIFY THE
TOOL BEFORE THEY WEAR AWAY. THUS, IT IS VERY
ECONOMICAL.
7-2 POUNDED DRESSING TOOLS SINGLE LAYER MULTI-LAYER

THIS TOOL IS VERY EFFECTIVE FOR GRINDING WHEELS
WITH FINE ABRASIVE GRAINS. THERE ARE THREE TYPES
OF POUNDED GRAINS.
[C] SUITABLE FOR COARSE GRINDING WHEELS OF #54

OR BELOW.
[M] SUITABLE FOR MEDIUM GRINDING WHEELS BETWEEN
#60 AND #120.
[F] SUITABLE FOR FINE GRINDING WHEELS OF #120 OR
OVER.
- 147 -
7-3 ROTARY DRESSING TOOLS
THE TREND IN GRINDING OPERATION HAS BEEN TOWARD HIGH-SPEED, HEAVY GRINDING, AND
FURTHER TOWARD HIGH-EFFICIENCY AND HIGH-PRECISION OPERATIONS.
DRESSING ACCOUNTING FOR A PORTION OF THE TOTAL CYCLE TIME IS NO LONGER NEGLIGIBLE.
FURTHERMORE, DRESSING DETERMINES THE FINAL SHARPNESS AND THE GEOMETRICAL ACCURACY.
IN THIS CONTEXT, IT IS IMPERATIVE TO SELECT MOST SUITABLE DRESSING METHOD ACCORDING TO
RESPECTIVE GRINDING REQUIREMENTS. TO SATISFY SUCH DEMAND, THE ROTARY DRESSING TOOL
WAS DEVELOPED AND PUT IN PRACTICAL USE.
(1) WHAT IS ROTARY DRESSING TOOL?

ON THE EXTERNAL SURFACE OF ROLL WITH HIGH HARDNESS, DIAMONDS OF AN ADEQUATE SIZE
ARE MOUNTED IN THE ORDER OF 10 pc/cm2. THE FIXED ROLL DRESSES A GRINDING WHEEL.
THE ROTARY DRESSING TOOLS ARE CLASSIFIED ACCORDING TO THE ROLL SHAPE AND THE
DRIVING SYSTEM.
MAJOR CLASSIFICATION MINOR CLASSIFICATION FEATURES

PLUNGE TYPE DRIVE TYPE SINGLE MOTOR DRIVE
BREAKING TORQUE IS APPLIED TO THE ROLL TO PRODUCE

BREAKING THE RELATIVE MOTION BETWEEN THE ROLL AND THE
WHEEL.
EITHER THE ROLL OR THE WHEEL IS DRIVEN AND THE

INTERLOCKING
OTHER IS INTERLOCKED.
THE ROLL COPIES MOTION WHILE ROTATING. STRAIGHT

TRAVERSE TYPE ROLL ROTATING
TYPE ROLL IS USED.
ROLL INDEX THE ROLL COPIES MOTION WITHOUT ROTATING.
7-4 KEY POINTS OF SINGLE CRYSTAL DRESSING TOOL AND FORMING DRESSING TOOL
(1) SINGLE CRYSTAL DRESSING TOOL
-1 STRUCTURE OF DRESSING TOOL
[MOUNTED TYPE]
A: SHANK
B: SINTERED COMPACT
C: DIAMOND
A SINGLE CRYSTAL DIAMOND IS MOUNTED BY SINTERING. THUS, THE MOUNTED DIAMOND DOES
NOT MOVE OR FALL OFF WHEN IN USE.
-2 PARAMETERS TO DETERMINE CARATS
AN IDEAL APPROACH IS THE CALCULATION BY THE FOLLOWING FORMULA APPLYING SUCH
PARAMETERS AS DIAMETER AND WIDTH OF GRINDING WHEEL.
WHEEL DIA. + (2 X WIDTH OF WHEEL) = ct

250
- 148 -
-3
(INSTALLATION OF DRESSING TOOL)
(2)
-1
-2
- 149 -
HOW TO USE
TILT THE DRESSING TOOL AT AN ANGLE OF 10°- 15°.
TILT IT AT AN ANGLE OF ABOUT 10°TO THE CIRCUMFERENCE OF GRINDING WHEEL.
ROTATE THE DRESSING TOOL AFTER SEVERAL DRESSING TO CHANGE ORIENTATION SO THAT THE
DRESSING IS DONE ALWAYS WITH A SHARP EDGE FOR IDEAL DRESSING.
(INSTALLATION OF DRESSING TOOL)
DIRECTION OF FEED
FORMING DRESSING TOOL

STRUCTURE
A PREREQUISITE OF FORMING DRESSING TOOL IS THAT
X IS LARGER THAN Y. DUE TO REPEATED MODIFICATION,
X TENDS TO BE EQUAL TO Y AND EVENTUALLY BECOMES
LARGER THAN Y, RESULTING IN A FALL OF CRYSTAL.
IT IS IDEAL THAT THE LIMITATION OF X IS PREDETERMINED

TO DECIDE IF THE TOOL IS BEYOND REPAIR.
FEATURES AND DIRECTIONS FOR USE
* THE PROTRUSION IS A ROOF SHAPE.
* THE TIP IS ROUNDED
[THIS IS BECAUSE THE TIP OF UNIT IS ROUNDED AND THE SHAPE OF TEMPLATE IS COPIED TO THE
GRINDING WHEEL.]
* THERE IS A LIMIT IN LENGTH OF PROTRUSION OF CRYSTAL. (1.5 mm)
[THE AMOUNT OF EMBEDDING IS CONSTANT IN ORDER TO HOLD THE CRYSTAL.)
- 149 -
TOUCHES THE SIDE FACE OF
WHEEL AND CRACKS.
(NO GOOD)
(GOOD)
[INSTALLATION OF FORMING DRESSING TOOL]

* SINCE THE GENERAL DRESSING TOOL USES A SHARP CUTTING EDGE, THE INSTALLATION IS
RELATIVELY EASY.
BECAUSE THE FORMING DRESSING TOOL HAS A ROOF SHAPE PROTRUSION, TILTED OR IMPROPER
INSTILLATION COULD LEAD TO SUCH PROBLEMS THAT THE CUTTING EDGE DOES NOT CONTACT THE
SURFACE OF A GRINDING WHEEL, AND INSTEAD OF THAT, THE BODY CLEARANCE MAY TOUCH THE
SURFACE, OR THE TOOL MAY SUFFER BREAKAGE. FURTHERMORE, THE FORM OF TEMPLATE AND THE
FORM OF DRESSED SURFACE OF A GRINDING WHEEL MAY BE DIFFERENT. THEREFORE, IT IS VERY
IMPORTANT TO INSTALL THE TOOL PROPERLY.
* MAKE SURE TO FEED COOLING FLUIDS (TO PREVENT TEMPERATURE RISE AND WEAR)
* REGRIND THE TOOL IN GOOD TIME. (OVERUSE OF TOOL CAUSES THE TIP TO INCREASE IN
ROUNDNESS AND THE CONTACT SURFACE TO INCREASE, RESULTING IN POOR SHARPNESS AND
LARGER FRICTION RESISTANCE.)
FORMING DRESSING TOOL IS USED FOR COPY DRESSING OPERATIONS. THE TRACER COPIES THE
PRECISELY DROWN FORM OF TEMPLATE, WHICH IS PRECISELY
COPIED BY THE FORMING DIAMOND TOOL ON TO THE PERIPHERY AND
SIDE FACE OF A GRINDING WHEEL. THE DRESSING IS DONE
SIMULTANEOUSLY.
IT IS NECESSARY FOR THE DIAMOND TOOL TO PRECISELY COPY THE

FORM OF TEMPLATE ON TO THE GRINDING WHEEL AND TO HAVE AN
ADEQUATE TRAVERSE STRENGTH TO BEAR DRESSING RESISTANCE.
7-5 DIRECTIONS FOR USE OF DIAMOND TOOLS

(1) WHEN YOU PICK UP A DIAMOND TOOL, CHECK FOR A CRACK AND LOOSENESS OF CRYSTAL THAT
COULD LEAD TO BREAKAGE. INSTALL IT TO A HOLDER WITH PROPER STIFFNESS. SPECIAL
ATTENTION SHOULD BE PAID TO THE INFLUENCE AND POSSIBLE DAMAGE OF A GRINDING WHEEL DUE
TO VIBRATION.
(2) DURING DRESSING, FEED COOLING AGENTS AS MUCH AS POSSIBLE TO PREVENT OXIDATION AND
WEAR OF DIAMOND DUE TO HEAT.
(3) DRESSING BY A DULL EDGED TOOL LEADS TO INCREASED FRICTION RESISTANCE AND EXCESSIVE
HEAT GENERATION, RESULTING IN PREMATURE WEAR AND CRACKS OF DIAMOND.
(4) MAINTAIN THE RECOMMENDED FEED AND DEPTH OF CUT.
(5) AS FOR TRUING BY A FORMING DRESSING TOOL, BEAR IN MIND THAT FRICTION RESISTANCE IS NOT
ALWAYS EXERTED IN ONE DIRECTION.
- 150 -
8 DIAMOND WHEELS ･･･ (1), (2)
8-1 STRUCTURE OF DIAMOND WHEELS
DIAMOND WHEELS ARE BROADLY CLASSIFIED INTO THE METAL BONDED WHEELS AND THE RESINOID
BONDED WHEELS ACCORDING TO THE TYPES OF BONDS THAT HOLD TOGETHER THE DIAMOND GRAINS.
(1) METAL BONDED WHEELS ･･･ Cu IS GENERALLY USED.
THE STRENGTH TO HOLD TOGETHER THE GRAINS IS LARGE. THUS, THE WEAR OF WHEEL IS
LESSER AND TOOL SERVICE LIFE IS LONGER. HOWEVER, THEY ARE INFERIOR TO OTHER TYPES
OF BONDED WHEELS IN TERMS OF GRINDING EFFICIENCY. THEY ARE USED FOR WET
OPERATIONS SUCH AS ROUGH SEMI-FINISHING AND CUTTING OF CEMENTED CARBIDES, AND CHIP
BREAKER PROCESSING.
(2) RESINOID BONDED WHEELS

DIAMOND GRAINS ARE HELD TOGETHER BY BAKELITE BOND. ALTHOUGH THE GRINDING
EFFICIENCY IS HIGH, THE HEAT RESISTANCE IS LOW: MAX. 160℃. FURTHERMORE, BECAUSE OF
SOFT BONDING MATERIAL, THE BONDING STRENGTH IS LOW AND TOOL SERVICE LIFE IS SHORT.
THEY ARE USED FOR FINISHING OF CEMENTED CARBIDES AND PRISM, UNDER EITHER DRY OR
WET OPERATIONS.
8-2 SHAPE AND MARKING SYSTEM OF WHEELS

(1) MARKING
CODE SYSTEM0 100 N 100 B 3
GRAIN GRAIN SIZE GRADE STRUCTURE BOND THICKNESS
# 80 H 100 [DENSE] METAL [M]

MARKING
72 ct/inj
50 [MEDIUM] THICKNESS
DIAMOND OF DIAMOND
36 ct/inj RESINOID [B] LAYER
# 800 T 25 [OPEN] VITRIFIED [V]
18 ct/inj
(2) SHAPE OF WHEELS

1. STRAIGHT WHEEL ･･･
2. TAPER CUP WHEEL ･･･
3. DOUBLE-CUP WHEEL ･･･
4. DISH-SHAPED WHEEL ･･･
5. OTHERS ･･･
(3) SELECTION OF WHEELS
IN GENERAL, A FINE-GRAIN WHEEL IS
SELECTED FOR FINISHING, AND A ROUGH-
GRAIN WHEEL FOR ROUGH FINISHING. FOR
WORKPIECE WITH HIGH HARDNESS, A LOW-
GRADE WHEEL IS SELECTED. A DENSE
STRUCTURE WHEEL IS USED FOR
FINISHING AND AN OPEN STRUCTURE
WHEEL IS USED FOR ROUGH FINISHING.
[REFER TO THE TABLE.]
- 151 -
EXAMPLES OF SELECTION OF GRAIN SIZE FOR DIAMOND WHEELS
ROUGHNESS APPLICATION
# 80 ROUGH GRINDING
# 120 - 150 TURNING TOOL, ROUGH GRINDING, REGRINDING, CHIP BREAKER
# 220 - 240 FINISH GRINDING OF CEMENTED CARBIDES, PRECISION FINISHING OF
CYLINDRICAL SURFACE AND INTERNAL SURFACE
# 320 - 400 ULTRA PRECISION FINISH GRINDING, FINISHING OF B TURNING TOOLS
# 500 LAPPING OF SHARP EDGES
# 600 - 800 FINISHING OF CEMENTED CARBIDE GAUGE, ETC.
# 1200
(4) GRINDING CONDITIONS

-1 GRINDING SPEED ･･･
RESINOID BONDED WHEEL: 1,500 - 1,800 m/min
METAL BONDED WHEEL: 1,000 - 1,500 m/min
GENERALLY, WHEN THE GRINDING SPEED IS REDUCED, THE WHEEL WEAR OCCURS RAPIDLY. IF
THE PERIPHERAL VELOCITY OF A WHEEL IS INCREASED, THE EFFICIENCY INCREASES. BUT,
SOME ADVERSE EFFECTS SUCH AS VIBRATION OCCURS. SO, THERE IS A LIMITATION IN
INCREASING THE GRINDING SPEED.
-2 GRINDING RESISTANCE
RELATIVELY SMALLER THAN THE GRINDING WHEEL. IF THE WORKPIECE IS PRESSED AGAINST
THE WHEEL, THE AMOUNT OF GRINDING INCREASES AND SO DOES THE WHEEL WEAR.
-3 DEPTH OF CUT
DEPTH OF CUT VARIES DEPENDING ON THE TYPE OF WORKPIECE AND WHEEL. IN GENERAL, 0.1
mm IS APPROPRIATE.
- 152 -
9 BORAZON GRINDING WHEEL ･･･ (3), (4)
9-1 WHAT IS BORAZON?
BORAZON IS A TRADEMARK BY GE, AN AMERICAN MANUFACTURER, FOR A SUBSTANCE NAMED AS CUBIC
BORON NITRIDE.
HEXAGONAL BORON NITRIDE (hBN), WHITE AND SOFT SUBSTANCE, UNDER GO THE HIGH-PRESSURE/HIGH-
TEMPERATURE PROCESSING, THE SAME TECHNIQUE FOR SYNTHETIC DIAMOND, TO BECOME DARK BROWN
AND HARD CUBIC SYSTEM CRYSTALS.
GE IS THE FIRST PRODUCER OF IT. THE BORAZON WHEELS ARE A GRINDING WHEEL IN WHICH BORAZON IS
USED AS ABRASIVE.
BORAZON WHEELS ARE SUPERIOR IN GRINDING SUCH MATERIALS AS TOOL STEEL, VANADIUM STEEL, DIES
STEEL WHICH HAVE CONVENTIONALLY BEEN CATEGORIZED AS POOR GRAINDABILITY MATERIALS.
9-2 TYPES, FEATURES AND APPLICATION OF BORAZON WHEELS
TYPE METAL COATING COLOR FEATURES BOND APPLICATION
ELECTRODEP * STEEL OF H C 50 OR OVER

* BLOCKY CRYSTALS
OSITION R
CBN-I NO COATING DARK BROWN * GOOD FRIABILITY METAL (HIGH-SPEED, DIES STEEL, SHAFT
BEARING STEEL, CEMENTED CARBIDES,
VITRIFIED ETC.)
* BLOCKY CRYSTALS RESIN BOND * STEEL OF HRC 50 OR OVER
CBN-II Ni COATING (HIGH-SPEED, DIES STEEL, SHAFT

* GOOD FRIABILITY BEARING STEEL, CEMENTED CARBIDES,
ETC.)
* POSSIBLE TO GRIND WIDER RANGE OF

(COMPARED TO CBN-I)
ELECTRODEP STEELS
OSITION
* BETTER CRYSTAL FACE AND
TRANSPARENT ELECTRODEPOSITION * LONGER SERVICE LIFE THAN CBN-I
CBN-500 NO COATING
LIGHT BROWN
* MORE BLOCKY TWIN
CRYSTAL FOR GRINDING * SUITABLE FOR OPERATION WHERE
WHEEL MATERIAL REMOVAL IS REQUIRED.
* STRONG AND ROBUST
* WIDER RANGE OF STEELS REGARDLESS

* COMPLEX CERAMIC FACE VITRIFIED
OF HARD OR SOFT
* HIGH WEAR RESISTANCE * SUITABLE FOR OPERATION WHERE

METAL BOND
AND FRACTURE RESISTANCE MATERIAL REMOVAL IS REQUIRED.
CBN-510 NO COATING SILVER GRAY
* BLOCKY. COMBINED * SUITABLE FOR OPERATION WHERE

FOR GRINDING
CHEMICALLY IN METAL BOND. BOND FRACTURE IS A FACTOR OF
WHEEL
HIGH BONDING STRENGTH FAILURE.
- 153 -
9-3 CHARACTERISTICS
(1)
(2)
(3)
(4)
10 ULTRA GRINDING WHEELS ･･･ (3), (4)

10-1 WHAT IS ULTRA GRINDING WHEEL?
A GRINDING WHEEL HAVING A SINGLE-PLATED LAYER OF BORAZON GRAINS AND DIAMOND GRAINS ON THE
STTEL BASE METAL IS REFERRED TO AS "ULTRA GRINDING WHEEL" AT HONDA.
10-2 FEATURES
THE ULTRA GRINDING WHEEL HAS A HIGHER STABILITY, AND THUS HIGH SPEED AND HIGH EFFICIENCY CAN BE
OBTAINED. IT IS SUITABLE FOR A FORMED GRINDING WHEEL OF HARD MATERIAL. IT IS MAINLY USED FOR
GRINDING OF CAMSHAFT, ISOCHRONOUS JOINT, ENGINE VALVES, ETC.
- 154 -
CHARACTERISTICS
HIGH HARDNESS AND STRONG
HIGH THERMAL AND CHEMICAL STABILITY
LESS HEAT GENERATION DUE TO GRINDING
VERY LITTLE INFLUENCE ON WORKPIECE DUE TO TEMPERATURE RISE.
ULTRA GRINDING WHEELS ･･･ (3), (4)

WHAT IS ULTRA GRINDING WHEEL?
A GRINDING WHEEL HAVING A SINGLE-PLATED LAYER OF BORAZON GRAINS AND DIAMOND GRAINS ON THE
STTEL BASE METAL IS REFERRED TO AS "ULTRA GRINDING WHEEL" AT HONDA.
FEATURES
THE ULTRA GRINDING WHEEL HAS A HIGHER STABILITY, AND THUS HIGH SPEED AND HIGH EFFICIENCY CAN BE
OBTAINED. IT IS SUITABLE FOR A FORMED GRINDING WHEEL OF HARD MATERIAL. IT IS MAINLY USED FOR
GRINDING OF CAMSHAFT, ISOCHRONOUS JOINT, ENGINE VALVES, ETC.
- 154 -
11 PERFORMANCE COMPARISON, GENERAL GRINDING WHEEL VS. BORAZON GRINDING WHEEL
WHEEL
GENERAL BAKING WHEEL (Al2O3, SiC)
ITEM
* RAPID WHEEL WEAR
WHEEL WEAR
* SHORT REPLACEMENT INTERVALS
PROCESS * LOW GRINDING REMOVABILITY DUE TO RAPID WEAR.
EFFICIENCY
* UNGROUND MATERIAL AFTER GRINDING IS LARGE, AND
THUS PROCESS EFFICIENCY IS LOW
(SHARPNESS)
* TRUING (DRESSING) INTERVALS ARE SHORT AND

FREQUENT; LARGE WASTE OF TIME.
TRUING AND * CONDITIONING OF FORMED WHEEL IS RELATIVELY EASY.

DRESSING
* HIGHLY DEPENDENT ON EXPERIENCE AND SKILL TO

ENSURE ACCURACY DUE TO LARGE WHEEL WEAR.
* TOOL: SHORT REGRINDING INTERVALS AND SHORT

SERVICE LIFE (i.e. AFFECT ON MATERIAL DUE TO GRINDING
IS LARGE)
GRINDING
ACCURACY &
QUALITY * SHORT WHEEL LIFE AND POOR ACCURACY STABILITY
* AUTOMATION IS DIFFICULT.
* HIGHLY DEPENDENT ON MANPOWER AND EQUIPMENT
REINFORCEMENT
* LARGE AMOUNT OF POWDER DUST

* SULFUR TREATED WHEEL INVOLVES POLLUTION PROBLEM
WORK
ENVIRONMENT
* UNIT COST OF WHEEL IS LOW.

* ALTHOUGH COST OF WHEEL IS LOW, PROCESS COST IS
HIGH. (TIME EFFICIENCY IS POOR)
UNIT COST AND
COST OF WHEEL * IT IS OFTEN THE CASE THAT TOTAL COST IS RELATIVELY
HIGH
HANDLING * BECAUSE OF LOW COST OF WHEEL, IT CAN BE USED

FREELY.
* GENERAL PURPOSE TOOL (GOOD COMPATIBILITY)
- 155 -
ING WHEEL VS. BORAZON GRINDING WHEEL
BORAZON WHEEL
* VERY LITTLE WHEEL WEAR

* LONG REPLACEMENT INTERVALS
* VERY GOOD SHARPNESS AND VERY LITTLE WEAR
* UNGROUND MATERIAL AFTER GRINDING IS LESS;
GRINDING REMOVABILITY IS HIGH.
* PROCESS EFFICIENCY IS HIGH.

* IT IS OFTEN THE CASE THAT TRUING (DRESSING) IS NOT
REQUIRED.
* TRUING AND DRESSING TIME IS SOMEWHAT LONGER.
* IT IS DIFFICULT TO CONDITION FORMED WHEELS.

* ACCURACY STABILIZES BECAUSE OF LITTLE WHEEL WEAR
AND HIGH GRINDING REMOVABILITY.
* LESS DEPENDENT ON SKILL TO ENSURE ACCURACY.

* TOOL: LONG REGRINDING INTERVALS AND LONG SERVICE
LIFE. (i.e. AFFECT ON MATERIAL DUE TO GRINDING IS
SMALL.)
* LONG WHEEL LIFE AND STABLE ACCURACY

* AUTOMATION IS POSSIBLE
* VERY LITTLE AMOUNT OF POWDER DUST FROM WHEEL.
* HOWEVER, USE OF NONAQUEOUS GRINDING FLUIDS IS

ACCOMPANIED WITH SOME PROBLEMS.
* UNIT COST OF WHEEL IS MUCH HIGHER THAN THAT OF

GENERAL WHEEL.
* ALTHOUGH COST OF WHEEL IS HIGH, PROCESS COST IS

OVERWHELMINGLY LOW. (TIME EFFICIENCY IS GOOD).
* TOTAL COST CAN BE LOW.

* SPECIAL CARE IS REQUIRED FOR HANDLING AND
MACHINES.
* NOT SO MUCH COMPATIBLE AS GENERAL WHEELS
- 155 -
[16] TEORI PEMOTONGAN
= DAFTAR ISI =
1. SUSUNAN SERPIHAN (1), (2)

2. TERBENTUKNYA TEPI (1), (2)
3. KETAHANAN PEMOTONG (3), (4)
4. TEMPERATUR PEMOTONGAN (3), (4)
5. KECEPATAN PEMOTONGAN (1), (2)
6. KECEPATAN MAKAN (1), (2)
7. DAYA YANG DIBUTUHKAN (3), (4)
8. KEMAMPUAN MESIN (3), (4)
9. TABEL KONDISI PEMOTONGAN
(KONDISI AKTUAL DI HM) (3), (4)
- 157 -
AN
HALAMAN
158
160
161
163
164
164
165
166
167
- 157 -
[16] TEORI PEMOTONGAN
PEMOTONGAN LOGAM ADALAH PROSES UNTUK MENGHILANGKAN BAHAN DARI PERMUKAAN BENDA KERJA
DENGAN MENGGUNAKAN GAYA GAYA YANG MENGARAH KE KOMPRESI DAN MENYEBABKAN PERGESARAN
DALAM BAHAN.
DALAM URUTAN PEMOTONGAN, PAHAT MENGHILANGKAN BAHAN DENGAN PEREGANGAN YANG DISEBABKAN
OLEH EFEK TEKANAN. TEKNIK INI AKAN TERJADI DENGAN MEMBUTUHKAN SUDUT MAKAN YANG KECIL DARI TEPI
PEMOTONGAN. DENGAN SUDUT MAKAN YANG KECIL TERSEBUT, NAMUN, SUDUT PEMOTONGAN DAPAT
MEMPERTAHANKAN TEGANGAN YANG TERLIBAT DALAM PEMOTONGAN LOGAM, BAHAN KAKU.
PAHAT KUAT DALAM PEMOTONGAN LOGAM DENGAN SUDUT MAKAN BESAR YANG DIGUNAKAN UNTUK
MEMBERSIHKAN MATERIAL DARI BENDA KERJA DENGAN MENGGUNAKAN GAYA TEKAN.
DALAM URUTAN PEMOTONGAN, PISAU

MENGHILANGKAN SERPIHAN DENGAN
PEREGANGAN YANG DISEBABKAN OLEH EFEK
TEKANAN.
DALAM PEMOTONGAN LOGAM, GAYA MEMOTONG
BERSAMA DENGAN GAYA TEKAN MEMBAWA
BAHAN DARI PERMUKAAN BENDA KERJA.
1 SUSUNAN SERPIHAN ･･･ (1), (2)

1-1 LANGKAH PEMOTONGAN SUDUT
SUDUT PEMOTONGAN MEMAKAN BENDA KERJA. KETIKA GAYA DITERAPKAN DALAM ARAH ANAK PANAH,
ALAT PEMOTONGAN UNTUK PERMUKAAN YANG TIMBUL MEMBUAT TEKANAN KUAT PADA BENDA KERJA
DAN MENYEBABKAN DEFORMASI PLASTIK DI AREA ITU. JIKA GAYA YANG DITERAPKAN PADA ALAT POTONG
LEBIH BESAR DARI GAYA YANG BERKELANJUTAN PADA BENDA KERJA, YANG MENYEBABKAN DAERAH
YANG MENGALAMI PERGESERAN DAN TERPISAH. BAHAN YANG TERPISAH DISEBUT "SERPIHAN".
LANGKAH PEMOTONGAN INI SAMA DENGAN EFEK TEKANAN

1-2 SUDUT PEMOTONGAN
PEMOTONGAN MEMAKAN BAGIAN BIDANG
KERJA. BIDANG KERJA INI PADA φ, DISEBUT
SUDUT PEMOTONGAN. SUDUT PEMOTONGAN SUDUT MAKAN
DAPAT DIPEROLEH OLEH FORMULA BERIKUT.
SUDUT
PEMOTONGAN
PAHAT
( t 1 / t 2 )cosα SUDUT
tanθ= PERMUKAAN
1-( t 1 / t 2 )sinα PERMUKAAN
POTONG
α= SUDUT MAKAN DARI ALAT POTONG
θ= SUDUT POTONG BIDANG POTONG
GIGI
t1 = KEDALAMAN POTONG
t2 = KETEBALAN SERPIHAN
KETEBALAN SEPIHAN BERKURANG DENGAN BERTAMBAHNYA SUDUT PEMOTONGAN. SEBAGAI AKIBAT,

RATA RATA SERPIHAN YANG TERBUANG MENINGKAT DAN KINERJA DARI SERPIHAN BERKURANG.
MAKSUT DARI PARAMETER PEMOTONGAN SEHARUSNYA DIATUR UNTUK MEMBUAT SUDUT PEMOTONGAN
YANG LEBAR
(SUDUT PEMOTONGAN MENINGKAT KETIKA KECEPATAN POTONGNYA TINGGI, SUTU MAKAN BESAR DAN
KEDALAMAN MAKAN KECIL).
- 158 -
1-3 JENIS TERBENTUKNYA SERPIHAN
MENURUT 4 JENIS TERBENTUKNYA SERPIHAN DALAM PEMOTONGAN LOGAM TERGANTUNG DARI BAHAN BENDA
KERJA DAN KONDISI PEMOTONGAN (KECEPATAN PEMOTONGAN, KEDALAMAN POTONG, KECEPATAN MAKAN,
BENTUK TEPI POTONG DAN FLUIDA PEMOTONGAN)
JENIS FENOMENA
GAYA KOMPRESI MENYEBABKAN DEFORMASI
JENIS POTONGAN SERPIHAN ALUR TERBENTUKNYA SERPIHAN
ALAT PLASTIS DAN PERGESARAN TEPI

POTONG
PEMOTONGAN; KEMUDIAN TERBENTUKLAH
SERPIHAN.
SUDUT MAKAN KIRA KIRA 10 DERAJAT DAN

KETEBALAN TEKAN TEPI POTONG MENINGKAT.
PERGESERAN BAHAN TIDAK ADA DAN
SERPIHAN SALING TERBENTUK.
SERPIHAN MENEMPEL PADA PERMUKAAN

JENIS SOBEKAN SERPIHAN
PAHAT DAN TEPI PEMOTONGAN BERLANJUT

MEMBUANG BAHAN DENGAN SERPIHAN YANG
MENEMPEL. CELAH YANG TERJADU DIDEPAN
ALAT DAN BERKEMBANG KEDALAM. SERPIHAN
AKHIRNYA LEPAS DARI BENDA KERJA.
RETAKAN SERPIHAN TERUS MENERUS DAN

JENIS RETAKAN SERPIHAN
JATUH DARI BENDA KERJA.
1-4 HUBUNGAN ANTARA SUSUNAN SERPIHAN DAN GAYA KOMPONEN BESAR
JENIS ALUR JENIS POTONGAN JENIS SOBEKAN

GAYA KOMPONEN BESAR
GAYA KOMPONEN BESAR

GAYA KOMPONEN BESAR
GAYA KOMPONEN BESAR
WAKTU WAKTU WAKTU
- 159 -
GAYA KOMPONEN BESA
WAKTU
GAYA KOMPONEN BESA

WAKTU
- 159 -
GAYA KOMPONEN BE
WAKTU
GAYA KOMPONEN BES

GAM TERGANTUNG DARI BAHAN BENDA
AMAN POTONG, KECEPATAN MAKAN,
BAHAN
MATERIAL HALUS
SEPERTI BAJA RINGAN,
TEMBAGA, LOGAM
CAMPURAN, ALMUNIUM
CAMPURAN.
BAJA RINGAN PALING

HALUS, TEMBAGA
CAMPURAN DAN
ALUMUNIUM
CAMPURAN, LEBIH
HALUS DARI SEMUA
ITU DENGAN JENIS
ALUR SERPIHAN.
BAHAN GETAS SEPERTI

BESI COR, BESI COR
LUNAK, PERUNGGU.
JENIS RETAKAN
GAYA KOMPONEN BESAR
WAKTU
- 159 -
GAYA KOMPONEN BES
WAKTU
- 159 -
2 TEPI ATAS TERBENTUK ･･･ (1), (2)
TEPI ATAS TERBENTUK, MENGANDUNG LAPISAN BAHAN DARI BENDA KERJA YANG BERHENTI TERBENTUKNYA
DIATAS ALAT, DAPAT TERBENTUK DIATAS ALAT SELAMA PEMOTONGAN LOGAM. GESEKAN PANAS DAN TEKANAN
ANTARA TEPI PEMOTONGAN DAN SERPIHAN ADALAH PENYEBAB TERBENTUKNYA BAGIAN ATAS. TERBENTUKNYA
TEPI ATAS TERULANG KARENA SOBEKAN DAN FORMASI SIKLUS PADA JANGKA NORMAL SELAMA CUTTING.
2-1 TERBENTUKNYA SUSUNAN DAN PENGHILANGAN TEPI
KEJADIAN BERKEMBANG PERUBAHAN
2-2 FAKTOR TERBENTUKNYA SUSUNAN DAN PENGHILANGAN TEPI

(1) PERMUKAAN ALAT MAKAN ･･･
DENGAN
･･････PENYELESAIAN
･･････ PANTULAN PERMUKAAN MAKAN, SERPIHAN
BERGESAER DENGAN HALUS, DIMANA BERKURANGNYA TERBENTUKNYA
SUSUNAN TEPI
(2) KARBIDA YANG DISEMEN ･･･BAHAN
･･･ MENGANDUNG KOBALT BESAR CENDERUNG MENYEBABKA
TERBENTUKNYA TEPI
(3) SUDUT MAKAN ALAT ･･････JIKA SUDUT MAKAN KECIL, KONTAK TEKANAN ANTARA SERPIHAN DAN
PERMUKAAN MAKAN TINGGI DAN TEMPERATUR PERMUKAAN KONTAK JUGA
TINGGI, YANG MANA CENDERUNG MENYEBABKAN TERBENTUKNYA SERPIHAN.
SUDUT MAKAN DENGAN 30 DERAJAT ATAU LEBIH TIDAK CENDERUNG
MEMBENTUK TEPI
(4) KEDALAMAN PEMOTONGANBERTAMBAHNYA

･････････ KEDALAMAN POTONG MENYEBABKAN KONTAK TEKANAN DAN
TEMPERATUR MENINGKAT, YANG MANA HASILNYA MENYEBABAN SUSUNAN TEPI.
DENGAN PENGECUALIAN BERTAMBAHNYA KEDALAMAN POTONG MENYEBABKAN
TEMEPRATUR MENINGKAT DAN MENGHALUSKAN FENOMENA YANG TERJADU,
YANG MANA MENGURANGI KEMUNGKINAN TERBENTUKNY A TEPI.
BAJA RINGAN 30 - 50 m/min

150 m/min LEBIH
ALUMINUM 200 m/min LEBIH
KECEPTAN POTONG KRITIS ･･･
(6) FLUIDA PEMOTONGAN ･･･ FLUIDA PEMOTONGAN MENGURANGI PANAS GAYA GESEK DAN JUGA SUSUNAN
TERBENTUKNYA TEPI
(7) BENDA KERJA ･･･ LOGAM KAKU DAN BAHAN DENGAN JENIS ALUR SERPIHAN CENDERUNG UNTUK
MENAHAN TERBENTUKNYA TEPI.
(SEPERTI BAJA RINGAN, STAINLESS STEEL, ALUMINUM)
2-3 PENGARUH TERBENTUKNYA TEPI

(1) ALAT POTONG ･･･ KETIKA TERBENTUKNYA TEPI BERAKHIR, INI MENGHILANGKAN BAHAN DARI
SUDUT PEMOTONGAN DAN MENJADI BAGIAN YANG BAGUS. DAN JUGA, SUDUT
PEMOTONGAN CENDERUNG MENAHAN TERJADINYA SERPIHAN.
KETIKA TERBENTUKNYA TEPI BERAKHIR, TEPI AKAN MENEMPEL DENGAN
SERPIHAN PAHAT PADA PERMUKAAN MAKAN DAN MEMBENTUK CEKUNGAN.
(2) BENDA KERJA ･･･ PENYELESAIAN PERMUKAAN YANG BURUK
DEVIASI UKURAN.
- 160 -
RI BENDA KERJA YANG BERHENTI TERBENTUKNYA
OTONGAN LOGAM. GESEKAN PANAS DAN TEKANAN
EBAB TERBENTUKNYA BAGIAN ATAS. TERBENTUKNYA
LUS PADA JANGKA NORMAL SELAMA CUTTING.
TERPOTONG
ANTULAN PERMUKAAN MAKAN, SERPIHAN

US, DIMANA BERKURANGNYA TERBENTUKNYA
ALT BESAR CENDERUNG MENYEBABKA
KONTAK TEKANAN ANTARA SERPIHAN DAN

I DAN TEMPERATUR PERMUKAAN KONTAK JUGA
RUNG MENYEBABKAN TERBENTUKNYA SERPIHAN.
DERAJAT ATAU LEBIH TIDAK CENDERUNG
AN POTONG MENYEBABKAN KONTAK TEKANAN DAN

YANG MANA HASILNYA MENYEBABAN SUSUNAN TEPI.
ERTAMBAHNYA KEDALAMAN POTONG MENYEBABKAN
DAN MENGHALUSKAN FENOMENA YANG TERJADU,
KEMUNGKINAN TERBENTUKNY A TEPI.
TEPI TERJADI
TEPI TIDAK TERJADI
TEPI TIDAK TERJADI
TEPI MENGHILANG
GURANGI PANAS GAYA GESEK DAN JUGA SUSUNAN
DENGAN JENIS ALUR SERPIHAN CENDERUNG UNTUK

TEPI.
AINLESS STEEL, ALUMINUM)
PI BERAKHIR, INI MENGHILANGKAN BAHAN DARI

MENJADI BAGIAN YANG BAGUS. DAN JUGA, SUDUT
G MENAHAN TERJADINYA SERPIHAN.
PI BERAKHIR, TEPI AKAN MENEMPEL DENGAN
RMUKAAN MAKAN DAN MEMBENTUK CEKUNGAN.
- 160 -
3 KETAHANAN PEMOTONG ･･･ (3), (4)
3-1 KONDISI KETAHANAN PEMOTONG
KETAHANAN PEMOTONG TERDISI DARI 3 FAKTOR KETAHANAN 3 KOMPONEN KETAHANAN PEMOTONG
YANG TERJADI KETIKA SERPIHAN TERPOTONG, GAYA GESEK PADA
PERMUKAAN SERPIHAN, GAYA BALIK YANG TERJADI KETIKA
SERPIHAN MENGHIANGKAN BENTUK BENDA KERJA
(1) KETIKA BATANG DIPOTONG SECARA LONGITUDINAL OLEH P1: GAYA KOMPONEN BESAR
ALAT PEMOTONG, KETAHANAN ALAT POTONG BIASANYA P2: GAYA KOMPONEN MAKAN
P3: GAYA KOMPONEN BELAKANG
DIPENGARUHI OLEH 3 GAYA.
GAYA KOMPONEN BESAR (P1) ･･･ KETAHANAN GAYA DI ARAH PEMOTONGAN. GAYA KOMPONEN
BESAR SANGATKAH BESAR. ENERGI PEMOTONGAN DAN
KEMAMPUAN MESIN DITENTUKAN OLEH PENGUKURAN GAYA
KOMPONEN BESAR
(2) GAYA KOMPONEN MAKAN (P2) ･･･ KETAHANAN GAYA PADA ARAH MAKAN. INI TERJADI PADA
MEKANISME PEMAKAN.
(3) GAYA KOMPONEN BELAKANG (P3) ･･･ KETAHANAN GAYA ITU CENDERUNG UNTUK MEMBAWA ALAT DARI
BENDA KERJA.
3-2 FAKTOR YANG MEMPENGARUHI KETAHANAN PEMOTONGAN
(1) BENDA KERJA･･･ KETAHANAN PEMOTONGAN MENIGKAT DENGAN BERTAMBAHNYA KEKUATAN
LULUH DAN KEKERASAN.
HUBUNGAN ANTARA KEKUTAN LULUH DAN KETAHANAN PEMOTONGAN
KEKUATAN LULUH (kg/mm2) 30 - 40 40 - 50 50 - 60 60 - 70 70 - 80 90 - 100
RASIO KETAHANAN PEMOTONGAN 1 1.10 1.18 1.29 1.45 1.70
DAERAH PEMOTONGAN DAN KETAHANAN

(2) DAERAH PEMOTONGAN ･･･ KETAHANAN PEMOTONGAN PEMOTONG
MENINGKAT DENGAN (PEMOTONGAN BAJA)
MENINGKATNYA DAERAH
KETAHANAN PEMOTONGAN
PEMOTONGAN.
(kg)
DAERAH PEMOTONGAN(mm2)
(3) KECEPATAN PEMOTONGAN ･･･
KETAHANAN PEMOTONGAN KECEPATAN PEMOTONGAN DAN KETAHANAN PEMOTONG
BERKURANG DENGAN
GAYA KOMPONNEN BESAR (kg)
MENINGKATNYA KECEPATAN
PEMOTONGAN. DI KECEPATAN RAKE ANGLE
TINGGI, INI MENJADI SECARA

RAKE ANGLE
TERUS MENERUS DAN
KONSISTEN.
KECEPTAAN PEMOTONGAN (m/min)
(4) SUDUT ALAT MAKAN ･･･ DENGAN SUDUT MAKAN YANG * FAKTOR DAN SIFAT YANG MEMPENGARUHI KETAHANAN
POTONG
BESAR JENIS ALUR SERPIHAN
SUDUT MAKAN DAN
KETAHANAN PEMOTONG TERBENTUK DAN KETAHANAN BERKURANG ← KETAHANAN POTONG →
FAKTOR
PEMOTONG SANGAT KECIL. MENINGKAT
GAYA KOMPONEN BESAR (kg)
(1) BENDA KERJA

KETAHANAN PEMOTONG KECIL ← KEKUATAN LULUH → BESAR
MENINGKAT DENGAN (2) DAERAH KECIL ← DAERAH POTONG → BESAR

PEMOTONGAN
BERKURANGNYA SUDUT (3) KECEPATAN BESAR ←KECEPATAN POTONG → KECIL
MAKAN. POTONG
(4) SUDUT MAKAN L (POSITIF) ← SUDUT MAKAN → (NEGATIF) S
(5) SUDUT
PEMOTONGAN TEPI KECIL ← SUDUT PEMOTONGA TEPI → BESAR
SUDUT MAKAN(°)
- 161 -
N KETAHANAN PEMOTONG
AN. GAYA KOMPONEN

MOTONGAN DAN
PENGUKURAN GAYA
NI TERJADI PADA
TUK MEMBAWA ALAT DARI
ERTAMBAHNYA KEKUATAN
ONGAN DAN KETAHANAN

EMOTONG
TONGAN BAJA)
OTONGAN DAN KETAHANAN PEMOTONG
RAKE ANGLE
AAN PEMOTONGAN (m/min)
ANG MEMPENGARUHI KETAHANAN
BERKURANG ← KETAHANAN POTONG →

MENINGKAT
KECIL ← KEKUATAN LULUH → BESAR
KECIL ← DAERAH POTONG → BESAR
BESAR ←KECEPATAN POTONG → KECIL
POSITIF) ← SUDUT MAKAN → (NEGATIF) S
CIL ← SUDUT PEMOTONGA TEPI → BESAR
- 161 -
HUBUNGAN ANTARA SUDUT MAKAN (α°) DAN KETAHANAN PEMOTONG
HUBUNGAN ANTARA SUDUT MAKAN (α°) DAN KETAHANAN PEMOTONG
GAYA KOMPONEN PEMAKAN (kg)

GAYA KOMPONEN BESAR (kg)
KCEPATNAN POTONG V (m/min) KECEPATANAN POTONG V (m/min)
(5) SUDUT POTONG TEPI KETAHANAN POTONG MENINGKAT * SUDUT POTONG TEPI DAN 3 KOMPONEN
･･･ DENGAN MENINGKATNYA SUDUT GAYA
POTONG TEPI KARENA KETEBLAN
SERPIHAN BERKURANG
KERJA
GAYA KOMPONEN PEMAKAN (kg)

P1 GAYA KOMPONEN BESAR
SERPIHA
* SUDUT POTONG TEPI DAN KETEBAALAN NN
KONDISI
SERPIHAN (t1 > t2 > t3)
P2 GAYA KOMPONEN PEMAKAN
P3 GAYA KOMPONEN BELANKANG
SUDUT POTONG TEPI

* KETEBALAN SERPIHAN DAN KETAHANAN
PEMTONG SPESIFIK
REFERENSI * KETAHANAN PEMOTONG KEKUATAN LULUH
MENINGKAT DENGAN
BERKURANGNYA KETEBALAN
SERPIHAN
KETAHANAN PEMOTONG SPESIFIK
(kg/mm2)
0.04 MAKAN (mm/rev)
(6) JARAK HIDUNG ･･･ KETAHANAN PEMOTONG MENINGKAT DENGAN MENINGKATNYA JARAK HIDUNG
KARENA KETEBALAN SERPIHAN BERKURANG.
* JARAK HIDUNG DAN 3 KOMPONEN GAYA
KERJA
P1 GAYA KOMPONEN
KETAHANAN PEMOTONG(kg)
BESAR SERPIHAN
PENAHAN
P2 GAYA KOMPONEN MAKAN
KONDISI
P3 GAYA KOMPONEN
BELAKANG
JARAK HIDUNG (mm)
(7) FLUIDA PEMOTONGAN FLUIDA

･･･ PEMOTONG MENGURANGI GAYA GESEK YANG TERJADI ANTAR SUDUT ALAT
PEMOTONG DAN BAGIAN BELAKANG SERPIHAN, DAN SAYAP ALAT DAN PERMUKAAN
BENDA KERJA. PELUMAS MENGURANGI KEKUATAN MENGIKAT LEMBARAN LOGAM,
DAN JUGA KETAHANAN PEMOTONG BERKURANG.
- 162 -
4 TEMPERATUR PEMOTONGAN ･･･ (3), (4)
PROSES PEMOTONGAN BERSAMA DENGAN TIMBULYA PANAS. PANAS MENCAPAI TEMPERATUR ALAT
PEMOTONG, BENDA KERJA, DAN SERPIHAN. HASLINYA, TEMPERATUR MEMPERPENDEK UMUR ALAT
PEMOTONG DAN MENGURANGU EFISIENSI PEMOTONGAN. INI JUGA MEBERIKAN EFEK YANG BURUK
UNTUK PENYELESAIAN PERMUKAAN BENDA KERJA, MENYEBABKAN MASALAH SEPERTI
MEMBURUKNYA BAHAN.
4-1 PENYEBAB TIMBULNYA PANAS PADA PEMOTONGAN

(1) DEFORMASI TERJADI SEBELUM PEMOTONGAN TEPI SERPIHAN DARI JUMLAH TERBESAR
PERMUKAAN BENDA KERJA. DARI
TIMBULNYAPANAS
(2) GAYA GESEK ANTARA SERPIGAN DAN PERMUKAAN MAKAN ALAT PEMOTONG
(3) PEMOTONGAN SERPIHAN DARI BENDA KERJA OLEH PEMOTONG TEPI JUMLAH TERKECIL
(4) GAYA GESEK ANTARA SAYAP ALAT POTONG DAN PERMUKAAN PEMESINAN. DARI GENERASI
PANAS
4-2 FAKTOR YANG MEMPENGARUHI TEMPERATUR PEMOTONGAN
(1) BENDA KERJA ･･･ TIMBULNYA PANAS MENINGKAT DENGAN MENINGKATYA CIRI MEKANIKA
(KEKUATAN LULUH, KEKRASAN, OLEH KARENA ITU TEMPERATUR
PEMOTONGAN TERJADI.
(2) ALAT PEMOTONG ･･･ TEMPERATUR PEMOTONGAN TEPI SANGATLAH RENDAH JIKA BAHAN
MEMILIKI KONDUKTIVITAS PANAS TINGGI. BENTUK DAN SUDUT TEPI
PEMOTONG DAPAT MENYEBABKAN TEMPERATUR TERJADI JIKA
KETAHANAN PEMOTONG DAN GAYA GESEK CENDERUNG MENINGKAT.
(3) KECEPATAN PEMOTONGAN

TEMPERATUR
･･･ TERJADI DENGAN MENINGKATNYA KECEPATAN POTONG.
(4) FLUIDA PEMOTONGAN FLUIDA
･･･ DENGAN EFEK ANTI GAYA GESEK TINGGI DAN EFEK PENDINGAN
MELAMBATKAN TIMBULNYA PANAS DAN MENHILANGKAN PANAS.
4-3 KEMIRINGAN TEMPERATUR, DIDALAM DIMASUKKAN KETIKA PEMOTONGAN

KONDISI
V = 180 m/min
f = 0.74 mm/rev
GAYA = 3 mm
BENDA KERJAE =
BAJA MANGAN
SUDUT MAKAN = 0°
KEBANYAKAN PANAS TIMBUL OLEH PEMOTONGAN MELEPASKAN SERPIHAN DAN 5-15 % DARI ITU
DISERAP OLEH BENDA KERJA DAN ALAT BUBUT. KETIKA PANAS DALAM JUMLAH BESAR DISERAP OLEH
ALAT BUBUT, KEMIRINGAN TEMPERATUR TERJADI DI PEMOTONGAN TEPI. DAERAH ITU MENAHAN
TEMPERATUR TINGGI PADA CEKUNGAN PERMUKAAN MAKAN, TIDAK DIDALAM TEPI PEMOTONGAN.
- 163 -
5 KECEPATAN PEMOTONGAN ･･･ (1), (2)
KECEPATAN PEMOTONGAN MERUPAKAN KECEPATAN LINIER DIMANA BENDA KERJA MELEWATI PEMOTONGAN
TEPI DENGAN UNIT/WAKTU. INI MENDEKATI HUBUNGAN UMUR SERVIS ALAT, KEAKURATAN PENYELESAIAN
PERMUKAAN, DAN EFISIENSI PROSES.
KECEPATAN PEMOTONGAN DAPAT DIHITUNG DENGAN RUMUS SEBAGAI BERIKUT.
V= π・D ・N ( m / min )
1000
V = KECEPTANA PEMOTONGAN (m/min)

D = DIAMTER BENDA KERJA YANG BEROTASI ATAU DIAMETER ALAT PEMOTONGAN TEPI (mm)
N = JUMLAH PUTARAN BENDA KERJA ATAU ALAT PER MENIT (rpm)
JIKA KECEPATAN PEMOTONGAN TERLALU BESAR UNTUK BAHAN ALAT PEMOTONGAN, PANAS DITIMBULKAN
OLEH MENINGKATNYA PEMOTONGAN DAN BERKURANGNYA KEKRASAN PEMOTONGAN TEPI, DIMANA DAPAT
MENIMBULKAN DEFORMASI PLASTIK ATAU AUS.
6 KECEPATAN MAKAN ･･･ (1), (2)

KECEPATAN MAKAN MERUPAKAN KECEPATAN LINEAR BENDA KERJA ATAU LAT BERPINDAH KETIKA
PEMOTONGAN DENGAN UNIT/WAKTU. INI MENDEKATI HUBUNGAN DENGAN UMUR SERVIS ALAT, AKURASI
PENYELESAIAN PERMUKAAN DAN EFISIENSI PROSES.
KECEPATAN MAKAN DAPAT DIHITUNG DENGAN RUMUS SEBAGAI BERIKUT.
f ・Z ・N
F= ( m / min )
1000
F = KECEPATAN MAKAN (m/min)

f = KECEPATAN MAKAN PER GIGI (mm/TOOTH)
Z = JUMLAH GIGI ALAT PEMOTONG
N = JUMLAH PUTARAN BENDA KERJA ATAU ALAT PER MENIT (rpm)
- 164 -
7 DAYA YANG DIBUTUHKAN
ENERGI YANG DIBUTUHKAN UNTUK MESIN SPINDLE UTAMA DIHITUNG DENGAN GAYA KOMPONEN BESAR (P1) GAYA
KOMPONEN BESAR DAPAT DIHITUNG DENGAN RUMUS SEBAGAI BERIKUT.
P1 = a X b X KS (kg) P1: GAYA KOMPONEN BESAR, Kg
a: KETEBALAN SERPIHAN, mm
b: PANJANG SERPIHAN LONGITUDINAL, mm
KS: KETAHANAN PEMOTONG SPESIFIK, kg/mm2
(f): KECEPATAN MAKAN, mm/rev
SUDUT PEMOTONGAN
(t): PEMOTONGAN, mm
ARAH MAKAN
NILAI KS TIDAK KONSTAN; INI BERVARIASI TERGANTUNG KETEBALAN SERPIHAN (a). MENURUT TABEL NILAI K S
SEBAGAI BERIKUT.
NILAI KS (kg/mm2): KETIKA SUDUT MAKAN 0°DAN SUDUT POTONG 90°

BAHAN KETEBALAN SERPIHAN mm 0.05 0.1 0.2 0.3 0.5 1.0
BAJA KARBON δB = 60 kg/mm 2
415 356 310 280 246 212
BESI COR HB 200 290 260 215 190 167 137
AL CAMPURAN HB 80 130 115 97 88 80 68
ENERGI YANG DIBUTUHKAN DIHITUNG OLEH GAYA KOMPONEN BESAR (P 1, kg) DAN KECEPATAN POTONG (V, m/min).
EFISIENSI MESIN η BERVASIARI SECARA SIGNIFIKAN TERGANTUNG STRUKTUR, KONDISI DAN PENGISIAN ALAT
MESIN, DIMANA INI BERADA ANTARA 0.7 DAN 0.85 KETIKA PENGISIAN PENUH. KEBUTUHAN ENERGI UNTUK EFISIENSI
DIHITUNG DENGAN RUMUS SEBAGAI BERIKUT.
P1 x V P1: GAYA KOMPONEN BESAR, Kg

ENERGI YANG DIBUTUHKAN=
102 x 60 x η
(Kw) V: KECEPATAN PEMOTONGAN, m/min
OR T: TORSI, Kg-cm
T x 2π x N N: JUMALAH PUTARAN, rpm
ENERGI YANG DIBTUHKAN= (Kw)
102 x 60 x 100 x η η: EFISIENSI MESIN
- 165 -
MPONEN BESAR (P1) GAYA
LONGITUDINAL, mm
TONG SPESIFIK, kg/mm2
NURUT TABEL NILAI K S
PATAN POTONG (V, m/min).

DAN PENGISIAN ALAT
N ENERGI UNTUK EFISIENSI
- 165 -
8 KEMAMPUAN MESIN ･･･ (3), (4)
8-1 APA ITU TINGAKT KEMAMPUAN MESIN ?
TINGKAT KEMAMPUAN MESIN MERUPAKAN PETUNJUK UNTUK MEMUDAHKAN PEMESINAN BAHAN
KECEPATAN PEMOTONGAN DIGUNAKAN SEBAGAI ACUAN, SEPERTI BAGAIMANA CEPAT BAHAN DAPAT
DIPOTONG. KECEPATAN PEMOTONGAN DENGAN ALAT HIDUP 20 MIN UNTUK MEMOTONG BAJA B1112 (AISI
STANDAR, KEKASARAN SAMA DENGAN STANDAR JIS) DIBERIKAN SAMPAI TINGKAT 100. TINGKAT MATERIAL
KEMAMPUAN MESIN SAMA DENGAN TINGKAT STANDAR KONDISI PEMOTONGAN DENGAN KECEATAN
PEMOTONGAN UNTUK ALAT HIDUP 20 MIN.
JIKA BAHAN MEMILIKI TINGKAT LEBIH KECIL, MAKSUTNYA KEMAMPUAN BAHAN PADA MESIN SANGATLAH
BURUK.
8-2 TINGKAT KEMAMPUAN BAHAN PADA MESIN
BAHAN TINGKAT BAHAN TINGKAT
PEMOTONGNA BAJA (B1112) 100 KUNINGAN 200 - 600
BESI COR (RINGAN) 80 TEMBAGA 60 - 70
0.23% C BAJA MOLIBDENUM 70 0.2% BAJA KROM, SCr 22 65
0.1% C (S10C) 50 0.47% C BAJA MORIBDENUM 55
0.4% C BAJA MANGAN 45 BAJA STAINLESS SUS 304 45
ALUMINUM 300 - 1500 BAJA KECEPATAN TINGGI 30
8-3 DEFINISI KEMAPUAN BAHAN MESIN BURUK
JIKA BAHAN DAPAT DIBPOTONG DENGAN MUDAH ATAU TIDAK MERUPAKAN PENDAPAT SUBJEKTIF.
KEMAMPUAN BAHAN MESIN BURUK SEHARUSNYA DIDISKUSIKAN DALAM PERATURAN HUBUNGAN ANTARA
BAHAN DAN ALAT. DAN JUGA, BAHAN DIMANA CIRI MEKANIKA DAN KOMPONEN KIMIA MEMILIKI PENGAURH
YANG BESAR TERHADAP KEMAMPUAN BAHAN MESUB DITENTUKAN SEPERTI KEMAMPUAN BAHAN MESIN
BURUK DALAM PENDAPAR OBJEKTIF.
KEMAMPUAN MESIN YANG BURUK DITENTUKAN OLEH KOMBINASI SEPERTI CIRI BAHAN SEPERTI
KEKUATAN, KEKERASAN, KEKAKUAN, KELENTURAN, PENGERASAN, PARTIKAN KERAS, CIRI TERMAL DAN
AFINITAS.
8-4 HUBUNGAN ANTARA TINGKAT KEMAMPUAN MESIN DAN KEKRASAN BRINELL
HUBUNGAN ANTARA TINGKAT KEMAMPUAN MESIN (MR) DAN KEKERASAN BRINELL
MR = K ・(HB) -13 ASALKAN, MR : TINGKAT KEMAMPUAN MESIN, HB: KEKRASAN BRINELL
K: PROPOSI KONSTAN (KONSTAN DENGAN KETENTUAN GRUP BAJA)
KARENA KEKERASAN BAHAN MENINGKAT, TINGKAT KEMAMPUAN MENURUN. INI MAKSUDNYA BAHAN
KERAS (BIASANYA KEKUATAN LULUH JUGA TINGGI) MEMILIKI KEMAMPUAN BAHAN MESIN SANGATLAH
BURUK.
- 166 -
9 TABEL KONDISI PEMOTONGAN (KONDISI AKTUAL DI HM) ･･･ (3), (4) V・B・f ARE NILAI RATA RATA
KONDISI WC (KARBIDA YANG
BAHAN ALAT H (KECEPATAN TINGGI) TIC KERAMIK LOGAM KERAMIK CBN (BORAZON) DIA
DISEMEN)
m/min mm/min m/min mm/min m/min mm/min m/min mm/min m/min mm/min m/min
PROSES BAHAN KERJA
V f V f V f V f V f V
FC (BESI COR) －－ 25 - 100 0.1 - 0.3 80 - 150 0.05 - 0.15 200 - 400 0.1 - 0.3 300 - 500 0.1 - 0.25
BUBUT (INCL.
HRC 60
BAJA (10 - 30) 0.1 - 0.25 30 - 100 0.1 - 0.3 120 - 160 0.05 - 0.15 (80 - 200) 0.05 - 0.1 0.05 - 0.15
FB)
100 - 150
FC CO-CUTTING
AL (50 - 100) 0.1 - 0.25 100 - 200 0.05 - 0.25 －－ 0.1 - 0.25 120 - 500
300 - 500
CO-MILLING FL
FC (BESI COR) 50 - 100 0.2 - 0.5 0.2 - 0.4 －－－－
PEMOTONG
800 - 1300
FRAIS
BAJA 50 - 120 0.2 - 0.5 100 - 200 0.1 - 0.4 －－－－
AL 800 - 1200 0.2 - 0.5 800 - 1300 0.2 - 0.5 －－ 1000 - 1500
FC 15 - 20 0.1 - 0.2 20 - 35 0.1 - 0.3

DRILL
BAJA 15 - 30 0.1 - 0.3 20 - 40 0.1 - 0.3

167 -
AL 20 - 40 0.15 - 0.3 40 - 80 0.15 - 0.3 －－ ON TRIAL
FC (10 - 15) 0.7 - 0.4 20 - 30 0.2 - 0.4 －－

REAMER
BAJA (10 - 15) 0.7 - 0.4 10 - 25 0.2 - 0.4 －－
AL (20 - 40) 0.7 - 0.4 30 - 80 0.2 - 0.4 50 - 100

DRILL TEMBAK
FC 60 - 90 0.01 - 0.03 －－
BAJA 60 - 120 0.015 - 0.045 －－
AL 100 - 150 0.02 - 0.07 －－－
FC 5 - 10 8 - 15
TAP
STEEL 5 - 10
AL 8 - 20 15 - 30
BIASANYA TIDAK DIGUNAKAN 1. KERAMIK TIDAK DIPAKAI DISETIAP PROSES.
TIDAK DIPAKAI DI HM 2. KERAMIK DAN KERAMIK LOGAM TIDAK BISA DIKERASKAN MAKA TIDAK DIPAKAI UNTUK GD
V・B・f ARE NILAI RATA RATA
DIA
mm/min
f
0.05 - 0.25
0.1 - 0.5
ON TRIAL
0.2 - 0.4
－
[17] FLUIDA PEMOTONGAN (SEMUA (1), (2))
=DAFTAR ISI =
1. KLASIFIKASI FLUIDA PEMOTONGAN DAN PENGETAHUAN DASAR

2. PEMBERIAN FLUIDA PEMOTONGAN
3. PEMBERIAN PELUMAS (GESEKAN YANG DIBOLEHKAN DAN TERBENTUKNYA TEPI)
4. MEKANISME PELUMASAN
5. FLUIDA PEMOTONGAN
6. PEKERJA TEKANAN EKSTREM
7. PEKERJA PERMUKAAN AKTIF
8. JARAK KONSENTRASI
9. KONTROL PH
10. PENAMBAHAN FLUIDA PEMOTONGAN
11. PERUBAHAN FLUIDA PEMOTONGAN
- 169 -
MUA (1), (2))
HALAMAN
170
170
170
170
171
171
172
172
172
173
173
- 169 -
[17] FLUIDA PEMOTONGAN ･･･ (SEMUA (1), (2))
1. KLASIFIKASI FLUIDA PEMOTONGAN DAN PENGETAHUAN DASAR
FLUIDA PEMOTONGAN SECARA LUAS DIKLASIFIKASIKAN MENJADI 2 JENIS : FLUIDA PEMOTONGAN
LARUT DALAM AIR DAN FLUIDA PEMOTONGAN TIDAK LARUT DALAM AIR. ITU SEMUA DIKLASIFIKASIKAN
BERDASARKAN KEGUNAAN FLUIDA PEMOTONGAN DAN FLUIDA PENGGERINDAAN. SECARA UMUM,
FLUIDA PEMOTONGAN YANG LARUT AIR DIGUNAKAN UNTUK OPERASI PEMOTONGAN. INI BIASANYA
EFEKTIF UNTUK PEMILIHAN FLUIDA PEMOTONGAN YANG COCOK BERDASARKAN PROSES PEMESINAN,
BAHAN BENDA KERJA DAN AKURASI YANG DIBUTUHKAN
2 PERMBIRAN FLUIDA PEMOTONGAN

FLUIDA PEMOTONGAN DIGUNAKAN UNTUK MENGURANGI GESEKAN ANTARA ALAT DAN SERPIHA/BENDA
KERJA, MENCEGAH KOROSI, MENGENDALIKAN TIMBULNYA PANAS DAN MENURUNKAN TIMBULNYA
PANAS, YANG MANA AKIBAT JANGKA PANJANGNYA TERHADAP UMUR ALAT, PERBAIKAN PENYELESAIAN
PERMUKAAN DAN MEMPERTAHANKAN AKURASI DIMENSI BENDA KERJA
3 PEMBERIAN PELUMAS (GESEKAN YANG DIBOLEHKAN DAN TERBENTUKNYA TEPI)
FLUIDA
PEMOTONGAN
CEKUNGAN
CHIP
SUDUT
PEMOTONGAN ALAT PEMBENTUKAN TEPI
SERPIHAN
TOOL
BENDA KERJA
BAHAN
PERMUKAAN MESIN
ALAT YANG DIPERBOLEHKAN DAN PENYELESAIAN PERMUKAAN

SEPERTI YANG DITUNJUKKAN DIGAMBAR, INI PENTING DALAM PELUMASAN MENGGANGU ANTARA
SUDUT ALAT MAKAN DAN SERPIHAN TEPI BELAKANG (O.A) DAN MENGGANGGU ANTARA GIGI ALAT DAN
PERMUKAAN BENDA KERJA (O.B) TERUTAMA GESEKAN YANG MENGGANGGU (O.A) TEKANAN DAPAT
MENCAPAI 100 KG/MM2 ATAU DIATAS DAN TEMPERATUR DAPAT MENCAPAI KURANG LEBIH 100 DERAJAT
TERGANTUNG PADA KONDISI PEMESINAN. AKIBATNYA, PARTIKEL LEMBUT BENDA KERJA TERBENTUK DI
DAERAH DEPOSIT DIATAS ALAT PEMOTONGAN SUDUT DAN TERBENTUKNYA TEPI. PEMBENTUKAN TEPI
SANGATLAH KERAS (BHN 500 ATAU LEBIH). JIKA INI MERUPAKAN UKURAN SEDANG, AKAN MELINDUNGI
TEPI PEMOTONGAN DAN JANGKA PANJANG UMUR SERVIS ALAT. BAGAIMANAPUN JUGA, JIKA INI
MELEBIHI UKURAN STANDAR, SUDUT MAKAN YANG EFEKTIF MENJADI CUKUP BESAR, YANG MANA AKAN
MENGAKIBATKAN KEDALAMAN POTONG MENJADI LEBIH BESAR DAN KETAHANAN PEMOTONG.
HASILNYA, KONTROL DIMENSI DILUPAKAN DAN PENYELESAIAN PERMUKAAN MENJADI BURUK.
SEBAGIAN BESAR FLUIDA PEMOTONGAN UNTUK MENGENDALIKAN TERBENTUKNYA SUSUNAN TEPI
DENGAN DIBERIKAN PELUMAS, CEKUNGAN DAN GIGI YANG ADA MENENTUKAN UMUR SERVIS ALAT
4 MEKANISME PELUMASAN
ADA 3 TINGKAT PEMBERIAN MEKANISME PELUMASAN.
4-1 FLUIDA PELUMAS
KONDISI PELUMAS UNTUK STRUKTUR MEKANIK BIASA DIMANA TIDAK ADA KONTAK ANTAR LOGAM DAN
LAPISAN OLI YANG MENDUKUNG PENGISIAN.
- 170 -
4-2 BATAS PELUMASAN
PADA TINGKAT DIMANA KEKENTASA OLI SENDIRI TIDAK AKAN CUKUP UNTUK MENCEGAH KONTAK ANTAR
LOGAM, PELUMAS INI EFEKTIF. BATAS LAPISAN DISERAP OLEH PERMUKAAN LOGAM, PEMBENTUKAN BATAS
LAPISAN ANTARA LOGAM OLEH TEKANAN GAYA GESEK.
4-3 PELUMASAN TEKANAN EKSTREM

PEKERJA INI DIDALAM KONDISI BERAT, DIMANA PELUMAS MEMBUAT LOGAM MENGHASILKAN LAPISAN PELUMAS
PADAT YANG MEMILIKI KEKUATAN PERGESERAN RENDAH PADA PERMUKAAN LOGAM, DAN LAPISAN INI
MENCEGAH KONTAK ANTAR LOGAM.
PADA UMUMNYA, KOMPOSISINYA FOSFOR, BELERANG, DAN KLORIN.
5 FLUIDA PEMOTONGAN
5-1 FLUIDA PEMOTONGAN YANG TIDAK LARUT AIR
(1) OLI MINERAL
JENIS INI CENDERUNG MENIMBULKAN BEBERAPA EFEK PELUMASAN TETAPI INI KURANG BAIK UNTUK
EFEK PENDINGINAN. INI JUGA TIDAK BERGUNA SEBAGAI FLUIDA PEMOTONGAN, DAN INI DICAMPUR
DENGAN OLI LAIN UNTUK OPERASI PEMOTONGAN
(2) OLI CAMPURAN

OLI CAMPURAN DAICAMPUR DENGAN MINERAL DAN OLI HEWANI, OLI SAYUR ATAU OLI ESTER, YANG
MANA DIGUNAKAN UNTUK OPERASAI PEMOTOGAN
(3) OLI TEKANAN EKSTREM
INI MERUPAKAN CAMPURAN OLI ATAU CAMPURAN OLI DENGAN PARTIKEL TEKANAN EKSTREM. BARU
BARU INI FLUIDA PEMOTONGAN YANG TIDAK LARUT DALAM AIR TIDAK DIGUNAKAN. ITU DIGUNAKAN
UNTUK KEGUNAAN LAIN, TERGANTUNG KANDUNGAN OLU, RASIO CAMPURAN PARTIKEL TEKANAN
EKSTREM DAN SUDUT AKTIVASI.
5-2 FLUIDA PEMOTONGAN DENGAN AIR

(1) EMULSI
OLI DIBAGI DALAM AIR DENGAN TAMBAHAN ZAT KIMIA PERMUKAANN AKTIF. INI MELEMAHKAN DENGAN
AIR 10-30 KALI. DIBANDINGKAN DENGAN FLUIDA BERBAHAN AIR, INI LEBIH BAIK EFEK PELUMASAN.
(2) LARUTAN
KOMPONEN UTAMANYA DALAH PARTIKEL PERMUKAAN AKTIF DAN KANDUNGAN OLI YANG KECIL. INI
MELEMAHKAN AIR 10-50 KALI UNTUK PEMOTONGAN DAN 50-100 KALI UNTUK PENGGERINDAAN. FLUIDA
MENJADI TEMBUH PANDAN ATAU TRANSPARAN.
DIBANDINGKAN DENGAN EMULSI, KEPADATAN INI LEBIH BALIK DAN EFEK PELUMASANNYA.
(3) SOLUSI
KOMPONEN UTAMANYA GARAM BUATANA. PERTIKEL PERMUKAAN AKTIF YANG MANA MEMBUAT FLUIDA
TRANSPARAN YANG DITAMBAHKAN 50-100 KALI MELEMAHKAN AIR UNTUK MEMPERBAIKI EFEK PELUMAS.
6 PARTIKEL TEKANAN EKSTREM

CAMPURAN ZAT KIMIA DITAMBAHKANDENGAN BELERANG, FOSFOR DAN KLORIN ATAU KOMPOSISI DARI ZAT
KIMIA ITU CIRI OLI DIBAWAH TEMPERATUR TINGGI DAN KONDISI TEKANAN TINGGI.
- 171 -
7 PARTIKEL PERMUKAAN AKTIF
ZAT AKTIF YANG MELEKAT DENGAN PERMUKAAN BERUPA CAIRAN ATAU PADAT DAN MENGURASI
TEGANGAN PERMUKAAN YANG MANA TIDAK BISA DISELESAIKAN.
7-1 KELEMBAMAN
OLI DENGAN BELERANG DAN LEMAK DENGAN EFEK KONDISI PANAS TINGGI DENGAN KECEPATAN
PEMOTONGAN SEDANG ATAU TINGGI.
7-2 AKTIF
OLI MINERAL BELERANG, YANG MANA LEBIH BAIK EFEK YANG LEBIH BAIK UNTUK PROSES PEMOTONGAN KECEPATAN REND
8 JARAK KONSENTRASI
JARAK MINIMAL KONSENSTRASI YANG BERBEDA TERGANTUNG JENIS FLUIDA.
% SOLUSI PEMOTONGAN (EMULSI) PENGGERINDAAN (LARUTAN)
1 100 FLUIDA YANG TERKONTAMINASI FLUIDA YANG TERKONTAMINASI
2 50 KARENA BAKTERI KARENA BAKTERI
3 33 KONSENTRASI YANG MEMADAI KONSENTRASI YANG MEMADAI
4 25 (REKOMENDASI PEMBUAT) (REKOMENDASI PEMBUAT)
5 20
6 17 PH TINGGI DAPAT MENYEBABKAN PH TINGGI YANG MENYEBABKAN KULIT
7 13 KULIT TERBAKAR DAN TERPOTONG TERBAKAR DAN TERPOTONG
8-1 METODE PENGUKURAN SIMPEL

UKURAN DENSITAS
9 PENGENDALIAN PH
FLUIDA PEMOTONGAN SPESIFIK JARAK PH DAPAT MENYEBABKAN POTONGAN DAN MEMBURUK.
9-1 JARAK PH YANG TEPAT (BATAS KONTROL PH BERBEDA TERGANTUNG PADA JENIS FLUIDA
pH PEMOTONGAN (EMULSI) PENGGERINDAAN (TIDAK LARUT AIR)
10
9 BATAS KONTROL PH
8
7
6 (1) POTONGAN (1) POTONGAN
5 (2) PROSES KONTAMINASI DENGAN (2) PROSES KONTAMINASI DENGAN
4 CEPAT CEPAT
9-2 METODE PENGUKURAN

UKURAN PH
9-3 METODE PENGUKURAN SIMPEL
KERTAS TES PH
- 172 -
10 PENAMBAHAN FLUIDA PEMOTONGAN
SOLUSI PELEMAHAN MENJADI TERKONSENTRASI KETIKA DIGUNAKAN MENGHASILKAN PENGUAPAN AIR.
PENGECEKAN PEMBUATAN KONSENTRASI PELEMAHAN SOLUSI SETELAH PENAMBAHAN AIR DAN
PENAMBAHAN FLUIDA PEMOTONGAN DALAM HAL INI.
10-1 PROSEDUR PENAMBAHAN

(1) SUMBER AIR
(2) SENAR KETIKA DIBERIKAN SOLUSI PELEMAHAN, PENAMBAHAN FLUIDA PEMOTONGAN
(3) JIKA SOLUSI PELEMAHAN INI DITABURKAN KE FLUIDA PEMOTONGAN, PENGEMULSIAN KEMUNGKINAN GAGAL
11 PERUBAHAN FLUIDA PEMOTONGAN

KETIKA DILAKUKAN PERUBAHAN FLUIDA PEMOTONGAN DAPAT MENJADI MEMBURUK, PENGHILANGAN
SERPIHAN DAN PENAMPUNGAN LUMPUR DI TEMBOK TANGKI DAN PIPA. KEMUDIAN, DESINFEKTAN DAN
STERILISASI DENGAN SISTEM SEBELM PENAMBAHAN FLUIDA PEMOTONGAN BARU.
11-1 PROSEDUR PERUBAHAN

(1) FLUIDA PEMOTONGAN MENJADI BURUK
(2) PENGHILANGAN SERPIHAN DAN LUMPUR TERBENTUK DI TEMBOK TANGKI DAN PIPA
(3) PENGISIAN TANGKI DENGAN AIR DARI TINGKAT MINIMAL DIBUTUHKAN UNTUK MEMBERSIHKAN DAN
PENAMBAHAN DESINFEKTAN. DI KOCOK SELAMA 20 SAMPAI 30 MENIT DAN PENURUNAN INI.
(4) PENGISIAN TANGKI DENGAN AIR. KETIKA MENYALA, PENAMBAHAN DITENTUKAN JUMLAH FLUIDA
PEMOTONGAN.
- 173 -
[18] INTERPRETASI GAMBAR (SEMUAN (1), (2))
= DAFTAR ISI =
1. METODE PROYEKSI
2. SATUAN DIMENSI
3. INDIKASI KEKASARAN PERMUKAAN
4. TOLERANSI DIMENSI
5. SUAIAN
6. SISTEM PENANDAAN GAMBAR HES
- 175 -
MUAN (1), (2))
HALAMAN
176
177
177
178
179
180
- 175 -
[18] INTERPRETASI GAMBAR ･･･ (SEMUA (1), (2))
KEBANYAKAN GAMBAR DATANG DALAM PENGGANDAAN DIAZO ATAU FOTOKOPI. KEMUDIAN MEMPRODUKSI PRODUK
MENURUT GAMBAR, OPERATOR TIDAK BOLEH MELEBIHI INTERPRETASI GAMBAR. MAKSUDNYA OPERATOR
MENGHARUSKAN UNTUK MEMPRODUKSI TUNTAS DENGAN PENDESAI. OLEH KARENA ITU, PENAMBAHAN PENJELASAN
LISAN PADA GRAFIK DAN SIMBOL GAMBAR TIDAK BOLEH DIBUAT.
GAMBAR MERUPAKAN ALAT UNTUK MENYAMPAIKAN MAKSUD PENDESAIN PADA PENENTUAN METODE PROYEKSI DAN
PENENTUAN RESEP, PERATURAN DAN GAYA, MAKSUD TITIK TITIK, GARIS GARIS DAN SIMBOL GAMBAR DALAM SATU
BIDANG DENGAN MUDAH DAN BERSIH DENGAN PRESISI, EKSPEDISI, DAN DAPAT DIUJI.
UNTUK MENAMPILKAN GEOMETRI DALAM KERTAS, PENTING SEPERTI METODE PRESENTASI DENGAN SIMPEL DAN
MUDAH UNTUK DIMENGERTI SEMUA ORANG. KEBANYAKAN ITU DIDASARKAN PERATURAN YANG ADA.
OLEH KARENA ITU, INI DAPAT DIKATAKAN BAHWA "GAMBAR MEMILIKI ATURAN DAN PENJELASAN YNAG DIGUNAKAN
DALAM LINGKARAN INDUSTRI YANG MENJELASKAN MAKSUD PENDESAI SECARA EKSTENSIF DAN DAPAT DIPERCAYA.
1 METODE PROYEKSI
METODE PROYEKSI MERUPAKAN LANGKAH MENJELASKAN SECARA KEBETULAN DALAM SATU BIDANG
GEOMETRI, UKURAN DAN LOKASI TEMPAT OBJEK DALAM JARAK TERTENTU. ADA BEBERAPA METODE PROYEKSI
TERGANTUNG DENGAN SUDUT PROYEKSI DAN ORIENTASI BENDA.
1-1 PROYEKSI ORTOGONAL ("PEMBUATAN GAMBAR OLEH METODE INI DISEBUT PROYEKSI GAMBAR ORTOGONAL")
1) PROYEKSI SUDUT PERTAMA

2) PROYEKSI SUDUT KEDUA
3) PROYEKSI SUDUT KETIGA
PADA PROYEKSI SUDUT KETIGA
DITUNJUKKAN DALAM GAMBAR 1 (a),
OBJEK DITEMPATAKAN PADA SUDUT
KETIGA. BIDANG A, DILIHAT DARI DEPAN,
DIPROYEKSIKAN KE BIDANG VERTIKAL
TERUS MENERUS. PROYEKSI BIDANG
MEREFERENSIKAN SUDUT PANDANG A'
BIDANG B, DILIHAT DARI ATAS,

DIPROYEKSIKAN KE BIDANG HORISONTAL
BIDANG SAMPING
DIATASNYA, YANG MANA ADA SUDUT

PANDANG ATAS B'. BIDANG C, DILIHAT
DARI BAGIAN TANGAN KIRI,
DIPROYEKSIKAN KE BIDANG VERTIKAL,
YANG MANA ADA BAGIAN SAMPING C'.
AKIBAT PROYEKSI OLEH METODE PROYEKSI KETIGA, SEPERTI YANG DITUNJUKKAN GAMBAR 1 (a), IDENTIK DENGAN BAGIAN
DIMANA OBJEK TERLETAK DI TENGAH KACA KOTAK DAN SETIAP SISI DIPROYEKSIKAN MENJADI OBJEK YANG BERHUBUNGAN
DENGAN BIDANG SECARA TURUT MENURUT, DAN KEMUDIAN KOTAK KACA YANG DIBENTANGKAN.
PRINSIP INI MERUPAKAN METODE PROYEKSI SUDUT KETIGA
- 176 -
[18] INTERPRETASI GAMBAR ･･･ (SEMUA (1), (2))
ANG DALAM PENGGANDAAN DIAZO ATAU FOTOKOPI. KEMUDIAN MEMPRODUKSI PRODUK
TOR TIDAK BOLEH MELEBIHI INTERPRETASI GAMBAR. MAKSUDNYA OPERATOR
EMPRODUKSI TUNTAS DENGAN PENDESAI. OLEH KARENA ITU, PENAMBAHAN PENJELASAN
MBOL GAMBAR TIDAK BOLEH DIBUAT.
UNTUK MENYAMPAIKAN MAKSUD PENDESAIN PADA PENENTUAN METODE PROYEKSI DAN

URAN DAN GAYA, MAKSUD TITIK TITIK, GARIS GARIS DAN SIMBOL GAMBAR DALAM SATU
AN BERSIH DENGAN PRESISI, EKSPEDISI, DAN DAPAT DIUJI.
METRI DALAM KERTAS, PENTING SEPERTI METODE PRESENTASI DENGAN SIMPEL DAN
I SEMUA ORANG. KEBANYAKAN ITU DIDASARKAN PERATURAN YANG ADA.
AT DIKATAKAN BAHWA "GAMBAR MEMILIKI ATURAN DAN PENJELASAN YNAG DIGUNAKAN

RI YANG MENJELASKAN MAKSUD PENDESAI SECARA EKSTENSIF DAN DAPAT DIPERCAYA.
MERUPAKAN LANGKAH MENJELASKAN SECARA KEBETULAN DALAM SATU BIDANG

DAN LOKASI TEMPAT OBJEK DALAM JARAK TERTENTU. ADA BEBERAPA METODE PROYEKSI
AN SUDUT PROYEKSI DAN ORIENTASI BENDA.
NAL ("PEMBUATAN GAMBAR OLEH METODE INI DISEBUT PROYEKSI GAMBAR ORTOGONAL")
BIDANG HORISONTAL
BIDANG VERTIKAL
TAMPAK ATAS
BIDANG SAMPING
TAMPAK DEPAN
TAMPAK SAMPING
H METODE PROYEKSI KETIGA, SEPERTI YANG DITUNJUKKAN GAMBAR 1 (a), IDENTIK DENGAN BAGIAN
AK DI TENGAH KACA KOTAK DAN SETIAP SISI DIPROYEKSIKAN MENJADI OBJEK YANG BERHUBUNGAN
RA TURUT MENURUT, DAN KEMUDIAN KOTAK KACA YANG DIBENTANGKAN.
N METODE PROYEKSI SUDUT KETIGA
- 176 -
1-2 PROYEKSI ISOMETRIS (PEMBUATAN GAMBAR DIBUAT DENGAN METODE INI DISEBUT "GAMBAR ISOMETRIK")
1-3 PROYEKSI TRIMETRIK (PEMBUATAN GAMBAR DIBUAT DENGAN METODE YANG DISEBUT "GAMBAR AXOMETRIK")
1-4 PROYEKSI MIRING (PEMBUATAN GAMBAR DIBUAT DENGAN METODE YANG DISEBUT "PROYEKSI MIRING")
1-5 PROYEKSI PERSPEKTIF (PEMBUATAN GAMBAR DIBUAT DENGAN METODE YANG DISEBUT "GAMBAR
PRESPEKTIF")
2 SATUAN DIMENSI
2-1 PANJANG
DIMENSI LINEAR MENGGUNAKAN MILIMETER. DISINGKAT MENJADI MM, MENGHILANGKAN. GAMBAR YANG
TERINDIKASI ANGKA ABSTRAK; SEPERTI 50 MM DIJELASKAN 50. JIKA SATUAN LAIN SEPERTI METER,M, ATAU
CENTIMETER,CM,DIGUNAKAN, INI TERINDIKASI. TITIK DESIMAL TERINDIKASI DENGAN TITIK. TIDAK
MENGGUNAKAN KOMA UNTUK MEMISAHKAN RATUSAN JIKA DIMENSI TERLALU BESAR ANGKA GIGIT
CONTOH: 125.35, 12.00, 12120

2-2 SUDUT
SUDUT DIJELASKAN DALAM DEARAJAT. INI PENTING, DIPERBOLEHKAN MEMAKAI MENIT DAN DETIK. UNTUK
MENJELASKAN DERAJAT, MENIT, DETIK, ENTER ','," PADA KANAN GAMBAR.
CONTOH: 90°, 22.5°, 3' 21", 0° 5', 6° 20' 5", 8° 0' 52"
3 INDIKASI KEKASARAN PERMUKAAN

KEKASARAN PERMUKAAN DIJELASKAN SECARA MAKSIMAL
KEKASARAN KETINGGIAN PERMUKAAN. SEPERTI YANG
DITUNJUKKAN DALAM GAMBAR, TITIK REFERENSI
DIPEROLEH DENGAN DPANJANG REFERENSI BIDANG
(PANJANG SAMPING DALAM MM). JARAK ANTARA PUNCAK
MAKSIMUM DAN YANG PALING DALAM DIJELASKAN
KETINGGIAN KEKASARAN MAKSIMAL.
AS JIS B 0601 DITETAPKAN, KEKASARAN PERMUKAAN

SECARA SPESIFIK DIKOMBINASIKAN DENGAN GAMBAR
1/1000 mm (SATUAN:μ) DAN SIMBOL, S (SINGKATAN
KEKSARAN PERMUKAAN) DENGAN SIMBOL PENYELESAIAN
SEDERHANA ∇.
- 177 -
BAR DIBUAT DENGAN METODE INI DISEBUT "GAMBAR ISOMETRIK")
AR DIBUAT DENGAN METODE YANG DISEBUT "GAMBAR AXOMETRIK")
DIBUAT DENGAN METODE YANG DISEBUT "PROYEKSI MIRING")
MBAR DIBUAT DENGAN METODE YANG DISEBUT "GAMBAR
ER. DISINGKAT MENJADI MM, MENGHILANGKAN. GAMBAR YANG

0 MM DIJELASKAN 50. JIKA SATUAN LAIN SEPERTI METER,M, ATAU
KASI. TITIK DESIMAL TERINDIKASI DENGAN TITIK. TIDAK
AN RATUSAN JIKA DIMENSI TERLALU BESAR ANGKA GIGIT
PENTING, DIPERBOLEHKAN MEMAKAI MENIT DAN DETIK. UNTUK

NTER ','," PADA KANAN GAMBAR.
PUNCAK MAKSIMAL (ARAH

PERBESARAN SEJAJAR)
ARAH
PERBESARAN
PANJANG
SPESIMEN
- 177 -
SIMBOL KEKASARAN TINGGI MAKSIMAL PANJANG
KATEGORI SIMBOL
PERMUKAAN μ SPESIMEN mm
KATA KATA : DILARANG MENGGUNAKAN SIMBOL KEKSARAN PERMUKAAN DENGAN ( ) SEBANYAK MUNGKIN.
CATATAN : DILARANG MENGHUBUNGKAN GAMBAR DAN S DALAM SIMBOL KEKASARAN PERMUKAAN
4 TOLERANSI DIMENSI
DALAM PRODUKSI KOMPONEN MESIN, PERMUKAAN, HARUS DISELESAIKAN DENGAN TEPAT PADA MESIN
DENGAN TOLERANSI DIMENSI, VARIASI YANG DIIJINKAN DALAM DIMENSI. TIDAK MUNGKIN DIMENSI AKTUAL
BENDA DARI PEMESINAN SAMA PERSIS DENGAN UKURAN DASAR (BATAS UKURAN REFERENSI) SPESIFIK
DALAM GAMBAR TIDAK PEDULI MESIN APA YANG DIGUNAKAN. KARENA, RENTANG VARIASI DIMESIN
PASTINYA DIBERIKAN SPESIFIKASINYA DARI AWAL. MAKSIMAL DAN MINIMAL BATAS YANG DIPERBOLEHKAN
SPESIFIK DAN BENDA BISA DISELELSAIKAN DALAM BATASAN ITU. SEPERTI BATASAN REFERENSI YANG
DIPERBOLEHAKN PADA UKURAN. BATAS ATAS MERUPAKAN MAKSIMAL YANG DIPERBOLEHKAN DAN BATAS
PALING BAWAH MERUPAKAN BATAS MINIMAL YANG DIOERBOLEHKAN. PERBEDAAN ANTARA BATAS
TERSEBUT ADALAH TOLERANSI DIMENSI.
- 178 -
CONTOH : BATAS MAKSIMAL DAN MINIMAL YANG DIPERBOLEHKAN
LUBANG φ50 + 0.025 POROS φ50 - 0.025

0 - 0.050
BATAS MAKSIMAL A = 50.025 mm a = 49.975 mm

BATAS MINIMAL B = 50.000 mm b = 49.950 mm
CONTOH : DIMENSI TOLERANSI

TOLERANSI DIMENSI LUBANG T = A - B = 50.025 - 50.000 = 0.025 mm
TOLERANSI DIMENSI POROS t = a - b = 49.975 - 49.950 = 0.025 mm
T (TOLERANSI DIMENSI) a (BATAS MAKSIMAL)
t (TOLERANSI
DIMENSI)
A (BATAS MAKSIMAL)
b (BATAS MINIMAL)
B (BATAS MINIMAL)
HUBUNGAN ANTARA BATAS MAKSIMAL DAN MINIMAL YANG DIPERBOLEHKAN

5 SUAIAN
MESIN MENGANDUNG BANYAK KOMPONEN YANG MEMILIKI SUAIAN POROS PADA LUBANG LINGKARAN
BEBERAPA POROS DIDESAIN UNTUK BERPUTAR. BEBERAPA TIDAK BERPUTAS TETAPI BERGESER.
BEBRAPA SUAIAN PAKSA DAN MEMBUAT TIDAK BISA BERGERAK. SEPERTI KONDISI POROS YANG
DIPASANG PADA LUBANG LINGKARAN JARAK AMAN CUKUP ATAU INTERFERENSI YANG
MEREFERENSIKAN "SUAIAN".
SEPERTI YANG DITUNJUKKAN PADA GAMBAR (a), JIKA DIAMETER POROS LEBIH KECIL DARIPADA
LUBANG LINGKARAN, PERBEDAAN DIAMETER DIREFERENSIKAN MENJADI JARAK AMAN SEPERTI PADA
GAMBAR (b), JIKA DIAMETER POROTS LEBIH BESAR DARI LUBANG LINGKARAN, INI MEREFERENSIKAN
INTERFERENSI.
DIAPLIKASIKAN PADA MESIN UNTUK MEMBUAT BAGIAN POROS-LUBANG PASANG.
JARAK AMAN
INTERFERENSI
JARAK AMAN INTERFERENSI
(a) JARAK AMAN (b) ITERFERENSI

KONTAK LUBANG DAN POROS
- 179 -
6 SISTEM PENANDAAN GAMBAR HES
6-1 KOMPOSISI GAMBAR : GAMBAR DIBUAT DENGAN 6 GAMBAR DAN SIMBOL, MENJELASKAN DESKRIPSI
YANG ADA.
NOMOR SERI
SIMBOL KLASIFIKASI MINOR
SIMBOL KLASIFIKASI MENENGAH
SIMBOL KLASIFIKASI MAYOR

(DALAM PENOMORAN ARAB 5 - 9)
(1) SIMBOL KLASIFIKASI MAYOR PADA SISTEM PENOMORAN TEKONTROL KOMPUTER,

MEREPRESENTASIKAN KEBUTUHAN ALAT DALAM
PENOMORAN ARAB 5 SAMPAI 9. KEMUDIAN NOMOR SERI
MENCAPAI 999, GAMBAR LANJUTAN DARI 5 KE 9 DALAM
URUTAN
(2) SIMBOL KLASIFIKASI MENENGAH MEREPRESENTAIKAN JENIS ALAT UNTUK MELIHAT TABEL
YANG ADA.
A J PENAHAN MATA BOR S PENCUKUR
B MESIN BUBUT K METERAN T TAP

C L ROLL PEMBENTUK U GERINDA BESAR
D DRILL M MILLING V PENITI
E ALAT INTAN N MATA BOR W
F ALAT LAIN O X
G GERINDA P ALAT PNEUMATIK Y ALAT DIGITAL
H GIR PEMOTONG Q Z MATA BOR PEMBALIK
I R MATA BOR
(3) SIMBOL KLASIFIKASI MINOR MEREPRESENTASIKAN GEOMETRI JENIS ALAT DALAM

SURAT NEGARA, MENJELASKAN PISAHAN LEMBARAN
UNTUK TABEL KLASIFIKASI
(4) NOMOR SERI MEREPRESENTASIKAN DALAM 3 DIGIT NOMOR ARAB, 001 -

999
- 180 -

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6 OIL HOLE REAMERS ･･･ (3), (4)

6-1 REAMER GEOMETRY AND APPLICATION

6-3 CUTTING CONDITIONS

CUTTING SPEED MACHINING

Al 40 0.2 WATER SOLUBLE 1 mm

6-4 CUTTING EDGE ANGLES

WORKPIECE RAKE ANGLE RELIEF ANGLE HELIX ANGLE CHAMFER ANGLE

LEFT HAND HELIX,

7 MACHINE REAMER ･･･ (1), (2)

7-1 REAMER GEOMETRY AND APPLICATION

5-4 CUTTING EDGE ANGLES

Al 0° 5° -10° STRAIGHT 45°

FC 0° 5° -10° ONE TYPE OF HELIX 45°

STEEL 0° 5° -10° REF. TO JIS 45°

8 HAND REAMERS ･･･ (1), (2)

8-1 REAMER GEOMETRY AND APPLICATION

9 ADJUSTABLE REAMERS ･･･ (3), (4)

11 REGRINDING AND HANDLING PRECAUTIONS ･･･ (1), (2)

12 TROUBLES AND CHECK POINTS ･･･ (3), (4)

NEARLY 100% OF REAMERS USED BY HONDA ARE MADE

CARE SHOULD BE TAKEN TO AVOID THUMPS AND

1. TYPES AND APPLICATION OF FACE MILLING CUTTERS (1), (2)

2. PART NAMES (1), (2)

3. TERMINOLOGY FOR CUTTER ANGLES AND FUNCTIONS (3), (4)

4. TIPS ON THROWAWAY CUTTER ADJUSTMENT AND RUN-OUT

5. CUTTER AND TOOL MATERIAL SELECTION BY WORKPIECE

6. CUTTING CONDITIONS (3), (4)

7. CUTTER ACCURACY AND WORKPIECE PRECISION (3), (4)

8. SURFACE FINISH ACCURACY (3), (4)

9. BUTTON CUTTERS (3), (4)

10. DEBURRING (3), (4)

11. TROUBLESHOOTING (3), (4)

1 TYPES AND APPLICATION OF FACE MILLING CUTTERS ･･･ (1), (2)

TYPE SHAPE APPLICATION MACHINE

EXTRA HARD WORKPIECE MATERIAL SUCH AS CAST

NEGATIVE- FOR AN OPERATION WITH GENERAL STEEL AND STEEL

ROUGH CUTTING OF DIE STEEL AND STAINLESS STEEL

FOR A PROCESS WHERE CHATTER MARKS TEND TO

FOR A PROCESS WHERE POOR CHIP DISPOSAL IS

BUTTON SUPER FINISHING OF CAST IRON, LIGHT ALLOY

BOSS OUTSIDE DIA.

KEY WAY WIDTH

AXIAL RAKE ANGLE

FACE CUTTING EDGE ANGLE

RADIAL RAKE ANGLE

FACE CUTTING EDGE

NEGATIVE-POSITIVE CUTTER DOUBLE POSITIVE CUTTER DOUBLE NEGATIVE CUTTER

3 TERMINOLOGY FOR CUTTER ANGLES AND FUNCTIONS ･･･ (3), (4)

(2) RADIAL RAKE ANGLE R.R

(3) PERIPHERAL CUTTING A.A HAS INFLUENCE ON CHIP THICKNESS AND

(4) TRUE RAKE ANGLE T.A ACTUAL RAKE ANGLE

(5) INCLINATION ANGLE I.A HAS INFLUENCE ON CHIP FLOW DIRECTION

PERIPHERAL CUTTING EDGE ANGLE

DOUBLE NEGATIVE CUTTER

WHEN LARGE ･･･ REDUCES CHIP THICKNESS AND

WHEN POSITIVE (LARGE) ･･･ IMPROVES CUTTING

WHEN NEGATIVE (SMALL) ･･･ ENHANCES CUTTING

WHEN POSITIVE (LARGE) ･･･ IMPROVES CHIP

Al 10°　-　15° 6° a) SMALL CUTTING RESISTANCE