Hardened Steel

Application Material Group

1.7 1.8
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 General Information
Examples of Workpiece Materials - Categorisation into Application Material Groups (AMG)
Application Material Group (AMG) Hardness Tensile Normal Chip EN Werkstoff DIN
HRc Strength Form Number
N/mm2
1.7 Alloy steel, Heat treated 49-55 >1620 middle EN - ISO 4957 1.2510 100MnCrW4
- HS2-9-1-8

1.8 Alloy steel, Hardened and wear resistant steel 55-63 <1960 short EN - ISO 4957 1.3343, 1.2344, S6-5-2,
- X40CrMoV5-1 GX40CrMoV5-1

2
Application Material Group (AMG) BS SS USA UNS JIS

1.7 Alloy steel, Heat treated BO1, BD3, BH13 HARDOX 500

1.8 Alloy steel, Hardened and wear resistant steel BM2, BH13 2242 HARDOX 600
 General Information
Contents

Classification of workpiece materials 2

Application Material Groups 4
Introduction to Hardened Steels 5
AMG 1.7 6
AMG 1.8 7
General Hints on Drilling 8
Drill Feed Chart 9
Drill Selection 10
General Hints on Tapping 12
Drill diameters for cutting taps 13
Tap Selection 14
General Hints on Milling 16
Milling parameters 17
Applications 18
Milling Feed Charts 19
Milling Cutters Selection 22
Table of cutting speeds 24

3
General Information
Application Material Groups

Application Material Groups (“AMGs”) are designed to

assist in the selection of the optimum cutting tool for a
particular application.

Dormer classifies materials into 10 major Application

Material Groups. Each major group is divided into sub-
groups on the basis of material properties, such as
hardness and strength, and chip formation. This booklet
concentrates on sub-groups 1.4 – 1.6 – Hardened
Steels.

Examples of national designations within each sub-group

are shown on page 2.

This booklet contains a selection of tools that are rated

“excellent” for machining Hardened Steels. Please see
the Dormer catalogue or Product Selector for the full
range, or contact your local Dormer representative or
Technical Helpdesk if you need further advice.

4
 General Information
Introduction to Hardened Steels

This group of alloy steels, which come into the

classification of “tool steels”, covers materials which
are almost fully hardened or which have been fully
hardened.

Their properties are:-

• High hardness, suited to the use of the end product.

• Wear resistance, which is dependent on the
hardness.
• Good tempering properties – no change to the
shape of the end product with use.
• Toughness in most cases.
• Good workability.

Chemical composition:-

• Predominantly alloy steels with a high Carbon

content of 0.4 – 2.3%.
• Typical alloying elements are Chromium (Cr),
Tungsten (W), Molybdenum (Mo), Vanadium (V).

5
General Information
1.7
Alloy Steel, Hardened
Hardness 49-55 HRc
Tensile strength <1620 N/mm2

Typical Composition

This group of alloy steels covers materials which are

almost fully hardened.

The tempering temperature at heat treatment is selected

to retain some ductility, but the overall objective is to
obtain wear resistance by increased hardness. These
tool steels have good dimensional stability combined
with high resistance to tempering.

Machining of these materials will be difficult, so care

must be taken to select the correct conditions. Please
see the tool selections in this book, or refer to the Dormer
catalogue or Product Selector.

Examples of uses
Typical end uses of AMG 1.7 are sprockets, wear
resistant plate, gears, cams and machine tool parts.

6
 General Information
1.8
Alloy steel, Hardened and wear resistant
Hardness 55-63 HRc
Tensile strength <1960 N/mm2

Typical Composition

The materials within this group have been fully hardened.

Heat treatment has taken place and the tempering
temperature has been selected to give maximum
hardness. Ductility is generally very low and wear
resistance properties are good.

Normally materials with these hardness values are

ground or hard turned to size. As with AMG 1.7,
machining of these materials will be difficult, so care
must be taken to select the correct conditions. Please
see the tool selections in this book, or refer to the Dormer
catalogue or Product Selector.

Examples of uses
Typical end uses of AMG 1.8 are cutting tools, circular
saws, knives, high wear resistant plate, dies and mining
tools.

7
General Hints on Drilling

1. Select the most appropriate drill for the application,

bearing in mind the material to be machined, the
capability of the machine tool and the coolant to be
used.

2. Flexibility within the component and machine tool

spindle can cause damage to the drill as well as the
component and machine - ensure maximum stability
at all times. This can be improved by selecting the
shortest possible drill for the application.

3. Tool holding is an important aspect of the drilling

operation and the drill cannot be allowed to slip or
move in the tool holder.

4. The use of suitable coolants and lubricants are

recommended as required by the particular drilling
operation. When using coolants and lubricants,
ensure a copious supply, especially at the drill point.

5. Swarf evacuation whilst drilling is essential in

ensuring the correct drilling procedure. Never allow
the swarf to become stationary in the flute.

6. When regrinding a drill, always makes sure that the

correct point geometry is produced and that any
wear has been removed.

8
 Ø [mm]

1 2 3 4 5 6 8 10 12 15 16 20
S 0.008 0.014 0.020 0.025 0.030 0.037 0.050 0.080 0.100 0.123 0.130 0.150
T 0.015 0.028 0,040 0.050 0.060 0.070 0.090 0.110 0.130 0.160 0.170 0.190
U 0.026 0.048 0.070 0.080 0.090 0.107 0.140 0.170 0.200 0.223 0.230 0.240
V 0.038 0.069 0.100 0.115 0.130 0.153 0.200 0.250 0.280 0.310 0.320 0.340
mm/rev ± 25%

9
 R022 R520 R558 R590

3.0 - 17/32 3.0 - 16.5 3.0 - 20.0 8.0 - 16.0

1.7 ■30U ●35U ■40V ■30U

1.8 ■30U ●30T ■30V ■25U

■ Excellent
● Good 10
 R002 R510 R554

3.0 - 14.0 3.0 - 14.25 3.0 - 20.0

■30T ●35T ■30U 1.7

■30T ●30S ■25U 1.8

11
General Hints on Tapping

1. Select the correct design of tap for the component

material and type of hole, i.e. through or blind, from
the Application Material Groups chart.

2. Ensure the component is securely clamped - lateral

movement may cause tap breakage or poor quality
threads.

3. Select the correct size of drill (see opposite). Always

ensure that work hardening of the component
material is kept to a minimum.

4. Select the correct cutting speed as shown in the

tap selection pages, the catalogue or the Product
Selector.

5. Use appropriate cutting fluid for correct application.

6. In NC applications ensure that the feed value

chosen for the program is correct. When using a
tapping attachment, 95% to 97% of the pitch is
recommended to allow the tap to generate its own
pitch.

7. Where possible, hold the tap in a good quality torque

limiting tapping attachment, which ensures free
axial movement of the tap and presents it squarely
to the hole. It also protects the tap from breakage if
accidentally ‘bottomed’ in a blind hole.

8. Ensure smooth entry of the tap into the hole, as an

uneven feed may cause ‘bell mouthing’.

12
Drill Diameters for Cutting Taps -
Recommendation tables
METRIC COARSE THREAD Drill diameter can be
calculated from:
TAP Max. DRILL DRILL
Internal
Pitch Diam. Diam. Diam. D = Dnom- P
M mm mm mm inch
1.6 0.35 1.321 1.25 3/64
1.8 0.35 1.521 1.45 54
D = Drill diameter (mm)
2 0.4 1.679 1.6 1/16
2.2 0.45 1.833 1.75 50
2.5 0.45 2.138 2.05 46 Dnom = Tap nominal
3 0.5 2.599 2.5 40 diameter (mm)
3.5 0.6 3.010 2.9 33
4 0.7 3.422 3.3 30
4.5 0.75 3.878 3.8 27 P = Tap pitch (mm)
5 0.8 4.334 4.2 19
6 1 5.153 5 9
7 1 6.153 6 15/64
8 1.25 6.912 6.8 H
9 1.25 7.912 7.8 5/16
10 1.5 8.676 8.5 Q
11 1.5 9.676 9.5 3/8
12 1.75 10.441 10.3 Y
14 2 12.210 12 15/32
16 2 14.210 14 35/64
18 2.5 15.744 15.5 39/64
20 2.5 17.744 17.5 11/16
22 2.5 19.744 19.5 49/64
24 3 21.252 21 53/64
27 3 24.252 24 61/64
30 3.5 26.771 26.5 1.3/64

METRIC COARSE THREAD RECOMMENDED DIAMETERS WHEN

FOR ADX/CDX USING DORMER ADX AND CDX DRILLS
TAP DRILL The above table for drill diameters refer to
Pitch Diameter ordinary standard drills. Modern drills such
M mm mm as Dormer ADX and CDX produce a smaller
4 0.70 3.40 and more accurate hole which makes it
5 0.80 4.30 necessary to increase the diameter of the
6 1.00 5.10 drill in order to avoid breakage of the tap.
8 1.25 6.90 Please see the small table to the left.
10 1.50 8.70
12 1.75 10.40
14 2.00 12.25
16 2.00 14.25

13
 Other thread types available.
Please see Dormer catalogue. DIN
T100 T110

M3 - M12 M3 - M12

1.7 ■6 1.7 ●6
1.8 ●4 1.8 ■4

■ Excellent
● Good 14
 Other thread types available.
Please see Dormer catalogue.
J100 J101 J105

A
ap= ap=
Ø 1 x d1 2 x d1
3,2 0,010 0,005
4,1 0,009 0.007
4,8 0,012 0,009
6,5 0,017 0,014
8,2 0,021 0,018
9,9 0,024 0,020
11,6 0,031 0,025
13,6 0,039 0,032

ap =

M4-M16 M6 - M16 M8 - M16

d1 =
●50A ■50A ●50A 1.7
●30A ■30A ●30A 1.8

15
General Hints on Milling

1. Where possible, use climb milling (down milling)

for longer tool life. Climb milling allows easier chip
disposal, less wear, improved surface finish and
lower power requirements compared to conventional
milling (up milling).

2. Always use a cutter in good condition.

3. Use well-maintained machine tools with sufficient

power.

4. Use correct clamping system according to working

operation and type of tool.

5. Check for damage or wear on the tool shank or in the

holder itself.

6. Use the shortest cutters recommended for your

application and work as close to the machine head
as possible.

7. For optimum productivity, use coated or Solid

Carbide cutters.

16
Milling parameters

1. Identify the type of end milling to be carried out

- type of end mill
- type of centre

2. Consider the condition and the age of the machine

tool.

3. Select the best end mill dimensions in order to

minimize the deflection and bending stress
- the highest rigidity
- the largest mill diameter
- avoid excessive overhand of the tool from the tool
holder.

4. Choose the number of flutes

- more flutes - decreased space for chips - increased
rigidity - allows faster table feed
- less flutes - increased space for chips - decreased
rigidity - easy chip ejection.

5. Determining the correct cutting speed and feed rate

can only be done when the following factors are
known:
- type of material to be machined
- end mill material
- power available at the spindle
- type of finish.

17
 Ø mm
mm/z ± 25%
Z >0,5 0.6 0.8 1 2 3 4 5 6 8 10 12 14 16 18 20
A 0.015 0.020 0.025 0.030 0.035 0.040 0.050 0.060
↕ 1,5 0.045 0.050 0.060 0.075 0.080 0.090 0.100 0.110
>4 B
↔ 0,05
C 0.065 0.075 0.090 0.110 0.120 0.130 0.150 0.170

A 0.010 0.020 0.030 0.040 0.045 0.050 0.060 0.075 0.080 0.090 0.100 0.120
↕ 1,5 0.015 0.030 0.040 0.055 0.065 0.075 0.090 0.110 0.120 0.130 0.150 0.170
3-4 B
↔ 0,1
C 0.015 0.030 0.040 0.055 0.085 0.100 0.120 0.140 0.150 0.170 0.200 0.220

A 0.001 0.003 0.005 0.008 0.010 0.013 0.020 0.027 0.035 0.040 0.050 0.055 0.060
↕1 0.002 0.004 0.008 0.012 0.015 0.020 0.030 0.040 0.050 0.060 0.070 0.080 0.090

18
3-4 B
↔ 0,5
C 0.003 0.005 0.010 0.015 0.020 0.025 0.040 0.050 0.065 0.080 0.090 0.105 0.120

A 0.001 0.001 0.002 0.002 0.005 0.009 0.013 0.017 0.020 0.023 0.035 0.040 0.050 0.055 0.060 0.070
↕ 0,5 0.001 0.002 0.003 0.003 0.007 0.013 0.020 0.025 0.030 0.035 0.050 0.060 0.070 0.080 0.090 0.100
2-3 B
↔1
C 0.002 0.003 0.004 0.004 0.009 0.017 0.025 0.033 0.040 0.045 0.065 0.080 0.090 0.105 0.120 0.130

↕ 0,5
↔1
3-4 B 0.035 0.040 0.055 0.065 0.080 0.090 0.100 0.110
↕1
↔ 0,5
 ↕ A 0.010 0.017 0.023 0.028 0.032 0.040 0.050 0.055 0.070 0.080
0,1 -
2 BC 0.015 0.022 0.030 0.035 0.040 0.050 0.060 0.070 0.085 0.100
0,5mm
&
4 ↔
0,1 -
0,5mm
↕ A 0.040 0.050 0.055 0.065 0.080
0,01
BC 0.050 0.060 0.070 0.080 0.100
4 - 0,1
↔
≤1

Application

19
Slotting Roughing Corner
radius

Ball nose Finishing

 S102 S122 S302 S322 S241 S276 S282 S522

z2 z2 z3 z3 z4 z4 z6-16 z2

2.0 - 20.0 2.0 - 20.0 2.0 - 20.0 2.0 - 20.0 3.5 - 20.0 2.0 - 25.0 6.0 - 16.0 1.0 - 16.0

1.7 ■50A ■45A ■50A ■45A ■61A ■61A ■80A ■140A

1.8 ●40A ●36A ●40A ●36A ■50A ■80A
az 1 1 1 1 1 1 1 1
■ Excellent
● Good 20
 S502 S503 S532 S190 S290 S170 S150 S152

z2 z2 z4 z2 z4 z2-4 z2 z2

1.0 - 16.0 1.0 - 16.0 6.0 - 16.0 3.0 - 16.0 6.0 - 16.0 2.0 - 12.0 0.4 - 1.0 0.5 - 1.0

■127A ■140A ■140A ■140A ■140A ■70A ■70A ■70A 1.7

■72A ■80A ■80A ■80A ■80A ■40A ■40A ■40A 1.8
1 1 1 1 1 1 1 1 az

21
 General Information

Table of Cutting Speeds, <10mm

PERIPHERAL CUTTING SPEED
Metres/Min. 5 8 10 15 20 25 30 40 50 60 70 80 90 100 110 150
Feet/Min.
16 26 32 50 66 82 98 130 165 197 230 262 296 330 362 495
Tool
Diameter REVOLUTIONS PER MINUTE (RPM)
mm inch
1,00 1592 2546 3138 4775 6366 7958 9549 12732 15916 19099 22282 25465 28648 31831 35014 47747
1,50 1061 1698 2122 3183 4244 5305 6366 8488 10610 12732 14854 16977 19099 21221 23343 31831
2,00 796 1273 1592 2387 3183 3979 4775 6366 7958 9549 11141 12732 14324 15916 17507 23873
2,50 637 1019 1273 1910 2546 3183 3820 5093 6366 7639 8913 10186 11459 12732 14006 19099

22
3,00 531 849 1061 1592 2122 2653 3183 4244 5305 6366 7427 8488 9549 10610 11671 15916
3,18 1/ 500 801 1001 1501 2002 2502 3003 4004 5005 6006 7007 8008 9009 10010 11011 15015
8
3,50 455 728 909 1364 1819 2274 2728 3638 4547 5457 6366 7176 8185 9095 10004 13642
4,00 398 637 796 1194 1592 1989 2387 3183 3979 4775 5570 6366 7162 7958 8754 11937
4,50 354 566 707 1061 1415 1768 2122 2829 3537 4244 4951 5659 6366 7074 7781 10610
4,76 3/ 334 535 669 1003 1337 1672 2006 2675 3344 4012 4681 5350 6018 6687 7356 10031
16
5,00 318 509 637 955 1273 1592 1910 2546 3183 3820 4456 5093 5730 6366 7003 9549
6,00 265 424 531 796 1061 1326 1592 2122 2653 3183 3714 4244 4775 5305 5836 7958
6,35 1/ 251 401 501 752 1003 1253 1504 2005 2506 3008 3509 4010 4511 5013 5514 7519
4
7,00 227 364 455 682 909 1137 1364 1819 2274 2728 3183 3638 4093 4547 5002 6821
7,94 5/ 200 321 401 601 802 1002 1203 1604 2004 2405 2806 3207 3608 4009 4410 6013
16
8,00 199 318 398 597 796 995 1194 1592 1989 2387 2785 3183 3581 3979 4377 5968
9,00 177 283 354 531 707 884 1061 1415 1768 2122 2476 2829 3183 3537 3890 5305
9,53 3/ 167 267 334 501 668 835 1002 1336 1670 2004 2338 2672 3006 3340 3674 5010
8
10,00 159 255 318 477 637 796 955 1273 1592 1910 2228 2546 2865 3183 3501 4775
 Table of Cutting Speeds, >10mm
PERIPHERAL CUTTING SPEED
Metres/Min. 5 8 10 15 20 25 30 40 50 60 70 80 90 100 110 150
Feet/Min.
16 26 32 50 66 82 98 130 165 197 230 262 296 330 362 495
Tool
Diameter REVOLUTIONS PER MINUTE (RPM)

mm inch
11,11 7/ 143 229 287 430 573 716 860 1146 1433 1719 2006 2292 2579 2865 3152 4298
16
12,00 133 212 265 398 531 663 796 1061 1326 1592 1857 2122 2387 2653 2918 3979
12,70 1/ 125 201 251 376 501 627 752 1003 1253 1504 1754 2005 2256 2506 2757 3760
2
14,00 114 182 227 341 455 568 682 909 1137 1364 1592 1819 2046 2274 2501 3410
14,29 9/ 111 178 223 334 446 557 668 891 1114 1337 1559 1782 2005 2228 2450 3341
16
15,00 106 170 212 318 424 531 637 849 1061 1273 1485 1698 1910 2122 2334 3183
15,88 5/ 100 160 200 301 401 501 601 802 1002 1203 1403 1604 1804 2004 2205 3007

23
8
16,00 99 159 199 298 398 497 597 796 995 1194 1393 1592 1790 1989 2188 2984
17,46 11/ 91 146 182 273 365 456 547 729 912 1094 1276 1458 1641 1823 2005 2735
16
18,00 88 141 177 265 354 442 531 707 884 1061 1238 1415 1592 1768 1945 2653
19,05 3/ 84 134 167 251 334 418 501 668 835 1003 1170 1337 1504 1671 1838 2506
4
20,00 80 127 159 239 318 398 477 637 796 955 1114 1273 1432 1592 1751 2387
24,00 66 106 133 199 265 332 398 531 663 796 928 1061 1194 1326 1459 1989
25,00 64 102 127 191 255 318 382 509 637 764 891 1019 1146 1273 1401 1910
27,00 59 94 118 177 236 295 354 472 589 707 825 943 1061 1179 1297 1768
30,00 53 85 106 159 212 265 318 424 531 637 743 849 955 1061 1167 1592
32,00 50 80 99 149 199 249 298 398 497 597 696 796 895 995 1094 1492
36,00 44 71 88 133 177 221 265 354 442 531 619 707 796 884 973 1326
40,00 40 64 80 119 159 199 239 318 398 477 557 637 716 796 875 1194
50,00 32 51 64 95 127 159 191 255 318 382 446 509 573 637 700 955

General Information