Tool Selection Using Chip Classifications

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TOOL SELECTION USING CHIP CLASSIFICATIONS
1 CHIP CLASS
2 FIND THE MATERIAL BEING MACHINED
3 CONFIRM CHIP FORM - BASED ON DRILL CHIP
4 LOCATE CHIP CLASS
NON-FERROUS LONG CHIPS
CHIP
CLASS		 20

ALUMINUM ALLOY - CAST       308.0, 356.0, 360.0, 380.0, 390.0, 514.0
ALUMINUM ALLOY - WROUGHT       3003, 4032, 5052, 6061, 7075
COPPER ALLOY - TOUCH       110, 170, 172, 175, 280, 425, 610, 655
LEAD ALLOY       ALLOYS 7, 8, 13, 15, 1Sb-9Sb
NON-METAL AND PLASTIC       Bakelite, Nylon, Polystyrene, PVC
ZINC - DIE CAST ALLOY       AC41A, AG40A, AMS4803, ZDC NO.7

LONG STRINGY CHIPS
(WROUGHT ALUMINUM, COPPER, AND PLASTIC)
MEDIUM LENGTH CURLED CHIPS
(ALL OTHER MATERIALS)
  • Chip evacuation is key when drilling or reaming these materials
NON-FERROUS LONG CHIPS
CHIP
CLASS		 20
NON-FERROUS SHORT CHIPS
CHIP
CLASS		 40

ALUMINUM BRONZE       614, 952-958
BRASS - LEADED AND FREE CUTTING       340, 342, 353, 360, 370, 485
BRASS - YELLOW, RED, NAVAL       268, 270, 464-467
COMMERCIAL BRONZE (LEADED)       314
MAGNESIUM ALLOY       AM60A, AZ21A, AZ91B-C, K1A
NICKEL SILVER       745-770, 973-978

SHORT CHIPS
  • These materials create no major drilling or reaming problems
NON-FERROUS SHORT CHIPS
CHIP
CLASS		 40
CAST IRONS
CHIP
CLASS		 60

DUCTILE CAST IRON - AUSTENTIC       D-2, D-2B, D-2C, D-2M, D-3, D-3A, D-4, D-5
     FERRITIC       60-40-18, 65-45-12, D4018, D4512
     FERRITIC-PEARLITIC       80-55-06, D5506
     PEARLISTIC-MARTENSITIC       100-70-03, D7003
     MARTENSITIC       120-90-02, DQ&T
GRAY CAST IRON       20, 25, 30, 35, 40, 45, 50, 55
MALLEABLE CAST IRON - FERRITIC OR PEARLITIC       32510, 35018, 45008, M3210, M4504

DISCONTINUOUS CURLED CHIPS
  • These materials are very abrasive which can cause rapid wear of the tool margins and cutting edges
CAST IRONS
CHIP
CLASS		 60
LOW STRENGTH STEELS
CHIP
CLASS		 80

LOW AND MEDIUM CARBON STEEL - WROUGHT       1005-1029, 1030-1050
LOW CARBON STEEL - CAST       1010, 1020
MEDIUM CARBON STEEL - CAST       1030, 1040, 1050

LONG CONTINUOUS CHIPS
  • Heat treatment may improve the machinability of some of these materials
  • Carbide tipped drills are not generally recommended for plain carbon steel
LOW STRENGTH STEELS
CHIP
CLASS		 80
MEDIUM STRENGTH STEELS
CHIP
CLASS		 100

LOW AND MEDIUM CARBON ALLOY STEEL       4320, 4340, 4620, 5015, 8620, 9310
LOW AND MEDIUM CARBON ALLOY STEEL - FREE MACH       4140, 4142Se, 4145Te, 4150, 86L20
MEDIUM AND HIGH CARBON ALLOY STEEL - LEADED       41L30, 41L40, 41L50
STAINLESS STEEL - 300 SERIES (FREE MACH.)       303, 303MA, 303Pb, 303 PLUS X, 303Se
STAINLESS STEEL - 400 SERIES       409, 410, 420, 430, 436
STAINLESS STEEL - 400 SERIES (FREE MACH.)       416, 416Se, 420F, 430F, 440F

THICK CURLED CHIPS
  • Heat treatment may improve the machinability of some of these materials
  • Coolant fed drills are generally recommended for these materials
MEDIUM STRENGTH STEELS
CHIP
CLASS		 100
HIGH STRENGTH STEELS
CHIP
CLASS		 120

ARMOR PLATE       HY-80, HY-100, HY-180, MIL-S-12560
HIGH CARBON ALLOY STEEL       50100, 51100, 52100
HIGH STRENGTH STEEL - WROUGHT       300M, 4330V, 98BV40, HP 9-4-20
MARAGING STEEL       GRADES 200, 250, 300, 350, HY230
NITRIDING STEEL       Nitralloy 125, 135, 135 Mod., 230
TOOL STEEL       SERIES A2, D2, H13, M50, P20, S7, W1

SHORT WIRY CURLED CHIPS
  • Chip discoloration is common with these materials
  • These steels are difficult to machine due to the high carbon and alloy content
  • Coolant fed drills are generally recommended for these materials
HIGH STRENGTH STEELS
CHIP
CLASS		 120
HIGH TEMPERATURE ALLOYS
CHIP
CLASS		 140

IRON BASE ALLOY       A-286, Discaloy, Incoloy 800-802
NICKEL BASE ALLOY       Hastelloy C, Inconel 600, 625, 718, 825
STAINLESS STEEL - 300 SERIES       302, 304, 309, 314, 316, 330, 347, 385
STAINLESS STEEL - PH SERIES       15-5PH, 16-6PH, 17-4PH, AM-350
TITANIUM ALLOY       Ti-6Al-4V, Ti-10v-2Fe-3Al, 98.9, 99.5

LONG WIRY CHIPS
  • Chip discoloration is common with these materials
  • This group may work harden if not machined with correct feed rates
  • Coolant fed drills are generally recommened for these materials
HIGH TEMPERATURE ALLOYS
CHIP
CLASS		 140
 
4 SELECT FROM RECOMMENDATION
IN TOOL SELECTOR BOX
TOOL SELECTOR
CHIP
CLASS 		MATERIAL MACHINED TOOL TYPE
 20   NON-FERROUS LONG CHIPS       
 40   NON-FERROUS SHORT CHIPS       
 60   CAST IRONS       
 80   LOW STRENGTH STEELS       
 100   MEDIUM STRENGTH STEELS       
 120   HIGH STRENGTH STEELS       
 140   HIGH TEMPERATURE ALLOYS       

HANNIBAL'S
RECOMMENDED TOOL TYPE(S)
APPEAR IN TOOL SELECTOR BOX
FOR EACH CATALOG ITEM

"/" = PREFERRED TYPE NOTED FIRST (e.g, "459/458")
"or" = NO PREFERENCE (e.g., "620 or 622")

MILLING STAINLESS STEELS
CHIP CLASSIFICATIONS
MATERIAL MACHINED CHIP
CLASS
FREE MACHINING 300 SERIES   60  
FERRITIC 400 SERIES
MARTENSITIC 400 SERIES		   100  
AUSTENITIC 200 OR 300 SERIES
PH SERIES		   140  

HANNIBAL'S CHIP CLASSIFICATIONS
ARE BASED ON EACH MATERIAL'S MOST
COMMON CONDITION. SPECIAL HEAT
TREATMENTS OR PROCESSING MAY
CHANGE THE MATERIAL'S MACHINING
CHARACTERISTICS. THIS HANNIBAL
GUIDE IS A SUGGESTED STARTING POINT
FOR TOOL SELECTION.
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