UNCLASSIFIED

AD NUMBER

AD485297

NEW LIMITATION CHANGE

TOApproved for public release, distributionunlimited

FROMDistribution authorized to U.S. Gov't.agencies and their contractors;Administrative/Operational Use; JUN 1966.Other requests shall be referred to AirForce Materials Lab., ManufacturingTechnology Div., Attn: MATF,Wright-Patterson AFB, OH 45433.

AUTHORITY

Air Force Materials Lab ltr dtd 21 Jun1967

THIS PAGE IS UNCLASSIFIED

AIR FORCE MACHINABILITY DATA CENTERCincinnati, Ohio 45209

MACHINING DATA FOR BERYLLIUM METAL

AFMDC 66-3

(SUPPLIED IN RESPONSE TO YOUR RECUEST

CHECKED [] ON USER FILE ANNOUNCEMENT No. 1)

COST OF ADDITIONAL COPIES

OF

MACHINING DATA FOR BERYLLIUM METAL

AFMDC 66-3 Robert E. Snider

Number of Copies Price per Copy John F. Kahles

1 - 9 $1.00

10 - 49 .90

50 - 99 .80

100 or Over .70JUNE 1966

Please direct your Purchase Order to:

Air Force Machinability Data Center3980 Rosslyn DriveCincinnati, Ohio 45209

Attn: Mrs. Mary Jane FinnSupervisor, User File

Advanced Fabrication Techniques BranchManufacturing Technology DivisionAir Force Materials LaboratoryResearch and Technology Division

Air Force Systems CommandUnited States Air Force

Wright-Patterson Air Force Base, Ohio

This document is subject to special export control and each transmittal to foreigngovernments or foreign nationals may be made only with prior approval of the Manu-facturing Technology Division.

I

MACHINABILITY DATA PRODUCTS AND REPORTS

AIR FORCE MACHINABILITY DATA CENTER (AFMDC)

COPIES OF THESE REPORTS MAY BE OBTAINED FROM AFMOC UNTIL THE SUPPLY IS EXHAUSTED. ONE COPY OF EACH

REPORT IS AVAILABLE, WITHOUT CHARGE, TO THE AEROSPACE INDUSTRY, DEPARTMENT OF DEFENSE (INCLUDING ALLOF THE MILITARY SERVICES AND THEIR CONTRACTORS), AND OTHER GOVERNMENT AGENCIES. TECHNICAL INSTITUTIONS,AND NONMILITARY INDUSTRIES IN A POSITION TO ASSIST THE DEFENSE EFFORT. PRICE LISTS FOR ADDITIONAL

COPIES ARE PROVIDED WITH EACH REPORT.

QUALIFIED REQUESTERS MAY ALSO ORDER COPIES OF THESE REPORTS FROM THE DEFENSE DOCUMENTATION CENTER(0DB). CAMERON STATION, ALEXANDRIA, VIRGINIA 22314.

REPORT NO. TITLE

AFMDC 65-1 MACHINING DATA FOR TITANIUM ALLOYS, AUGUST 1965, AD-623 588

AFMOC 65-2 FIRST ANNUAL REPORT OF IHE AIR FORCE MACHINABILITY DATA CENTER,FEBRUARY 1966, AD-482 278

AFMOC 66-;.l MACHINING DATA FOR NUMERICAL CONTROL - TURNING, JUNE 1966, AD-483 994

AFMDC 66-2 GRINDING RATIOS FOR AEROSPACE ALLOYZ, JUNE 1966, AD-483 995

AFMDC 66-3 MACHINING DATA FOR BERYLLIUM METAL, JUNE 1966

DATA PRODUCTS IN PREPARATION:

AFMDC 66-1.a MACHINING DATA FOR NUMERICAL CONTROL - FACE MILLING

AFMDC 66-1 .3 MACHINING DATA FOR NUMERICAL CONTROL DRILLING

AFMDC 66-1 .4 MACHINING DATA FOR NUMERICAL CONTROL - PERIPHERAL END MILLING

AFMDC 66-1 .5 MACHINING DATA FOR NUMERICAL CONTROL - END MILL SLOTTING

AFMDC 66-1 .6 MACHINING DATA FOR NUMERICAL CONTROL - TAPPING

AFMDC 66-1 .7 MACHINING DATA FOR NUMERICAL CONTROL REAMING

AFMDC 66-1 MACHINING DATA FOR NUMERICAL CONTROL (COLLECTION OF 661.1 THROUGH 66-1.7 IN

ONE VOLUME)

i

TABLE OF CONTENTS

INTRODUCTI ON . . . . . . . . . . . . . . . . . . . . . . .

1GENERAL COMMENTS..................... .. . . .... .. .. ......

1.1 THE METAL BERYLLIM ........................

1.2 GENERAL MACHINING PROBLEMS.....................21.2.1 TOXICITY..........................21.2.2 TWINNING AND MICROCRACKING..................2.2.3 CHIPOUT AND SPALLING....................2

1.3 CUTTING FLUIDS..........................4

2. MACHINING DATA CHARTS .

2.1 TURNING............................

2.2 MILLING...........................7

2.3 DRI LLING...........................8

2.4 BAND SAWING...........................9

2.5 GRINDING...........................10

2.8 BORING, TREPANNING, REAMING. ROUTING, AND TAPPING. ...... ...... 11

2.7 ELECTRICAL DISCHARGE MACHINING (EDM)................12

2.8 ELECTROCHEMICAL MACHINING (ECM)..................13

2.9 CHEMICAL MILLING, CHEMICAL BLANKING OF SHEET AND ELECTROPOLISH ING 14

3. CUTTING TOOL AND GRINDING WHEEL NOMENCLATURE...............15

4. CARBIDE GRADE CHART.........................19

5. IDENTIFICATION AND TYPE CLASSIFICATION OF HIGH SPEED TOOL STEELS .. . . .20

8. ROCKWELL-BRINELL - ULTIMATE TENSILE STRENGTH HARDNESS CONVERSION CHART . . .21

7. DESCRIPTION OF AFMDC........................22

INTRODUCTION

Within the past several years there has been an increasing effort toward developing beryl, umas a fully acceptable structural material. Recent improvements in strength obtained fromfoiged and extruded beryllium have stimulated new desig considerations. In turn, newdesigns have created a need for additional technology in all areas of fabrication, includingmachining.

An increasing number of inquiries to the Air Force Machinability Data Center for berylliummachining information plus a scarcity of data compiled in convenient formats prompted theissuance of this pamphlet.

A review of beryllium literature, correspondence with companies, and personal contactsrevealed that there was adequate information on beryllium properties, including toxicity,microcracking and twinning. Thus it was decided that this pamphlet would best serve theaerospace industry and its subcontraciors by emphasizing machining parameters and minimizingmaterial properties.

iv

V

I. GENERAL COMMENTS

1.1 THE METAL BERYLLIUM

Beryllium of commercial purity can be considered a complex alloy rather than a pure metal.Although Most pure beryllium contains 98 to 99% Be, the following analysis of QMV, HotPressed, Hot Rolled or Hot Upset, reveals the complexity of the material:

Be Be0 Fe Si Al Mg Mn Ni Cr C

98.9 1.0 0.118 0.03 0.08 0.08 0.09 0.018 0.013 0.12

Beryll ium has some excellent qualities such as high strength-to-weight ratio, excellentmodulus, high thermal conductivity, low coefficient of thermal expansion, but these aresomewhat offset by its generally low ductility. Thus, beryllium's primary usage until onlyrecently has been in the reactor areas and for stable platforms and other components of spaceguidance systems. Some recent developments in primary fabrication such as vacuum hot press-ing, forging and hot rolling, and extruding have shown improvements warranting an increasedconsideration of beryllium as a structural material.

Beryllium can be obtained from producers in various forms and conditions such as pressed, hotpressed, warm extruded, hot extruded, warm rolled, hot rolled, forgings, high purity castings,etc. These forms are produced from beryllium powder or resintered block. Some typical desig-nations for raw material and worked products which will come to the attention of personnelassociated with machinability of beryllium are listed below:

NUCLEAR GRADE - REACTOR BUILDING GRAOE

SP-100-A )SP-200-A )STANDARD STRUCTURAL GRADES FRO POWDERP-100 )P-200 )

1-400 INSTRUMENT GRADES (fine grained, min. of 47r BeO)HP-40 )

PF-20 FORGINGS

QMV VACUUM HOT PRESSED BLOCK

QMV VACUUM CAST ) COARSE GRAIN RAW CAST MATERIALvc-5o )VACUUM CAST DISTILLEOULTRA-HIGH PURITY - HIGH QUALITY MATERIAL (has better than average ductility)

PR-20 ROLLED SHEET

Data available to AFMDC to date indicate that, in most respects, all of the above berylliumproducts machine similarly. It has been reported that slight improvements in machinability,surface finish and dimensional control were noted on extruded beryllium.

It should be realized that optimum machining conditions can be developed for beryllium, asfor other materials, by machinability programs or by a careful study of production machiningoperations. Therefore, all machining data charts in this report provide starting conditionsonly.

p?

-- -- _ - -- -

i

1.2 GENERAL MACHINING PROBLEMS

Machining of beryllium should not be undertaken without consideration of the followingproblems:

1.2.1 Toxicity - The Atomic Energy Commission has taken the position that "it is safest toregard beryllium and all its compounds as potentially toxic." Exposure may developskin reactions and respiratory illness. The letter, called berylilosis, is the mostdangerous and is the result of inhalation of beryllium compounds, especially the fluo-ride or sulfate.

A Materials Advisory Board panel conducted a study on the toxicity of beryllium whichlater resulted in an Atomic Energy Commission publication, "Recommendations for Controlof Beryllium Hazards", August 10, 1951. Standards have since been republished by theNavy (BuAer) and Air Force as Technical Order T.O. 00-BOBB-1 (Jan. 10, 1938),and alsoin "Hygienic Guide" (1958) by the American Industrial Hygiene Association with nochanges in the allowable atmospheric concentrations set by AEC in 1951. AEC states"The inplant atmospheric concentration of beryllium should not exceed two microgramsper cubic meter as an average concentration throughout an B-hour day."

This pamphlet was designed to present machining data on beryllium. Subjects such astoxicity, microcracking, twinning, etc. were included to emphasize their importanceand relationship to machining. The Air Force Machinability Data Center will, uponrequest, furnish references to other documents dealing with the subjects of toxicityand dust control on machining operations.

1.2.2 Twinning and Microcracking - Mechanical working of beryllium in certain machiningoperations causes twinning as well as microcracking. When beryllium is subjected tohiah loads in structural applications, these surface changes can cause prematurefailures.

Studies have disclosed that twinning depths are related to and can be influenced bythe type of machining operation, depth of cut, cutting speed, feed, tool geometry andsharpness of cutting tools. These studies have also con'rrned that the effects oftwinning can be minimized by electrical discharge machininy electrochemical machiningor by a series of diminishing depths of cuts followed by removing approximately 0.002inch from the surface by chemical milling.

1.2.3 Chipout and Spelling - Beryllium is brittle and therefore is prone to chipout, crack-ing and spalling. These problems have an important bearing on scrappage since thebase cost of beryllium is $50-75 per pound and semi-finished components such as gyroplatforms have values nearing $1000 per pound.

Companies using beryllium have developed techniques for controlling chipout, crackingand spalling. A few of these techniques are listed as follows:

- Drilling Thin Sheet - One company solved the problem of breakout on the exitside of the holes by sandwiching a thin beryllium sheet between heavier gagesheets of beryllium or mild steel and drilling with very sharp drills.Earlier attempts at sandwiching between aluminum plates resulted in severecracking.

2

- Drilling Holes (3 times the diameter and deeper using carbide drills) -

A manufacturer of guidance components controlled breakout on the underside ofparts by setting a depth stop which allowed only the point of the drill tobreak through while the drill was under power feed. The stop was thenremoved, and the drill was fed through by hand.

- Turning Bars - Beryllium tends to chip or break off in pieces as the toolleaves the work. This chipping may be reduced by chamfering both ends of thebar to a diameter slightly larger than the desired finish diameter. One endof the bar may be turned slightly larger than finish diameter for a shrtdistance; then reverse the bar and finish the turning operation.

- Threading on Lathes - Threads should be chased using a single point tool.Thread dies and chasers are not recommended, because beryllium breaks intopieces and jams the tool, causing torn threads and tool breakage.

- Band Sawing - Sawing beryllium produces a heavy burr and rough edge. Enoughstock should be allowed on sawed parts for milling, filing or sanding to thefinished dimensions.

- End Mill Flaking - End milling flat surfaces on beryllium parts frequentlycauses surface crazing which produces microcracking. The microcracks arenormal to the surface and the depth of the twinned layer. End milledsurfaces may show surface damage similar to that which would occur in amaterial having lamellar defects. Investigations have shown that the mate-rial was sound, but surface cracking occurred behind the tool in thedirection opposite the feed direction. It was theorized that this 'flaking'was a result of material springback as the compression stresses generated bythe tool were relieved. Flaking may be minimized by gradually decreasingthe depth of cut for each pass until the finish cut is made.

Face Mill Flaking - Face milling produces the same type of microcracking asend milling. However, it has been found that face mill defects are moreprominent and occur when extreme care is exercised.

End Mill & Face Mill Breakout - Climb milling should be used when face mill-ing or end milling so that the cutting forces are directed into the materialmass. Conventional cutting will tend to cause breakage on entiance and exitof the cutter.

When end milling a groove through a part, the end mill should be stoppedbefore exiting. The end mill should then be reset to mill from the oppositeside.

Tapping Damage - Tapping is a difficult operation due to the low ductilityand high abrasiveness of beryllium. Trained operators are required for thisoperation.

A manufacturer of beryllium space guidance components developed a techniqueto minimize tap breakage and hole breakout. The sequence of operations isas follows:1) Rough machine thickness of part to be drilled and tapped; 2) Drill

required holes; 3) Countersink drilled holes; 4) Tap the drilled holes:

5) Finish machine thickness of part.The above procedure eliminates hole breakout.

Breakout of tapped holes located near the outside edges of flanges on berylliumrings was eliminated by leaving additional stock on both the flange faces andthe outside diameter of the flange. The above drilling and tapping procedurewas then performed.

1.3 CUTTING FLUIDS

A majority of machine shops are machining beryllium dry. On some machining operations,cutting fluids are beneficial from a standpoint of tool life. A cutting fluid is a necessityfor operations such as deep-hole drilling, reaming and tapping. Increased tool life,through the use of cutting fluids, may not be economically justified due to the followingconsiderations:

a) Cutting dry on hooded machines with strong vacuum systems is more efficient than anyother method for the control of beryllium fumes and dust in the machining area.

b) Clean beryllium chips have a high reclamation value. It is difficult to clean chipscollected from operations where cutting fluids have been used.

c) Evaporation of liquid from the used cutting fluid may leave beryllium dust, which canbecome a hazard.

Various types of cutting fluids have been used successfully f~r machining beryllium. Themost commonly reported fluid is a soluble oil and water, mixed 1:30 for operations such asturning, drilling, grinding and milling; and approximately 1:20 for operations such astapping and reaming and others requiring more lubricity than cooling.

Other cutting fluids reportedly being used successfully are:

a) A chemical coolant mixed 1:40 with water for deep-hole drilling, krinding and abrasivecutoff operations.

b) Kerosene was found to be a satisfactory coolant for gun dri ling very deep holes. Thekerosene was pumped through the drill at 200 psi.

A search for information on adverse effects or reactions on beryllium caused by types ofcutting fluids disclosed nothing pro or con. Apparently no extensive studies of a non-proprietary nature have been reported. Data are lacking on possible effects of chlorides

or other chemicals causing problems such as stress corrosion, cracking or decreased fatiguestrength.

In lieu of any information on detrimental effects resulting from the use of cutting fluids,the Air Force Machinability Data Center recommends that whenever possible beryllium machiningbe performed dry. When the particular operations req:,ire either a coolant or lubricant, thestandard types of cutting fluids currently being used or similar operations on cast iron andsteel should be satisfactory.

The Air Force Machinability Data Cen-er recommends that f luids used in the machining ofhighly stressed beryllium structural parts should be evaluated for their effect on surfaceintegrity which in turn could adversely influence structural integrity.

4

2. MACHINING DATA CHARTS

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3. CUTTING TOOL AND GRINDING WHEEL NOMENCLATURE

3.,I TURNING

Side Rake (SR) .-- HEnd Cutting Edge Angle (ECEAJ

Side Relief 'ooooNoeRadius

Side Cutting Edge Angle (SCRA)

back R ake (BR)(Pos.)

3.2 END MILLING

Secondary ClearanceCorner Angle Peripheral Relif

Ielix Angle

~d End Relief

jnd Cutting Edge Angle (ECEA) J.adial Rake (RR)(Pos.)

15

_ _ _ _ _ _ _ _

3.3 FACE MILLING

End Cutting Edge Angle (tCEA)

Corner Angle (CA) Peripheral Relief

Radial Rake (RR)(Ni

Axial Rake (AR)(PQ S. End Relief

3. DRILLING

Margin t ~Chisel Edge /Point Angle

Angle

Pan P HeixAnl

Land Web Thickness le

Lip Relief Angle

Standard Point Crankshaft Point

3.5 TAPPING

LandChamfcr Relief

Chamnfer Angle

-I y>t ./_Cutting Edge

T 0 Rake Angle-

t~v Flute

Heel

Hook Angle

18

3.6 CARBIDE PRECISION BORING

(ECREA)

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Side Rake (SR)

(Poe.)

Sidp Cu.g Edge Angle

(SC EA)

Back Rake (BR)(Pos.

-1LEnd Relief

3.7 CARBIDE TIPPED REAMERS

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LeadAnglLegthamf ead Ane (Po.)

LeadAnge Lngt 0 eadAnre T Primar Relief

-I-T Secondary ~

Hellix Angle

17

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4. CARBIDE GRADE CHART C-1 to C-8MACHINING APPLICATIONS

CARBIDE _____ __ ___INDUSTRY CODE_____ _____ ____

MANUFACTURERS C-I C-2 C-3 C-4 C-5 C-6 C-7 C-0

A 07ADAMAS 6 AM PW AAA 51 X C5CC0W 4464Titan 000

AA ~i tan 500 ___

ANCARI -- 15 -- *--__________ 013 10

01043 20

BESLY-WELLES 8 , 816 8108 B211 B219 00 024 B207_

370 350 32CABLY4A860 95 895 78B 78 7832

CARBOLY 44A895 320 350 ______ _____

CA4 C- A8 CA-B1D CA-8OB CA-71ll CA-704CRE A3 CA- CAi C- CAi0 C-20_____CAIN? CA3 CA443 CA-740__ CA-720_ _____

COROMANT H20 H413 Hi iP 105 S2 SIP F02*1420 _______ S4

FIRTH-LOACH FA-5 FA-B PA-i VA-B FT-3 FT-62 FT-B2 FT-i2FT-5 P-2 FT2 FT?

FRHSELN N A T04 TX H T22 T31FIT4SELN -23 HE HF NTA T22 TEL Ill

FUTUPM ILL -- DMC21 -- OMC32 M3 DC5-

K6 O KM K2S R45KENNAMETAL RI C8735 K68 KR K%3 KSH K7

K68 K8K2S K4H KiNK 65

MULTI METALS OMi OM2 31113 0M4 4M5 - --

NEWJCOMER 1410 1420 N430 N40 N50 N460 NMiT3 NM- 93N-3 NH-9S'

Fe r r- FerIro- Fetro- Ferro-SINTERCAST Tic I Tic I -- Tic J Tic ______

SPEEDICLIT MITIA A B I C C TAiD TTA TE TE

C-3 CAS S'0 S-90'1 S 2 S9TALIDE C-89 C-91 C9 I9 -8 S-900 SO

IIIT 9s 81TUNGSTEN ALLOY 9 9N 9C 9B 9S IO015 5SJ ___IV O 5S

I U5 uioU73UNMTUoU20 U30 U40 U53 U533 U7086

UNU60UI U7 980

VALENI TL VC-1 VC-2 VC3 V- VC*i25 AC-125 VC7 VC-83

VC- 22 8 C3 V VC-55 AC-B VC-ss'AC. 2 _____ _____ _______VR-73 H

2A-68 2A-5 2AS YR5 Al R-7S5 IVVAI'WESSON VR5 A7 VR-B57 aRi HVA- VPA1

VR-- 54 54R2-65 VR-BA AM N

WA-141 WA2 WA-35~ W- A-O W- VA-147WALUET #A-I VA-63 WAA-3-

WA-159 WA1 WAlB WA-5 A-B Ai W-

WENT-SONIS CO 12 C 02 CQ3 COW CY12 CYS6 CY2 C181

WICKALOY N H 141 ANN X7A GB GX FX

WILEYSEB945E 606 BAX_ILE a S E 3 S 8A 6 A50

CAST IRON, NON-FERROUS AND NON-METALLIC MATERIALS STEEL AND STEEL ALLOYS

C-I Roughing C-S RoughingC-2 General Purpose C-B General PurposeC-3 Finishing C-7 Finishing

C4 Pracisien Finishing c-8 rcso iihn

Listings do not neessarily imply equivalency of various manulacturer's grades.Thin chart is not to be considerved an endorsement of or an app roved !ist of any manufacturer's products.

.Grades connriirmg more than~ 50% Tttaniam Carbide.

19

5. IDENTIFICATION AND TYPE CLASSIFICATIONOF HIGH SPEED TOOL STEELS

SYMBOL M, MOLYBOENUM TYPES

TYPE IDENTIFYING ELEMENTS, IN PER CENT APPLICATION

l .0 1. 50 8.00 4.00 1.00 GENERAL PURPOSEM2 .85 8.00 5.00 4.00 2.00 GENERAL PURPOSE

13 CLASS 1 1.05 6.00 5.00 4.00 2,40! FINE EDGE TOOLSM3 CLASS 2 1.20 6.00 5.00 4.00 3.00 FINE EDGE TOOLS

N4 1.30 5.50 4.50 4.00 4.00 ABRASION RESISTANTNM .80 4.00 5.00 4.00 1.50 12.00 HEAVY CUTS . ABRASION RESISTANTv? 1.00 1.75 8.75 4.00 2.00 - FINE EDGE TOOLS - ABRASION RESISTANTMIO .90 - 8.00 4.00 2.00 - GENERAL PURPOSE - HIGH STRENGTH1I5 1.50 6.50 3.50 4.00 5.00 5.00 HEAVY CUTS - ABRASION RESISTANTU30 .80 2.00 8.00 4.00 1.25 5.00 HEAVY CUTS - ABRASION RESISTANTN33 .90 1.50 9.50 4.00 1.15 8. HEAVY CUTS - ABRASION RESISTANTM34 .90 2.00 8.00 4.00 2.00 I 8.00 HEAVY CUTS - ABRASION RESISTANTM35 .80 6.00 5.00 4.00 2.001 5.00 HEAVY CUTS - ABRASION RESISTANTN38 .80 6.00 5.004.00 2.001 8.00 HEAVY CUTS - ABRASION RESISTANTM41 1.10 6.75 3.75 4.25 2.001 5.00 HEAVY CUTS - ABRASION RESISTANTM42 1. 10 1.50 0.50 3.75 1.15 8.00 HEAVY CUTS - ABRASION RESISTANT143 1.25 1 1.75 8.75 3.75 2.00 B.25 HEAVY CUTS - ABRASION RESISTANTN44 1.15 15.25 8.2514.25 2.25 12.00 HEAVY CUTS - ABRASION RESISTANT

SYMBOL T, TUNGSTEN TYPES

TI .70 18 00 - 4.00 1.001 - GENERAL PURPOSET2 .80 18:00 4.00 2.00 - GENERAL PURPOSE - HIGHER STRENGTHT4 .7518.00 4.00 1.00 5.00 HEAVY CUTST5 .80 18.00' 4.00 2.001 8.00 HEAVY CUTS - ABRASION RESISTANTTB .80 20.00 4.50 1.50 12.00 HEAVY CUTS - HARD MATERIAL

.75 ,4.00 4.00 2.00 - PLANER TOOLS17 5 14. 0 ,21 0 5T8 .75 1 4.00 4.00, 2.00 5.00 GENERAL PURPOSE - HARD MATERIALT9 1.20 :18.00 4.00 4.00 - EXTREME ABRASION RESISTANTT15 1.50 12.00 4.00 5.00 5.00 EXTREME ABRASION RESISTANT

GENERALLY ALL OF THE ABOVE HIGH SPEED STEELS ARE MANUFACTURED BY THE FOLLOWING COMPANIES:

ALLEGHENY LUDLUM STEEL CORPORATION

BETHLEHEM STEEL CORPORATION

BRAEBURN ALLOY STEEL DIVISION. CONTINENTAL COPPER 1 STEEL INDUSTRIES. INC.

THE CARPENTER STEEL COMPANY

COLUMBIA TOOL STEEL COMPANY

CRUCIBLE STEEL COMPANY OF AMERICA

FIRTH STERLING. INC.

JESSOP STEEL COMPANY

LATROBE STEEL COMPANY

H. A. PORTER COMPANY. INC., VULCAN-KIOD STEEL DIVISION

SIMONOS SAW AND STEEL COMPANY

UNIVERSAL-CYCLOPS STEEL CORPORATION

VANADIUM-ALLOYS STEEL COMPANY. DIVISION OF VASCO METALS CORPORATION

HIGH SPEED STEELS M41 THROUGH M44 ARE MADE BY:141 - CRUCIBLE STEEL COMPANY OF AMERICA

142 - VANAOIUV-ALLOYS STEEL COMPANY. DIVISION OF VASCO METALS CORPORATION

M43 - LATROBE STEEL COMPANY

144 - BRAEBURN ALLOY STEEL DIVISION. CONTINENTAL COPPER & STEEL INDUSTRIES. INC.

This chare is not to be considered an endorsement of any manufacturer's product or an approved list ofany manufacturer's products.

20

_____ _ __ p -

6. ROCKWELL-BRINELL ULTIMATE TENSILE STRENGTHHARDNESS CONVERSION CHART

ROCKWELL C to BRINELL 3000 KG ROCKWELL B to BRINELL 500 and 3000 KG.FCR HAPENEC STEEL ANC AL,AYS FOR LNHAA£%ED S L, S EEL or S-F7 ~E[ ER, GRAY ANa

.ALLEABLL rAST IRPN AND MOST 'EARROS YETAL

ROCKWELL C BR;NELL ROCKWELL B BRINELL BRINELL150 Kg. Load 3000 Kg. Load 100 Kg. Load, 50 Ka. Load 3000 Kg. Load"Brale 10 mm Ball 1/16 Oa . al 10 mm Ball 10 mm Ball

60 614 100 201 24059 600 99 195 23458 587 98 189 22857 573 97 184 22256 560 96 179 21655 547 95 175 21054 534 94 171 20553 522 93 167 20052 509 92 163 19551 496 91 160 19050 484 90 157 18549 472 89 154 18048 460 88 151 17647 448 87 148 17246 437 86 1 145 1 16945 426 85 142 16544 415 84 140 16242 393 83 137 15940 372 82 135 1-638 352 81 133 153

36 332 80 130 15034 313 79 128 14732 297 78 126 14430 283 77 124 14128 270 76 122 13926 260 75 120 13724 250 74 118 3522 240 72 114 13020 230 70 11 0 125

- 68 107 121

66 104 117BRINELL 3000 KG. 64 101 4

TO ULTIMATE TENSILE STRENGTH 62 98 1060 95 107

FOR STEELS 58 92 10456 90 101

SRINELL 54 873000 Kg. Load ULTIMATE TENSILE 52 85 i10 mm Ball STRENGTH, psi 50 83 I

48 _ 81

200 100,000 46 79225 108.000 44 78250 122.000 42 76

275 141,000 40 74S38 73

300 158.000 36 71325 174.000 34 70

350 188.000 32 6830 I 67

375 202.000 28 66

400 215.000 24 64425 227.000 20 B2

450 238.000 16 60

475 249.000 12 588 56

500 258.000 4 55525 267.000 0 53550 282.000575 295.000Boo 308,000 .. ,.0

21

7. DESCRIPTION OF AFMIDC

AIR FORCE MACHINABILITY DATA CENTER, 3980 Rosslyn Drive, Cincinnati, Ohio 45209.Operated for the Air Force Materials Laboratory, Manufacturing Technology Division,under Contract AF 33(615)-5262, by Metcut Research Associates Inc.

SCOPE

The Air Force Mactinab;l ity Date Center (AFMOC) celiac's, evaluates, stores, and disseminatesmaterial removal information includlnk specific and detailed machining date for the benefit ofindustry and government. Strong emphasis is given to engineering evaluation for the purposeof developing optimized material removal parameters, such as speeds, feeds, depths of cut.tool material and geometry, cutting fluids and other significant variables. Data are beingprscessed for all types of materials and for all kinds of material removal operations such asturning, milling, drilling. tapping, grinding, electrical discharge machining, electrochemicalmachining, etc.

COLLECTIONAFMDC has a mechanized system in which punch cards are used to store and retrieve all types ofmaterial removal information including all significant numerical data. Early in 1986, a nowlow-cost computer wil I be used tor storing and processing data from a master card and diskfile and for computer decoding. The focal concept for acquisition, interrogotion. or presen-

tation of information is the specific material (with definiLe chemical, physical, or mechon-

icel properties) and the specific material removal operation being used. When necessary, card

source control coples may be used to retrieve original documents which are in document storage

at AFMDC.

INFORMATION SERVICES

AFMOC places strong emphasis on providing specific and detailed answers to technical inquiriesin the field of material removal. A User File, consisting of important users in the field ofmaterial removal, has been developed to receive informatioii products including machining datapamphlets and tables on materials of current interest, state-of-the-art reports, technicalannouncements, and other appropriate items. Services are available without charge to theaerospace industry, Department of Defense (including all of the military services and theircontractors), and other governmenr agencies, technical institutions, and non-militaryindustries in a position to assist the defense effort.

TO REQUEST MACHINING INFORMATION .......Telephone: 513-271-9510TWX: 513-577-1785 orWrite: Air Force Machinability Data Center

3960 Rosslyn DriveCincinnati, Ohio 45209

TO HELP US ANSWER YOUR INQUIRY. IF POSSIBLE PLEASE:

1. Identity the material being machined (specification or tradename); condition, (as cast,hot rolled, cold drawn, annealed, quenched and tempered, etc.); microstructure andhardness.

2. Identify the material removal operation in question (turning, milling, drilling, tapping,surface grinding, electrical discharge machining (ELD), electrochemical machining (ECHI),etc.).

3. Specify reasons for requiring data unless your needs are proprietary. This enables AFMOCto broaden the scope of its technical advice.

4. Specify delivery requirements.

5. Indicate to whom the inquiry reply should be sent.

8. Transmit all details concerning present practices, including feeds, speeds, cutting toolmaterial and geometry. cutting fluids, etc., In the event your inquiry pertains toimprovement of an existing machining situation.

NOTE: Association of the names of companies and individuals with specific requests is keptconfidential. However, data developed remain the property of AFMDC for dissemination asrequired for answering similar inquiries and for developing data products.

22L ___ _ _____ _

UnclassifiedSecurity Classification

DOCUMENT CONTROL DATA - R&D(Scurity classification of title, body of abstract .,nd indexing annttion. mus.t be entered uft~n the ii..t.II rpott Is clea,.ii.d)

I. ORIGINATIN G ACTIVI!"I (Cotpotate author) 1.REPORT SECURITY C LASSIFICATION

Air Force Machinability Data Center UnclassifiedMetcut Research Associates Inc. 2b GROUPCincinnati, Ohio 45209 N/A

3. REP014T TITLE

Machining Data for Beryllium Metal

4. DESCRIPTIVE NOTES (Type of report and Inclusive dates)

Collected and Evaluated Machining Data for Beryllium5. AUTHOR(S) (Lost name. firt notm., mnilat.)

Snider, Robert E.Kahies, John F.

6. REPO RT DATE 70. TOTAL NO. OF PAGES I7h. NO. OF REPSJune 1966 26 2

Be. CONTRACT OR GRANT No. 941. ORIGINATOR'S REPORT NUMBER(S)

AF 33(615)-5262 AFMDC 66-3kPROJECT NO0

9-700c. Sb.hi OM r J PORT NO(S) (Any othet numbors Mi.may be assigned

d.

10. AVAILABILITY/LIMITATION NOTICES Qualified requesters may obtain copies of this reportfrom DDC. This document is subject to export-controls and each transmittal toforeign governments or foreign nations may be made only with prior approval ofthe Air Force Materials Laboratory (MATF).

II. SUPPLEMENTARY NOTES 2.SPONSORING MILITARY ACTIVITY

Manufacturing Technology DivisionAir Force Materials Laboratory

_____________________________ Wright-Patterson Air Force BaseIS. ABSTRACT

This report contains evaluated machining information for beryllium whichhas been extracted from many sources. Machining data are tabulated andpresented in chart form for the following processes: Turning, Milling,Drilling, Band Sawing, Grinding, Boring, Trepanning, Reaming, Routing,Tapping, Electrical Discharge Machining, Elec trochemical Machining,and Chemical Machining. Also included is a General Comment Sectiondealing with the problems associated with beryllium machining, such astwinning, microcracking, to-xicity, chipout and spalling, and cuttingfluids.

D F ORM1A'DD JANG 473I~ UnclassifiedSecutity Classification

Unclas sifiedSecurity Classification

14. LINK A LINK B LINK CKEY WORDS____ROLE WT ROLE WT ROLE WT

Machining DataGrinding DataElectrical Discharge Machining DataElectrochemical Machining Data

Chemical Machining DataToxicityMicrocrackingTwinningBerylliumAerospace AlloyChipoutSpalling

INSTRUCTIONS

1. ORIGINATING ACTIVITY: Enter the name and address imposed by security classification, using standard statementsof the contractor, subcontractor, grantee, Department of De- such as:fense activity or other organizatien (corporate author) issuing (1) "Qualified requesters may obtain copies of thisthe report. report from DDC."2a. REPORT SECURITY CLASSIFICATION: Enter the over- (2) "Foreign announcement and dissemination of thisall security classification of the report. Indicate whether re ign b nnDD c eent a ndhoize i f"Restricted Data" is included. Marking is to be in accord- rance with appropriate security regulations. (3) "U. S. Government agencies may obtain copies of

this report directly from DDC. Other qualified DDC2b. GROUP: Automatic downgrading is specified in DoD Di- users shall request throughrective 5200. 10 and Armed Forces Industrial Manual. Enterthe group number. Also. when applicable, show that optionalmarkings have been used for Group 3 and Group 4 as author- (4) "U. S. military agencies may obtain copies of thisized. report directly from DDC. Other qualified users3. REPORT TITLE: Enter the complete report title in all shall request throughcapital letters. Titles in all cases should be unclassified,If a meaningful title cannot be selected without classifica-tion. show title classification in all capitals in parenthesis (5) "All distribution of this report is controlled. Qual-immediately following the title. ified DDC users shall request through4. DESCRIPTIVE NOTES: If appropriate, enter the type of ___

report, e.g., interim, progress, summary, annual, or final. If the report has been furnished to the Office of TechnicalGive the inclusive dates when a specific reporting period is Services, Department of Commerce, for sale to the public, indi-covered. cate this fact and enter the price, if known.5. AUTHOR(S): Enter the name(s) of author(s) as shown on IL SUPPLEMENTARY NOTES: Use for additional explana-or in the report. Ente last name, first name, middle initial, tory notes.If military, show rank and branch of service. The name ofthe principal -n-thor is an absolute minimum requirement. 12. SPONSORING MILITARY ACTIVITY: Enter the name of

the departmental project office or laboratory sponsoring (pay-6. REPORT DAT. Enter the date of the report as day, ing for) the research and development. Include address.month, year; or month, year. If more than one date appearson the report, use date of publication. 13. ABSTRACT: Enter an abstract giving a brief and factual7*. TOTAL NUMBER OF PAGES: The total page count summary of the document indicative of the report, even thoughshould follow normal pagination procedures. ie., enter the it may also appear elsewhere in the body of the technical re-port. If additional space is required, a continuation sheet shallnumber of pages containing information. be attached.7b. NUMBER OF REFERENCE& Enter the total number of It is highly desirable that the abstract of classified reportsreferences cited in the report. be unclassified. Each paragraph of the abstract shall end with&a. CONTRACT OR GRANT NUMBER: If appropriate, enter an indication of the military security ciassification of the in-the applicable number of the contract or grant under which formatin in the paragraph, represented as (TS). (S), (C), at (U)the report was written. There is no limitation on the length of the abstract. How-9Sb, &c, & 8d. PROJECT NUMBER: Enter the appropriate ever, the suggested length is from 150 to 225 words.military department identification, such as project number,subproject number, system numbers, task number, etc. 14. KEY WORDS: Key words are technically meaningful terms

or short phrases that characterize a report and may be used as9a. ORIGINATOR'S REPORT NUMBER(S): Enter the offi- index entries for cataloging the report. Key words must becial report number by which the document will be identified selected so that no security classification is required. denti-and controlled by the originating activity. This number must fiers, such as equipment model designation, trade name, militarybe unique to this report. project code name, geographic location. may be used as key9b. OTHER REPORT NUMBER(S): If the report has been words but will be followed by an indication of technical con-assigned any other report numbers (either by the originator text. The assignment of links, rules, and weights is optional.or by the sponsor), also enter thus number(s).

10. AVAILABILITY/LIMITATION NOTICES: Enter any lim-itations on further dissemination of the report, other than those

UnclassifiedSecurity Classification