There are some general rules of thumb that can be applied when machining stainless steels, to avoid (to some extent) the problems described, or at least to minimise them.
These rules are particularly important when machining austenitic and ferritic-austenitic stainless steels.
- Always use rigid machine tools, as the machining of stainless steels involves high cutting forces.
- Tools and work pieces must be firmly clamped, and the tool overhang must be as small as possible. (Long overhangs, or unstable machining conditions, increase the already substantial risk of vibration when machining stainless steels.)
- Do not use too great a nose radius, as this can cause vibration.
- Use tools with good edge sharpness and high edge strength. (Cemented carbide tools should have a positive cutting edge, with a protective negative land, although this must not be greater than necessary to ensure that the edge is effectively sharp. At the same time, the edge must be strong, which means that it is necessary to find a compromise between strength and sharpness of the edge.)
- Use sufficient cutting depths, so that the cutting edge tip reaches below the work-hardened zone from the previous cut.
- Replace the insert more frequently than when machining carbon steel, as a dull edge produces greater work-hardening than does a sharp edge.
- When using cutting fluid, ensure that it is always applied. (If possible use oils and emulsions with EP additive.)