Dura Bar Machining Guide
Dura Bar Machining Guide
Dura Bar Machining Guide
Machinability
Dura-Bar is an engineered iron that offers machining advantages over carbon and alloy steel as well as other continuous cast iron bars.
Insert Wear Rate Wear Rate Comparison
Dura-Bar Ductile iron is often machined at speeds exceeding 1000 sfm Machinability ratings based on tool life differences at 450 sfm
By using Dura-Bar you will be able to reduce overall costs by decreasing your cycle time, thereby increasing your parts per hour. You will see significant improvement over steel in: Machinability Tool Wear Chip Control Surface Finish Minimal Deburring
200 1045
400 1117
600
SFM
800
1000 G2
1200 65-45-12
1400
80-55-06
The Dura-Bar advantage is the ability to machine at high speeds with little increase in the wear rate of the insert. The difference between Dura-Bar ductile iron and carbon steel is the ability to machine at speeds in excess of 800 sfm without a dramatic decrease in insert life.
Machinability Rating
G2 65-45-12 80-55-06 80% 30% 60% 57% 91% 100-70-03 8620 1045 1117 12L14
100% 160%
Grade
150%
0%
20%
40%
60%
80%
100%
120%
140%
160%
180%
Machinability rating of Dura-Bar vs. carbon steel. Ratings based on percentage of tool life at 450 sfm using high speed steel tooling compared to 1212 steel at 100%.
Chip Control
Dura-Bar gray iron chips: fine, compact, consistent and controllable chip formation
Quick Tips:
Inserts: For best results, use standard coated carbide insert grades, developed specifically for cast iron. Chip Breakers: You will get good results with or without a chip breaker. A complex chip breaker design is not required due to the free-machining properties of Dura-Bar. Coolant: Use water soluble or semi-synthetic coolant at a 4-6% concentration level. Surface Finishes: In drilling, milling and turning Dura-Bar, excellent surface finishes, similar to 1144 steel, can be achieved. Faster Speeds: Due to its dense fine-grained microstructure, Dura-Bar is clean and consistent, allowing for faster machining speeds than sand castings.
Typical Depth of Cut: Rough Turn = .100" .175" and Finish Turn = .010" .050" * Note: The recommended speeds listed above should be used on Dura-Bar cast iron only. These grades are specially produced to maximize speeds and feeds. Carbides, inclusions and other processing variables that have not been properly controlled will not allow all cast iron grades to be machined at the above speeds, and serious damage may occur to machine tools.
A Commitment to Quality
Dura-Bar is an ISO-9001 Registered company comitted to quality. We maintain our position as industry leader by producing the most consistently reliable, highest quality products. Dura-Bar is pleased to offer its Zero Defect Guarantee against foundry defects. This Guarantee provides for the replacement of defective material and reimbursement of your cost of machining. Please contact us for details about the guarantee, or visit our website at www.dura-bar.com.
Quick Formulas:
RPM = (SFM x 3.82) / Diameter of Cut SFM = (RPM x Diameter of Cut) / 3.82
1800 West Lake Shore Drive Woodstock, Il 60098 800-227-6455 815-338-7800 FAX: 815-338-1549 Internet: www.dura-bar.com E-Mail: sales@dura-bar.com