How to Use the KENNA PERFECT Insert Selection System... 4

Transcription

1 Table of Contents page How to Use the KENNA PERFECT Insert Selection System KENNA PERFECT Insert Selection System Negative Wiper Inserts Positive Wiper Inserts Negative Inserts Positive Inserts Insert Systems Tool Tips New Cutting Tool Technologies Metallurgy and Machinability of Cast Irons Cast Iron Material Properties Cast Iron Cross-Reference/Workpiece Comparison Table Expert Application Advisor (Troubleshooting Guide) Failure Mechanism Analysis Insert Edge Preparations Chip Control Geometries Carbide and Ceramic Grades Technical Application Data Standard Inserts Your Local Sales Representative Name: Phone #: Cell Phone #: Pager #: Office #: For quick technical assistance, call: USA & Canada: Outside USA & Canada: Available Monday thru Friday: 7am 7pm Eastern Time Zone 3

2 KENNA PERFECT Insert Selection System KENNA PERFECT, Kennametal s 3-step cutting tool selection system, makes choosing and applying the most productive tool as easy as 1, 2, 3. Tool recommendations are based on six workpiece material groups, optimizing selection accuracy. Example: 6 workpiece material groups Example: ductile cast iron 60 KSI tensile 1st Step Select the insert geometry Given: Unknown: Solution: depth of cut =.040 and feed =.016 ipr insert geometry -UN 2nd Step Select the grade Given: Geometry: Unknown: Solution: cutting conditions: lightly interrupted cut -UN grade KC9315 3rd Step Select the cutting speed Given: Unknown: Solution: grade KC9315 cutting conditions cutting speed 750 sfm 4

3 KENNA PERFECT Insert Selection System Steel Stainless Steel Cast Iron Non-Ferrous High-Temp Alloy Hardened Material 1st Step Negative Inserts Roughing Selection of the Insert Geometry..MA -T0820 -S0820 Medium Machining -UN -UN -T0820 -RP Finishing -FN -T0820 2nd Step Selection of the Grade Insert Geometry Cutting Condition Finishing Med. Machining Roughing -T0820 -FN -T0820 -UN (-RP) -T0820..MA heavily interrupted cut KC9315 KY3500 KC9325 KY3500 KC9325 lightly interrupted cut varying depth of cut, casting or forging skin smooth cut, pre-turned surface 3rd Step KY3400 KY3400 Speed - sfm (m/min) KC9315 KT315 KT315 Selection of the Cutting Speed KY3400 KY3400 KY3400 KC9315 KC9315 KC9315 KY3400 KY3400 KY3400 KC9315 KC9315 KC9315 Starting Cond. grade sfm m/min (90) (135) (180) (225) (275) (320) (360) (410) (460) (500) (550) (600) KT KC KC KY KY

4 KENNA PERFECT Negative Wipers Cast Iron Ductile and Gray Irons 1st Step Select the Insert Geometry Negative Wiper Inserts -MW Medium Wiper -T0820 FW -T0420 FW -FW Finishing Wiper -T0420FW -T0820FW -T0420FW -T0820FW -FW Finishing Wiper 2nd Step Select the Grade Gray Iron Cutting Condition heavily interrupted cut lightly interrupted cut varying depth of cut, casting or forging skin smooth cut, pre-turned surface *KY1310 available January Insert Geometry -FW -MW -T0420FW, -T0820FW KY3500 KC9315 KC9325 KY3500 KT315 KC9315 KY1310* KT315 KC9315 KY1310* Ductile Iron heavily interrupted cut lightly interrupted cut varying depth of cut, casting or forging skin smooth cut, pre-turned surface Cutting Condition Insert Geometry -FW -MW -T0420FW KC9315 KC9315 KY3500 KT315 KC9315 KY3400 KT315 KC9315 KY3400 6

5 KENNA PERFECT Negative Wipers Cast Iron 3rd Step Select the Cutting Speed Gray Cast Iron ASTM A48: class 20, 25, 30, 35, 40, 45, 50, 55, 60 SAE J431: grade G1800, G3000, G3500, G4000 grade KT KC KC KY KY1310* *KY1310 available January Speed - sfm (m/min) (120) (305) (490) (670) (855) (1035) (1130) Starting Conditions sfm m/min Ductile, Compacted Graphite & Malleable Cast Irons (<80 KSI tensile strength) ASTM: A536; , , SAE J434: D4018, D4512, D5506 ASTM A47: grade 32510, SAE J158: grade M3210, M4504, M5003, M5503, M7002 ASTM: A842; grade 250, 300, 350, 400, 450 grade Speed - sfm (m/min) (120) (200) (275) (350) (430) (505) (580) Starting Conditions KT KC KY KY sfm m/min Ductile, Malleable & Austempered Cast Irons (>80 KSI tensile strength) ASTM: A536; , SAE J434: D7003 SAE J158: grade M8501 ASTM: A897; , , , , grade Speed - sfm (m/min) (120) (200) (275) (350) (430) (505) (580) Starting Conditions KT KC KY KY sfm m/min To further optimize your operation, please reference pages for Tool Tips and the Expert Application Advisor on pages

6 KENNA PERFECT Positive Wipers Cast Iron Ductile and Gray Irons 1st Step Select the Insert Geometry Positive Wiper Inserts -MW Medium Wiper -FW Finishing Wiper SCG-FW Kyon Finishing Wiper 2nd Step Select the Grade Gray Iron heavily interrupted cut lightly interrupted cut varying depth of cut, casting or forging skin smooth cut, pre-turned surface heavily interrupted cut lightly interrupted cut varying depth of cut, casting or forging skin smooth cut, pre-turned surface Cutting Condition *KY1310 available January Ductile Iron Cutting Condition Insert Geometry -FW SCG-FW -MW KY3500 KC9315 KY3500 KC9315 KC9315 KY1310* KC9315 KT315 KY1310* KT315 Insert Geometry -FW SCG-FW -MW KC9315 KY3500 KC9315 KC9315 KY3400 KC9315 KT315 KY3400 KT315 8

7 KENNA PERFECT Positive Wipers Cast Iron 3rd Step Select the Cutting Speed Gray Cast Iron ASTM A48: class 20, 25, 30, 35, 40, 45, 50, 55, 60 SAE J431: grade G1800, G3000, G3500, G4000 grade KT KC KY KY1310* *KY1310 available January Speed - sfm (m/min) (120) (305) (490) (670) (855) (1035) (1130) Starting Conditions sfm m/min Ductile, Compacted Graphite & Malleable Cast Irons (<80 KSI tensile strength) ASTM: A536; , , SAE J434: D4018, D4512, D5506 ASTM A47: grade 32510, SAE J158: grade M3210, M4504, M5003, M5503, M7002 ASTM: A842; grade 250, 300, 350, 400, 450 grade Speed - sfm (m/min) (120) (200) (275) (350) (430) (505) (580) Starting Conditions KT KC KY KY sfm m/min Ductile, Malleable & Austempered Cast Irons (>80 KSI tensile strength) ASTM: A536; , SAE J434: D7003 SAE J158: grade M8501 ASTM: A897; , , , , grade Speed - sfm (m/min) (120) (200) (275) (350) (430) (505) (580) Starting Conditions KT KC KY KY sfm m/min To further optimize your operation, please reference pages for Tool Tips and the Expert Application Advisor on pages

8 KENNA PERFECT Negative Inserts Cast Iron Ductile and Gray Irons 1st Step Select the Insert Geometry Negative Inserts -RN Roughing..MA -T0820 -S0820 -MN Medium Machining -UN -T0820 -RP Finishing -FN -T0820 *RP geometry can be used in medium machining operations to reduce tool pressure in high-strength metals. 2nd Step Select the Grade Gray Iron Cutting Condition heavily interrupted cut lightly interrupted cut varying depth of cut, casting or forging skin smooth cut, pre-turned surface *KY1310 available January Ductile Iron Cutting Condition heavily interrupted cut lightly interrupted cut varying depth of cut, casting or forging skin smooth cut, pre-turned surface Insert Geometry Finishing Med. Machining Roughing -T0820 -FN -T0820 -UN (-RP) -T0820..MA -S0820 KC9315 KY3500 KC9325 KY3500 KC9325 KB9640 KC9315 KY3500 KC9325 KY3500 KC9325 KB9640 KY1310* KT315 KY1310* KC9325 KY3500 KC9325 KB9640 KY1310* KT315 KY1310* KC9315 KY1310* KC9315 KB9640 Insert Geometry Finishing Med. Machining Roughing -T0820 -FN -T0820 -UN (-RP) -T0820..MA KC9315 KY3500 KC9325 KY3500 KC9325 KC9315 KY3400 KC9315 KY3400 KC9315 KY3400 KT315 KY3400 KC9315 KY3400 KC9315 KY3400 KT315 KY3400 KC9315 KY3400 KC

9 KENNA PERFECT Negative Inserts Cast Iron 3rd Step Select the Cutting Speed Gray Cast Iron ASTM A48: class 20, 25, 30, 35, 40, 45, 50, 55, 60 SAE J431: grade G1800, G3000, G3500, G4000 grade KT KC KC KB KY1310* KY *KY1310 available January Speed - sfm (m/min) (60) (180) (305) (430) (550) (675) (800) (920) (1040) (1160) Starting Conditions sfm m/min Ductile, Compacted Graphite & Malleable Cast Irons (<80 KSI tensile strength) ASTM: A536; , , SAE J434: D4018, D4512, D5506 ASTM A47: grade 32510, SAE J158: grade M3210, M4504, M5003, M5503, M7002 ASTM: A842; grade 250, 300, 350, 400, 450 grade Speed - sfm (m/min) (90) (135) (180) (225) (275) (320) (360) (410) (460) (500) (550) (600) Starting Conditions KT KC KC KY KY sfm m/min Ductile, Malleable & Austempered Cast Irons (>80 KSI tensile strength) ASTM: A536; , SAE J434: D7003 SAE J158: grade M8501 ASTM: A897; , , , , grade Speed - sfm (m/min) (90) (135) (180) (225) (275) (320) (360) (410) (460) (500) (550) (600) Starting Conditions KT KC KC KY KY sfm m/min To further optimize your operation, please reference pages for Tool Tips and the Expert Application Advisor on pages

10 KENNA PERFECT Positive Inserts Cast Iron Ductile and Gray Irons 1st Step Select the Insert Geometry Positive Inserts -MN Medium Machining -MF -T0820 Finishing -LF -T0820 Fine Finishing -11 Cermet -UF -T0820 2nd Step Select the Grade Gray Iron Ductile Iron Cutting Condition heavily interrupted cut lightly interrupted cut varying depth of cut, casting or forging skin smooth cut, pre-turned surface *KY1310 available January Cutting Condition heavily interrupted cut lightly interrupted cut varying depth of cut, casting or forging skin smooth cut, pre-turned surface Insert Geometry Fine Fin. Finishing Med. Machining -T0820 -T0820 -LF -T0820 -MF KY3500 KC9325 KY3500 KC9325 KY3500 KC9325 KY3500 KC9325 KY1310* KY1310* KC9325 KY3500 KC9325 KY1310* KY1310* KC9315 KY1310* KC9325 Insert Geometry Fine Finishing Finishing Med. Machining -T /-UF -T0820 -LF -T0820 -MF KY3500 KC9325 KY3500 KC9325 KC5010 KY3400 KC9315 KY3400 KC9315 KY3400 KT315 KY3400 KC5010 KY3400 KC9315 KY3400 KT315 KY3400 KT315 KY3400 KC

11 KENNA PERFECT Positive Inserts Cast Iron 3rd Step Select the Cutting Speed Gray Cast Iron ASTM A48: class 20, 25, 30, 35, 40, 45, 50, 55, 60 SAE J431: grade G1800, G3000, G3500, G4000 grade Speed - sfm (m/min) (60) (180) (305) (430) (550) (675) (800) (920) (1040) (1160) Starting Conditions KC KC KY1310* KY *KY1310 available January sfm m/min Ductile, Compacted Graphite & Malleable Cast Irons (<80 KSI tensile strength) ASTM: A536; , , SAE J434: D4018, D4512, D5506 ASTM A47: grade 32510, SAE J158: grade M3210, M4504, M5003, M5503, M7002 ASTM: A842; grade 250, 300, 350, 400, 450 grade Speed - sfm (m/min) (90) (135) (180) (225) (275) (320) (360) (410) (460) (500) (550) (600) Starting Conditions KT KC KC KC KY KY sfm m/min Ductile, Malleable & Austempered Cast Irons (>80 KSI tensile strength) ASTM: A536; , SAE J434: D7003 SAE J158: grade M8501 ASTM: A897; , , , , grade Speed - sfm (m/min) (90) (135) (180) (225) (275) (320) (360) (410) (460) (500) (550) (600) Starting Conditions KT KC KC KC KY KY sfm m/min To further optimize your operation, please reference pages for Tool Tips and the Expert Application Advisor on pages

12 Negative Insert Systems Kenloc Negative Inserts Kenloc inserts are your first choice for general machining of all materials on medium to large lathes. Kenloc inserts offer the best economy for high metal removal rates. Available in flat top and chip control geometries with both molded and ground peripheries, suitable for all workpiece materials. Top Notch Turning Inserts Ceramic Top Notch Turning inserts are your first choice for high-speed roughing and finishing of cast iron parts. Available in flat top geometries with molded and ground peripheries. Kendex Negative Inserts Kendex ceramic negative rake inserts are recommended for the machining of cast irons. Available in flat top geometries with molded and ground peripheries. Wide selection of standard toolholders. 14

13 Positive Insert Systems Screw-On Positive Inserts Screw-on inserts are your first choice for ID turning of all materials and OD turning on small to medium size lathes. Available in flat top and chip control geometries with both molded and ground peripheries, suitable for all workpiece materials. Kendex Positive Inserts Kendex positive ceramic inserts can be effectively used for productive machining of cast irons on medium to large lathes. Available in flat top geometries with ground periphery. Top Notch Turning Inserts Maximize rigidity for optimum ceramic insert performance. Ideal for applications ranging from heavy roughing to finishing. Excellent performance for continuous to severely interrupted cuts. 15

14 Kenclamp The Industry s Quickest Insert Indexing Quick-release clamping system reduces machine downtime. 1.5 turns releases the insert. Robust clamping design reduces chatter and improves tool life. The Kenclamp design ensures insert repeatability and seating. Fewer moving parts than competitive systems. Improved shim screw design provides consistent shim and insert alignment. Torx Plus Drive hardware increases clamping forces and hardware life. One wrench fits both the shim screw and the clamp screw. 16

15 Top Notch Turning THE SUPERIOR TOOLHOLDER SYSTEM FOR CERAMIC INSERTS! Top Notch-style clamping is a proven, superior system for holding ceramic inserts rigidly in the pocket in turning and profiling operations. Kennametal Top Notch turning toolholders use standard insert sizes and shapes of 80, 75, and 55 diamond, and square as well as the new trigon TNT. These inserts offer excellent value with their double-sided cutting edges. The Top Notch turning system is supplied with the MX style clamp for use with Top Notch turning inserts. New Top Notch Turning trigon inserts offer an economical six cutting edges for turning, profiling, and facing. 17

16 KENNA PERFECT Inserts Cast Iron Tool Tips: Wiper Inserts Wiper inserts are an excellent choice for straight OD, ID, and facing cuts. Feed rates can be doubled, reducing machining time by 50% while maintaining the surface finish. Insert nose radius has no effect on finish since the wiper radius generates the final finish. Wiper inserts typically last longer since the work is spread over a longer cutting edge. Grade KC9315 Grade KC9315 is the first choice for machining ductile irons. The thick medium-temperature CVD TiCN layer combats flank wear, which is the usual failure mechanism when machining ductile irons with a tensile strength of 50 ksi and greater. Use geometries..ma, MG-UN, and MG-RP. Grade KC9325 Grade KC9325 is ideally suited for machining gray irons and low-strength ductile irons (<45 ksi). Crater wear is the primary wear mechanism when machining gray irons at high speeds. Grade KC9325 combats crater wear with a very thick Al 2 O 3 layer. The grade s unique combination of toughness and speed capability make it a first choice for gray iron machining up to 1300 sfm. MG-RP Geometry The -RP geometry is available in a wide variety of grades and can be used to reduce cutting forces on unstable cuts or where work holding is not optimal. This is particularly advantageous when machining high-strength ductile irons ( 80 ksi). Reduced forces lower the temperature at the cutting interface, providing long, predictable tool life. Grade KC9110 Grade KC9110 is an excellent choice for interrupted cutting conditions where grades KC9315 and KC9325 are not tough enough. Its unique combination of speed capability and outstanding toughness makes it an excellent choice for heavily interrupted cuts. Use MG-RN geometry as a first choice. 18

17 KENNA PERFECT Inserts Cast Iron Tool Tips: Grade KY3500 Kyon 3500 is your first-choice ceramic cutting tool for tough gray cast iron applications, especially those with interruptions and scale. KY3500 is the most dependable ceramic grade for harsh gray cast iron applications, and can be run wet or dry. Grade KY1310 (available January 2004) Kyon 1310 is designed specifically to maximize tool life in dry, continuous gray cast iron applications. Although not as tough as KY3500, KY1310 possesses good toughness at a high hardness level to optimize abrasive wear properties. Use KY1310 for continuous cutting in tandem with KY3500 for more severe gray cast iron cutting applications to maximize tool life and minimize costs. Top Notch Turning System for Ceramics When cutting with ceramics at high speeds, it is important to maximize the rigidity of the insert and toolholder. The Top Notch tooling system used in tandem with grades KY3500, KY1310, and KY3400 dimple inserts provides ultimate rigidity for cast iron applications. Insert Failure Analysis Check the insert thoroughly for signs of failure. To optimize your metalcutting process, remove inserts from the toolholder and inspect regularly for wear. Signs of chipping, deformation, built-up edge, cratering, flank wear, and thermal cracking are very evident in the early stages of wear but are almost impossible to detect after total insert failure. Boring with Wiper Inserts When boring with wiper inserts, chatter may increase due to the large wiper radii. To offset this lateral tool pressure, decrease the nose radius and increase the depth of cut. Remember that the nose radius of a wiper insert doesn t affect surface finish. 19

18 New Cutting Tool Technologies Grade KC9315 During the last 20 years, dramatic improvements have been made in turning insert performance through the development of innovative coating materials such as aluminum oxide (Al 2 O 3 ) and medium-temperature titanium carbonitride (MT-TiCN). In recent years, cutting tool materials have advanced even further through improvements in coating interface adhesion, which can provide thicker and more complex coating layers. This innovative processing produces smoother, less reactive coating surfaces that resist edge build up, microchipping, and chip hammering. Coating Systems The thickness and of layers of coatings on an insert typically have been limited to ensure the integrity and stability of the coating. A coating thickness of 10 to 14 microns typically was the limit, which is significantly less than the optimum value. New technologies now make it possible to increase both the and thickness of the layers by providing high-strength interface transition zones that increase the adhesion between the coatings. We employ this new technology on our new 18-micron coating system for grade KC9315. In conjunction with a hard deformation-resistant substrate, KC9315 is designed especially for high-performance machining of ductile irons and high-strength steels. This new coating consists of three main layers. The bottom layer is titanium carbonitride to protect against flank wear a major failure mechanism in ductile iron and steel turning. This layer is applied in a medium-temperature chemical vapor deposition coating process that reduces the mismatch in thermal contraction rates during cooling to provide fewer coating cracks and a tougher cutting edge. The middle layer is fine-grained alpha crystal structure alumina that protects against the elevated temperatures encountered in high-speed cutting and provides an abrasion-resistant, chemically inert TiN/TiCN }18 µm Al 2 O 3 total (alpha crystal structure) K-MTCVD TiCN Micro-finished edge barrier. The alpha crystal structure is more stable than the more common kappa structure and improves the coating resistance to failure. The top layer is a 2-micron titanium nitride/titanium carbonitride layer that provides additional wear resistance and serves as a wear indicator. Grade KC9315 has an improved post-coating surface treatment that contributes to increased tool performance. Polishing the outer coating surface to a higher-than-normal degree minimizes the potential for built-up edge. In particular, the surface treatment removes the outer TiN / TiCN coating from the tool-chip interface zone to further reduce the possibility of built-up edge. The net advantage is the ability to run at higher speeds and feeds relative to existing coated materials without suffering a reduction in tool life. KC9315 is an excellent performer at finishing to medium machining at the elevated speeds required to be competitive when machining cast iron. 20

19 KC9315 Proven Solutions market: product: material: automotive turbine housing ductile iron COMPETITOR KENNAMETAL KC9315 on Ductile Iron Savings: 28% of process cost, or $26,282. grade: coated carbide KC9315 insert: CNMG-543 CNMA-543 speed: 700 sfm 1000 sfm feed:.015 ipr.015 ipr doc: RESULTS: Grade KC9315 ran 43% faster and produced 10% more parts per edge than did the competitive grade. market: product: material: automotive differential case ductile iron 250 HB COMPETITOR KENNAMETAL KC9315-MW on Ductile Iron 250 HB Savings: 38% of process cost, or $89,716. grade: coated carbide KC9315 insert: CNMG-433ASW CNMG-433MW speed: 900 sfm 900 sfm feed:.015 ipr.018 ipr doc: RESULTS: The Kennametal insert ran at a 20% higher feed rate and produced 35 parts per edge compared to the competitor s 7. market: product: material: automotive suspension component gray cast iron COMPETITOR KENNAMETAL KC9315-UN on Gray Cast Iron Savings: 22% of process cost, or $43,845. grade: coated carbide KC9315 insert: CNMA-543 CNMG-543UN speed: 850 sfm 850 sfm feed.020 ipr.025 ipr doc: RESULTS: Grade KC9315 produced 65% more parts per edge at a 25% higher feed rate than a competitive brand. 21

20 New Cutting Tool Technologies Grade KC9325 Kennametal s reengineered KC9325 grade uses a coating technology similar to KC9315 and is designed specifically to maximize performance in gray cast irons. This coating features an extra thick top layer of fine alpha alumina to maximize resistance to crater wear. An under layer of medium-temperature titanium carbonitride provides excellent resistance to flank wear. A tough, deformation-resistant substrate is designed to work together with this new coating to maximize resistance to crater wear. The application range of KC9325 is expanded with improved performance in medium to heavy machining of both ductile irons and steels. Grade KC9325 also uses a mechanical post-treatment process to condition the surface to resist microchipping and chip hammering. The smooth alumina top layer provides excellent resistance to build up and enables the cut chip to flow quickly and easily over the cutting edge for significantly longer tool life. Coating: CVD Post coat treatment Al 2 O 3 16 µm total KMTCVD TiCN} Kennametal Tooling System Solutions Lathe Tooling Catalog 1010 Includes: Over 6,000 new products The KENNA PERFECT insert selection system A2 Cutoff System...unequaled clamping, even at high feed rates A3 Deep Grooving System...when depth exceeds 1.5 times width Wiper Insert Technology (double your productivity or achieve unsurpassed surface finishes) Request A01-44! 22

21 KC9325 Proven Solutions market: product: material: automotive power train component ductile iron COMPETITOR KENNAMETAL KC9325-UN on Ductile Iron Savings: 22% of process cost, or $123,516. grade: coated carbide KC9325 insert: CNMG-433ENZ CNMG-433UN speed: 500 sfm 700 sfm feed:.014 ipr.014 ipr doc: RESULTS: Grade KC9325 ran 40% faster and produced 10% more parts per edge than the competitive grade. market: product: material: automotive dampener ductile iron 210 HB COMPETITOR KENNAMETAL KC9325 on Ductile Iron 210 HB Savings: 7% of process cost, or $997. grade: coated carbide KC9325 insert: WNMA-433 WNMA-433 speed: 750 sfm 750 sfm feed:.026 ipr.026 ipr doc: : RESULTS: The Kennametal insert produced 100 parts per edge compared to 80 by the competitor, a 25% increase in tool life. market: product: material: automotive suspension component ductile iron COMPETITOR KENNAMETAL KC9325-UN on Ductile Iron Savings: 9% of process cost, or $21,853. grade: coated carbide KC9325 insert: CNMA-433UM CNMG-433UN speed: 155 sfm 155 sfm feed:.014 ipr.014 ipr doc: RESULTS: Grade KC9325 produced 125% more parts per edge than the competitive brand. 23

22 New Cutting Tool Technologies KB9640 the Metalcutting Industry s First CVD Alumina-Coated PCBN Grade! KB9640 is a truly innovative grade that provides the ultimate in crater wear protection. By defeating the main failure mechanism confronting PCBN cutting tools, Kennametal offers a new grade with superior tool life compared with uncoated PCBN and ceramic tools. Not only has KB9640 demonstrated performance improvements when machining hardened irons, steels, and powder metals, it has also shown tremendous success in machining softer low-ferrite-containing cast irons. In particular, KB9640 has achieved excellent results in the machining of gray cast iron brake discs. Beyond the performance advantages of its coating, solid PCBN KB9640 is economical, too, with multiple cutting edges per insert. The CVD alumina coating on grade KB9640 provides the best-known protection against thermal and chemical erosion. In addition, grade KB9640 offers a gold TiN outer layer for easy wear identification. CVD TiN coating CVD alumina coating tough PCBN substrate These two coatings must adhere properly to the tough high-content PCBN substrate for maximum performance. Kennametal's special adhesion technology ensures the coatings will remain intact. As a result, the protective element of the coating is prolonged. The combination of coating technology and extremely durable solid PCBN substrate results in a tool life nearly three times longer than traditional uncoated PCBN inserts. Kennametal Tooling System Solutions A4 Grooving & Turning System Catalog 2013 Tooling for accurate grooving and side turning, even at high metal removal rates For turning, facing, grooving, face grooving, and cutoff operationsin OD or ID applications Eliminates turret indexing time, minimizes insert inventory, and reduces tooling cost Request A02-46! 24

23 KB9640 Proven Solutions market: product: material: braking systems brake drum C.G.I. platinum series COMPETITOR KENNAMETAL KB9640 on C.G.I. Platinum Series Savings: 23% of process cost, or $26,395. grade: ceramic KB9640 insert: RNG-43T0820 RNM-42S0820 speed: 1400 sfm 1000 sfm feed:.025 ipr.025 ipr doc: RESULTS: The ceramic tool typically achieved two parts per edge. Kennametal s KB9640 achieved 36 parts per edge, an 18X performance advantage for less downtime, better productivity. market: product: material: clutch industry flywheel gray iron G4000 COMPETITOR KENNAMETAL KB9640 on G4000 Gray Cast Iron Savings: 69% of process cost, or $5,561. grade: tipped CBN KB9640 insert: CNGA-433 CNM-323 speed: 1280 sfm 1280 sfm feed:.017 ipr.017 ipr doc: RESULTS: Grade KB9640 achieved 450 parts per edge versus 150 parts per edge for the competitive CBN insert. The customer ran 1800 parts per insert with KB9640 versus 150 parts per insert with the competitive brand. market: product: material: brake systems drum gray cast iron COMPETITOR KENNAMETAL KB9640 on Gray Cast Iron Savings: 3% of process cost, or $15,374. grade: ceramic KB9640 insert: RNM-43T0820 RNM-42S0820 speed: 1800 sfm 1800 sfm feed:.030 ipr.030 sfm doc: RESULTS: KB9640 ran 132 parts per edge versus 9 parts per edge from the ceramic tool. Total tool changes per year decreased from nearly 9,000 with the ceramic tool to just over 600 with grade KB

24 New Cutting Tool Technologies Silicon Nitride Ceramics for Gray Cast Iron Silicon nitride-based ceramics are the predominant ceramic tools used for cast iron machining, particularly gray cast irons. These tools excel in cast iron applications because of a unique combination hardness, fracture toughness, and thermal conductivity. High hardness maintained at elevated temperatures (see figure 1) is key to the high-speed application of these tools and gives dramatic performance advantages over coated carbide tools. The combination of high hardness, good thermal conductivity, and high fracture toughness results in a very consistent, reliable tool that excels in demanding cast iron applications. In the 1980s and early 1990s, hot pressed silicon nitride ceramics were used in very few gray cast iron machining applications. The introduction of Kennametal s Kyon 3500 in 1993 changed that. Using breakthrough technology, KY3500 was produced using basic powder metallurgy methods and eliminated the need for onerous hot pressing. Today, Kyon 3500 remains the industry standard as the most dependable commercial ceramic grade on the market. KY3500 differentiates itself from the competition in difficult applications that involve aggressive conditions and interrupted cutting. Kyon 1310 continues the legacy of Kennametal breakthrough ceramic products. Through state-ofthe-art material development and processing, the wear resistance of KY1310 is greatly enhanced. KY1310 targets continuous turning of gray cast iron to provide superior wear resistance. It is ideal for automotive and truck brake disk and rotor applications. Proven Superiority Recently, we tested KY3500 and KY1310 against an incumbent competitor silicon nitride grade in a customer s continuous turning application on gray cast iron automotive valve rings. The speed, feed, and depth of cut of the operation (previously optimized for the competitor grade) were not changed for this test. Results achieved: COMPETITOR silicon nitride: 50 rings KENNAMETAL KY3500: 300 rings KY1310: 440 rings Figure 1: Hot hardness of cutting tool materials 26

25 New Cutting Tool Technologies Kyon 1310* for Continuous Gray Cast Iron Turning Developed specifically for continuous turning of gray cast iron. Unmatched tool life in brake disk and rotor applications! KY sialon ceramic grade specifically engineered for continuous turning applications in gray cast iron formulated to provide maximum abrasion resistance for long-lasting tool life proven performer in a broad range of applications, from roughing to finishing, including through scale run at speeds up to 3700 sfm available in Top Notch Turning and wiper styles for dramatic performance advantages KY1310* COMING SOON: Molded-tolerance style of KY1310! *KY1310 is available January Kyon 3500 for Difficult Gray Cast Iron Turning Silicon nitride ceramic engineered to provide combined superior toughness and wear resistance for interrupted and difficult cast iron applications. KY the industry standard for high-speed turning and milling of gray cast iron proven performer in the most difficult gray cast iron applications, particularly interrupted cuts provides unsurpassed reliability run at speeds up to 3400 sfm available in Top Notch Turning and wiper styles for dramatic performance advantages available in molded and ground tolerance styles to maximize economy for your applications works well in difficult interruped cuts in ductile or malleable cast iron (<70 ksi tensile strength) at speeds of 900 to 1600 sfm KY

26 KY1310* Proven Solutions market: product: material: application: automotive brakes brake rotor gray cast iron continuous KY1310 on Gray Cast Iron Savings: 10% of process cost, or $10,517. COMPETITOR KENNAMETAL grade: ceramic KY1310 insert: CNGX-454T0820 CNGX-454T0820 speed: 2600 sfm 2600 sfm feed:.022 ipr.022 ipr doc: RESULTS: KY1310 machined 255 pieces, more than double the competitor s 110 pieces, at a savings of more than $10,000. market: product: material: application: automotive brakes brake rotor gray cast iron continuous KY1310 on Class 30 Gray Iron Savings: 40% of process cost, or $43,252. COMPETITOR KENNAMETAL grade: ceramic KY1310 insert: CNG-453T0820 CNGX-453T0820 speed: 3000 sfm 3000 sfm feed:.020 ipr.020 ipr doc: RESULTS: KY1310 machined 440 pieces, more than 8 times the 50 pieces by the competitor, at a cost savings greater than $45,000. market: product: material: application: automotive valve ring gray cast iron continuous KY1310 on Gray Cast Iron Savings: 8% of process cost, or $1,303. COMPETITOR KENNAMETAL grade: ceramic KY1310 insert: CNGA-433T0820 CNGA-433T0820 speed: 2000 sfm 2000 sfm feed:.016 ipr.016 ipr doc: RESULTS: KY1310 machined 735 pieces, a 140% increase over the competitor s 300 pieces, at a cost savings of more than $1,000. *Kyon 1310 available January

27 KY3500 Proven Solutions market: product: material: application: automotive brakes brake drum gray cast iron continuous KY3500 on Gray Cast Iron Savings: 74% of process cost, or $3,687. COMPETITOR KENNAMETAL grade: carbide KY3500 insert: CNGA-544KM CNGA-544T0820 speed: 500 sfm 2000 sfm feed:.012 ipr.011 ipr doc: RESULTS: Kyon 3500 ran 40 pieces per edge versus the competitor s 30 pieces per edge at 4 times the speed. market: product: material: application: automotive carrier gray cast iron interrupted KY3500 on Gray Cast Iron Savings: 9% of process cost, or $8,525. COMPETITOR KENNAMETAL grade: ceramic KY3500 insert: CNGX-454T CNGX-454T0820 speed: 2500 sfm 2500 sfm feed:.025 ipr.025 ipr doc: RESULTS: Kyon 3500 achieved 75% greater production by running 1,000 pieces per edge versus 250 pieces per edge by the competition. market: product: material: application: automotive brakes brake rotor gray cast iron variable depth of cut KY3500 on Gray Cast Iron Savings: 13% of process cost, or $3,297. COMPETITOR KENNAMETAL grade: ceramic KY3500 insert: SNMX-554 SNGX-554T0820 speed: 2625 sfm 2625 sfm feed:.024 ipr.024 ipr doc: RESULTS: Kyon 3500 more than doubled production by running 460 pieces per edge versus the competitor s 150 pieces per edge. 29

28 New Cutting Tool Technologies Kyon 3400 for Ductile Iron Turning An advanced CVD-coated silicon nitride ceramic for high-speed turning of malleable and ductile cast irons. KY has the toughness of silicon nitride ceramics combined with a coating for added wear resistance. your first choice ceramic material for high-speed turning of ductile irons (>75 ksi tensile strength) run at speeds from 1200 to 1900 sfm available in Top Notch Turning and wiper styles for optimized performance Micro-Machining Tooling Catalog 2090 Single-source for proven micro-machining and small turning center solutions Features the revolutionary KM Micro Quick-Change System for micro-machining Request A01-135! 30

29 KY3400 Proven Solutions market: product: material: application: automotive differential case ductile iron varied depth KY3400 on Ductile Iron Savings: 38% of process cost, or $36,430. COMPETITOR KENNAMETAL grade: ceramic KY3400 insert: CNGA-643 CNGA-643 speed: 1380 sfm 1430 sfm feed:.012 ipr.012 ipr doc: RESULTS: Kyon 3400 ran 25 pieces per edge at a higher speed versus the 10 pieces per edge run by the competitor. market: product: material: application: automotive liner ductile iron varied depth, finish boring KY3400 on Ductile Iron Savings: 28% of process cost, or $3,688. COMPETITOR KENNAMETAL grade: ceramic KY3400 insert: CNGA-434T0820 CNGA-434T0820 speed: 1300 sfm 1300 sfm feed:.010 ipr.010 ipr doc: RESULTS: Kyon 3400 achieved nearly 4 times greater production by running 15 pieces per edge versus the 4 pieces per edge by the competitor. market: product: material: application: automotive end plate ductile iron varied depth KY3400 on Ductile Iron Savings: 34% of process cost, or $1,400. COMPETITOR KENNAMETAL grade: carbide KY3400 insert: TNMG-432 CNGA-432T0820 speed: 1100 sfm 1100 sfm feed:.011 ipr.011 ipr doc: RESULTS: Kyon 3400 ran 3 pieces per edge, while the competitor ran 1 piece per edge. 31

30 Metallurgy and Machinability Metallurgy Overview Cast irons are iron-carbon-silicon alloys containing large amounts of carbon either as graphite or as iron carbide. They have higher carbon (>1.7%) and silicon ( %) contents than steel. Silicon promotes dissociation of iron carbide to iron and graphite. By increasing the silicon content in cast iron, a greater proportion of graphite can be obtained at the expense of combined carbon. The microstructure and mechanical properties of cast irons can be controlled not only by chemical composition but also by cooling rate. Increasing the cooling rate will refine the graphite size as well as the matrix structure and will increase strength and hardness. It also may increase the chilling tendency, which may increase the hardness but decrease the strength. Alloys within the broad group of cast irons include white iron, gray cast iron, mottled cast iron, malleable cast iron, and ductile cast iron. Each of these alloys may be modified by alloy additions to obtain specific properties. Below are selected ASTM standards for different classes of cast irons. Selected ASTM Standards for Cast Irons Unalloyed Cast Irons A47 Malleable iron castings A48 Gray iron castings A126 Gray iron castings for valves, flanges, and pipe fittings A159 Automotive gray iron castings A197 Cupola malleable iron A220 Pearlitic malleable iron castings A278 Gray iron castings for pressure-containment with temperatures up to 345 C (650 F) A319 Gray iron castings for elevated temperatures non-pressure containing parts A395 Ferritic ductile iron pressure-retaining castings for elevated temperatures A476 Ductile iron castings for papermill dryer rolls A536 Ductile iron castings A602 Automotive malleable iron castings Low and Moderate Alloyed Cast Irons A319 A874 Gray iron castins for elevated temperatures for non-pressure containing parts Ferritic ductile iron castings for low-temperature service parts High-Silicon Cast Irons A532 Abrasion-resistant cast irons High-Nickel Austenitic Cast Irons A436 Austenitic gray iron castings A439 Austenitic ductile iron castings 571 Austenitic ductile iron castings for pressurecontaining parts for low-temperature service 32 Machinability Overview Machinability refers to the ease with which a workpiece can be machined and measured in terms of tool life, metal removal rates, surface finish, ease of chip formation, or cutting forces. It is not an intrinsic property of a material, but is a result of complex interactions between the mechanical properties of the workpiece, cutting tools, lubricants used, and machining conditions. Cast iron machinability varies greatly depending on the type of iron and its microstructure. Ferritic cast irons are easiest to machine, while white irons are extremely difficult to machine. Other grades of cast iron, such as malleable, ductile, compacted graphite, and alloyed cast irons, are in between ferritic and white irons in ease of machinability. Additionally, hard spots in castings formed during rapid cooling and in presence of excessive levels of carbide forming elements can seriously degrade machinability. Alloy cast irons (ASTM A532, A518) can be classified as white cast irons, corrosion-resistant irons, and heat-resistant irons. Generally, they are based on the iron (Fe) - carbon (C) - silicon (Si) system and contain one or more alloying elements that are added (>3%) to enhance one or more useful properties (corrosion resistance or strength or oxidation resistance at elevated temperatures). Small amounts of ferrosilicon, cerium, or magnesium that are added to control the size, shape, and distribution of graphite particles are called inoculants, rather than alloying elements. Inoculation does not change the basic composition or alter the properties of the constituents in the microstructure. The alloyed irons for corrosion resistance are either 13-36% nickel (Ni) gray and ductile irons (also called Ni-resist irons) or high silicon (~14.5% Si) gray irons. For elevated temperature service, nickel (Ni), silicon (Si), or aluminum (Al) alloyed gray and ductile irons are employed. Figure 1: Microstructure of white cast iron

31 Metallurgy and Machinability White cast irons, also known as abrasion-resistant cast irons, are an iron-carbon alloy in which the carbon content exceeds 1.7%. White cast iron does not have any graphite in the microstructure. Instead, the carbon is present either as ironcarbide or complex iron-chromium carbides (Figure 1), which are responsible for high hardness and resistance to abrasive wear. White iron shows a white, crystalline fracture surface because fracture occurs along the carbide plates. White iron can be produced either throughout the section or only on the surface by casting the molten metal against graphite or metal chill. In the latter case, it is referred to as chilled iron. Corrosion-resistant cast irons obtain their resistance to chemical wear primarily from their high alloy content of silicon, chromium, or nickel. Depending on which of the three alloys dominates the compositions, the corrosion-resistant material can be ferritic, pearlitic, martensitic, or austenitic. Machinability Alloy Cast Irons White irons and corrosion-resistant high-silicon (14.5%Si) gray irons are the most difficult cast irons to machine. Alloyed white irons such as nickel-hard (Ni-hard) alloys and high-silicon irons (ASTM A518) are generally ground to size or turned with a polycrystalline cubic boron nitride (PCBN) tool material such as Kennametal grades KB9640, KD120, or KB5625 Gray cast irons (ASTM A48, A126, A159, ASME AS278 and SAE J431) are named such because their fracture has a gray appearance and consists of graphite flakes embedded in a matrix of ferrite or pearlite, or a mixture of the two depending on the composition and cooling rate (Figures 2a-2d). Ferrite is a soft, low-carbon alpha iron phase with low tensile strength but high ductility. Pearlite consists of lamellar plates of soft ferrite and hard cementite. Gray irons contain 2.5 to 4% carbon (C), 1-3% silicon (Si), and manganese (Mn) (~0.1% Mn in ferritic gray irons and as high as 1.2% Mn in pearlitic gray irons). Sulfur (S) and phosphorus (P) may be present as residual impurities. Manganese is deliberately added to neutralize the sulfur. The resulting manganese sulfide is uniformly distributed in the matrix of gray iron as inclusions. ASTM specification A48 classifies gray cast irons in terms of tensile strength (class 20 with 20 ksi minimum tensile strength to class 60 with 60 ksi minimum tensile strength). The fluidity of liquid gray iron and its expansion during solidification due to the formation of graphite are responsible for the economic production of shrinkage-free, intricate castings such as engine blocks. Most gray iron components are used in the as-cast condition. However, for specific casting requirements, they can be heat treated (annealed, stress relieved, or normalized). Other heat treatments include hardening and tempering, austempering, martempering, and flame or induction hardening. Figure 2a: Type C flake graphite in gray iron Figure 2c: Coarse pearlite in gray cast iron Machinability Gray Cast Irons Figure 2b: Pearlite-ferrite gray cast iron Figure 2d: Pearlitic gray cast iron Most gray cast irons are easier to machine than other cast irons of similar hardness and virtually all steels. This is because the graphite flakes in the microstructure act as chip breakers and serve as a lubricant for the cutting tool. Machining difficulties can still occur in gray iron if chills are present in corners and thin sections or when sand is embedded in the casting surface. The material also shows a tendency to break out during exit from the cut. Although the graphite in cast iron imparts its free-machining characteristics, the matrix surrounding the graphite determines tool life. In fully annealed state, cast irons have a ferritic matrix and exhibit the best machinability. (While not as soft as ferrite in steel, the ferritic cast iron shows better machinability than ferritic steel due to the slight hardening effect of the dissolved silicon and the chip breaking and lubricating effect of the graphite.) As the ferrite content decreases Photomicrographs courtesy of Buehler Ltd., Lake Bluff, Illinois, USA, 33

32 Metallurgy and Machinability and pearlite increases, tool life decreases rapidly. Both iron and alloy carbides, when present as large particles, are detrimental to tool life. Irons with higher phosphorous contents (~0.4%) form a hard constituent called steadite, which has a detrimental effect on tool life. Gray cast irons are productively turned and milled with multi-layered alumina and TiCN coated inserts. The substrate tool material can be either carbide or silicon nitride-based ceramic. Cermet grades such as KT315 are ideal for light depth-ofcut applications. A pure silicon nitride grade such as KY3500 often yields the highest productivity on general turning and milling applications at high speeds. Drilling applications are highly dependent on the drill geometry as well as drill grade. Kennametal solid carbide drills in the TF (triple flute) and SE (sculptured edge) geometries in TiALN-coated grades KC7210 and KC7215 are the most desirable. For indexable insert drilling applications, TiALN-coated KC7725 and alumina coated KC7935 grades are the first choice for high-speed, high productivity applications. Ductile (nodular) irons (ASTM A395, A476, A439, A536 and SAE J434), previously known as nodular iron or spheroidal-graphite cast iron, contain nodules of graphite embedded in a matrix of ferrite or pearlite or both (Figures 3a-3c). The graphite separates as nodules from molten iron during solidification because of additives cerium (Ce) and magnesium (Mg) introduced in the molten iron before casting. The nodules act as crack arresters and impart ductility to the material. By contrast, neither white iron nor gray iron shows a significant amount of ductility. Ductile iron is of higher purity (low phosphorus [P] and sulfur [S]) and is stronger than gray iron. With a high percentage of graphite nodules present in the microstructure, the matrix determines the mechanical properties of ductile iron. Table B compares the composition of ductile iron with that of gray iron and malleable iron. The ASTM classifies different grades of ductile irons in terms of tensile strength in ksi, yield strength in ksi, and elongation in percent. For example, ASTM A536 specifies five standard ductile iron grades: / (ferritic ductile iron), (ferritic-pearlitic ductile iron), (pearlitic ductile iron), and (quenched and tempered martensitic ductile iron). Ferritic ductile iron the ferrite matrix provides good ductility and impact resistance and tensile strength equivalent to low-carbon steel. Ferritic ductile iron can be produced as-cast or may be given an annealing treatment to obtain maximum ductility and low-temperature toughness. Ferritic-pearlitic ductile irons usually produced in the as cast condition and feature both ferrite and pearlite in the microstructure. Properties are intermediate between ferritic and pearlitic ductile irons. Figure 3a: Ferritic annealed ductile iron Figure 3b: Pearlite/ferrite ductile iron Figure 3c: Coarse lamellar pearlite in ductile iron Table B Typical composition ranges for unalloyed cast irons 34 material total carbon manganese silicon (Si) chromium (Cr) composition % nickel (Ni) molybdenum (Mo) copper (Cu) phosphorus (P) sulfur (S) cerium (Ce) magnesium (Mg) gray iron max 0.15 max malleable iron max ductile iron max max

33 Metallurgy and Machinability Pearlitic ductile irons - the pearlitic matrix provides high strength, good wear resistance, and moderate ductility and impact resistance. While the aforementioned three types of ductile iron are most common and used in as-cast condition, ductile irons also can be alloyed and/or heattreated to provide additional grades as follows: Martensitic ductile irons are produced using sufficient alloy additions to prevent pearlite formation, and a quench-and-temper heat treatment to produce a tempered martensitic matrix. These materials have a high strength and wear resistance but lower levels of ductility and toughness. Bainitic ductile irons are produced through alloying and/or by heat treatment to provide a hard, wear-resistant material. Austenitic ductile irons are produced through alloying additions to provide good corrosion and oxidation resistance, magnetic properties, and strength and dimensional stability at high temperatures. Machinability - Ductile Irons The spherical graphite in ductile iron acts similar to the flake graphite in gray iron in chip breaking and lubrication in machining. Machinability increases with silicon content up to 3%, but decreases significantly at higher silicon levels. As in the case of gray cast iron, machinability decreases with increasing pearlite content in the microstructure. Finer pearlite structures also decrease machinability. Still, pearlitic ductile irons are considered to have the best combination of machinability and wear resistance. Cast irons with tempered martensitic structure have a better machinability than pearlite with similar hardness. Other microstructures such as acicular bainite and acicular ferrite formed during heat treatment of ductile irons have machinability similar to martensite tempered to the same hardness. The higher tensile strength of ductile irons compared to gray cast iron requires better rigidity within the machining system. Tool performance life may be slightly lower if run at gray cast iron surface speeds. Ductile cast irons can be productively turned and milled with multi-layered alumina and TiCN or PVD TiALN-coated inserts but at slightly slower speeds than gray cast irons. Malleable cast irons (ASTM A602 and A47) consist of uniformly dispersed and irregularly shaped graphite nodules (often called temper graphite because it is formed by the dissolution of cementite in the solid state) embedded in a matrix of ferrite, pearlite (Figure 4), or tempered martensite. Malleable iron is cast as white iron and then heat-treated to impart ductility to an otherwise brittle material. Malleable iron possesses considerable ductility and toughness due to the nodular graphite and a lower carbon metallic matrix. It has good fatigue strength and damping capacity, good corrosion resistance, good magnetic permeability, and low magnetic retention for magnetic clutches and brakes. Malleable iron, like medium-carbon steel, can be heat treated to obtain different matrix microstructures (ferrite, pearlite, tempered pearlite, bainite, tempered martensite, or a combination of these) and mechanical properties. Malleable and gray irons differ in two respects: the iron carbide is partially or completely dissociated in malleable cast iron; the dissociation occurs only when the alloy is solid. However, the dissociation in gray cast iron occurs during the early stages of solidification; hence the difference in the character of graphite in each material. Figure 4: Coarse pearlite in annealed malleable iron Machinability Malleable Cast Irons The machinability of malleable iron is considered to be better than that of free-cutting steel. Use lowstrength ductile iron machining recommendations. Austempered ductile irons (ADI) (ASTM A897-90) are used as cast, but some castings are heat treated to achieve desired properties. Austempered ductile irons are produced from conventional ductile iron through a special two-stage heat Photomicrographs courtesy of Buehler Ltd., Lake Bluff, Illinois, USA, 35

34 Metallurgy and Machinability treatment. The microstructure consists of spheroidal graphite in a matrix of acicular ferrite and stabilized austenite (called ausferrite) (Figure 5). The fine-grained acicular ferrite provides an exceptional combination of high tensile strength with good ductility and toughness. ADI can be given a range of properties through control of austempering conditions. Compared to conventional grades of ductile iron, ADI offers twice the tensile strength for a given level of elongation. Compacted graphite iron (CGI) (ASTM A842) has a microstructure in which the graphite is interconnected like the flake graphite in gray cast iron, but the graphite in CGI is coarser and more rounded (Figure 6). In other words, the structure of CGI is between that of gray and ductile iron. The graphite morphology allows better use of the matrix, yielding higher strength and ductility than gray irons. The interconnected graphite in CGI provides better thermal conductivity and damping capacity than the spheroidal graphite in ductile iron. Although the CGI is less section-sensitive than gray iron, high cooling rates are avoided because of the high propensity of the CGI for chilling and high nodule count in thin sections. Figure 5: Austempered ductile iron Machinability Austempered Ductile Irons The machinability of the softer grades of austempered ductile iron (ADI) is equal or superior to that of steels with equivalent strength. ADI can be machined complete in the soft, as-cast state before heat treatment. This enables faster machine feeds and speeds and significantly increases tool life. As the hardness of ADI increases, tool life decreases substantially. For this reason, only the 125/80/10 and 150/100/7 grades of ADI are machined after austempering. Processing sequence for parts processed to the higher strength: cast the component subcritically anneal to a fully ferritic matrix machine austemper finish machine (if required) finish operations (rolling, grinding, peening, if required) Follow high-strength ductile iron recommendations during machining. Figure 6: Compacted graphite Machinability Compacted Graphite Iron The graphite morphology in compacted graphite iron enables chipbreaking but is strong enough to prevent powdery chip formations. This combination is ideal for good machinability. As a result, the machinability of compacted graphite iron lies between that of gray iron and ductile iron for a given matrix structure. Use low-strength ductile iron machining recommendations. Photomicrographs courtesy of Buehler Ltd., Lake Bluff, Illinois, USA, 36

35 Metallurgy and Machinability Gray Cast Irons & Gray, Austenitic standard materials UNS tensile strength hardness HB ASTM 48 ASTM A126 ASTM A159 & SAE J431 ASTM A278 & ASME AS278 ASTM A319 ASTM A436 Gray Cast Irons F10001 generally below MPa 207 (30 ksi) Class l F10002 at or above 207 MPa (30 ksi) Class ll F10003 generally at or above 276 MPa (40 ksi) Class lll F MPa (18 ksi) min. 187 max G1800 F MPa (25 ksi) min G2500 F MPa (30 ksi) min G3000 F MPa (35 ksi) min G3500 F MPa (40 ksi) min G4000 F MPa (20 ksi) min (A-C) 20 F MPa (21 ksi) min. 156 Class A F MPa (25 ksi) min (A-C) 25 F MPa (30 ksi) min (A-C) 30 F MPa (31 ksi) min. 210 Class B F MPa (35 ksi) min (A-C) 35 F MPa (40 ksi) min (A-C) F MPa (41 ksi) min. 235 Class C F MPa (40 ksi) min F MPa (45 ksi) min (A-C) F MPa (45 ksi) min F MPa (50 ksi) min (A-C) F MPa (50 ksi) min F MPa (55 ksi) min (A-C) F MPa (55 ksi) min F MPa (60 ksi) min (A-C) F MPa (60 ksi) min F MPa (70 ksi) min. 70 F MPa (80 ksi) min. 80 Gray, Austenitic F MPa (25 ksi) min F MPa (30 ksi) min b F MPa (25 ksi) min F MPa (30 ksi) min b F MPa (25 ksi) min F MPa (25 ksi) min F MPa (20 ksi) min F MPa (25 ksi) min Grade, Type or Number 37

36 Metallurgy and Machinability Malleable Cast Irons & Pearlitic, Martensitic standard materials UNS tensile strength yield strength hardness HB ASTM A47 ASTM A220 ASTM A602 & SAE J158 Malleable Cast Irons F MPa (50 ksi) min MPa (32 ksi) min. 156 max. M3210 F MPa (65 ksi) min MPa (45 ksi) min M4504 F MPa (75 ksi) min. 345 MPa (50 ksi) min M5003 F MPa (75 ksi) min MPa (55 ksi) min M5503 F MPa (90 ksi) min MPa (70 ksi) min M7002 F MPa (105 ksi) min. 586 MPa (85 ksi) min M8501 F MPa (50 ksi) min. 224 MPa (32 ksi) min. 156 max F MPa (53 ksi) min. 241 MPa (35 ksi) min. 156 max Malleable, F MPa (60 ksi) min. 276 MPa (40 ksi) min Pearlitic & F MPa (65 ksi) min. 310 MPa (45 ksi) min Martensitic F MPa (65 ksi) min. 310 MPa (45 ksi) min.; elongation 6% min F MPa (70 ksi) min. 345 MPa (50 ksi) min F MPa (70 ksi) min. 345 MPa (50 ksi) min F MPa (80 ksi) min. 483 MPa (70 ksi) min F MPa (95 ksi) min. 552 MPa (80 ksi) min F MPa (105 ksi) min. 621 MPa (90 ksi) min Ductile Cast Iron & Ductile, Austenitic Grade, Type, or Number standard materials UNS tensile strength yield strength hardness HB ASTM A395 A476 A536 ASTM A439 ASTM A571 AMS SAE J434 MIL-I Ductile Cast Iron F30000 as required as req d DQ & T F MPa (60 ksi) min. 276 MPa (40 ksi) min. 170 max D4018 F MPa (65 ksi) min. 310 MPa (45 ksi) min D4512 F MPa (60 ksi) min. 310 MPa (45 ksi) min (A) F MPa (80 ksi) min. 379 MPa (55 ksi) min D5506 F MPa (80 ksi) min. 414 MPa (60 ksi) min F MPa (100 ksi) min. 483 MPa (70 ksi) min D7003 F MPa (120 ksi) min. 621 MPa (90 ksi) min Ductile, Austenitic F MPa (58 ksi) min. 207 MPa (30 ksi) min D-2 F MPa (58 ksi) min. 207 MPa (30 ksi) min D-2B F MPa (58 ksi) min. 193 MPa (28 ksi) min D-2C F MPa (55 ksi) min. 207 MPa (30 ksi) min D-3 F MPa (55 ksi) min. 207 MPa (30 ksi) min D-3A F MPa (60 ksi) min. 207 MPa (30 ksi) min D-4 F MPa (55 ksi) min. 207 MPa (30 ksi) min D-5 F MPa (55 ksi) min. 207 MPa (30 ksi) min D-5B F MPa (65 ksi) min. 207 MPa (30 ksi) min D-2M-1, D-2M-2 F MPa (50 ksi) min. 207 MPa (30 ksi) min. (B) F MPa (50 ksi) min. 172 MPa (25 ksi) min. (C) 38 Grade, Type, or Number

37 Metallurgy and Machinability Austempered Ductile Iron (ADI) standard materials UNS tensile strength yield strength hardness HB ASTM A Austempered n/a 850 MPa (125 ksi) min. 550 MPa (80 ksi) min./elongation 10% Ductile Iron (ADI) n/a 1050 MPa (150 ksi) min. 700 MPa (100 ksi) min./elongation 7% n/a 1200 MPa (175 ksi) min. 850 MPa (125 ksi) min./elongation 4% n/a 1400 MPa (200 ksi) min MPa (155 ksi) min./elongation 1% n/a 1600 MPa (230 ksi) min MPa (185 ksi) min Grade, Type, or Number Compacted Graphite Iron (CGI) standard materials UNS tensile strength yield strength hardness HB ASTM A842 Compacted n/a 250 MPa min. 175 MPa min./elongation 3% 179 Max. 250 Graphite Iron (CGI) n/a 300 MPa min. 210 MPa min./elongation 1.5% n/a 350 MPa min. 245 MPa min./elongation 1.0% n/a 400 MPa min. 280 MPa min./elongation 1.0% n/a 450 MPa min. 315 MPa min./elongation 1.0% Grade, Type, or Number Nickel (Ni) Hard / White Cast Iron standard materials UNS properties hardness HB ASTM A532 (class) Austempered F45000 nickel-chromium irons (I) A, Ni hard Ductile Iron (ADI) F45001 nickel-chromium irons (I) B, Ni hard F45002 nickel-chromium irons (I) C, Ni hard F45003 nickel-chromium irons (I) D, Ni hard F45004 chromium-molybdenum irons (II) A, white iron F45005 chromium-molybdenum irons (II) B, white iron F45006 chromium-molybdenum irons (II) C, white iron F45007 chromium-molybdenum irons (II) D, white iron F45008 chromium-molybdenum irons (II) E, white iron F45009 chromium-molybdenum irons (III) A, white iron Grade, Type, or Number 39

38 Metallurgy and Machinability Cast Iron Cross-Reference / Workpiece Comparison Table UNS USA Australia Belgium Denmark France Gray Cast Iron ASTM 48, ASME SA278, ASTM A159, SAE J431 F10004 G1800 F10005 G2500 F10006 G3000 F10007 G3500 F10008 G4000 F A T150 FGG10 GG10 FGL FGG15 GG15 FGL150A F A FGL200A 25 FGL250A F A T220 FGG20 GG20 FGL F A FGG25 GG25 FGL FGL300A F A F A FGG30 GG30 FGL FGL350A FGL400A F A FGG35 GG35 FGL F A FGG40 GG40 50 F A FGL Gray, Austenitic ASTM A436 F L-NiCuCr1562 L-NUC1562 F b L-NiCuCr1563 L-NUC1563 F L-NiCr202 L-NC202 S-NiCr202 F b L-NC203 F L-NiCr303 S-NiCr303 F NiSiCr3055 L-NSC2053 L-NSC3055 F L-Ni35 L-N35 S-NiCr353 F Malleable Iron ASTM 602, SAE J158, ASTM A7 F20000 M3210 M4504 M5003 M5503 M7002 M8501 F F

39 Metallurgy and Machinability Germany Great Britain International Italy Japan Sweden Gray Cast Iron ASTM 48, ASME SA278, ASTM A159, SAE J431 Ch Ch Ch Ch Ch GG G10 FC FC15-2 GG G15 GG G20 FC G25 FC GG-25 FC GG G30 FC30-5 GG G35 FC Gray, Austenitic ASTM A436 GGL-NiCuCr1562 F1 L-NiCuCr1562 GGL-NiCuCr1563 F1 L-NiCuCr1563 GGL-NiCr202 F2 L-NiCr L-NiCr202 GGL-NiCr203 F2 L-NiCr203 GGL-NiCr303 F3 L-NiCr303 GGL-NiSiCr3055 L-NiSiCr2053 L-NiSiCr3055 L-Ni35 Malleable Iron ASTM 602, SAE J158, ASTM A7 S2 41

40 Metallurgy and Machinability Cast Iron Cross-Reference / Workpiece Comparison Table Ductile Cast Iron UNS USA Australia Belgium Denmark France ASTM A395, ASTM A476, ASTM A536, SAE J434 F FNG FGS D FGS350-22L FGS FGS FGS400-18L F FNG42-12 D4512 F F FNG FGS500-7 D5506 F F FNG FGS700-2 D FNG FGS800-2 F FGA900-2 Ductile Cast Iron, Austenitic ASTM A439 F43000 D-2 S-NC202 F43001 D-2B L-NiCr203 S-NC203 S-NiCr203 F43002 D-2C S-Ni22 S-N22 F43003 D-3 S-NC303 F43004 D-3A S-NiCr301 S-NC301 F43005 D-4 S-NiSiCr3055 S-NSC3055 F43006 D-5 S-Ni35 S-N35 F43007 D-5B S-NC353 D-5S F43010 D-2M-1 S-NM234 D-2M-2 42

41 Metallurgy and Machinability Germany Great Britain International Italy Japan Sweden Ductile Cast Iron ASTM A395, ASTM A476, ASTM A536, SAE J434 GGG / GS FCD /22L L FCD / /18L L GGG-50 GS FDC45-2 GGG / GS500-7 FCD FCD60-4 GGG / GS700-2 FCD / GS800-2 FCD80-6 GGG / Ductile Cast Iron, Austenitic ASTM A439 GGG-NiCr202 S2 S-NiCr202 S2W GGG-NiCr203 S2B S-NiCr203 GGG-Ni22 S2C S-Ni22 GGG-NiCr303 S3 S-NiCr303 GGG-NiCr301 S3 S-NiCr301 GGG-NiSiCr3055 S-NiSiCr3055 GGG-Ni35 S-Ni35 GGG-NiCr353 S-NiCr353 GGG-NiMn234 S2M S-NiMn234 43

42 Expert Application Advisor Cast Irons Gray Cast Iron and Austenitic, Gray Iron ( HB) ASTM: A48I: class 20, 25, 30, 35, 40, 45, 50, 55, 60 ASTM: 126: class A, B, C ASTM: A159 & SAE: J431; G1800, G2500, G3000, G3500, G4000 ASTM: A436; 1, 1b, 2, 2b, 3, 4, 5, 6 Material Characteristics out-of-balance condition may exist chucking on cast surface can be difficult tendency to break out during exit from cut contains abrasive elements; sand may be embedded in the cast surface potential for chatter on thin wall sections corners and thin sections can be chilled (hard and brittle) potential scale, inclusions Common Tool Application Considerations Problems & Solutions excessive edge wear 1. Use grade KC9315 or KT315 if running at moderate to high speeds. 2.. Use silicon nitride-based ceramic grades Kyon 3500 or Kyon 1310, or PCBN grades, if running at ultra-high speeds. Machining system must have the rigidity and horsepower required to run at ultra-high speeds. 3. Increase the feed to reduce in-cut time. chipping 1. Increase toolholder lead angle. 2. Use a grade with good edge strength, such as grade KC Ensure proper insert seating. 4. Use strong, negative-rake insert geometries such as MA, GX-T or GA-T. 5. Use inserts with an MT-land edge prep. workpiece breakout 1. Use PVD-coated grade KC5010 at moderate to low speeds. 2. Reduce feed rate during exit. 3. Pre-chamfer casting edge at exit. 4. Increase toolholder lead angle. workpiece chatter 1. Use a smaller nose radius. 2. Apply insert geometries that are free-cutting, such as MG-FN and MG-RP. 3. Increase feed to stabilize workpiece. 4. Shorten toolholder or bar overhang. 5. Check toolholder and workholding system for rigidity. 6. Use Top Notch Turning (GX-T style) insert for increased tooling rigidity. 44

43 Expert Application Advisor Cast Irons Ductile Iron ( HB) ASTM: A395, A476, A536; , , , , , SAE: J434; DQ & T, D4018, D4512, D5506, D7003 AMS: 5315, 5316 ASTM: A439. A571; D2, D2B, D2C, D3, D3A, D4, D5, D5B, D2M Material Characteristics graphite is in spherical form, rather than flake form customary in gray cast iron hard spots are common concentrations of carbide in the structure workpiece material structure may vary dramatically Malleable Cast Iron ( HB) ASTM: A47: 32510, ASTM: A602 & SAE J158; M3210, M4504, M5003, M5503, M7002, M8501 ASTM: A220; 40010, 45008, 45006, 50005, 60004, 70003, 80002, machining difficulties may develop from flank and crater wear on the tool higher tensile strength requires good rigidity in machining system decreased tool life should be expected, compared to machining gray or malleable cast iron Material Characteristics graphite is in irregular-shaped nodules, rather than flake form customary in gray cast iron generally easy to machine at aggressive conditions. Common Tool Application Considerations Problems & Solutions excessive edge wear 1. Apply grade KC9315 to achieve higher speeds and longer tool life. 2. Use grade KC9325 for general purpose and interrupted cutting. 3. Apply grade KC9315 or KT315 if edge wear is excessive in smooth cuts. 4. Use ceramic grade Kyon Increase speed and make sure the machining set up and workpart clamping is rigid. 5. Increase feed to reduce time in cut. crater wear 1. Apply grade KC9315 or KT Reduce speed to lower the heat at cutting edge. 3. Apply ceramic grade Kyon 3400 when machining at high speeds. 4. Apply large amounts of flood coolant. chipping 1. Use a strong negative-rake insert geometry. Apply the MX-T, GA-T, or MA insert geometry as a first choice; use MG-UN insert geometry as a second choice. 2. Select a T-land or large hone edge prep for greater edge strength. 3. Increase toolholder lead angle. 4. Reduce toolholder or boring bar overhang. 5. Ensure proper insert seating. 6. Apply grade KC Use grade KC9325, increase speed, and decrease feed when cutting with interruptions. 8. Choose grade Kyon 3500 to replace Kyon 3400 for heavy interruptions. catastrophic failure 1. Reduce speed and feed. 2. Use a T-land plus hone edge prep. torn or dull workpiece 1. Apply insert geometries that are free-cutting surface finish, such as the MG-FN. 2. Use a larger nose radius insert. 3. Use coated cermet grade KT

44 Expert Application Advisor Cast Irons Austempered Ductile Iron ( HB) ASTM: A897; , , , , and Material Characteristics material is produced by heat treating (austempering) high-quality ductile iron grades and are hard and not recommended for machining with carbide tooling Austempered ductile irons machine similarly to high-strength ductile irons. Due to the higher strength of these materials, tool life is shortened compared to conventional irons. Use high-strength ductile iron (>80 ksi) machining recommendations for these materials. See KENNA PERFECT recommendations on pages Compacted Graphite Iron (CGI) ( HB) ASTM: A842; Grade 250, 300, 350, 400, 450 Material Characteristics graphite is in compacted (vermiform) shapes and relatively free of flake graphite lower hardness levels than gray irons of equivalent strength hard or brittle enough to produce short chips; not hard enough to produce powder Compacted graphite irons are machined similar to lower-strength ductile irons. Kennametal Tooling System Solutions KM Kenclamp Tooling Catalog 2014 Our newest quick-release (1.5 turns) clamping design Robust clamping design reduces chatter and improves tool life Ensures insert repeatability and seating Fewer moving parts vs. competitive systems Request A02-132! 46

45 Failure Mechanism Analysis Edge Wear* Chipping Corrective Action Increase feed rate. Reduce speed (sfm). Use more wear resistant grade. Apply coated grade. Corrective Action Utilize stronger grade. Consider edge preparation. Check rigidity of system. Increase lead angle. Heat Deformation Depth-of-Cut Notching Corrective Action Reduce speed. Reduce feed. Reduce depth-of-cut (doc). Use grade with higher hot hardness. Corrective Action Change lead angle. Consider edge preparation. Apply different grade. Adjust feed. Thermal Cracking Built-Up Edge Corrective Action Properly apply coolant. Reduce speed. Reduce feed. Apply coated grades. Corrective Action Increase speed (sfm). Increase feed rate. Apply coated grades or cermets. Utilize coolant. Edge prep (smaller hone). Crater Catastrophic Breakage Corrective Action Reduce feed rate. Reduce speed (sfm). Apply coated grades or cermets. Utilize coolant. Corrective Action Utilize stronger insert geometry grade. Reduce feed rate. Reduce depth-ofcut (doc). Check rigidity of system. *NOTE: Generally, inserts should be indexed when.030 flank wear is reached. If it is a finishing operation, index at.015 flank wear or sooner. 47

46 Machinability Data Cast Iron Gray Cast Iron The ideal turning insert geometry for machining gray cast iron should have the following characteristics: square or diamond shaped for maximum strength negative insert geometry for maximum strength and of cutting edges minimum or no positive-rake chip-forming insert geometry for maximum edge strength medium edge hone on carbide inserts and a T-land edge prep on ceramic/sialon-grade inserts Ductile Cast Iron The ideal turning insert geometry for machining ductile cast iron should have the following characteristics: square or diamond shaped for maximum strength negative insert geometry for maximum strength and of cutting edges positive-rake chip-forming insert geometry for freer cutting action and chip control light edge hone on carbide inserts and a T-land edge prep on ceramic/sialon-grade inserts Pre-chamfer workpiece whenever possible to avoid workpiece material breakout and interrupted cut shock damage to insert edge. 48

47 Insert Edge Preparation Edge Preparation for Kennametal s Advanced Cutting Tool Materials Edge preparation is the term for the intentional modification of the cutting edge of an indexable insert to enhance its performance in a metalcutting operation. Ceramic cutting tool materials have a much higher hardness, but lower toughness, compared to conventional carbide materials. Because of this, ceramic materials have good bulk strength but lower edge strength versus carbide. To optimize performance of ceramic cutting tools, it is critical that tool material, workpiece material, and machining conditions be considered relative to edge preparation. To achieve optimum edge preparation, make the minimum amount of modification necessary to distribute forces sufficiently enough to prevent chipping and catastrophic insert failure. Edge preparations for standard inserts made with specific ceramic grades are determined by target applications and listed in the KENNA PERFECT insert selection system. There are three choices of edge preparation for ceramic materials: There is a tradeoff to the benefits of this edge preparation. Increasing the width T of the T-land or the angle A increases the overall cutting forces acting on the insert. This can negatively affect the wear rate of the insert and/or deformation of a thin-walled workpiece. For most cast iron turning applications, use a T-land width smaller than the feed rate. For heavily interrupted turning, hard turning (workpiece >50 HRC), and milling applications, use a T-land width larger than the feed rate. 2. Hone Hones protect the insert cutting edge by eliminating the sharp edge and distributing the cutting forces over a larger area. Hones generally are recommended for continuous or finishing operations; however, depending on the workpiece material, they can be used for interrupted or heavy cutting. 1. T-land 2. hone 3. T-land plus hone 1. T-land T lands protect the insert cutting edge by directing forces into the greater part of the insert, rather than to the smaller cross section of the sharp edge, during the metalcutting process. This helps prevent chipping and catastrophic failure. 3. T-land plus hone In aggressive applications, such as interrupted turning, chipping can occur at the intersection of the T-land and flank surface of the ceramic insert. This condition may be eliminated by applying a small hone to the intersection while leaving the other attributes of the T-land unchanged. 49

48 Chip Control Geometries Kenloc Inserts operation insert style application insert geometry profile feed rate inches depth of cut inches wiper, finishing MG-FW (0,2-0,4) (0,3-2,0) wiper, medium machining MG-MW (0,3-0,6) (0,8-5,1) wiper, roughing MM-RW (single sided) (0,3-1,3) (1,3-12,7) finishing MG-FN (0,1-0,3) (0,3-2,5) medium machining MG-UN (0,2-0,5) (0,8-3,8) roughing MG-RP (0,3-0,6) (1,1-6,4) roughing MG-RN (0,3-0,6) (1,1-6,4) heavy roughing MM-RM (single sided) (0,3-1,0) (1,3-12,7) heavy roughing MM-RH (single sided) (0,4-1,3) (1,3-12,7) feed rate (mm) 0,04 0,063 0,01 0,16 0,25 0,4 0,63 1,0 1,6 2,5 5,0 0,1 0,16 0,25 0,4 0,63 1,0 1,6 2,5 4,0 6,3 10,0 depth of cut (mm) 50

49 Chip Control Geometries Screw-On Inserts operation insert style/ application insert geometry profile feed rate inches depth of cut inches wiper, finishing MT-FW (0,1-0,3) (0,2-1,5) wiper, medium machining MT-MW (0,1-0,5) (0,4-3,3) fine finishing MT (0,1-0,3) (0,2-1,3) fine finishing MT-UF (0,1-0,3) (0,1-1,3) finishing MT-LF (0,2-0,4) (0,8-2,3) medium machining MT-MF ,2-0, ,1-2,3 feed rate (mm) 0,04 0,063 0,01 0,16 0,25 0,4 0,63 1,0 1,6 2,5 5,0 0,1 0,16 0,25 0,4 0,63 1,0 1,6 2,5 4,0 6,3 10,0 depth of cut (mm) 51

50 Kennametal Grade System for Cutting Materials Cermet (CERamics with METallic binders) grade coating composition and application C class ISO class KT315 composition: A multi-layered, PVD TiN/TiCN/TiN, coated cermet turning grade. application: Ideal for high-speed finishing to medium machining of most carbon and alloy steels and stainless steels. Performs very well in cast and ductile iron applications too. Provides long and consistent tool life and will produce excellent workpiece finishes. C3 C7 K10 - K20 M10 - M20 P10 - P20 PVD Coated Carbide Grades grade coating composition and application C class ISO class KC5010 composition: A PVD TiAlN coating over a very deformation-resistant unalloyed, carbide substrate. application: The KC5010 grade is ideal for finishing to general machining of most workpiece materials at higher speeds. Excellent for machining most steels, stainless steels, cast irons, non-ferrous materials and super alloys under stable conditions. It also performs well machining hardened and short chipping materials. C3 C4 K10 - K20 M10 - M20 P10 - P20 CVD Coated Carbide Grades grade coating composition and application C class ISO class KC9315 KC9325 composition: A multi-layered CVD coating with a very thick K-MTCVD layer of TiCN, for maximum wear resistance, is applied over a substrate specifically engineered for cutting cast and ductile irons. application: The KC9315 grade delivers longer tool life when high-speed machining ductile and cast irons. The thick K-MTCVD TiCN coating ensures a tremendous tool life advantage, especially when cutting higher tensile strength ductile and cast irons where workpiece size consistency and reliability of tool life are critical. This new Kennametal grade is excellent when used for either straight or lightly interrupted cut applications. Moreover, if you re looking for high productivity performance, the KC9315 grade is an ideal choice. composition: A TiCN and alumina-coated grade with a strong, reliable substrate. application: Grade development for the KC9325 grade focused on a variety of ductile and cast iron operations. The coating and substrate are optimized for flexibility. If you are machining different types of ductile or cast irons where application confidence, flexibility and broad range reliability are your primary requirements, the KC9325 grade is the perfect choice. C3 - C4 K10 - K25 C2 - C3 K15 - K30 Silicon Nitride-Based Ceramic grade coating composition and application C class ISO class KY1310* composition: An advanced sialon ceramic grade. application: Grade KY1310 provides maximum wear resistance. Use it for high-speed continuous turning of gray cast iron, including through scale. *KY1310 will be available January K05-K15 KY3400 composition: CVD coated pure silicon nitride grade. application: Excellent combination of toughness and edge wear resistance; used for general purpose machining of gray cast irons and ductile or nodular cast irons. C3 K10 - K30 KY3500 composition: Pure silicon nitride grade. application: Maximum toughness; used at high feed rates for rough machining of gray cast iron, including machining through interruptions. C2 K15 - K35 M15 - M30 PCBN Polycrystalline Cubic-Boron Nitride grade coating composition and application C class ISO class KB9640 composition: A high CBN content, solid PCBN structure having multiple cutting edges and a CVD alumina coating. application: The KB9640 grade is applied in the roughing to semi-finishing of fully pearlitic gray cast iron, chilled irons, high chrome alloy steels, sintered powdered metals, and heavy cuts in hardened steels (>45 HRC). Use for finished chilled cast iron and fully pearlitic cast iron. Do not apply on finishing hardened steels. KB9640 can be applied effectively when roughing hardened steels. C1 K05-K15 52

51 Kennametal Grade System for Cutting Materials Gray Cast Irons Ceramic Cutting Tools Ductile Cast Irons Ceramic Cutting Tools KY3500 Carbide Cutting Tools Carbide Cutting Tools 53

52 KENNAMETAL TOOL MANAGEMENT SOLUTIONS No matter how intricate your metalworking manufacturing operations or equipment, Kennametal s new ToolBoss System, powered by our exclusive, built-to-suit ATMS software, will enable your machinists to spend more time machining parts far less energy locating tools. ToolBoss System Our unique, new, easy-to-use/ easy-to-audit tool dispenser can help reduce your: tool-buying costs by as much as 90%! tool-inventory costs by up to 50%! tool-supply costs by nearly 30%! 54

53 Technical Information page Wiper Insert Application Guidelines Conversion Tables Nose Radius Selection for Surface Finish Insert Size Selection Guide Tool Performance Report Form Insert Identification System

54 Three Ways To Improve Your Turning Operations! Kennametal introduces three new geometries that are the latest in state-of-the-art turning technology. Our new -RW (Roughing Wiper), -MW (Medium Wiper) and -FW (Finishing Wiper) inserts employ a modified corner radius design that delivers a superior surface finish compared to conventional inserts. This technology allows you to choose the metalcutting benefit that s most important to your application. Double Productivity Kennametal s new wiper geometries allow you to double your current feed rate and still achieve surface finishes comparable to conventional inserts. You ll also see equivalent or better tool life using the appropriate KENNA PERFECT grade specifically designed for your workpiece material. Better Workpiece Finish These new wiper geometries also will give you a markedly improved surface finish at your current machining conditions. Under typical conditions, you ll see as much as a 250% improvement in the workpiece surface finish, all with inserts that meet your corner radius specifications. You choose! Either way, we re sure you ll agree that the new wiper geometries from Kennametal provide an outstanding way to optimize your turning operations. Please see the accompanying information for proper application guidelines. Conventional Turning Insert doc feed ipr speed...1,100 sfm finish R a (µin.) Kennametal Wiper Technology MW doc feed ipr speed...1,100 sfm finish...60 R a (µin.) 56

55 Negative Wiper Inserts Application Technology Surface Finish Theoretical Surface Finish R a µin. (µm) insert feed rate ipr (mm/rev) FW, MW, & RW (0,2) (0,3) (0,4) (0,5) (0,6) (0,7) (0,8) (0,9) (1) (1,1) (1,2) 3/8 IC (0,3) (0,75) (1,3) (2) 1/2 IC (0,6) (1) (1,6) (2,2) (3) (4) (5) (6,2) 3/4 + 1 IC (2,6) (3,5) (4,6) (5,8) (7,2) (8,7) (10,3) How It Works Wiper Insert Standard Insert LEGEND f feed r corner radius r w wiper radius R a surface finish Corner Radius Configuration CNMG and WNMG wiper inserts create a true corner radius on the workpiece, just as a standard insert does. DNMG and TNMG wiper inserts do not provide an exact corner radius on the workpiece. The radius produced falls within a ±.0025 tolerance band. (blue lines) 57

56 Negative Wiper Inserts Application Technology C and W Style Inserts Kenloc Toolholders surface with wiper effect surface with standard insert edge CN.. 80 corner insert requires MCLN 5 reverse lead angle toolholder CN corner insert requires MCRN 15 lead angle toolholder CN corner insert requires MCKN 15 lead angle toolholder WN.. 80 corner insert requires MWLN 5 reverse lead angle toolholder D and T Style Inserts Kenloc Toolholders surface finish with wiper effect surface with designated insert nose radius surface finish with.016 radius DN.. 55 corner insert requires MDJN 3 reverse lead angle toolholder TN.. 60 corner insert requires MTJN 3 reverse lead angle toolholder S Style Inserts Kenloc Toolholders surface with wiper effect surface with standard insert edge SN..90 corner insert requires MSRN 15 lead angle toolholder SN.. 90 corner insert requires MSKN 15 lead angle toolholder NOTE: The holder guidelines above also apply to ceramic/pcbn wiper inserts in similar insert shapes; i.e.: CNGA, CNGX, DNGA, etc. 58

57 Positive Wiper Inserts Application Technology Positive geometry wiper inserts offer the same advantages as negative style inserts. When compared to conventional inserts, feed rates can be doubled while maintaining surface finish, or surface finish can be improved by a multiple of 2.5 while maintaining productive feed rates. Surface Finish -FW Finishing Wiper -MW Medium Machining Wiper Theoretical Surface Finish R a µin. (µm) insert FW, MW feed rate ipr (mm/rev) (0,05) (0,10) (0,15) (0,20) (0,25) (0,30) (0,35) (0,40) (0,45) (0,50) 1/4 IC (0,03) (0,15) (0,35) (0,55) (0,90) (1,25) 3/8 IC (0,02) (0,10) (0,20) (0,35) (0,55) (0,75) (1,00) 1/2 IC (0,02) (0,06) (0,15) (0,25) (0,40) (0,60) (0,80) (1,00) (1,30) (1,60) CCMT and CPMT Inserts Screw-On Toolholders and Boring Bars surface with wiper effect surface with designated insert nose radius C.MT 80 inserts require 5 reverse lead SCL toolholders. C.MT 100 inserts require 15 lead SCK toolholders. DCMT and DPMT Style Inserts surface finish with wiper effect surface with designated insert nose radius surface finish with.016 radius SDN SDU SDJ D.MT 55 inserts require a 3 reverse lead angle and can be used in SDN, SDU, and SDJ style toolholders and boring bars. 59

58 Application Guidelines Cast Iron Conversion Charts hardness Brinell Rockwell HB HRB HRC Brinell Rockwell HB HRB HRC NOTE: Values in shaded areas are beyond normal range and given for information only. inch to metric diameter Ø inches mm.315 8, , , , , , , , , , , , , , , , , ,5 Turning Formulas to find sfm rpm diameter Ø inches mm , , , , , , , , , , , , , , , , , ,0 formula d x rpm 3.82 sfm x 3.82 d mpm sfm 3.27 sfm mpm x 3.27 ipr ipm ipm rpm ipr x rpm mm inch x 25.4 inches mm 25.4 cut loc time ipr x sfm (minutes) 60 doc inches mm.010 0, , , , , , , , , ,700 ipr feed mm/rev speed sfm m/min surface finish (Ra) µinch µm , , ,2 63 1,6 31 0,8 16 0,4 Abbreviations sfm = surface feet per minute rpm = revolutions per minute mpm = meters per minute ipr = inches per revolution ipm = inches per minute d = diameter mm = millimeters loc = length of cut

59 Application Guidelines Cast Iron Nose Radius Selection and Surface Finish for Conventional Inserts* Nose radius and feed rate have the greatest impact on surface finish. To determine the nose radius required for a theoretical surface finish, use the following procedure and the chart above. 1 Locate the required surface finish (rms or AA) on the vertical axis. 2 Follow the horizontal line corresponding to the desired theoretical finish to where it intersects the diagonal line corresponding to the intended feed rate. 3 Project a line downward to the nose radius scale and read the required nose radius. 4 If this line falls between two values, choose the larger value. If no available nose radius will produce the required finish, feed rate must be reduced. Reverse the procedure to obtain surface finish from a given nose radius. *NOTE: See pages for radius and surface finish specifications using wiper-style inserts. NOTE: Peaks produced with a small radii insert (top) compared to those produced with a large radius insert (bottom). 61

60 Insert Size Selection Guide Cast Iron Geometries C-80 Diamond D-55 Diamond cutting insert shape IC edge length finishing MG-FN MG-FW MA-T0820 T0420-FW maximum depth of cut general purpose MG-UN MG-RP MG-MW roughing MX-T0820..MA S R-Round S-Square T-Triangle V-35 Diamond W-Trigon

61 Turning Tool Performance Report COMPANY & LOCATION DATE ENGINEER CUSTOMER NAME MATERIAL TYPE AND CONDITION HARDNESS PART DESCRIPTION CUTTING CONDITION (CIRCLE) MACHINE & TYPE OPERATION CONDITION OF MACHINE HP CONSTANT SFM YES PART CONFIGURATION COMMENTS NO PERFORMANCE, TECHNICAL & COST DATA TEST 1 TEST 2 TEST 3 1 OPERATION NUMBER 2 TURRET POSITION 3 TOOLHOLDER 4 INSERT STYLE 5 GRADE 6 DEPTH OF CUT 7 LENGTH OF CUT 8 FEED RATE (IPR) 9 WORKPIECE DIAMETER 10 CUTTING SPEED RPM SFM 11 CUTTING TIME PER PIECE (MINUTES) (30 SECONDS =.5) 12 PIECES PER EDGE 13 CUTTING TIME PER EDGE (MINUTES) (11 x 12) 14 CUTTING EDGES PER INSERT 15 PIECES PER INSERT (14 x 12) 16 REASONS FOR INDEXING 17 TYPE OF COOLANT 18 HORSEPOWER REQUIRED 19 FINISH (RMS) 20 CHIP CONTROL (GOOD, FAIR, POOR) 21 INSERT COST 22 INSERT COST PER PIECE (21 15) 23 MACHINE COST PER HOUR 24 MACHINE COST PER PIECE (11 x 23 60) 25 TOTAL COST PER PIECE ( ) 26 ESTIMATED ANNUAL PRODUCTION PIECES 27 ESTIMATED ANNUAL COST (26 x 25) 28 ESTIMATED ANNUAL SAVINGS 63

62 KENNA PERFECT Inserts Steel Stainless Steel Cast Iron Non-Ferrous Metals High-Temperature Alloys Hardened Materials 64

63 Table of Contents page Insert Identification System Kenloc Negative Inserts Screw-On Inserts Top Notch Turning Inserts Kendex Inserts